COVER TEST MAY 2021:Layout 1 14/5/21 09:24 Page 1

ISSN 1756 560X

ISSUE NO 55 MAY 2021

Innovations in the food and beverage industry CONTENTS:Layout 1 14/5/21 09:57 Page 2

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Published by Print Workshop Publications Innovations in Food Processing & Packaging is published ISSN 1756 560X quarterly in February, May, August and November

17 ASHCROFT COURT • BURNHAM • BUCKS • SL1 8JT UNITED KINGDOM Subscriptions: Printed version: EDITORIAL UK: £55.00 (inc postage) Tel/Fax: +44 (0)1628 666176 Europe: £85 (Airmail including p+p) Email: [email protected] Rest of the World: £90.00 (Airmail including p+p) Online only: ADVERTISING £30.00 Tel: +33 4 66 580 562 • Fax: +33 970 629185 Email: [email protected] © Copyright of Innovations in Food Processing & Packaging. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means without the prior written permission of Advertising and Business Development Director Print Workshop Publications David Copperfield Tel: +33 466 580 562 Fax: +33 466 209 238 PRINT WORKSHOP Email: [email protected] PUBLICATIONS LIMITED Publications Director: Terry Prior Email: terryprior@innov ationsfood.com

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EDITORIAL CALENDAR 2021 / 2022

AUGUST 2021 NOVEMBER 2021 FEBRUARY 2022

• technology • PET technology • Bar coding • X-ray inspection systems • -in- technology • Freeze drying • Labelling solutions • Food safe lubricants • Thermoformed packaging • machines • Conveyor belt systems • Food safe lubricants • Colour sorting • Robotic automation • Conveyor belt systems • UC/EB technology • • Strapping machines • Flooring innovations • • X-ray inspection • PET technology • Steam processing technology • PET technology • Bottling developments • Bagging technology • Steam processing technology • Bar coding • Ready meal packaging • Stainless steel bespoke products • Vacuum packaging • Weighers • Vacuum pouch technology • Sensors for packaging • Food safe maintenence lubricants • Bagging technology • • Cryogenic freezing • Waste management • Computer software • X-ray inspection advancements • UV/EB technology • Food traceability • Bar coding • Food traceability • Barrier films • Barrier films • Barrier films • Filling systems • Robotic automation • Colour sorting • Labelling solutions • Dairy packaging • Filling systems

PREVIEW: ANUGA FOODTECH 2022

Copy deadline: July 31 2021 Copy deadline: October 23 2021 Copy deadline: January 31 2022

2 Innovations in Food Processing & Packaging May 2021 www.innovationsfood.com CONTENTS:Layout 1 14/5/21 09:57 Page 3 Contents ISSUE 55 MAY 2021

PROCESSING 22 The chemistry of contaminant detection Fortress Technology / Sparc Systems 4 A new format for functional gummies 24 Kühne packs barbecue sauces and remoulade using 5 Loma Systems® launches CW3 Run-Wet® Combo and flexible Schubert technology checkweigher systems for harsh washdown Gerhard Schubert environments

28 Plastics in consumer goods manufacturing: Fresh 6 Proseal’s fast and flexible solutions prove invaluable strategies for more sustainability for soft fruit growers Omron

7 Integrated Ishida solution brings speed, efficiency 32 Food Interceptor saves pork producer’s bacon and quality benefits Fortress Technology

8 Microban® technology strikes a new level of clean for the CODING, LABELLING,

30 Rotech launch new modular conveyors to simplify 9 Minebea Intec’s upgrade for checkweighers: When packaging coding high speed meets precision Rotech Machines

10 Enhanced freezing capabilities developed by Air Products provide a sustainability boost for manufacturers

26 Packaging automation set to aid food manufacture 11 Hi-Line boosts environmental credentials even further growth in the wake of Covid-19 with switch to R513a refrigerant Endoline Automation

12 Considerations for effective cleaning-in-place (CIP) 33 SIG announces launch of tethered caps for packs systems three years ahead of EU regulatory requirements HRS Heating Exchangers SIG

14 Bühler’s moulding solution ChocoX is ready for 35 TOMRA confirms excellent detection of V-Shapes customers as Buhler TOMRA

15 Cap closed 36 Schwarzwaldmilch first to opt for SIG’s innovative IDS Imaging combiMaxx closure

16 Growth market for sensitive products: KHS provides 37 New BOPP film with improved thermal resistance numerous innovations for system solutions KHS 38 VAC 95+ for recycling at the highest level 18 Cobot palletiser set to revolutionise robotic uptake Omron 39 The bad, the ugly and the good – New consumer research highlights packaging frustrations and delights 19 Hyperspectral seal inspection system detects contamination in rigid plastic packaging, even through printed film 40 Brupac chooses new disposable, yet recyclable, Engilico in-cup drinks packaging solution

20 Key Technology introduces Global View™ 41 New Sealed Air’s shrink packaging is Key Technology designed-for-recycling for circular economy

21 GEA has the cure that will inject value into bacon 42 Reflex launch Pack Plus: A more sustainable GEA packaging solution

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A new format for Duravant functional gummies acquires Foodmate, provider of poultry processing solutions

uravant LLC (“Duravant”), a global engineered Dequipment and automation solutions provider to the food processing, packaging and material handling sectors, announced today that it has entered into a definitive agreement to acquire Foodmate, a leading manufacturer of poultry processing equipment dual-headquartered in Ball Ground, Georgia, and Numansdorp, the Netherlands. Foodmate’s automated secondary processing solutions for poultry are widely recog- nized as the gold standard in the industry. “We are absolutely thrilled with this part- nership,” said Mike Kachmer, President and CEO of Duravant. “Foodmate is the preferred provider of processing systems in the poultry processing industry globally. Combine that with their culture of laser-focused innovation and superior engineering expertise, Foodmate is a wonderful addition to the Duravant family.” This partnership brings together two global engineered equipment leaders and extends Duravant’s ability to serve customers and partners in over 190 countries worldwide within the food aker Perkins and Rousselot have extended degradation. processing sector. Bthe range of gummy delivery forms for the Starch-free depositing is inherently more “We’re excited to be a part of and collab- functional and pharmaceutical sectors by develop- hygienic than starch processing but the Baker orate with the Duravant family of world-class ing a completely new format – the gummy cap. Perkins equipment brings many more benefits to brands,” said Scott Hazenbroek, President of The important difference is the incorporation of the the producers of functional and pharmaceutical Foodmate US. “Duravant and Foodmate are clearly active ingredient in a liquid or gel centre-filling gummies. aligned with a shared culture and Duravant’s global instead of the gelatin gummy. The design of the depositing nozzles footprint will assist us in continuing to deliver Gummy caps combine the appealing taste provides very high dosing accuracy with very little premium solutions, optimize yield, improve quality and texture of a gummy with the efficient delivery of waste and the machines are easy to operate and and reduce labor costs for our customers. a capsule and may be used in a wide range of clean. Outputs range from 50 to 1,000kg/hr, Duravant’s lifecycle management via the company’s nutraceutical and OTC healthcare products. ensuring that a system is available for every SupportPro services complements and enhances This new delivery form reflects the rise in production requirement from small batch to high our existing field service offerings that will further popularity of gummies for medicinal purposes, volume. increase customers’ productivity and efficiency particularly amongst children: compared with The gummy fillings are water or oil based. goals.” capsules, gummies are visually appealing with a Supplements in the filling could include vitamins The Foodmate brand of processing pleasant taste. Taking a daily supplement in this and botanical/herbal supplements; probiotics; machinery has been a competitive force in the full format becomes a treat, not a chore and the ability Essential Fatty Acids; and anti-oxidants. Pain relievers, line processing of poultry for over 15 years. With a to create a variety of 3D shapes with the option of cough suppressants and antihistamines are typical strategic global footprint featuring manufacturing sugar-free production extend marketing opportuni- pharmaceutical ingredients. and engineering hubs in Europe, demo and show- ties. SiMoGel is a gelatin solution, specifically room facilities in the US and the Netherlands The gummy cap process maximises the designed for functional gummy production. It and sales and assembly in the US, Foodmate’s utilisation of expensive active ingredients. An excess creates gelatin-based nutrient rich gummies for customers are further supported by a local presence quantity is used when they are added to hot syrup which Baker Perkins starch-free depositing is the in 55 countries. Foodmate’s deep engineering and to offset heat degradation but this is avoided by ideal production process as it maximises hygiene development capabilities allow for the custom carrying them in a liquid or gel. As an example, an and process security by eliminating the risk of cross- design of complete automated solutions from the 80mg Vitamin C gummy cap requires 30% less contamination of active ingredients associated with weighing and grading of the poultry product, to the Vitamin C in the formulation than a traditional the starch mogul. cutting and deboning process. Recognized for functional gummy. . The process is rapid - 20 minutes setting advanced technology around software for vision There is more freedom on types of time compared with up to 24 hours for a mogul. and grading capabilities using proprietary software, nutraceutical and active ingredients - Vitamin B8 can With no-starch, no dryers, no storage space, and and R&D capabilities supported by deep application be used in gummy caps. There is also a higher compact equipment it is highly cost effective. There know-how, Foodmate continues to grow its global nutrient content possible, compared to traditional is great flexibility with scalable design, and deposit- presence. nutraceutical gummies. ing into easy-to-clean silicone or metal moulds or David Hazenbroek, President of Foodmate The development is made possible by the directly to a . The elimination of dust B.V. The Netherlands, said, “Foodmate has an accuracy, hygiene and rapid cooling of Baker Perkins’ during production maximises hygiene. installed base of over 900 units serving the largest starch-free depositing technology combined with Production outputs range from 50 to 1500 poultry processing companies globally. By partner- Rousselot’s fast-setting SiMoGel gelatin formulation. kg/hour. ing with the Duravant companies, we look forward Between them, they ensure that the temperature to continuously delivering on our customer-first of the filling is kept low to minimise additive www.bakerperkins.com approach to innovation and service excellence.”

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Economic water activity measurement - now with live demonstration service!

he latest Aqualab Pawkit water activity meter Tfrom Labcell makes the measurement of water activity available at an economic price to food https://www.loma.com/en/products/combination-systems/cw3-run-wet-combo?utm_source=iifpap&utm_campaign=cw3- industry. New for customers is a live-demonstration runwet service so that potential users can see the product in practice while talking to the key technical team - securely and confidentially. By using a video conferencing facility and using samples of your ® products, Labcell is able to offer a truly bespoke trial Loma Systems launches of the Aqualab 4TE. The battery-powered device can be carried anywhere within the production plant or wider ® supply chain for taking on-the-spot measurements. CW3 Run-Wet Combo Water activity can be measured in a range of locations, from the field to the factory, shop and restaurant. and checkweigher systems The Pawkit is placed over a sample dish containing solid, liquid, paste or powdered material, and readings are obtained in five minutes or less. Each Pawkit is supplied with a robust carry for harsh washdown , sample cups/, verification salts, operating instructions and a calibration certificate. For more information or to book a demon- environments stration, visit the website at www.labcell.com, c all Labcell on 01420 568150 or e-mail [email protected] s a leader in the design and manufacture of Ainspection equipment for food and pharma- ceutical industries, ‘Check & Detect’ specialists, LOMA SYSTEMS®, recently launched their new groundbreaking CW3 RUN-WET® Combo and CW3 RUN-WET® Checkweigher systems. The move follows increased demands from food manufactur- ers for improved hygiene and cleaning efficiency for inspection equipment, as well as reduced https://www.loma.com/en/products/checkweighing/cw3- machinery downtime due to frequent, harsh wash- run-wet?utm_source=iifpap&utm_campaign=cw3-runwet down regimes. With both being fully IP69 rated and ments, such as protein, dairy produce, meat, fish, designed to follow the latest industry leading convenience food and more. principles for optimum hygiene standards, Loma’s Following many of the EHEDG guidelines, CW3 RUN-WET® Combo provides a combined the RUN-WET® Combo and Checkweigher systems checkweigher and metal detector in one, whereas offer a host of new features and smart design the CW3 RUN-WET® Checkweigher is a standalone techniques to keep factories running better. They checkweigher system. include easier to wash frames that use surfaces for ifm offers easy route With current inspection systems, costly quicker water run off, minimal welds and reduced production delays can often occur from both time contaminant traps for optimum deep cleaning, with to Industry 4.0 consuming, difficult cleaning, and waiting for the reduced risk of water ingress. Removable top equipment to dry. Unprotected sensitive electrical panels provide easy access to clean the conveyor he new moneo starter kit from ifm electronic parts of machines often need to be ‘bagged’ prior to belt without compromising safety, and enclosed Tprovides everything needed for users to start washdown to prevent any kind of water ingress - motors, controls and pneumatics are all high- exploring and enjoying the benefits of Industry 4.0 one of the most common causes of system and pressure and high-temperature washdown proof to and the Industrial Internet of Things (IIoT). Devel- component failure. Furthermore, certain check- IP69 rating. As an additional benefit, the systems oped specifically to be easy to use, the kit includes weigher and metal detection systems are not suit- require no drying time following cleaning; this all the hardware and software required to imple- able for high care food production environments immediate start functionality greatly improves ment condition monitoring for motors, fans, pumps where hygiene standards are highest and harsh overall equipment effectiveness, helping to provide and other simple machines. Not only is the solution washdown cycles are frequent. This lack of clean- fast-paced food manufacturing and processing provided by the kit comprehensive and fully ing efficacy means that bacterial contamination in facilities with valuable gains in production time and functional, it also offers almost unlimited scalability food still remains one of the biggest causes of cost savings. and easy integration with existing IT infrastructure. product recall. “Loma has worked with the food industry “Most manufacturing companies now see Loma’s RUN-WET® systems were devel- for over 50 years, and our teams strive to under- that Industry 4.0 is the best route to a secure and oped in combination with feedback from many stand inspection challenges faced by food manu- profitable future,” said Paul Stansfield of ifm customers. By producing a far more sanitary design facturers and processors,” said Toby Kemp, Loma’s electronic, “but many are daunted by the apparent that is both quicker and easier to clean, the risk of Director of Marketing & Innovation. “We always cost and complexity of starting out on this route. Our bacterial contamination can be minimized, thereby engineer with the customer in mind, and already moneo system addresses these issues and the new increasing food safety and satisfying the strictest we’re being told how our new CW3 RUN-WET® moneo starter kit is the perfect way for companies Codes of Practice and Food Safety Standards. Combo and CW3 RUN-WET® Checkweigher to ‘dip their toes in the water’. But it’s much more Created to withstand harsh, high-pressure systems are helping to increase production line than just a trial package or a training aid – it’s a very and high-temperature deep cleaning regimes, the efficiencies and improve overall food safety.” useful standalone system that can easily be systems are suitable for high-care food environ- www.loma.com extended to cover additional machines and plant.”

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Proseal’s fast and flexible solutions prove invaluable for soft fruit growers

roseal’s advanced tray sealing machines are and sizes of trays with efficiency and accuracy,” I-Cut 122 Phelping growers meet ever-increasing demand explains Proseal sales director Tony Burgess. “This, for soft fruit - which has been particularly strong combined with our innovative technologies and during the current pandemic - by providing high production lead times, make us a world leader in TrimSort quality, flexible sealing solutions that also deliver on tray sealing soft fruits. sustainability. “ProMotion™ our continuous infeed tech- sorts it out As soft fruit volumes continue to climb, nology, for example, has the potential to increase and with the market for fruit grown in the UK now the speed of a tray sealer by up to 30%, while oultry processors are facing QSR (Quick estimated to be worth over £670 million a year, creating calm machine operations which ensure a PService Restaurants) and retail customers manufacturers are looking for flexible solutions that smoother, more stable journey to the sealing asking for high volumes of typical portioned can meet the demanding high-speed requirements station. This is particularly beneficial to delicate products such as crispy tenders, medallions, strips, driven by the seasons. Equally important is the need produce, such as soft fruit.” nuggets, cubes and more. They can now automate to minimise the use of packaging materials without Proseal also manufactures a diverse and many manual portioning and sorting processes. impacting on the effectiveness of the pack, in customisable line of intelligent conveyor systems, Marel’s I-Cut 122 has always been able to perform particular its ability to provide product protection to designed to create ultimate line control and multiple cuts. It is now able to sort different cut help reduce food waste. optimisation and therefore perfect for the fast- products produced in the same integrated process. moving soft fruit industry. From a single stream of incoming products, I-Cut The company has pioneered several 122 TrimSort can make two separate streams of cut important sustainability initiatives throughout its 23 products and the trim cut from them. This further years. Proseal was the driving force behind the reduces giveaway with no need for human inter- replacement of traditional clam-shell punnets with vention. top film sealed varieties, which has now become So far, I-Cut 122, combined with Speed- commonplace in soft fruit markets across Europe Sort, was able to separate cut products into two and now North America, helping to minimise conveyor belt streams. Now, the integrated TrimSort plastic usage by around 45% in most cases. functionality and smarter software allow for the More recently, the company has been at distribution of many more combinations of cut the forefront of the introduction of new recyclable product to the two integrated belts. All of this is and compostable trays and film for fruit that can done in one smart system with a small footprint, further reduce plastic usage by as much as 96%. without the need for a separate SpeedSort. I-Cut “Proseal continues to strive to develop the 122 TrimSort can generate various high-value most effective and sustainable sealing solutions for products while accurately splitting the product flow its customers,” concludes Tony Burgess. at the highest speeds. Proseal offers an extensive range of high- “We are proud of the many innovations quality manual, semi-automatic and fully automatic we have developed for the effective and efficient tray sealers, designed to be flexible and incorporat- tray sealing of soft fruit. And we will continue to ing a number of unique design features that develop the appropriate technologies to help maximise speeds and efficiencies. In addition, support sustainable solutions that deliver quality.” Anderol B.V. Proseal machines’ two-minute rapid-tool-change Proseal is part of the JBT Corporation means endless varieties of tray formats, materials family, a leading global technology solutions and sizes can be sealed on one machine, allowing provider to high-value segments of the food launches new users to quickly switch from one tray type to processing industry, committed to providing a another. service that surpasses customer expectations. extreme long life “Our tray sealing machines offer fruit growers greater flexibility to seal different designs www.proseal.com synthetic screw compressor lubricant Eclipse Magnetics becomes nderol B.V. has launched a new synthetic Acompressor lubricant with extreme long life properties. SHAPA member Available for food grade and industrial applications, Anderol® SYNcom (FG) HiPerf 46 is a high performance screw compressor lubricant clipse Magnetics ha announced its membership SHAPA’s standing as the UK’s top trade organisation specially formulated to last a full maintenance cycle. Ewith the Solids Handling & Processing Associa- is the ideal partnership for Eclipse Magnetics and its Along with its extreme long life properties, tion (SHAPA), the UK’s leading trade body for the range of innovative products. the lubricant has been developed to provide low solids handing and processing industry. Technical Manager, Dr Ewan Goodier, said: deposit formation, outstanding oxidation and Established for over 40 years, SHAPA’s “We are delighted to be associated with SHAPA and thermal stability, as well as low evaporation, fast members include leading names in mechanisation to have obtained membership to their association. water separation and copper and steel protection. for bulk materials handling and storage systems. At Eclipse Magnetics, we pride ourselves on provid- Ingrid Ooms, Global Technical Manager at Covering Food, Pharmaceutical and Chemical ing high quality and effective magnetic solutions, Anderol B.V. explained: “Equipment can operate for processing equipment manufacturers, it provides an and it’s a great privilege to be a part of something much longer without interruption with Anderol® industry voice and enables members to keep that acknowledges that, as well as offering the SYNcom (FG) HiPerf 46 which means reduced abreast of the latest product developments and means to help us progress as a business. It’s maintenance requirements and enhanced produc- legislation in a wide range of solids and bulk han- fantastic news for Eclipse and I’m looking forward to tivity. It also offers a more sustainable solution as dling technologies. working with SHAPA moving forward.” the longer oil life properties means less oil Eclipse Magnetics manufacture high- Find out more about Eclipse Magnetics’ consumption and less waste. 122 TrimSort can performance magnetic separation and metal products online at www.eclipsemagnetics.com or generate various high-value products while detection equipment, including magnetic grids for contact the team at [email protected] accurately splitting the product flow at the highest safety critical applications in processing industries. speeds.

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Integrated Ishida solution brings speed, efficiency and quality benefits

he installation of three high-performance Ishida them for a short time before supplying them to Tintegrated Total Packaging Systems (iTPS) at another row of 14 weigh hoppers. As soon as a leading German snack manufacturer WURZENER weigh hopper becomes empty and is available for Nahrungsmittel GmbH has improved weighing its next filling process, a signal is sent to the corre- speeds by around 75% and almost eliminated sponding pool hopper. product giveaway, while delivering higher quality The system's software then takes just a snacks with fewer rejects and less product and fraction of a second to calculate the three best film waste. This has led to a fast payback on invest- weigh hopper combinations, check them again and ment. select the combination that come closest to the The Ishida iTPS’s are part of three new required target weight. packing lines for WURZENER’s range of extruded The Ishida multihead weighers can corn snacks, including the company’s top-selling complete many more weighing cycles than peanut-flavoured Erdnussflips, onion rings and WURZENER’s previous volumetric system. For a cheese puffs. The iTPS is a fully integrated snack standard 150g bag, the company’s managing food packing system which combines a multihead director Stefan Kuhl says the weighing speed has weigher from the high-performance CCW-RV series been increased from 60 to more than 100 weigh- with the Ishida Inspira, the world's most efficient ments per minute. “The significant improvement in into each carton during end-of-line packing. There bagmaker specifically developed for snack foods. accuracy is also important to us,” he adds, explain- are 500 pre-sets to simplify product changes, while Both machines are seamlessly integrated and ing that overfilling has been dramatically cut from features such as easy forming loading and operated via a single control panel. 7.5% to almost zero. unloading, film spindle, tension rollers and a splice “Snacks, especially our Erdnussflips, are top The weighed snacks are transferred to the table light-bar enable fast product and film sellers at WURZENER,” explains Managing Director bagmaker via a high-speed parabolic chute with changeovers and increased productivity. Stefan Kuhl, adding that the company has integrated throat metal detector. “This is another In addition, the open frame structure of the “excellent market prospects” when it comes to sell- benefit of the new packing system,” comments bagmakers provides easy access for these adjust- ing to top German retailers. Stefan Kuhl. ments to take place as well as enabling efficient Because of these prospects, upgrading cleaning and maintenance. production capacity was a logical step, especially Perfect seals, free of product particles The overall result, says Stefan Kuhl, is snack replacing the company’s packing technology, which The Ishida Inspira bagmakers are suitable bags of a “higher quality across the board”, with dated back to the 1990s and was no longer for a wide range of film materials and sizes. At fewer rejects and less product and film waste. capable of meeting demand. The situation was all WURZENER, they produce pillow bags between 75g the more pressing because there were only two and 450g. Exceptional seal quality and seal integrity Bagmakers and multihead weighers from a packing lines available for three production lines. are essential, because the bags do not contain inert single supplier Each individual snack weighs just 1g, gas, meaning it is only their tight seals that prevent WURZENER uses the Ishida iTPS in a which can present a challenge for an automated the snacks from oxidising. Automatic film centring three-shift mode. The company has calculated that weighing system. It is also essential to minimise any and clamping functions ensure a consistent film its investment will pay for itself within two and a half build-up of seasoning during the flavouring process, delivery. Sealing takes place at high pressure, with years. Stefan Kuhl says he chose Ishida because of as this can reduce speed and require more frequent product or flavouring being prevented from entering the technology manufacturer's wealth of expertise cleaning. the sealing area thanks to a stripping mechanism and experience in the snacks market, as well as the and product-in-seal detection on the sealing jaws. way that the machines can be integrated. “While Fill rate almost doubled there are plenty of manufacturers of bagmakers and Funnels guide the snacks to the gantry- Simplified operations and increased rather fewer suppliers of multihead weighers, it is mounted Ishida CCW-RV multihead weigher. productivity only Ishida that offers both products as an integrated Loadcells underneath the multihead’s dispersion The bagmakers are also fitted with solution,” he points out. tables allow for a consistent product flow to the ra- controlled deflator plates to ensure consistent bag dial feeder troughs. The vibrating troughs transfer air-fill and pack thickness. This gives WURZENER the the product to a set of 14 pool hoppers, which hold assurance that the correct number of bags will fit www.ishidaeurope.com

Demand grows for improved water treatment systems

tringent discharge rules for trade effluents are fuelling enquiries into the benefits of the latest wastewater Sprocessing technology, says Axium Process. The filtration specialist has seen a rise in demand for customised membrane systems as environ- mental responsibility, operational costs, and discharge limitations put increasing pressure on companies to find improved solutions for trade effluents. Derek Davies, Business Development Director at Axium Process, said “A growing number of industrial companies need to balance their discharge consent against increased levels of production and spikes in output linked to manufacturing processes. Failure to do so can result in hefty fines, snap inspec- tions, and reputational damage. “Even similar industries have very different filtration requirements, so the ideal solution is a purpose-designed treatment process for each application. To identify and optimise the best solution, our engineers first conduct investigative pilot trials on the feed material either at our test facility in Swansea or the manufacturer’s premises. The trial results will clearly identify the main requirements for the project and associated benefits.” Advances in effluent processing techniques mean that crossflow membrane filtration can filter raw effluent and recover high quality water. It allows highly customised solutions to be developed that can meet ambitious sustainability goals. As it is a physical process no chemicals are required to separate suspended or dissolved materials. The technology has the potential to significantly reduce effluent disposal costs while recovering up to 95% clean reusable water. Water recycling systems from Axium Process can be used in almost any industry, including pharmaceutical, food, drink, textiles, chemical and automotive. They can also be used to complement other waste treatment processes such as anaerobic digestion. www.axiumprocess.com

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Microban® technology strikes a new level of clean for the food industry

he potential for food product recalls from Microban International develops built-in Regulatory compliance Tsurface or environmental contamination is a antimicrobial technologies that help to address The prevention of contamination is more constant challenge for manufacturers and caterers these challenges. Common surface disinfectants important than ever as food safety regulations who must adhere to stringent safety regulations that have limited residual activity once they dry, allowing change and, in many instances, become more govern the industry; the importance of cleaning in bacterial populations to quickly rebound, however, rigorous, and the implementation of innovative the sector cannot be over-emphasized. Microbes integrated antimicrobial protection provides an solutions to help this at each stage of the production are present all around us and can spread through additional 24/7 layer of protection against the process is actively encouraged. However, comply- various touchpoints, and many factors – from growth of bacteria for the lifetime of any surface, ing with the various regulatory requirements can reusing equipment for multiple purposes without utensil or vessel. Treated articles can be used along- prove to be a minefield for manufacturers to thorough cleaning in between, to the effects of side thorough handwashing practices and regular negotiate, not least because of stringent rules for excess moisture – can boost bacterial populations disinfection routines, enabling food industry substances in direct food contact, and the fact that and contribute to premature food spoilage. Even professionals to maintain a cleaner environment for the use of antimicrobials is controlled by different with rigorous processes in place, human error and the storage, delivery, processing, preparation and agencies – with different rules and legal limits – in lapses in cleaning protocols can still occur, resulting serving of food for human and animal consump- different countries. in food contact surfaces that might look clean but, tion. It is crucial that manufacturers of food in fact, harbour harmful bacteria. service products only use antimicrobial additives that are specifically registered for direct food contact, and can be integrated into a wide range of food service materials, including plastics, ceramics and . Microban has an in-house regulatory department that works diligently to ensure its antimicrobial additives are safe for food contact, for example, its silver-based formula is notified with the EU’s Biocidal Products Regulation (BPR) and the US Environmental Protection Agency (EPA) specifically for use with articles in contact with food. Choosing the right chemistry for the right application with full regulatory compliance and support from knowl- edgeable and experienced partners, will help the industry to guard against surface, utensil and vessel contamination for longer.

www.microban.com

EXHIBITIONS&CONFERENCES 5-7 July 2021 30 Jan - 2 Feb 2022 14-17 June 2022 FOODEX 2021 PROSWEETS 2022 EXPO PACK MEXICO 2022 NEC,Birmingham,UK Cologne,Germany Mexico City,Mexico www.foodex.co.uk www.prosweets.com www.expopackmexico.com.mx

27-29 September 2021 22-23 March 2022 23-26 October 2022 PACKEXPO LASVEGAS 2021 PACKEXPO EAST PACKEXPO 2022 LasVegas,USA Pennsylvania Convention Center,Philadelphia Chicago,USA www.packexpolasvegas.com PA,USA www.packexpo.com www.packexpoeast.com 28-30 September 2021 12-16 September 2022 FACHPACK 2021 26-29April 2022 drinktec 2022 Nuremburg,Germany ANUGA FOODTEC 2022 Munich,Germany www.fachpack.de Cologne,Germany www.drinktec.com www.anugafoodtec.com 9-12 November 2021 22-25 October 2022 ANDINA PACK 2021 26-29April 2022 süedback 2022 Bogota,Columbia LABELEXPO EUROPE 2021 Messe Stuttgart,Stuttgart,Germany www.andinapack.com Brussels Expo,Belgium www.messe-stuttgart.de/suedback/en/ www.labelexpo-europe.com 24-27 November 2021 23-26 October 2022 FOOD INDUSTRYTECHNOLOGY 12-14 May 2022 PACKEXPO 2022 SHOW KOREA 2021 LABELEXPO SOUTHEASTASIA 2022 Chicago,USA Coex Center,Seoul,South Korea BITEC,Bangkok,Thailand www.packexpointernational.com www.kfoodtech.co.kr www.labelexpo-seasia.com 2 – 6 May 2023 7-10 December 2021 14-19 May 2022 METPACK 2023 LABELEXPOASIA 2021 IFFA 2022 Messe Essen,Germany Shanghai New International Expo Center Frankfurt,Germany www.metpack.de www.labelexpo-asia.com www.iffa.messefrankfurt.com

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Minebea Intec's upgrade for checkweighers: When high speed meets precision

ith the new WZED load cell with electro- Wmagnetic force compensation from Minebea Intec, our checkweigher models receive a turbo upgrade: the new load cell with digital controller have received MID approval in the legal-

for-trade range for belt speeds of up to 3 metres Ltd Technologies BEKO © per second – this means up to 600 pieces per minute. The upgrade package contains many more features that pay off for user of high-speed applica- How BEKO’s expertise in tions. As a provider of weighing and inspection solutions, Minebea Intec is continuously working to compressed air can safeguard improve existing products as well. With its upgrade to the new generation load cell, the company has put together a complete package of features that a supplier’s contract will be included in all verifiable checkweigher models which use a high-precision load cell with lthough compressed air plays a key role in food customer wants to know what improvements are electro magnetic force compensation the future. Aand beverage production, its impact on food possible, BEKO will suggest a solution. “Because safety is often underestimated. The tough regula- every food site is different,” says Paul Mucklow, The upgrade for optimal efficiency in tory requirements to ensure health and hygiene BEKO’s Product Support Manager, “we always checkweighing standards in food processing and production are supply a customer with a one-off, site-specific The upgrade consists of three elements: one key consideration; the other is the market clout solution.” The necessary investment, e.g. in the The new WZED load cell with electromagnetic force of the major retail chains. They carry out regular equipment to generate dry, dust-free and oil-free compensation and integrated high-speed electron- audits of their food and beverage suppliers to check compressed air to meet strict food safety require- ics with digital controller. The advantages for the compliance with their extremely high standards. In ments, may not be cheap. But the loss of a key customer are therefore many and varied: for many cases contracts worth millions may be at contract to supply a major retail chain would be a lot example, the new weighing sensor in combination stake. How sure are you that your compressed air is more expensive. with the digital controller offers increased reliability up to standard? and precision. In addition, the sensor allows for an Keeping up to standard extremely low minimum weight: products from five Where contamination can occur When you ask BEKO to carry out a grams can be verified according to all standards. Contaminated compressed air in the food precautionary check on your compressed air In addition to the higher weighing speed chain is one of the ways the safety of a food or equipment, you can count on expert personnel. and increased precision, the digital controller also beverage may be compromised during production, BEKO trains its product support staff to the highest offers lower susceptibility to disturbances such as processing, handling, packaging or transporting. The standards through its own online training temperature, humidity or wind. The legal-for-trade most common contaminants are dirt, water and oil, programme, British Compressed Air Society courses checkweigher models equipped with this load cell though microbiological organisms (e.g. bacteria) and advanced training at the parent company in upgrade are, due to the reduced minimum weight, may also be a source of contamination in a Germany. “Many food manufacturers admit they very well suited for dynamic weighing with low- compressed air system. If compressed air comes don’t know enough about compressed air,” weight products, such as in the confectionery into direct contact with the food or beverage, a Matthew says. “So they come to us looking to industry or canned products, In other industries such much higher standard of contaminant control is safeguard their contracts with retailers. Our expert- as pharmaceuticals, chemicals or cosmetics manu- required. When food retailers send their auditors to ise can give them peace of mind.” facturing, the reduced minimum weight, together check health and hygiene standards at a food site, If you’re uncertain about the quality of your with support for higher belt speeds, increases the quality of the compressed that comes into direct compressed air, feel free to contact BEKO efficiency and throughput. Minebea Intec’s check- or indirect contact with the products could well be Technologies. They will send a sales engineer to first weighers are highly precise and provide reliable checked. So if an audit is due, it’s a good idea to ask check if the overall constellation of your compressed control for numerous weighing applications, the experts from BEKO Technologies to check in air equipment makes a validation test possible. “We completeness checks and filling process optimisa- advance for compliance, e.g. with the relevant ISO can first arrange a free visit by a sales engineer,” Paul tions, allowing customers to optimise their output 8573 standard. points out. “Then there’s the possibility of a free test and efficiency. – naturally without any obligation.” It could be a BEKO’s check – a pre-emptive precaution contract saver. MID approval as starting signal for high-speed “To manage food safety you have to BEKO Technologies develops, manufac- weighing measure,” says Matthew Harrison, BEKO’s Sales tures and sells components and systems worldwide With MID (Measuring Instruments Manager UK & Ireland. “Customers come to us for for optimised compressed air quality. With an Directive) certification for legal-for-trade applications, our expertise in compressed air technology and extensive program the company stands for the WZED load cell is certified for belt speeds of up because we’re known for our excellent technical compressed air technology at its best. For more than to 3 metres per second - this means processing background.” It’s only in the past two decades, three decades, our company has developed, speeds of 600 products per minute. Matthew adds, that standards such as ISO 8573 or manufactured and sold high-quality, reliable and Thanks to the integration into the weigh the Code of Practice issued by the British efficient components and systems for compressed cell housing, the new electronics of the WZED load Compressed Air Society have become the norm. air processing and condensate technology. We now cell consumes less space and at the same time “That’s probably one of the reasons why we still see offer a complete program and solutions that allow for better cleanability in accordance with Hy- food sites with very basic compressed air equip- safeguard the required quality in our customers’ gienic Design. The new housing allows for easy in- ment – and correspondingly low standards.” production processes, and make those processes stallation and improved accessibility of the load cell When a customer calls in BEKO’s product more energy-efficient. Expert advice and a qualified for servicing or in case of maintenance support staff to check the quality of compressed service are the trademark of this independent and Initially, this upgrade will reach all Minebea air at a food site, the company’s expertise and family-owned company. Intec checkweigher series.. However, this is only the experience in testing the relevant equipment are the For more information visit beginning: www.minebea-intec.com preconditions for an objective assessment. If the https://www.beko-technologies.com/en-gb/gb/.

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Enhanced freezing capabilities developed by Air Products provide a sustainability boost for food manufacturers

ew generation cryogenic freezing technology faster rate. Air Products’ new batch freezer has been Dimaco to Nhas been developed by Air Products that puts specifically designed for ultra-fast freezing or chilling efficiency at the heart of the freezing process. The of batches – ideal for those in the food service move comes as year-on-year growth in the United sector or those with discontinuous production highlight range Kingdom (UK) frozen food sector is up 13.8 processes. percent - above that of total grocery sales, accord- Neil Hansford, UK&I Freshline Applications ing to British Frozen Food Federation data. Product Line Manager at Air Products, said: “Air of high The next generation technology, which has Products has been developing innovations in the been incorporated into the company’s new food processing sector for decades, and we’re Freshline® High Performance batch freezer, pioneers incredibly proud of the latest advances we’ve made performance in terms of freezing homogeneity and efficiency, in freezing technology. Ultimately, we want to delivering a higher quality frozen product and support food producers to create the most stream- Veri-Pack helping food manufacturers to respond faster and lined manufacturing process possible, especially more efficiently to growing consumer demand for during these uncertain times. The improved quality frozen food. homogenous freeze and the improved cleanability machine vision Producers are increasingly looking to adapt delivered by the new batch freezer are great steps their operations as they place a greater emphasis forward. on sustainable working. Underpinning this desire for “More than ever food manufacturers need systems sustainability, the freezer allows operators to reduce greater control over their food processes to cater the amount of liquid nitrogen used as a coolant, to the changing needs of the market. This new imaco – part of Jenton Group – will be high- while increasing food product throughput and giving technology will bolster resilience and ensure Dlighting its wide range of Veri-PACK greater control over the freezing process. manufacturers are ready for continuing and future verification equipment at Foodex 2021. Further With an increased freezing capacity of up challenges.” underlining its commitment to helping food to 30 percent, food producers can also reduce manufacturers reduce waste and improve carbon operating costs and deliver a quality product at a www.airproducts.com footprint, the company’s high performance systems, which ensure are correct, accurately located and of pristine quality, reduce costly product rejects, recalls and repackaging. Label related defects are a major reason RMGroup’s robotic palletisers why food is returned to the manufacturer with typical errors including incorrect use by dates or missing allergen information. These can be caused create production efficiencies by operator error or printer faults during production and means otherwise perfectly good food is wasted with increased carbon footprint. As a result, it is at Radnor Hills essential to find labelling issues early in the process. Offering excellent return on investment obotics and automation specialists, RMGroup, and forming a vital link in the traceability chain, Rhas installed three of their end-of-line robotic Dimaco’s robust Veri-PACK label and data verifica- palletisers for award-winning soft drinks business, tion equipment checks the correct labels have been Radnor Hills. The move has enabled the manufac- applied and all essential pre-printed and overprinted turer to benefit from process efficiencies throughout data such as barcodes, dates, price and weight are their production. accurate and legible. It will also ensure that the Manufacturing a wide range of spring labels are correctly positioned without rips and other waters, flavoured waters, functional waters, school imperfections. compliant drinks, premium sparkling pressés, fruit Not only does Dimaco’s label verification juices and own label brands, Radnor Hills first system prevent incorrect packs leaving the factory, approached RMGroup in 2018 to investigate but it also facilitates end of line packing automation. automating an end-of-line palletising operation with Normally the manual packers are the last line of a robot arm. cases per minute; a third line was installed on defence, ensuring product is correctly labelled but if On the line, packs of needed to be Radnor’s line, involving a much higher the role is automated it removes the crucial link in palletised at a rate of 14 packs per minute. Given output of 24 packs, 12 of which needed to be the chain. Plus, the manual packers generally only the throughput and stack formats, RMGroup palletised on euro , at 20 cases per minute. check a sample of the packs for correct labelling, needed to ensure that the robotic solution could “The benefits of working with RMGroup the data they are checking against is often multi pick packs up to four at any one time, and and what we feel they particularly do well, is first unreliable and there is no record of the check then place them onto a pallet in one’s, two’s, three’s and foremost they listen to us,” said David Pope, having been made. or four’s, to keep up with the production line Radnor Hills’ general manager. “They take on board Available as off-line sampling stations, throughput. our requirements - they don't tell us what we should online systems integrated into other packaging By using ABB robot studio, RMGroup’s be doing, they listen and come back with us with machines or as independent conveyorised units mechanical design and technical department solutions to make it happen. The whole team has with reject devices, Dimaco’s Veri-PACK units are recommended the use of a bespoke gripper, been a pleasure to work with, especially the engi- capable of scanning images of labels or packaging thereby enabling the robot to stack the packs onto neers, who have been extremely knowledgeable film to detect and read characters, barcodes and pallets at the desired rate. Robot studio also helped and helpful throughout the whole process.” numbers using the best OCR (optical character RMGroup to decide which ABB robot would be best William Watkins, Radnor Hills’ Managing recognition) software available. suited for the project, thereby optimising the ROI. Director added: “I think RMGroup’s experience, Dimaco’s Veri-PACK label verification Following the success of the initial their backup and the fact that they have a very systems check text to ensure it is clear and legible installation, RMGroup has since supplied another conscientious team, means that they really make to the standard set by the customer. It then uses two ABB end-of line palletising systems at the site. sure that they don't leave you until you are Dimaco’s unique Veri-CENTRAL database, which A second was installed on Radnor’s tetra pack line, absolutely 100% happy that the machinery they’ve coordinates all data with producer and retailers’ the requirement being to palletise cardboard installed is working absolutely as you expect it to.” databases, to check the variable and non-variable from dual production lines at a rate of 6 www.rmgroupuk.com data is accurate.

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Filling of liquid Hi-line boosts powders environmental credentials owders in the conventional sense are known Pas solids. Their classic manufacturing process even further with switch to is called Powder Compaction: Dry powders are compacted with a pounder to form a solid unit (a disc or other form). Finished products are i.e. eye shadow or blush. R513a refrigerant However, in some manufacturing processes these powders are formulated in a liquid i-line Industries, an established and reputable another attribute of these class-leading dryers. For phase. This often results in complex fluid character- HUK manufacturer of high-quality compressed instance, by controlling the fan speed on the istics. The behavior is sometimes rheopex, i.e. air purification equipment, has released the 2021 refrigerant circuit there is no need for fan-pressure shear-thickening over a period of time. Shear causes version of its energy-efficient Tundra refrigeration switches, which can often become defective in the solid component to compress, the liquid is dryers. Most notable among the enhancements is a dryers of this type. The fewer moving parts, the extracted, and the product can therefore no longer switch of refrigerant to R513a in models up to more reliable the product, making it ideal for be dosed. The solution: These rheopex fluids or and including Tundra 115 (115 cfm, 195 m3/hr applications that include workshop air and machine liquid powders can be dosed using a low-shear capacity). A HFC/HFO blend, R513a refrigerant has air in general manufacturing, as well as further uses dosing method. The ViscoTec endless piston no ODP (Ozone Depletion Potential) and a much in sectors that include packaging, textile, food, principle is particularly advantageous for this reduced CO2 impact in comparison with the beverage, medical, dairy and automotive. application. It allows continuous and low-pulsation previous R134a refrigerant. As a result, customers Hi-line’s standard Tundra range is available dosing and filling. can rest assured that Hi-line is continuing its ex-stock at from the company’s Burton factory for After the actual dosing process, the inter- commitment to sustainability in manufacturing by next-day delivery. Six models in the series feature mittent dispersing phase is evaporated - the minimising its carbon footprint. suspended solids form a solid structure. In this way, The F-Gas regulation means that refriger- color gradients can be achieved in addition to ants with a GWP (Global Warming Potential) of shapes, such as lettering or patterns. Different more than 2500 are now subject to a ban. products can also be combined. However, while R134a is below this limit and The ViscoDuo VM HD, a 2-component remains legal, it is sufficiently high for the regulation Hygienic Dispenser, is used to combine different to stipulate an incremental phasing-down of products. The mixing ratio of two material compo- production quotas to help reduce environmental nents can thus be flexibly adjusted. impact. R513A is widely viewed as the optimum www.viscotec.de replacement. Importantly, R513a is an A1 safety group refrigerant and is neither toxic nor combustible. Unlike flammable refrigerants, R513a is subject to less stringent regulations in handling, maintenance intervals and compulsory leak tests, thus saving time Spiroflow and money. Switching to R513a builds on the sustain- R513a refrigerant, with dryer selection based on able credentials of the Tundra range, which is factors such as maximum compressed air flow, strengthens already renowned for its optimised energy efficiency lowest operating pressure, maximum ambient air via capabilities such as minimal pressure drop and temperature and maximum air inlet temperature. lower absorbed power. Reduced energy consump- Expert assistance from Hi-line’s applications team global customer tion is vital in today’s ultra-competitive marketplace, can help customers to select the optimum dryer. which is why Hi-line has worked hard to offer As a final note, since the UK’s departure customers a dryer solution that drives down energy from the EU, new legislation has entered force support costs. concerning the import of Freons. Any company The company’s integrated Direct importing pre-charged refrigeration equipment that eading bulk materials handling specialist, Expansion technology delivers a constant +3°C carries a CO2 impact of more than 100 tonnes per LSpiroflow, has announced that it has selected dewpoint, unlike a chilled mass dryer, which can be annum is required to register on the Environment Cairo-based firm, Alriad, as representative agents in as high as +10°C during its thermal cycle. Further- Agency website for an F-Gas account and record Egypt. Backed by Spiroflow’s extensive engineering more, the single-cell, all-aluminium heat exchanger the CO2 amount in tonnes relating to those imports. and manufacturing resources, Alriad will be module provides highly efficient heat transfer at low As Hi-line imports the refrigeration units for its providing local support to the company’s Egyptian energy cost, while a further notable energy-saving Tundra range, the company has successfully customers. attribute is the variable-speed fan, which only obtained a new licence and fully discloses its Alriad International Agencies and Trading is consumes the energy necessary to meet essential imports and volumes in order to comply completely a leader in the field of industrial processing and operational needs. with the legislation. packaging solutions. With over 40 years experience, A robust, high-quality build standard is www.hilineindustries.com their engineers are expert in understanding needs, designing solutions, consulting and supplying highest quality machines and equipment. Alriad ® collaborates with leading brands and technologies Liquibox Encore celebrates 15th anniversary across multiple sectors, such as pharmaceutical, food, commodities, chemicals and textiles indus- with 500 million items sold tries. Spiroflow’s head of export, Craig Suttle, fter designing Encore® in 2006, Liquibox® has become the leading manufacturer in the industry, said: “Alriad were chosen as a good fit with Spiroflow Asupplying over 30 million units globally each year. This easy‐to‐use connection system is ideal for based on a recommendation from one of our UK connecting bag‐in‐box to beverage dispensing machinery and continues to be the preferred choice for based partner companies, who could not speak multinational brands. highly enough of the Alriad team. After initial Created and produced at the Liquibox state‐of‐the‐art facility in Upper Sandusky (Ohio, USA), meetings with both managing director, Arshraf, and Encore fitment and connector system has revolutionised bag‐in‐box packaging ensuring precise and brand manager, Karim, it was clear that they had a controlled mixes of post‐mix syrup, pulpy juice, and highly viscous beverages, among others. The triple seal clear vision for their business and understood the design makes the system virtually leakproof and its rugged durability ensures it performs this way for years. importance of customer service and relationship Customers continue to trust Liquibox to supply the popular universal line‐side bag‐in‐box fitment building. Alriad already has extensive knowledge of and connector system for post‐mix syrups around the world. “The Liquibox advantage does not stop at our the materials handling sector based on relationships reputable product offering—our reliability, customer support and innovative research and development team they have with existing principals and customers are a priceless benefit of our value as a supplier. With a focus on partnership and commitment to sustain- going back decades. Spiroflow’s equipment portfo- ability, it is no surprise that the top beverage brands have trusted Liquibox for years,” says Kevin Grogan, lio really adds to Alriad’s already extensive offering.” Chief Commercial Officer at Liquibox.

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Considerations for effective cleaning-in-place (CIP) systems

Matt Hale International Sales & Marketing Director HRS Heat Exchangers

he production of safe food and drink products is of paramount importance to producers and maintaining hygienic – in some cases sterile – production environ- mentsT and equipment is a key requirement for modern food processing machinery. Apart from the simplest systems, most equipment today, particularly that which contains pipework, enclosed spaces and small apertures, is cleaned in situ without the need for dismantling or opening, and with minimal operator intervention – a technique which is known as Cleaning-in-Place (CIP). Cleaning (or Clean) in Place has been around since the 1950s and can be defined as a method of automated cleaning of the interior surfaces of equipment, without major disassembly. One of the most widely quoted definitions is taken from the 1990 edition of the Society of Dairy Technology (SDT) Manual Cleaning In Place, which defines CIP as: “The cleaning of complete items of plant or pipeline circuits without dismantling or Different tanks and systems will have different CIP requirements opening of the equipment and with little or no manual involvement on the part of the operator. commonly used for equipment such as piping, food safety, and by reducing the effort and down- The process involves the jetting or spraying of tanks, and fillers, and CIP employs turbulent flow or time required for cleaning, they also ensure surfaces or circulation of cleaning solutions through spraying and can also be accomplished with filling, production cycles are efficient and cost-effective. the plant under conditions of increased turbulence soaking and agitation. Because of the automated or semi-automated and flow velocity.” As well as ensuring that production equip- nature of CIP systems, they provide improved ment is hygienically clean and suitable for use, CIP control of the cleaning parameters to ensure Design considerations for CIP also plays a number of other important roles. CIP consistent results, as well as automatic record The main purpose of CIP is to remove systems should ensure that no cleaning fluids or keeping for traceability and due diligence purposes. physical dirt and residues, as well as bacteria. It is contaminants remain in the equipment – ensuring Furthermore, being automatic reduces the need for human contact with potentially harmful cleaning agents or other chemicals. However, if CIP is to be effective, not only does the CIP system itself need to be well designed, but the production equipment itself needs to be designed from the beginning with effective CIP in mind. Equipment and machinery must be hygieni- cally designed and easy to manage, maintain and audit. Because of the specialised and custom nature of much food and drink processing machin- ery, some CIP systems will be designed specifically for a particular system or piece of equipment, although with careful design it is not uncommon to install a dedicated CIP system, such as those avail- able from HRS. The design process must not only ensure effective cleaning but should also be as efficient as possible in terms of water, chemical and energy use. Considerations for the equipment itself include areas such as surface roughness, clean welding and the prevention of inaccessible areas or corners where dirt and/or cleaning chemicals may build up. Reliability is also an important consideration and CIP systems must be designed to work for as long as the working lifetime of the equipment involved. It is also important to consider how user-friendly the control systems for the CIP are. For example, are they part of the overall control interface or a separate system? Another key element of an Many food systems, such as the HRS Aseptic Block, will often include integrated CIP systems effective system is monitoring and validation of the

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cleaning results for traceability and due diligence purposes, and from the beginning the design of the equipment should allow this to be done in an effective manner.

Typical CIP processes Most CIP employs a similar set of opera- tions, including: • Pre-rinsing – to remove large debris and residues • Detergent cleaning – to remove attached dirt and soiling using a caustic detergent • Rinsing – to remove detergent and dirt • Optional acid cleaning – if required to remove scaling or alkaline residues • Rinsing – to remove the acidic cleaning agent • Disinfection – heat or chemical treatment to disinfect the equipment • Final rinse – to remove all traces of chemicals and prevent contamination These steps may be combined or used in different ways. For example, using detergent at high temperatures may clean and disinfect equipment at the same time, or using steam may reduce the need for chemical detergents. Depending on the design of the system, and the risk of contamination, cleaning solutions may be reused multiple times or discarded immediately. There may also be differences between CIP and SIP (sterilise-in-place) systems. While the actual cleaning regime used will depend on a number of factors, including the risk HRS produces a range of dedicated CIP and SIP systems category of the food or drink product, the physical and chemical properties of the product, and the design of the machinery in question, in many Where detergents are required, one of the HRS CIP systems situations it is preferable to rely on water alone most common is caustic soda (NaOH), although HRS offers two types of CIP (and SIP) (together with temperature, pressure and agitation) many other alkali- and acid-based chemicals are systems. The first are those which are integrated into rather than additional cleaning chemicals which available depending on the nature of the product other systems, such as HRS pasteurisers and could present a contamination risk. In general, the and residues which need to be cleaned. Alkali sterilisers, as well as our Aseptic Block Series and higher temperatures and greater kinetic energy materials are generally more effective against aseptic fillers, for example. The second is the HRS provide more efficient cleaning, but the duration of proteins and fats, while acids perform better where series of stand-alone CIP and SIP systems. These the CIP cycle will be optimised according to the salts need to be removed. For sugars, water remains are available with single (ST) or multiple tanks, properties mentioned above. one of the most effective cleaning mediums. which are heated with an HRS K Series heat exchanger. Fully skid-mounted and modular design enables for quick and easy site installation, and the fully automated systems are supplied with a programmable logic controller (PLC) system, which can operate on its own, or be integrated into the Enhanced heat transfer factory’s main control system. in a smaller package

RS Heat Exchangers has introduced the in the same model heat transfer is more efficient. new C Series of industrial multitube heat This results in a more compact unit as the overall www.hrs-heatexchangers.com exchangers with a smaller tube diameter length of the heat exchanger can be reduced for a to improve heat transfer in certain given capacity, meaning that C Series units with situationsH and create a more compact unit. The new smaller tubes can be produced for areas where the Located in the UK, HRS Heat Exchangers is part of the C Series further increases the number of models in available space for installation is restricted and a larger HRS Group which operates at the forefront of thermal the HRS Industrial Multitube range. K Series may be unsuitable. technology, offering innovative heat transfer solutions The HRS C Series is suitable for applications Matt Hale, International Sales & Marketing worldwide across a diverse range of industries. With with low to medium viscosities, as well as heating Director at HRS Heat Exchangers, explains: “The almost 40 years’ experience in the food sector, special- CIP fluids and general industrial applications. Based standard internal tube diameter of our K Series of ising in the design and manufacture of an extensive range on the proven and well-established K Series of industrial heat exchangers is 18mm. In the past, of turnkey systems and components, incorporating our Industrial Multitube heat exchangers, the new C where clients have wanted a smaller tube diameter corrugated tubular and scraped surface heat exchanger Series also features HRS’s corrugated tube technol- for a specific project, we had to produce it as a technology, HRS units are compliant with global design ogy which increases heat transfer and thermal special item. However, we are now able to offer the and industry standards. HRS has a network of offices efficiency while also minimising the effects of C Series with 12mm tubes as a standard option, throughout the world:Australia,New Zealand,UK,Spain, fouling. The new standard option is expected to be meaning shorter production lead times and USA, Malaysia and India; with manufacturing plants in popular for use with industrial hot water and steam competitive pricing.” the UK, India and Spain. applications. As standard the C Series is manufactured The smaller tube diameter means that from stainless steel, with all standard connection more tubes can be fitted into each unit, meaning that types available. hrs heat exchangers

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Bühler’s moulding solution ChocoX is ready for customers

hocoX (pronounced “Choco Cross”), Bühler’s new moulding line with an entirely modular approach, is now entering sales. Following a plug-and-produce concept, the Cnew moulding line marks a breakthrough in the industry with its completely modular approach. ChocoX can be installed on site very quickly, reducing installation time by up to 80%. In addition, ChocoX slashes the time for a line expansion by half. Bühler has already installed the first line, which offers flexibility for super-fast adaptations of unlim- ited variations of chocolate products, addressing the consumer need for individualized products. Thanks to its entirely modular approach, ChocoX’s line arrangement can be used like a toolbox. Each module is built on wheels. This allows for easy reconfiguration of the sequence and, thus, more product variety. It takes 30 to 120 minutes to arrange new processes, depending on the sequence changes. And line extensions are ready in half the time than other solutions. “We can now offer ChocoX commercially to our customers. They will not only be more agile in their production set-up and their daily operation, but they can also take up consumer tastes much quicker than ever new ChocoX, however, Bühler is setting new Thus, the new ChocoX provides for a considerable before while drastically increasing their efficiency,” standards. All modules work without chains. In reduction of downtime thanks to less cleaning and says Fritz Dorner, Head of Business Unit Confec- addition to increased food safety, the chainless line maintenance efforts needed. tionery. design lowers the maintenance efforts. Cleaning Bühler has included a highly efficient time per module is only 30 minutes, also because Reduced footprint and quick on-site buffering system, which makes ChocoX almost there are no installations underneath the deposit- installation unstoppable. This buffering system makes the ing sections. “Large doors offer free accessibility to all Thanks to integrated control that extension with an external buffering system obso- modules from the front and the back,” says Frank replace all central switch cabinets, the new ChocoX lete and offers exceptional cost advantage. More- Huperz, Head of Technical Operation. comes with a reduced footprint. Optimized shaking over, the process keeps the important thermal The new ChocoX lets operators take out modules shorten the shaking time, and the consistency at an ideal level, including the transition the depositor and demoulding internals which are decreased cooling volume adds to the line’s lower to packaging. The smart buffering reacts to the normally hard to reach. The demoulding section, for energy consumption. packaging output, so the new ChocoX can keep example, comes with an extendable quick-change Together with its customers, Bühler can set running even during a stop in the packing process. system on wheels. In general, “depositing tool up the new ChocoX and launch its operation on site The fully automatic mould handling system further changes can be done while the modules are within one week. Thanks to standardized self- increases the line’s efficiency. running empty – with the highest level of safety,” contained modules, assembling and removal of Huperz adds. each module takes less than 30 minutes. Bühler Less cleaning and maintenance Finally, also the cooling coils offer easy was able to significantly shorten the delivery time of Another highlight of ChocoX is its hygienic access from both sides. The completely new standard modules. design. Moulding lines are prone to getting dirty cooling technology relinquishes the complicated, Visit the ChocoX website to learn more quickly and often they are hard to access. With the hard-to-clean, and voluminous Paternoster system. about Bühler’s plug-and-produce solution for moulding that cuts changing times to mere minutes. For more information about Bühler partnerships and product launches, visit the Bühler Virtual World 2021 website. For the Bühler Virtual World media conference, please register with the following link: Registration for Bühler Virtual World media confer- ence.

www.buhlergroup.com

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Camera-based cap control with artificial intelligence

trong price pressure combined with high quality requirements - the beverage and industry faces the classic dilemma of many industries. This is also the case in the Squality control department of a French manufacturer of plastic caps. Reliably detecting cracks and micro- cracks on plastic caps in 40 different colours and shades running at high speed on a production line is a real challenge. APREX Solutions from Nancy, France has successfully achieved this goal with the help of image processing technology and artificial intelligence. The basic images are provided by a USB 3 industrial camera from IDS Imaging Development Systems GmbH. SOLOCAP is a subsidiary of La Maison Mélan Moutet, "flavour conditioner since 1880" and manufactures all types of plastic caps for the food sector at its industrial site in Contrexéville. Among them, a top-class suitable for any or PET bottle. Thanks to a clampable lamella ring arranged around the bottle collar, it enables simple, fast, absolutely tight and secure seal. However, the slats must be reliably and extremely carefully checked for cracks, tears and twists during production. This is the only way to guarantee absolute tightness. The previous inspection system could not one camera is needed for this. However, APREX system and are immediately ready for use, as meet these high requirements. APREX Solutions TRACK C&M could handle up to 5 cameras. Romain Baude confirms: "The excellent colour realised the new solution with artificial intelligence “The difficulty of this project consisted reproduction of the UI-3280CP-C-HQ and its high individually on the basis of in-house software mainly in the very subtle expression of the defects resolution of 5 MP were decisive factors for us in algorithms. The necessary specifications were we were looking for and in the multitude of colours. choosing the camera. At the same time, the model developed in advance in cooperation with the With our software suite, it was possible to quickly set enabled a quick, uncomplicated integration into our customer. This also included several inspection up an image processing application. Despite the system." stages, one of which, for example, was the reject complexity," explains Romain Baude - founder control to avoid false reports. The introduction took APREX Solutions. The image from the camera Outlook place in two phases: provides the basis for the evaluations. It captures Anthony Vastel - Head of Technology and First, the specific "SOLOCAP application" every single cap directly in the production line at Industry at SOLOCAP - sees a lot of potential in the was trained with the help of the intelligent APREX high speed and makes the smallest details visible new inspection system: "APREX's AI-based Track AI solution. The software includes various to the software. approach has opened new doors for our 100% object detector, classifier and standard methods that vision-based quality control. Our requirements for operate at different levels. Networked accordingly, One crucial component: the camera product safety, but also for reject control, especially they ultimately deliver the desired result tailored to The UI-3280CP-C-HQ industrial camera in the case of false reports, were quickly met. We the customer. Four control levels with several test integrated into the system with the 5 MP IMX264 are convinced that we can go one step further by points guarantee a reliability rate of over 99.99%. CMOS sensor from Sony sets new standards in continuing to increase the efficiency of the system In the second step, this application was terms of light sensitivity, dynamic range and colour at SOLOCAP and transferring it to other production implemented in the production line right after the reproduction. The USB 3 industrial camera provides lines." AI offers quality assurance, but also all other first assembly run with APREX Track C&M. The latter excellent image quality with extraordinarily low-noise industries in which image processing technology is was specially developed for the diverse image performance - at frame rates up to 36 fps. CP stands used, new, undreamed-of fields of application. It processing requirements in the industrial sector. This for "Compact Power". This is because the tiny pow- makes it possible to solve tasks in which classic, includes, among other things, the control and erhouse for industrial applications of all kinds is fast, rule-based image processing reaches its limits. Thus, safeguarding of a production line up to the reliable and enables a high data rate of 420 highquality results can be achieved with compara- measurement, identification and classification of MByte/s with low CPU load. tively little effort - quickly, creatively and efficiently. defects in the production environment. The software Users can choose from a large number of APREX Solutions and IDS have recognised suite delivers the desired results quickly and modern CMOS sensors from manufacturers such this and offer solutions with intelligent products that efficiently, without time-consuming development as Sony, CMOSIS, e2v and ON Semiconductor with make it easier for customers to enter this new world. processes. After a short training of the AI methods, a wide range of resolutions. Its innovative, patented Image processing and AI - a real dream team on the complete system is ready for use at the housing design with dimensions of only 29 x 29 x course for growth... customer. In the case of SOLOCAP, it combines an 29 millimetres makes it suitable for tasks in the fields IDS UI-3280CP-C-HQ industrial camera, powerful of automation, automotive, medical technology and ring illumination and a programmable logic life sciences, agriculture, logistics as well controller (PLC) to provide comprehensive control as traffic and transport, among others. Screwable over all inspection processes. cables ensure a reliable electrical connection. At the same time, it records all workflows Thanks to the IDS-characteristic plug & play principle, in real time and ensures complete traceability. Only the cameras are automatically recognised by the www.ids-imaging.com

www.innovationsfood.com May 2021 Innovations in Food Processing & Packaging 15 KHS-3:Layout 1 14/5/21 08:50 Page 2

Growth market for sensitive products: KHS provides numerous innovations for system solutions

t is often a combination of small things that have a big impact, as is the case when filling sensitive beverages into PET and HDPE bottles. Here, with a whole range of innovations Ifor its system solutions KHS provides greater efficiency, more flexibility, increased ease of opera- tion and optimum product safety. Mixed milk beverages, juices, smoothies, iced teas and near-water products are in – and the list of sensitive beverages continues to grow. They make high demands of hygienic filling so that the consumer can enjoy them fresh. “When filling and capping beverages so as to prevent recontamina- tion, filling under aseptic conditions especially is a gentle process,” explains Manfred Härtel, filling product manager at KHS. There are hardly any alternatives to this technology. “With over 25 years of experience KHS is a real pioneer and specialist when it comes to hygiene and freshness. This is also demonstrated by the fact that we offer our customers a full range of systems tailored to suit very different requirements.” Proven technology, further developed to include numerous innovations: the KHS Innofill PET ACF-L linear aseptic KHS technology is always state of the art in the assembly shop regarding the task on hand, namely the sterile beverage filling of sensitive products, and continu- ously ensures the best possible hygienic conditions, transfer module that harmonizes the continuous As filling product manager as Härtel explains. Nevertheless, KHS is constantly PET bottle flow with the stepped filling process. This striving to further improve its lines and machines. At is done with the help of a transfer carousel that at KHS, Manfred Härtel is the moment, a total of seven optimizations for the separates the into units of ten. During a responsible for the entire modular KHS linear aseptic filler are helping to brief stop phase these are removed by grippers and filling technology portfolio, further boost its efficiency and flexibility in particular. placed in the filler’s carrier plates. There are three including aseptics Most machines can be retrofitted with the further variants of the module: one for blocking with a developed components. stretch blow molder, a second with an additional discharge to a Plasmax machine and a third Variable aseptic block with an extra bottle infeed that enables the filler to KHS’ linear aseptic fillers can be blocked process both PET and HDPE bottles. designs rapidly increasing, systems have to be more with a rotary stretch blow molder – in this case, an and more flexible. Unlike in the past, following a InnoPET Blomax V – to form an extremely compact Optimized bottle infeed format changeover the bottle infeed is now no unit. For this purpose, KHS has developed a With the number of bottle formats and longer set up in a repetitive process that involves loosening and fastening screws, running tests and making fine adjustments. Instead, handwheels marked with scales permit the exact height and diameter of a container to be easily configured and ensure that these settings can be reproduced at all times. This reduces the time for format changeovers by up to 40%.

Optional flexible servo capper Instead of one drive for all ten capping heads, each capping head is equipped with two servodrives apiece. While the first drive lifts and lowers the capper cone, the second drive controls the capping rotation. The servodrives are pro- grammed on the HMI. Automated conversion and the reproducibility associated with this allow different caps to be used, thus increasing flexibility without the operator having to make any manual adjustments. The parameters needed for correct capping of the PET bottles are stored in what are known as cap recipes; each cap used can be individually configured.

Improved bottle fixing Bottle grippers act as an anti-twist lock that With their larger contact surface, improved bottle grippers prevent unwanted rotation of the container during capping holds the container in place just above its base while

16 Innovations in Food Processing & Packaging May 2021 www.innovationsfood.com KHS-3:Layout 1 14/5/21 08:50 Page 3

for maintenance and overhauls of up to 20% within five years. Aseptic filling technology from KHS is complemented by an extensive portfolio of proven process engineering machines. “We provide systems and solutions from a single source,” Härtel emphasizes. “These range from the blending of components in the syrup room through deaeration and aseptic flash pasteurization just before filling to chunk dosing in a dual-flow process.”The Dortmund company thus provides the full bandwidth of technologies and services needed to make the increasingly popular beverages in the sensitive product segment – from acceptance of the raw material concentrate through design of the bottles and their components to filling and packaging of the product. The linear aseptic fillers from KHS

the screw capper screws the bottle cap closed. KHS New ring gap filling valve for pulp and fibers has now replaced the previous circular rubber If the portfolio requires it, beverages with bumpers held by one arm respectively by much pulp and fibers can be processed by the new ring larger half-shells that are attached to two arms each. gap filling valve without any loss of performance. The effect is similar to holding a bottle with two Products with fibers 15–20 millimeters long and a hands instead of with four fingers: the larger high pulp content can even be filled without the contact surface reliably prevents unwanted rotation machine becoming blocked or clogged. As opposed of the container. The bottles are correctly capped; to the usual filling valves with a gas lock, on the new the number of leaky containers channeled out and valves the valve cone is placed directly at the www.khs.com thus the reject rate are reduced. discharge so that nothing sprays or drips. What’s more, the filling jet is so homogenous and stream- Switching valves for optimum filling behaviour lined that a lot less foam forms in the bottle. The KHS Group is one of the leading manufacturers of Increasing product diversity in the filling and packaging systems for the beverage and liquid beverage industry means that some products are Longer maintenance intervals food industries. The KHS Group includes the following more challenging to fill than others because of their Whereas in the past maintenance was companies: parent company KHS GmbH and numerous foaming properties. Flexibility is called for here. A required at relatively short intervals for microbiolog- subsidiaries outside Germany, located in Ahmedabad new switching valve controls the volume of the ical reasons, with each session lasting five to eight (India), Waukesha (USA), Zinacantepec (Mexico), São inflow to the actual filling valve and thus permits a hours, maintenance intervals have now been Paulo (Brazil) and Suzhou (China). KHS manufactures total of four different infeed speeds. If the infeed is lengthened so that machines only need to be modern filling and packaging systems for the high- slower or at a lower volume, the amount of serviced once or twice a year. Thanks to improved capacity range at its headquarters in Dortmund,Germany, foaming is reduced. The infeed speed is stored in hygiene, increasing experience in the operation of and at its factories in Bad Kreuznach, Kleve,Worms and the product recipes; there is no need for manual machines and modern materials such as PTFE Hamburg. The KHS Group is a wholly owned subsidiary conversion. This improves filling accuracy and (polytetrafluorethylene or Teflon), KHS has been of the SDAX-listed SalzgitterAG corporation.In 2019 the means that the filling volume can be more easily able to reduce its safety buffer down to a reason- KHS Group and its 5,149 employees achieved a turnover reproduced. Foaming in the bottle during filling is able level. Now four times longer, these intervals of around €1.260 billion. also minimized. This results in a stable output of follow on from one another and include all tests beverages with different properties, in turn boosting previously performed during maintenance. This efficiency and the flexibility required to fill a wide gives beverage producers much higher machine assortment of products. availability. Operators also profit from cost savings khs group

Supply chain sustainability "must become cultural” for food processors, says Schoeller Allibert UK move ever closer to Net Zero targets, it’s vital that ments. ood processors need to remain focused on the the sector keeps its foot on the accelerator. We are Solutions developed by Schoeller Allibert Fwider supply chain as a ‘sustainability shifts to now at a stage where the demands of the – including an expansive range of boxes, pallets, become cultural, not just process-led’ says Schoeller consumer are influencing sustainability policies containers and dollies - are designed to help Allibert UK, a leading manufacturer and supplier of higher up in the value chain than ever before. operators increase supply chain efficiency, make returnable and recyclable plastic packaging solutions Shoppers want assurance that their purchases have better use of space and reduce food waste. In to the food processing sector. a low carbon footprint overall, not just the end response to growing automation across food Jon Walkington, Sales Director at Schoeller product and packaging in their hands. processing facilities, Schoeller Allibert UK has also Allibert UK, comments: “The environmental foot- “The consumer is powering sustainability developed full integration of tracking systems such print of the food manufacturing sector is firmly back through the wider food processing supply chain. as RFID tagging. in the spotlight. For many brands, sustainability took Eco-friendly operations, now more than ever, must Walkington concluded: “For continued a back seat to volume over the last year, but as we be treated as ingrained business culture. Innovation momentum, we cannot treat sustainability in begins from the top down – how brands are isolation– it takes full supply chain integration to be tackling goods handling, logistics and warehousing meaningful. As a leading name in returnable transit has real bottom-line impacts when the consumer packaging, we champion its tremendous benefits in is so switched-on to ‘greener’ thinking.” terms of cost efficiencies, recyclability and sustain- Schoeller Allibert UK, which supplies ability. Embracing the benefits of robust, well robust returnable and recyclable transit packaging designed, stackable and versatile containers to to the food manufacturing and processing sector, manage the complexities of today’s high-pressure has supported brands looking to drive sustainability food manufacturing industry is vital to protect the even deeper into business operations. Its portfolio bottom line and the planet!” includes the pioneering and often-imitated To find out more about the latest innova- Maxinest® stacking containers, created to add value tions in RTP from Schoeller Allibert, please visit in even the harshest of manufacturing environ- www.schoellerallibert.com/uk

www.innovationsfood.com May 2021 Innovations in Food Processing & Packaging 17 OMRON:Layout 1 14/5/21 08:52 Page 2

Cobot palletiser set to revolutionise robotic uptake

MRON and Reeco have taken collabora- tive robotics innovation to the next level with the development of the RB1200 cobot palletiser that costs up to 50% less andO has a 60% smaller footprint than a conven- tional robot palletiser. These game-changing metrics have a radical impact on project payback, making end-of-line robotic automation economically attractive to producers of all sizes for the first time. “The concept of collaborative robots working alongside humans has already been proven in automotive, warehousing and fulfilment environ- ments. We believe the time is right and the tech- nology is ready for this next-generation automation approach to be adopted for palletising tasks across a range of industries, from food and drink to personal care and pharmaceuticals,” comments Dan Rossek, Marketing Manager for OMRON UK. He continues: “Designed together with our solution partner Reeco Automation, the RB1200 has the potential to revolutionise palletising. Our offering is unparalleled in terms of its size, afford- ability and agility. The ease with which it can be set up for different products and layouts and redeployed around the factory floor is phenomenal.”

Cobots replace robots Although a mainstay of FMCG production The RB1200 cobot is fitted with a universal end-effector which lines for many years, robot palletisers take up be a huge undertaking, requiring a significant can handle 90%+ of box-based products considerable floor space, are complex to specify and logistics effort and considerable time,” explains Dan. programme, and are almost impossible to redeploy Measuring just 2.2 x 3.2m, the RB1200’s footprint is 60% to another location, making them cost-prohibitive for Changes at the touch of a screen smaller than a typical 4x4m cartesian palletiser many SMEs. Not only is it easy to relocate the RB1200, In contrast, Reeco and OMRON’s RB1200 but product, pack and layout configuration changes cobot palletiser is a compact plug-and-play system can be completed in minutes using Reeco’s that can be easily switched between lines. This EasyStack visual software. No programming skills or ensures users can maximise their investment by robot experience is required to redesign a pallet providing flexibility to cope with rapid changes in pattern – the operator simply has to enter a few demand across the factory. parameters such as box and pallet dimensions, As a leading company of automation centered on its define the layout for the first and second layers, then proprietary Sensing & Control + Think technologies, 60% smaller repeat for as many layers as required. OMRON Corporation is engaged in a wide range of Without the need for all-round guarding, businesses, including control equipment, electronic the RB1200 measures just 2.2 x 3.2m, which Off-the-shelf solution components, social systems, healthcare, and the equates to a 60% size reduction versus a typical From order to installation within 2-3 weeks, environment.In the field of industrial automation,OMRON 4x4m cartesian palletiser. The cobot is inherently the RB1200 slashes the wait time of a traditional supports manufacturing innovation by providing advanced safe, using optical laser scanners to monitor the robot by months. As well as minimal programming automation technologies and products,as well as through immediate area and stopping operation if potential requirements, to achieve fast fulfilment the extensive customer support, in order to help create a human contact is identified. plug-and-play cobot is fitted with a standard, unique, better society. universal end-effector which can handle 90%+ of www.industrial.omron.eu Up to 50% less expensive box-based products. Reeco Automation can also Based on a standardised platform and provide custom-designed tooling for special without the need of a heavy-duty sub-frame to application requirements. omron support a large robot arm, the RB1200 has a more streamlined automation infrastructure at a dra- Automation for all matically reduced cost. The purchase price is up to With a maximum payload of 10 kg and a Specialising in the design,development and integration of 50% less than a comparable traditional palletiser cycle time of 12 picks per minute, the RB1200 bespoke cobot solutions, REECO focuses on providing robot, making it a viable investment for many cobot palletiser is ideally suited for small to medium customers with turnkey automation applications that businesses that have previously ruled out robotics volume producers. provide real value by reducing production costs,increas- on cost grounds. As OMRON’s first cobot solution partner, ing efficiency and enabling flexibility by integrating around Reeco is looking forward to presenting the RB1200 existing equipment, operators and processes. REECO’s Maximum agility to the market in conjunction with OMRON. “The offering continues to expand as the market continues to The cobot’s intrinsic flexibility also c cobot palletiser is an off-the-shelf, market-ready innovate,providing customers with advanced automation ontributes to a compelling payback case; the lack of solution that represents great value for money, with equipment, technologies and expert support through the extraneous kit makes the RB1200 easy to move no hidden costs in design or engineering. Leasing supply of bespoke solutions and specialised automation between lines. options and a fixed service contract are also products. “The RB1200 is light and transportable; it available, making next-generation, end-of-line www.reeco.co.uk can easily be moved by pump truck to another line automation a reality for FMCG producers of all within minutes. By contrast, to redeploy a traditional sizes,” says Reeco Managing Director Llewelyn Rees. robot palletiser to another part of the factory would www.industrial.omron.eu reeco

18 Innovations in Food Processing & Packaging May 2021 www.innovationsfood.com ENGILICO:Layout 1 14/5/21 08:54 Page 3

Hyperspectral seal inspection system easily detects contamination in rigid plastic packaging, even through printed film

elgian seal inspection specialist Engilico visible range to include near-infrared frequencies. has introduced a new system for in-line Infrared waves are able to penetrate and verification of the integrity of hermetically as different materials react uniquely to infrared light, sealed plastic rigid packaging containing they can be reliably detected based on their specific food.B In addition to the established SealScope™ properties of transmission, reflection and absorption automated system for seal quality control of flexible of these wavelengths. The spectrum of each pixel in plastic packaging, the company has introduced a the acquired image is analysed to provide informa- new system, HyperScope™, for checking the seals tion about chemical composition. Any undesired on rigid trays, pots and other thermoformed materials in the plastic seal area such as meat, fat or packages sealed with plastic film, even when oil can be detected in high contrast, even through an printed. Product in seal often causes issues for opaque top film, and is shown on the control screen standard vision systems, as there might not be in a different colour. enough contrast between the plastic film and the It is noteworthy that hyperspectral imaging contamination. In case of packaging with a printed is perfect for this quality control process. Shorter top film, often used for more luxury products, the electromagnetic wavelengths from the other side of contamination can even not be seen. the visible spectrum, such as X-rays, are good for Engilico has solved the problem by seeing metal parts, for example, but have too much Engilico's new HyperScope in-line seal quality inspec- harnessing the power of hyperspectral imaging, penetrating power to resolve materials whose tion machine for rigid plastic packaging. which analyses a wider light spectrum than just the

density difference is small, such as plastic and food. Typical applications are 100% inspection of trays containing meat, cheese, fruits, ready meals and snacks. Investment in an automated quality control system directly integrated at the end of a food production line pays for itself quickly, as it minimises the production of faulty product and automatically rejects any packages that have passed through with an unsatisfactory seal. Additionally, the costs associated with line stoppage, manual re-pack- aging, food wastage and machine cleaning are avoided. Failure to detect contamination in a seal is a serious issue, as if the package finds its way onto Unlike a standard camera image built from three wavelength ranges (RGB), which only provides visible information, a a supermarket shelf, air ingress and leakage would render the consumption date advice on the label hyperspectral 3D map is built from hundreds of images in different wavelength bands. Every pixel is analysed individ- irrelevant. Even worse, it could result in health issues ually and differences in materials or chemical composition can be detected, even through printed film. for the consumer. In either case, an expensive product recall and potential brand damage are likely. Engilico's hyperspectral system is installed over an existing or its own conveyor belt and inspects every individual package at a rate of up to 160 per minute. HyperScope instantly recognises package orientation, processes the image and analyses the seal quality, the information being displayed on an operator-friendly touch screen. All production-related data such as product type, number of good/bad packages, date and time is saved for subsequent production quality analysis. In general, in-line seal inspection enables customers to realise better packaging quality, higher packaging productivity, end-of-line automation and a reduction in manual inspection.

A point along the seal with contamination has a different hyperspectral profile, indicating where the plastic package is compromised and leakage is likely to occur. It is shown on-screen as a high contrast area in a different colour. www.engilico.com

www.innovationsfood.com May 2021 Innovations in Food Processing & Packaging 19 KEY TECHNOLOGY:Layout 1 14/5/21 08:55 Page 2

Key Technology introduces Global View™

ey Technology, member of the Duravant family of operating companies, introduces Global View™, a patented new software- driven capability for their VERYX® digital sorters.K Global View combines product data collected from multiple sensors with different vantage points around the product stream and enables the sorter to consider each object in its entirety when making classification and sort decisions. This unique software optimizes product quality, increases yield, collects more sophisticated data and reduces manual inspection. “Without Global View, the sorter analyzes information from each sensor view independently, thereby relying on knowledge about a single side of an object to make an accept or reject decision. With Global View, multiple views of the same object are stitched together, and the accept or reject decision is based on information about the entire object,” explained Stephan Westcott, Global Automated Inspection System Product Manager at Key. “This allows us to recognize defects based on an analysis of the total, multi-sided surface area of an object. Food sorting technology has struggled to control Global View enables a sorter to consider each object in its entirety when making classification and sort decisions these types of defects until now. It’s very exciting and creates new possibilities for quality control.” of foreign material (FM) remains unchanged – the which increases the processor’s yield while still Global View applies a sorter’s ‘classification sorter targets all FM for removal, as always. meeting the required quality grade. logic’ to the combined object data from more than For example, almonds are graded with a Gummy candies provide other examples. one view to better remove defects, make grade quality score based on the percentage of scratched If good gummies are defined as having white foam and/or collect more complete data about food skin for each nut, among other things. If a grade on one side and a different, coloured ingredient on products. Combining data from multiple cameras, allows up to one-quarter of a nut’s total surface area the other side, whole-object inspection is needed lasers or hyperspectral sensors with different to be scratched, a traditional sorter equipped with to detect whether one ingredient has been under perspectives, defects can be defined by colour, two sensors considers each view independently – applied, thereby rendering the candy piece defec- size, shape, structural properties and/or chemical this requires processors to reduce the allowed tive. One customer makes gummy candies in the composition, depending on the sensor types and tolerance for each view in case both sides have shape of a dog with a red nose applied on one side. the needs of the processor. By considering the total some scratches, or else they run the risk of accept- To identify those with missing noses, the front and surface area of an object and, when needed, ing defective almonds. Global View considers front back of the candies need to be considered in determining the ratio of defects or other character- and back views together and calculates the true unison. For this manufacturer and others with istics to that surface area, Global View introduces a scratched surface area of the nut. This unique similar inspection requirements, Global View new way to manage product quality. The handling capability enables more accurate sort decisions, improves quality and reduces reliance on manual inspection to minimize labour. In addition to helping a sorter make more intelligent accept/reject decisions, Global View can be harnessed to collect valuable data based on each object’s entire surface. Equipped with Key’s Information Analytics software, the sorter can collect data about the sort process and about each and every object flowing through it, whether the data is used to make sort decisions or not. For some applications, Global View adds value to Information Analytics by revealing new patterns, trends and associations. Global View software is unique to Key’s VERYX digital sorters. As the world’s only sorter that achieves total in-air inspection on every platform configuration, each sensor sees the same object in the same place at the same time, which facilitates the fusing of each sensor’s data into whole-object views. Key manufactures VERYX in both the U.S. and Europe and supports customers worldwide through its global sales and service network.

KEY TECH LOGO

Gummy candy manufacturers benefit from Global View’s whole-object inspection For more information on VERYX, visit www.key.net/products/veryx.

20 Innovations in Food Processing & Packaging May 2021 www.innovationsfood.com GEA-1:Layout 1 14/5/21 08:56 Page 3

GEA has the cure that will inject value into bacon

o overcome the challenges faced by food producers curing bacon products, leading technology provider GEA Food Solutions has developed an advanced injection Ttechnique which contributes to high brine retention and low standard deviation – crucial to ensuring consistency of distribution, quality and yields. GEA’s Multijector, an automated injection system, introduces brine in a high-density injection pattern, combined with low injection pressure, avoiding injection points becoming saturated which can cause the brine to leak out. A higher density of needles allows less brine per needle to be injected at a lower pressure. Benefits for bacon producers using a high- density injection pattern include improved slicing yield, reduced post-injection purge and drip loss, optimum moisture and salt levels, while avoiding injecting air or foam, ultimately extending the of bacon by several weeks. Reduced purge not only impacts yields, it also means reduced down- time spent cleaning the equipment and surround- ing environment. GEA product expert, Wim Sturm, said: “Customers will not purchase bacon products which have inconsistent appearance, discolouration or a GEA MultiJector. Thanks to the Time-in-Meat tech- short shelf life. The distribution of brine should be nique, the needles stay in the product longer during even, consistent and well retained within the injection, which leads to better brine uptake and product. A tight needle pattern, in combination with more even brine distribution at a low injection immediate post-injection handling such as shaking pressure. As a result, product quality and consistency or vibration, helps needle marks to be closed and are significantly increased, and higher efficiency and the brine is more easily absorbed by the meat.” yields can be achieved. The quality of injection needles used also The meat and poultry sector can doubtless has an impact upon the efficiency of the process as benefit by taking greater control of the brine injection well as the quality of the end product. Bent needles process. This is driven by an understanding of the lead to under injected and over injected areas in the process and the quality of the equipment deployed final product, which causes inconsistent product to carry out the tasks involved - to ensure the quality, short shelf life, and can cause a tiger stripe benefits extend from the processor to the reseller pattern. GEA OptiFlex needles are stronger than and ultimately to the all-important end consumer. traditional stainless steel, and have the superior property of recovering their shape time and time again instead of becoming deformed or bent. Time-in-Meat is a GEA injection precision technique based on the specific combination of stroke height and injection cycle time, both optimised for each product type, running on the www.gea.com

GEA is one of the largest suppliers for the food process- ing industry and a wide range of other industries that generated consolidated revenues of approximately EUR 4.6 billion in 2017. The international technology group focuses on process technology and components for sophisticated production processes in various end-user markets.The group generates around 70% of its revenue in the food and beverages sector that enjoys long-term sustainable growth.As of December 31,2017, the company employed almost 18,000 people worldwide. GEA is a market and technology leader in its business areas.The company is listed on the German MDAX (G1A, WKN 660 200).In addition,GEA’s stock is included in the MSCI Global Sustainability Indexes. Further information is available on the internet at gea.com. gea

www.innovationsfood.com May 2021 Innovations in Food Processing & Packaging 21 FORTRESS TECH-3:Layout 1 14/5/21 08:58 Page 2 The chemistry of contaminant detection

elearning product characteristics when inspecting food applications is a common challenge for manufacturers. Density, water concentration, storage temperatures, Rheat, thawing and even seasonal and soil variations, are among the many factors that could affect the performance of food inspection machines. Phil Brown, European Managing Director of Fortress Technology and Sparc Systems explains the science and shares several examples of smart technologies, including AutoPhase that adapt to changing food characteristics. Digital technologies have quickly trans- formed how we all run processes. Machine learning especially is pushing the innovation boundaries in food manufacturing and streamlining production processes. It is a science which requires a deep understanding of the chemical makeup and molecular structures of foods. How fats, proteins, carbohydrates and sugars change during processing and storage will initiate a chemical reaction. To the naked eye, and even taste buds, these changes are barely notice- able. Yet, for wet and conductive foods, such as Farming practices, regional soil structures and natural crop cycles, although rare, can influence the nutrient content bread, meats, dairy products and ready meals, to a of fresh produce. © iStockPhoto ArtistGNDphotography sensitive metal detector inspecting the same foods over an eight hour shift, they can appear like completely different products. boned. stock - disrupts and mimics the metal detector Thermal changes and water content are Phil explains: “With boneless joints there’s signal causing traditional systems to react as if the main factors that can interfere with metal a greater concentration of meat, which means there’s a metal contaminant present and reject the detector signals. Dealing with higher amplitudes of they are denser and consequently weigh more. product.” product signal can be especially pronounced in This water content, which could be intensified Known as ‘product effect’, these false meat processing plants inspecting varying weights by ‘plumping’ – a common practice to maintain rejects more often than not result in perfectly good and sizes of joints, some boneless and others tenderised meat products by injecting salt water or food being discarded.

The power of ARM To identify a metal contaminant within conductive products, a metal detector must remove or reduce this ‘product effect’. The solution is to change the frequency of operation to minimise the effect of the product. But there’s a trade-off. Doing this can impact the ability to find different metals. Dropping the frequency tends to enhance ferrous metal detection. Yet this limits performance when it comes to non-ferrous metals, since the lower end of the frequency is more responsive to magnetic effects of the contamination. By the same token, the reverse happens when the frequency is taken higher – it starts to limit the ferrous detection capability but enhances the non-ferrous detection. Simultaneous frequency is the most reliable way to remove product effect without compromising the sensitivity of a metal detector. Fortress uses ARM microprocessors to adapt to these changing product characteristics. This pro- cessing technology powers the Fortress Interceptor, enabling it to run real-time analysis of the low- frequency and a high-frequency signals in parallel. By the same virtue, as products travel through processing facilities, environmental condi- tions change. Factory temperatures rise and dip. For example, bread dough can warm causing moisture to gradually evaporate. Alternatively, frozen food can thaw. A change of just 5°C is enough to affect the A change of just 5°C is enough to affect product characteristics and disrupt product signals, but can be overcome by product characteristics and disrupt product signals. metal detectors running multiple frequencies simultaneously Both Fortress and Sparc have a couple

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of technologies in their armoury to counteract changing food characteristics as they pass through the processing chain.

Automatic alignment AutoPhase is a useful tool available on Fortress Phantom, Stealth and Interceptor metal detectors that tracks long term changes within wet products, adapting and syncing to new characteris- tics. For example, batch conditions in baked bread can vary very slightly between recipes. Technologies like AutoPhase accommodate this gradual change without compromising metal detector sensitivity. “Even products that look different to the metal detector won’t be rejected,” emphasises Phil. Phil cites packaging as another common example where AutoPhase can help. Whereas inert plastic presents minimal signal, metallised films and the application of print can vary between rolls. “Just a small change can present itself as a big signal to a sensitive metal detector,” claims Phil. Although once deemed a major challenge for metal detec- tors, today’s advanced simultaneous frequency sys- tems are much more reliable inspecting pre- wrapped products. For food packaged in cans, tins or foil, x-ray MD Phil recalls an instance where cattle feed and geography influenced the characteristics of butter samples presenting inspection systems can play a critical complemen- as dry to the metal detector © iStock Photo tary role. “Often, a system like Sparc’s Apollo bridges the gap in inspection capabilities and ensures the “Butter is usually categorised as a wet product. weighing, bulk and combi systems, Fortress and most robust screening process for contaminants. If However, when we ran these butter samples Sparc have together got the whole food safety a product has been mispackaged, an x-ray can through a Fortress metal detector it automatically matrix covered.” pick this up, ensuring absolute quality of the end calibrated to a dry product. No one understood why. product,” says Phil. Further investigations tracked the cause down to the cattle feed and geographical environmental factors. Cause and effect The milk produced was influencing the butter The presence of xenobiotic compounds is characteristics. Causing it to present to the metal routinely monitored and tightly controlled by detector as a dry product.” regulatory bodies. However, farming practices, A metal detector that can run multiple regional soil structures and natural crop cycles, frequencies simultaneously, such as the Fortress although rare, can also influence the nutrient Interceptor, is ideal as it can accurately inspect a content of fresh produce. Inspecting potatoes variety of conductivities at the same time. Features grown, for example, in iron rich soils might require like single pass product learning and automatic a slightly different calibration setting to those grown calibration also help, as operatives are not constantly the other side of the country. resetting the machine to accommodate different Changeable protein levels in flour are product effect, shapes, sizes and orientation. another example of seasonal variations. Seldom Never underestimate the influence of would these changes directly impact the perform- environmental factors, advises Phil. “When it ance of inspection systems, however the raw comes to food safety, there’s always a cause and a ingredient changes can influence the chemical consequence. Having deep rooted experience composition of a baked product like bread. These about how different food products behave and changing attributes must be considered. change, the conditions that cause these reactions, Phil recalls an example of butter samples and the relearning limits of inspection equipment is that even tested his scientific wisdom. He recounts: critical. With expertise in metal detection, x-ray,

www.fortresstechnology.co.uk

Fortress Technology (Europe) Ltd based in Oxfordshire is a wholly owned subsidiary of the privately-ownedToronto based Fortress Technology Inc. Putting consumer safety first we’re trusted by thousands of domestic and global manufacturers to design, build, install and maintain inspection equipment that deliver exactly what they promise. From food to FMCG; pharmaceutical to bulk; SMEs to listed companies; metal detectors to check- weighers; x-ray to combination systems; Fortress inspection systems are renowned for their speed, accuracy and simple operation. All designed to catch contaminants,slash waste,spot product defects,comply with weights legislation and reduce production downtime. Fully customisable, for 20+ years we have offered the Fortress Never Obsolete guarantee. Ensuring future sustainability and compliance with HACCP and Codes of Practice.This guarantee now extends across all our new combination,x-ray and checkweighing systems. Fortress has manufacturing facilities in the UK, Canada and Brazil.Sales and service support is available globally both direct and through trusted distributors.

For food packaged in cans, tins or foil, x-ray inspection systems can play a critical role alongside metal detection fortress technology

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Kühne packs barbecue sauces and remoulade using flexible Schubert technology

mateur cooks can quickly conjure up a gourmet meal with the help of stocks, spice mixtures or pre-cooked vegetables. Kühne was a pioneer in this field from the veryA beginning: As early as in 1954, consumers were amazed at table-ready red cabbage. Today, it is impossible to imagine many households without the delicatessen products from the Hamburg-based family business. Kühne is the market leader in several categories and as such relies on high efficiency – in both production and packaging. In order to pack its growing product range quickly and with the flexibility available today, Kühne is using two robot-assisted TLM machines from Schubert for the first time. With a connection to the networked GRIPS.world platform and simple format changes, the system now packs barbecue sauces, remoulade and vinaigrettes into cartons in eight different formats – sustainably and very efficiently.

Facts & figures: Output of up to 210 bottles and 120 per minute on two lines A total of 8 different formats An F2 robot loads two boxes with eight bottles each at the same time. Format changeover in about 20 minutes Gentle product handling confirmed by its achieving a regular place among Quiet and unbreakable without a grouping Transmodul in use the top ten in GfK’s buyer reach ranking. chain To maintain this position and the favour of “Due to the high noise level and risk of buyers over the long term, Kühne is also increas- breakage, the production managers at Kühne A tasty sauce enhances any meal. It is ingly focusing on production and packaging wanted an alternative to the grouping chain,” says often a speciality from Kühne that adds the finishing processes that are sustainable and efficiently Andreas Keller, Sales Account Manager at Schubert, touch to fine dishes. Since 1722, the company has controlled. The commissioning of two robot-assisted describing the impetus for the robot technology. “For been developing delicious innovations that reflect packaging systems from Schubert represents a format changes, for example, from remoulade the nutritional and cooking habits of their time, further decisive step in this direction. The almost to sauce bottles, the employees also previously had under the motto “Food that is simply good”. It all identical lines have been packaging barbecue sauce to schedule around two shifts,” explains Keller. And started with the first bottled vinegar, followed by bottles and remoulade jars into cartons quickly and in the highly competitive B2C food market, this pickled cucumbers, red cabbage, salad dressings, flexibly since July 2020. The new TLM systems bring represented a time span that Kühne could and mustards and BBQ sauces – until finally, with the a sense of calm to production: The sensitive glass would no longer tolerate. This alone has made the vegetable snacks, the consumer’s demand for packages are now grouped by pick & place robots switch to Schubert systems worthwhile: The flexible “better” snacks was fulfilled. The company’s consis- instead of the usual grouping chain. solution now manages the changeover in a tent focus on consumer expectations is also maximum of 20 minutes. The grippers of the F4

Two almost identical lines pack barbecue sauces, vinaigrettes and remoulades into cartons at Kühne.

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Stefan Knoth, from Technical Support at Kühne, has already been able to achieve 20% more performance from the packaging process than before thanks to the implementation of GRIPS.world, according to preliminary OEE evaluations.

robots for the products (with bayonet Increased efficiency in every respect lock), magazine plates, box folding Christian Instenberg, Head of frames as well as the Transmodul Technical Support at Kühne, is already pick-up plates are all changed. After the very excited about the additional possi- changeover, the system then simply bilities that GRIPS.world can offer and continues to run with high quality confirms this: “The fact that the decision immediately and without ramp-up in favour of Schubert increases the times. efficiency of our processes has already been proven by the rapid format Two lines for eight formats changeover.”His colleague Stefan Knoth Due to two different perform- is also enthusiastic: “We are already ance levels of the upstream filling achieving 20% more output than stations, Kühne ordered two packaging before, according to the OEE evaluation. lines at the same time, which only The Schubert family has done an differed by the fact that the line for pack- excellent job.” Kühne is well equipped aging two formats of the remoulades in for the future with the Schubert jars required two more F4 robots. The systems: They can be extended for other line currently packs six formats of other formats without much effort. After the “Made for Meat” barbecue sauces in all, the market leader in convenience various sizes, as well as round glass Packed following the counterflow principle thanks to the Transmodul: Two case blanks products has often shown that new bottles of salad dressings (vinaigrettes). are placed onto the Transmodul, while pick & place robots pick up two bottles from the product ideas are very well received by On both lines, the packaging process product conveyor and place them in the desired quantity on the Transmodul. consumers. takes place in counterflow. Schubert’s Transmodul transport robot combines the process steps with exceptional efficiency: Two from records from the machine operators on carton blanks at a time are destacked, erected and individual production lines. However, these records placed on the Transmodul. Pick & place robots take did not consistently list the interruption times two bottles at a time from the product conveyor and because the elimination of a malfunction naturally place the desired number of bottles or jars to be took priority over the documentation process for Gerhard Schubert GmbH packed on the Transmodul with the erected boxes. the machine operators. This resulted in certain packaging machines The Transmodul moves to the next station, where inaccuracies in the documentation, which the Germany the two finished bottle or formations are gripped company urgently wanted to minimise. To this end, Tel: +49 7951 400-0 by an F2 robot and placed into the boxes. At the Kühne and Schubert are now working hand in hand Email: [email protected] last station, another F2 robot seals the cartons and on a new type of evaluation, as the new customer www.schubert.group places them onto an outfeed conveyor. has allowed Schubert access to the platform. “We are grateful for the trust Kühne has Packed sustainably with Big Data and placed in us,” Keller says. He looks forward to Gerhard Schubert GmbH is a globally recognised market GRIPS.world exploring the digital solution further with the manu- leader in top-loading packaging machines (TLM). For Big Data is the new currency in the facturer. Stefan Knoth, from Technical Support at its digital, robot-based packaging machines, the packaging industry, as well as everywhere else. But Kühne, agrees and is already entirely convinced: family-owned company based in Crailsheim (Baden- storing machine data alone is not enough. If you “Compared with our previous method, it is a real Württemberg, Germany) builds on an interplay of simple want to profit from machines, advantage that we now have a tool that automati- mechanics, intelligent control technology and high you need a meaningful analysis of the important cally records the reasons for disruptions and down- modularity. With this philosophy and a highly developed key figures and one-hundred-per-cent protection times. The weekly report provided by Schubert for culture of innovation,the company has been pursuing an against attacks from the Internet. Schubert makes this purpose provides an initial overview of the entirely independent technological path for more than 50 both possible: A GS.Gate is integrated into every entire line’s performance. Detailed statements are years. new TLM line as an industrial gateway. This is also possible with the program’s extensive analysis With its TLM technology, the machine manufacturer the case with Kühne. Schubert’s GS.Gate gateway functions. Another highlight is the ECO dashboard provides its customers with future-proof packaging evaluates all machine data and networks the Kühne for recording and evaluating power and compressed machine solutions that are easy to operate, flexible in lines with the GRIPS.world digital platform while air consumption. This allows us to provide detailed terms of format conversion, high-performance and adhering to the highest security standards. Based data to our energy management system.” He also stable in function. The TLM packaging machines pack on the current production data and reports that sees the possibility of exporting the processed products of all types and from all sectors – from are generated automatically on a weekly basis, data as a useful add-on and using it for further food, confectionery, beverages, pharmaceuticals and optimisation potential for the entire packaging evaluations. “In the future, together with Schubert’s cosmetics to technical products – into trays, cartons, process can be identified. For example, the targeted system development department, we intend to boxes or into flow-wrap bags. analysis of error messages increases machine integrate further upstream and downstream Well-known brands such as Ferrero, Nestlé, Unilever, availability. machines into the system to process error Mondelez and Roche rely on Schubert’s automation messages from these systems as plain text in real solutions, as do numerous small, medium-sized and Evaluation in detail and in real time time. We now have a powerful tool that provides us family-owned companies. Founded in 1966, the second Until now, Kühne used an OEE (Overall with excellent support in systems analysis and generation of the company now employs 1,400 people. Equipment Effectiveness) calculation program for its increased overall line effectiveness,” adds Knoth. production meetings, which obtained part of its data gerhard schubert gmbh

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Packaging automation set to aid food manufacture growth in the wake of Covid-19 Covid-19 could diminish the reliance UK food factories has on manual workers in favour of fully automated systems

utomation is set to play an increasingly tion, adoption was at a far slower pace than other are continually changing. Historically, this hasn’t larger role in safeguarding the future of the countries. However, Covid-19 has emphasised the always lent itself well to automation and manufac- UK’s food manufacturing industry, and the need to update manual manufacturing practices turers need assurances that the investment they AChancellor’s recent super-deduction tax that will prevent many from recovering quickly once make in end-of-line packaging automation is future- allowance on plant and machinery announcement social distancing measures are lifted. proof.” is set to give the sector the boost it needs. According to a recent post by the Interna- Fully automated end-of-line systems today While most UK food manufacturers tional Federation of Robots (IFR) in comparison to can manage an unprecedented range of case understood the efficiencies gained from automa- several countries across the world, the UK was the styles and sizes and have been re-engineered to only country, over a 10-year period, to report a handle a wide variety of case materials to suit retail 9 percent decrease in productivity per person. specifications, from poorly scored, lightweight cases, While coronavirus has undoubtedly put a to heavy, twin wall cases. Random systems, with strain on global productivity, UK manufacturers faced integrated bar code reading technology can significant issues because of workers being unable seal random sized cases at high speed – and be to work in production lines where they normally reconfigured remotely to manage new sizes and stand less than 50 cm apart on 12-hour shifts. orientations as and when required. There is an established link between automation and increased productivity, so now is Health & Safety the time for UK manufacturers to look at long term Getting health and safety right has never growth and invest in automation to support labour been more paramount. Food manufactures need intensive activities. to adhere to stringent measures and are being set So, why have UK food manufacturers greater guidance on the use of machinery through always been so reluctant to take the automation the Food Standard Agency’s regulatory model, plunge? facing stiffer sentences if they are non-compliant. Here, Andrew Yates, Managing Director of Tougher governance around health and Endoline Automation, discusses the reasons why safety shouldn’t be a deterrent to automation, the UK lagged behind its global counterparts, however it is vital that manufacturers do not take a how automated end-of-line packaging systems CE certified machine at face value. today meets manufacturer demands, and how “There are a number of other factors which machinery can be integrated into processing and need to be considered. Manufacturers need to packing lines quickly to ramp up output. understand the area the machine will be located in and assess the environment for any safety concerns Demonstrating flexibility such as access.” For some food manufacturers, a wariness End-of-line equipment in particular to change well established manual processes, and presented significant hazards. Not only do they an aversion to the risks that new technologies can operate automatically and, in some cases, at very bring, have created major roadblocks, preventing high speed, but the openings, to allow the cases to them from reaping the many benefits automated be transported through the system, are often large systems can yield. enough to be a potential for unauthorised access. Within food manufacturing, the variability Over the years quality, end-of-line systems of materials has played a major factor, particularly have been ergonomically designed offering safer as many believe that uniformity plays a vital role in operator access and the integration of Safety Light ensuring automation runs efficiently. To meet curtains not only safeguards the machine, but retail demand, manufacturers are producing an eliminates the need for additional safety guarding abundance of brand varieties in all shapes and sizes so reducing the overall footprint. Systems can which can cause greater complexities, due to the also be constructed from IP65 washdown rated Endoline’s Case Packer system demonstrates the variation in size, shape, quality, and weight of the stainless steel. high-tech, flexible capabilities of end-of-line packaging product. machinery “Retailers are constantly vying for Eliminating unnecessary downtime consumer attention, creating greater choices which Food manufacturing sites that are highly

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automated operate with fewer workers, resulting in a larger opportunity for uninterrupted processing. Tetra Pak and Rockwell Manufacturers are currently seeking to mitigate the risk of sending people home in virus-susceptible areas within their facilities, and automation is a big part of this solution. Automation collaborate to The risk of downtime, as a result of machinery failure, servicing or reprogramming has always been a bottleneck in the adoption of advance performance for automation. However, automation specialists have been driving the intelligence of end-of-line systems powder manufacturers forward for some time, and there is now a greater emphasis on linking these systems together and etra Pak and Rockwell Automation announce a and precise. Customers can leverage our food integrating them into a customers’ own specific data Tstrategic business collaboration for Cheese and application expertise, have access to production network. Consequently, food manufacturers can Powder Solutions. The combined business expert- data in real time and adapt their process variables to capture, process, and analyse big data from the ise will deliver data and technology to reduce match requirements – without any loss in quality, factory floor remotely, and improve productivity, variability and improve quality consistency, helping productivity, or throughput. This unique collabora- avoid downtime through predictive maintenance, ensure finished products are produced sustainably tion with Rockwell Automation provides the upload new case recipes, and optimise energy use. and cost effectively within demand-driven manu- foundation upon which this capability is based.” “Our systems built today feature an facturing environments. Matthew Fordenwalt, VP GM, Systems & integrated, Industry 4.0 compatible HMI interface The collaboration – starting with Evapora- Solutions, Rockwell Automation, says, “Rockwell enabling engineers to easily re-programme the tion and Spray Drying – has resulted in Tetra Pak’s Automation is delighted to build upon a relationship machine to allow for new configurations of case new Powder Plant Booster™ solution, to be that spans 35 years and collaborate with Tetra Pak, sizes remotely via a computer, tablet or even a packaged with Rockwell Automation’s Model a company that shares our view that deeply under- mobile.” Predictive Control (MPC) and its Pavilion8® and standing customers and their best opportunities for In addition, these SMART systems can be PlantPAx® MPC technology. productivity creates value. We believe shared also used to monitor the machinery and send alerts The combination of Tetra Pak’s food customers insights, coupled with technology and on any preventive maintenance issues and spares application expertise and the leading digital domain expertise, will deliver real value focused shortages. “End-of-line systems are very self- technology of Rockwell Automation1 will help outcomes to the industry.” sufficient.” producers to adapt to fluctuating demand-driven This business collaboration showcases manufacturing far more quickly and more cost how a combination of expertise can help customers Beyond Covid-19 effectively. achieve important business-critical goals, even on a Automation has always been an enabler Pavilion8 driven applications have been global scale. Tetra Pak can now offer its Evaporation to streamline and enhance efficiency and, as a shown by Rockwell Automation to deliver possible and Spray Drying customers proven Advanced result of the pressure created by the crisis on product quality variability reductions of up to 60%, Process Control and Model Predictive Control manual process, manufacturers should now be able reductions in off-spec products by up to 75%, solutions. that have demonstrated success all to clearly identify which areas would benefit from improved throughputs up to 9%, and reductions in around the world. automation. energy per unit of product up to 9%2. This allows The Powder Plant Booster™ solution – Covid-19 has undoubtedly heightened the producers to fully optimise their operations – with complementary Pavilion8 software – is a need for the UK to integrate automation into their helping them stay competitive while meeting process modelling, advanced control and optimisa- packing lines. By taking the steps to automate, changing market demands. tion platform that integrates with any control manufacturers will be prepared for any future crisis Fred Griemsmann, Vice President Cheese system to continuously provide real-time insight, or shutdown, while ensuring that their output levels & Powder Systems at Tetra Pak says, “The food and diagnostics, and advanced control. It achieves this and efficiencies remain high. drink industry now requires that producers have a by delivering an intelligence layer on top of basic level of agility never seen before. This means we automation systems, which, due to its built-in Super-deduction tax must be ready to offer our customers advanced performance metrics, continuously drives plants From April until March 31st 2023, manu- processing control technology that is both flexible towards addressing multiple business objectives. facturers can qualify for a 130% capital allowance deduction. This tax break will provide 25p off company tax bills for every £1 spent on qualifying plant and machinery. This measure – which is expected to boost UK investment by £20 billion a year – includes a super-deduction of 130% on most new plant Controlling ethylene fruit and machinery investments, which would have ordinarily qualified for 18% relief, and a first year allowance of 50% on most new plant and and vegetable ripening machinery investments which would have ordinarily qualified for 6% relief. Automation has always been an enabler thylene is the saviour and devil of fruit and optimally measure the permeability of any other to streamline and enhance efficiency and manu- Evegetable ripening – this gaseous plant gasses relevant to shelf-life and quality – including facturers should now be able to clearly identify hormone ripens product for display – but then they water vapour, oxygen, carbon dioxide, nitrogen and which areas would benefit and take advantage of over ripen and between 20 and 80% of all post- hydrocarbons. the 130% tax break. This will also make the UK harvest fresh fruits and vegetables have to be The company also offers both a laboratory- more competitive on the global production field. thrown away. The key to reducing this waste is based permeability testing service and a vapour testing the amount of ethylene that flows through permeability consultancy. (permeates) either into or out of the product‘s www.versaperm.com packaging. Versaperm’s vapour permeability meas- urement system measures this to an accuracy in the Parts Per Million (PPM) to PPB range – and can do it over a wide range of environmental conditions. The equipment is fast and simple to use and offers automated computerised control through a simple touch screen. Although it is often used on samples of the packaging, it also works with complete packages, multi-layer laminates and even coatings such as wax. It measures the permeabili- ties of several samples or packs at the same time and results can be available in as little as thirty minutes in some cases. In addition to measuring ethylene https://endoline-automation.com/robotics/ permeability, the Versaperm equipment can

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Plastics in consumer goods manufacturing: Fresh strategies for more sustainability

Reduce, recycle, reuse and redesign: How can automation help to improve efficiency and flexibility?

lastic and sustainability – at first glance, these terms fo not seem to fit together. Plastic waste, mainly single-use plastics and microplastics, polluting the sea is an issueP that has become increasingly the focus in recent years. For example, according to a Roland Berger study on sustainability, 12 million tons of plastic enter the ocean every year, which is around 8 million units a day. Likewise, researchers at the National Oceanography Centre (NOC) have found that there are currently an unimaginable 12 to 21 million tons of microplastics in the Atlantic – a huge danger to animals and humans. However, when packing and transporting food and other consumer goods (F&C), there is no real alternative that is more hygienic, safer, more efficient and cheaper. What is certain is that companies and decision-makers urgently need to find ways to promote sustainabil- ity and environmental protection while still packaging their goods and containers reliably and safely. Smart packaging lines, innovative robotics, technological innovations and AI can support this. Plastic waste, mainly single-use plastics and microplastics, polluting the sea is an issue that has become increasingly With the world eagerly awaiting the UN’s the focus in recent years COP26 conference to be held in Glasgow, Scotland, in November 2021 the issue of sustainability is gaining momentum. More and more companies usage of plastics whilst maintaining product sales bags – there is a new focus on less plastic and less are taking environmental measures, planning green and safety, so we’re seeing lower levels of plastic waste of end products. The trend is to reuse and actions and developing innovative approaches – used within the container or packing. Manufactur- redesign packaging, containers and more. So to be also when it comes to plastics. And while the ers increasingly focus on light-weighting to reduce more sustainable but equally aligned to customer’s amount of plastic packaging produced, used and plastic packaging. Moreover, there are changes in objectives, manufacturers should develop new disposed of worldwide urgently needs to be the composition of the plastics so they can be more packaging strategies based on the four “R’s”: reduce, reduced in this context, it is also important not to easily recycled. Another development is an recycle, reuse and redesign. completely ignore the advantages of plastics over innovative format design like pouches or resealable alternatives in the context of balanced sustainability.

There is a lot to be said for plastic packaging Plastics in packaging include a few benefits which cannot be dismissed out of hand. For the producer, these polymers provide a safety barrier to protect a variety of contents. Furthermore, they are easy to shape – for an appealing shelf presence – and they also offer convenience for transportation. Consumers on the other hand want convenience, choice, product integrity, value and more sustain- able practises. Here it is important to remember that whilst there is a lot of debate about plastics and rightly so, it still does have environmental advantages over other alternatives (e.g) metals or glass, which can be very energy-intensive to produce, ship and recycle. And even though unpackaged food is a trend in some cities and regions, in many places there is simply no viable alternative to plastic packaging for cost, hygiene and safety reasons.

Focus on “reduce, recycle, reuse and redesign” Currently, producers are balancing between making commitments to reducing overall Polymers provide a safety barrier to protect a variety of contents

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Manufacturers increasingly focus on light-weighting to reduce plastic packaging

Only a minimal proportion of the plastic is achieve the correct result. How can the result be 6 Closing: High-resolution servos are key recycled tested in real time? To be able to monitor Omron Electronics Ltd is the UK subsidiary of We’ve all seen the terrible images of multiple variables in real time, such as material Omron Corporation, a global leader in the field of plastics in the eco-system, harming wildlife and the thickness, contact time, temperatures and more, automation. Established in 1933, Omron has oceans in general. Today, we produce about the manufacturer needs an automation solution more than 35,000 employees in over 35 300 million tonnes of plastic waste every year. That's that can collect all applicable data via common countries working to provide products and equivalent almost to the weight of the entire human communication methods “at the edge” (at the services to customers in a variety of fields population. Approximately 20% of total packaging machine level). In addition, a facility to share and including industrial automation, electronic waste materials are plastics, about the same as glass visualize is required. In the future, more and more components industries, and healthcare. Omron and less than or cardboard – paper however AI will be embedded in a control system, so that Electronics Ltd provides a comprehensive sales can be more easily recycled. Sadly, according to the development is increasingly moving in the and support service for Omron’s vast range of the Environmental Protection Agency only a very direction of self-optimizing machines. industrial automation products including industrial small fraction of the plastics produced is recycled, 2 Forming: High-performance vision systems components, sensing and safety, automation approximately 8.4%. And despite all the discussions minimize faults systems and drivesThe previously mentioned about more sustainability, plastics production is set For producers of trays, bottles or packs who are trend for weight reduction can change the size to increase for decades to come, with some both trying to reduce the amount of plastic being and shape of containers, which can also affect the forecasts predicting a doubling of production by the used and their composition, it’s important to ask sealing process and other related workflows. year 2050. In particular, strong growth in flexible what effects changes like these might have on the Additionally, forces and torques can lead to scrap plastic is expected, but only slightly ahead of rigid integrity, colour or shape of the item: How are or production failures, which can lead to further plastics. processes affected and how can automation be problems. Many sealing techniques such as best used to check the characteristics? As well as capping rely on servo control. High-resolution Global initiatives to reduce plastic the process of creating the container, that requires servos connected via a machine network like So isn’t there any regulation at all, you close temperature control combined with the EtherCAT are therefore essential. might ask? Often mentioned are the UN Sustain- physical action like pressure, a key task is the able Development Goals, including climate action inspection of the container to ensure its integrity. OMRON supports sustainability efforts and responsible consumption and production. Ensuring no defective items enter the market- With its comprehensive and integrated There are also many and diverse regulations in place place requires high-performance vision systems innovative-automation technology platform, globally, all pushing for a reduction of plastic usage with the necessary tools to detect such issues as accompanied by a wide range of services available within our society. Some examples are the bans on microholes in plastics. worldwide, OMRON offers a tailored range of single-use plastics, such as straws and cups or 3 Winding: Close monitoring and control of film solutions to support all of the above challenges. reduction strategies in the EU which are With changes in material composition, it’s A global presence, a global network of linked to the Directive 2019/904, and will officially essential to analyze if machines such as flow integration and operation partners and an internal become law by July 2021. In other regions, the US, wrappers still maintain throughput and tension focus on the WHO's sustainability goals as an India and China have implemented their separate control without affecting the output or quality of Ecovadis platinum certified company, OMRON is plans. Global consumer goods producers have the end product. Only by close monitoring and the right partner in this path to build a more been making commitments for some time as well. control of the film, will a product be made that sustainable future. These pledges are diverse in their make-up. Some meets the specification, avoiding wrinkles and are in favour of increasing the proportion of stretching and therefore negatively impacting recycled PET in products. Others strive to make downstream processes. packaging more recyclable or rework the design of 4 Wrapping: Temperature and motion control packaging and containers to use less plastic. Similar to sealing, material changes can affect performance: Are integrity and stability still Six challenges and opportunities guaranteed when wrapping, for example? An for automation application is required that guarantees close www.industrial.omron.eu All of the above changes present potential control of temperature and movement, maintains challenges, and manufacturers need to develop tension and ensures that a secondary or tertiary new strategies and find innovative technology to packaging is wrapped correctly. Omron Electronics Ltd is the UK subsidiary of Omron overcome these hurdles – with automation as 5 Handling: Seamless communication between Corporation, a global leader in the field of automation. the foundation of all these plans. The following systems Established in 1933, Omron has more than 35,000 examples use specific application scenarios to show When reducing packaging, producers must employees in over 35 countries working to provide where producers can start to drive change. determine whether handling workflows supported products and services to customers in a variety of fields by sorting or pick-and-place solutions are accurate including industrial automation, electronic components 1 Sealing: Real-time monitoring and easy to repeat. An example being placing industries, and healthcare. Omron Electronics Ltd How can a manufacturer be sure that the pack- trays into retail-ready tertiary containers. A key provides a comprehensive sales and support service for aging is fit for purpose in the event of material aspect of handling is being able to “see” the Omron’s vast range of industrial automation products changes? Can the manufacturer still use the same products that enter the packaging area, as well as including industrial components, sensing and safety, equipment and configurations that it uses today? fast communication between the image process- automation systems and drives. (e.g.) A vertical form fill seal machine (VFFS) has ing system, the conveyor belt and the robot – all www.industrial.omron.eu many variables such as speed, pressure, while respecting the required throughput. In synchronization, temperature and more. Very addition, the robot’s configuration may need to close control of these variables is required to be changed to accomodate new film materials. omron

www.innovationsfood.com May 2021 Innovations in Food Processing & Packaging 29 CODING&LABELING&ADHESIVES:Layout 1 14/5/21 09:01 Page 2

Rotech launch new modular conveyors to simplify packaging coding

otech Machines, one of the UK’s leading Rmanufacturers of coding and marking technol- ogy, has launched a new range of high-quality modular conveyor systems, designed specifically printers anywhere on the line, such as thermal inkjet used independently or interlocked for long applica- for food, pharmaceutical, medical and industrial or large area printers. Users can rapidly apply codes tions, and can also be used as individual packing packaging operations. onto all packaging types including cartons, bottles, and coding stations. The small, modular, interlocking conveyors flat packaging or direct onto outer boxes. offer customers greater packing and coding flexibil- Available with either fixed feet or castors, the free- Full installation support ity, allowing users to pack goods and print codes at standing modular conveyors will improve packaging Rotech’s team of coding and marking speed in any location. The all-in-one conveyor efficiency, save space and speed up output. specialists will carry out a full assessment of systems are particularly beneficial where space is Custom-built conveyors for variable speeds customer needs prior to build and installation, along limited, where coding and packing is currently and loads with specialist advice on the most suitable and performed in different locations, or where a Because Rotech conveyors are built to efficient type of printer technology. conventional industrial conveyor is too large. order, specific drive systems can be fitted to suit For more information about Rotech’s new speed and load requirements – this is particularly modular conveyors, or their wider range of packag- Designed for fast, flexible printing onto useful for high throughput or industrial goods. ing coding and marking technology, please all packaging types Rotech conveyors are available in 500mm visit www.rotechmachines.com or call 01707 Each Rotech conveyor is designed for the increments, with a standard belt length of 1.5m and 393700. easy installation of a range of small, high-speed a width of 400mm. Each conveyor module can be Full wrap labelling for fish and seafood

he variety of fish and seafood products is almost possible to automatically apply a self- full balance as well. “When compared with cardboard Tendless - as is the wide range of pack types and wrap label on up to four sides of a pack. The sleeves, the full wrap label can reduce the weight of materials. An effective impression at the point of sale maximum label width is 500 mm, and the labelling the banderole by half, and even higher material can only be successful however, if the pack design output is up to 120 packs per minute. Depending savings are possible in comparison with complete is true to the product and brand, as well as being in on the requirements, a wide range of thermal cartons,” says the labelling expert Michael Reffke. harmony with the labelling. MULTIVAC's full wrap transfer or thermal inkjet printers can be integrated labelling offers an innovative solution, which makes into the labeller. Maximum flexibility a lasting impression in the chill cabinet. Thanks to the automated labelling process, There are also practically no limits with full Fish and seafood products are usually producers and packers benefit from a high level of wrap labelling, when it comes to application packed in skin packs, MAP trays, aluminium trays or precision, process reliability, and above all through- scenarios and design variants. The possibilities range cans. The fresh or frozen products are generally put. The labeller can be equipped with a zero down- from a banderole for skin packs through to a labelled with either a simple top/bottom label or time function for even higher overall output. complete full wrap with cut-out sections alternatively a cardboard sleeve or complete carton. Optional label and print inspection ensures, that only and overlapping, and right up to an allover label for The cardboard sleeve encloses the product like a perfectly labelled products get onto the market. tray-packed ready meals. Even where the lowest- banderole - it is pushed over the outer edge of the cost material is used, this packaging concept is still pack and is completely wrapped around it like an Focus on sustainability highly impressive with its high-quality look and feel, envelope. The problem with the label approach is With its wide range of suitable label since the print design, shape and type of material that the labels often materials and adhesives, MULTIVAC offers the right can be individually adapted to the product and do not reflect the high solution for every requirement. In addition to PP and brand. quality of the product. PET labels, materials made of paper or from other Depending on the requirement, additional If cardboard sleeves renewable sources are available for selection. functions such as perforation, opening aids, viewing are used however, the Consumers today are increasingly focusing their window or adhesive-free zones can be integrated manual application is attention on recyclable and sustainable packaging into the full wrap label. The material range from very time-consuming concepts - particularly when it comes to natural MULTIVAC includes label thicknesses from 70 to and costly. products and high-quality foods. 130 g/m², so that every product can be presented “By matching the label material to the attractively and cost-effectively. Powerful labeller packaging material, we can ensure that the with a high level of constituent parts of the pack can be separated to Added value thanks to large space output meet the recycling requirements. If we also use for information MULTIVAC adhesives, which can be dissolved or washed off, And last but not least, full wrap labelling offers an efficient and the individual packaging components can easily be offers a large area for product information and brand attractive alternative separated after use, so that they can then be communication. If required, an additional label can with its L 310 full wrap directed to the particular recycling stream,” explains also be applied from below to the pack on the same conveyor belt labeller. Michael Reffke, Product Manager at MULTIVAC machine. Michael Reffke: “Full wrap labelling far This flexible model Marking & Inspection. exceeds the classic top/bottom labelling in every with its patented, Particularly light label material also reduces respect. It is also in no way inferior to cardboard servo-driven press-on the transport weight of the packs along the entire sleeves, as well as being significantly more efficient brushes makes it supply chain - and this therefore improves the CO2 than a complete carton.”

30 Innovations in Food Processing & Packaging May 2021 www.innovationsfood.com CODING&LABELING&ADHESIVES:Layout 1 14/5/21 09:01 Page 3

DataLase releases TSC Printronix Auto ID new laser coding announces biggest ever overhaul and marking solution for of its best-selling industrial metal decoration printers and print engines

lobal coding and marking specialists, DataLase, ew models and advances in security, wireless remotely. Ghas launched a UV offset (UVO) litho metal Nconnectivity, remote management and Vast improvements in printhead manage- decoration coating, designed for use on offset litho printhead management mark just some of the ment help prevent incorrect or poor quality labels presses equipped with UV curing units. sweeping changes TSC Printronix Auto ID has made entering the supply chain. The printhead mecha- Suitable for use on treated tin plate, the across its popular barcode printers and print nisms checks and reports bad dots on the printhead functional coating can be used to help address the engines. in real-time. Users get alerted in advance to replace challenges faced by production and manufacturing More powerful and adaptable wireless faulty printheads thereby avoiding production down- companies with product coding requirements, such connectivity options in the newly improved printers, time. The new printheads incorporate a feature as printing QR codes and expiry dates onto primary including wireless 802.11a/b/g/n/ac and enabling printhead usage to be stored in the print- packaging applications. It can be used for food & Bluetooth® 4.2 modules, enable faster roaming and head mechanism giving users a clear indication of drink, home, pharmaceutical, medical and industrial greater productivity. The enhanced connectivity output levels as well as the printhead’s health and packaging. works especially well in facilities with Wi-Fi networks replacement status. DataLase UVO litho metal decoration boasting multiple access points, ensuring no data is "We’re committed to delivering the most formulations have been optimised to deliver lost between roaming from one access point to advanced thermal print technology to customers unsurpassed product stability and excellent flow another. across demanding industrial environments like properties. When used in combination with an The MX Series, MH Series and PEX Series logistics, manufacturing and retail,“ says Sabine appropriate CO2 laser marking system, consistent have all been upgraded with new electronics to Mayer, Senior Marketing Manager of TSC Printronix high quality, high contrast, permanent black-on- improve their operational performance. TSC has Auto ID EMEA. "Our radical new line-up of rugged white coding can be achieved. DataLase UVO litho also added two 6-inch industrial thermal transfer printer models are competitively priced yet bring metal decoration provides brands with the ability to printers to its MH261 Series; the MH261T and unprecedented performance and precision to improve the traceability of their goods, and the MH361T. users.“ tamper proof and anti-counterfeit nature of the The upgraded printers are all supported by Further information on the upgraded solution can assist with advancing the security of SOTI Connect, which gives greater visibility and devices can be found at: www.tscprinters.com and products. real-time data on the health and performance of an www.printronixautoid.com The DataLase UVO litho metal decoration entire fleet of printers allowing them to be managed solution provides a number of key benefits, being heat, water, scuff and rub resistant when used in conjunction with standard thermal overprint varnish. The marking, which provides sharp and clear quality, can also be cured under traditional UV lamps; a process which can improve overall productivity when combined with an appropriate CO2 laser marking system and eliminates consum- ables from production and manufacturing environ- ments. The solution is suitable for non-direct food contact packaging applications and designed for tamper-proof, anti-counterfeit coding and marking. DataLase’s CSMO, Paul Dustain, said: “The new DataLase UVO litho metal decoration offering is an important functional coating, providing multi- ple benefits for production environments in various markets, particularly in improving security, traceabil- ity and anti-counterfeiting. In addition, it also offers brands additional marketing and engagement opportunities, enabling connected packaging. DataLase will continue to push forward with increased technological advancement in order to further develop our market leading Photonic Printing Solutions.” www.DataLase.com/uvo-metal/ Avery Dennison Smartrac launches new Circus™ Pro inlays with high-performing web capabilities

and Beverage, Apparel and Beauty markets. NDEF container. This results in a high-performance, very Dennison Smartrac has extended its The security offered by the Circus Pro highly secure tag with Advanced Product Authenti- Amarket-leading Circus™ Pro family of NFC family’s advanced encryption features is now cation capabilities built in, and offering one-to-one products by launching new Circus Pro and Circus enhanced by the use of the EM Microelectronic consumer engagement that drives brands closer Pro Flex NFC inlays that feature the new high- em|linq (EM4332) chip. This IC is NFC Type 2 than ever to consumers. performance Web Authentication em|linq compliant and delivers state-of-the-art radio “EM is excited to support Avery Dennison (EM4332) chip. These newest additions to the frequency and cryptographic performance in a cost- Smartrac’s solutions with its Swiss-engineered Circus Pro portfolio enable secured, end-to-end effective package. technology” said Christophe Ratajczak, Smart brand protection solutions requiring an encrypted Its highly optimized cryptographic hard- Systems BU Manager at EM Microelectronic. “We digital "birth record" for packaged products, a trusted ware implementation provides best-in-class Web trust this partnership will unlock the full market product identity validation service and platform- Authentication brand protection to consumers’ potential behind the NFC-based product authenti- agnostic consumer engagement capabilities for smartphones using a dynamically generated HMAC- cation.” customers within Consumer Packaged Goods, Food SHA1 code appended to the URL stored in the www.averydennison.com

www.innovationsfood.com May 2021 Innovations in Food Processing & Packaging 31 FORTRESS TECH-2:Layout 1 14/5/21 09:59 Page 2 Food Interceptor saves pork producer’s bacon

our Interceptor metal detectors from Fortress Technology has enabled a North American pork producer to meet its new fast-food customer’s tough requirements for Faccurately and reliably inspecting high volumes of bacon. Thanks to the Interceptor’s increased sensitivity and simultaneous multi-frequency innovation, the producer has not only satisfied its client’s stringent food safety specifications, it has also eliminated false rejects by isolating product effect. Winning a major contract with a big fast- food chain, the pork producer’s investment in a higher-quality metal detection system was crucial to meeting its new client’s quality assurance and HACCP standards. The company’s existing inspec- tion equipment was struggling to cope with the notorious product effect common with meat products that are wet and highly conductive. Salty products such as bacon can be especially challenging to inspect as it increases the conductivity of the wet product. This impacts a metal detector’s ability to distinguish between any metal contaminants, including stainless steel, that may The North American pork producer installed for Interceptor machines to meet the exacting inspection demands of a have been introduced during processing and the new fast-food customer false signal given by the combination of product attributes. These different factors can lead to false readings and consequently higher product waste. metal detectors installed throughout its production The Interceptor works by carrying out a European Commercial Manager at Fortress facility, trust and familiarity with Fortress equipment real-time analysis of a low-frequency and a high- Technology Jodie Curry comments: “Product effect was already firmly established. frequency output signal simultaneously. Although can make it difficult for standard detectors to tell User friendly features that support quick the size of metal contaminant that’s detectable the difference between the signal generated by the set up are always highly valued by any busy depends on the product size and temperature, as bacon itself and any signal given off by a metal production plants, notes Jodie. well as the aperture size, typically the Interceptor can contaminant. As well as resulting in a high volume Inspecting retail and bulk packages of improve detection levels for stainless steel by as of false rejects, there’s greater potential for real bacon ranging from five to seven kilograms, single much as 100 percent in contrast to standard metal contamination to be missed.” pass product learning and automatic calibration detectors. The result is a more reliable and accurate means that operatives are not having to constantly reading regardless of size, shape and orientation of Size sensitive in one pass reset and recalibrate the metal detector for the metal particles. With the fast-food chain demanding more different pack sizes. “Automated technology features Additionally, a built-in Noise Immunity stringent sensitivity specifications, the bacon like these make the manufacturing process much structure minimizes external electrical disturbances, producer sought a solution to conquer product simpler for production staff and significantly reduces further lowering the occurrence of false rejects. effect once and for all. A longstanding and satisfied the time spent introducing and checking operating The enhanced sensitivity, accuracy and Fortress customer with over 50 of the company’s protocols,” adds Jodie. cost efficiencies have more than satisfied the producer’s new clients’ exacting demands. Having invested in four new Interceptor, the pork plant continues to retain its solid reputation for quality and food safety. “With the digitally advanced Interceptor, Fortress continues to safeguard some of the leading products and brands by challenging traditional detection expectations and ensuring product effect does not compromise inspection performance or operational efficiencies,” highlights Jodie. “The combination of 100% increased metal detection sensitivity, elimination of false product rejects and easy to use automated features continues to offer reassurance and brand protection to the hundreds of customers we support internationally.”

Single pass product learning and automatic calibration stops operatives constantly resetting and recalibrating the metal detector for different pack sizes www.fortresstechnology.co.uk

32 Innovations in Food Processing & Packaging May 2021 www.innovationsfood.com SIG:Layout 1 14/5/21 09:03 Page 3

SIG announces launch of tethered caps for carton packs three years ahead of EU regulatory requirements

IG has announced that its tethered caps will be launched for its beverage cartons in Europe in the second half of 2021, well ahead of the July 2024 deadline set by EU regulations.S The redesigned caps do not compromise on convenience and will be compatible with existing filling machines and closure applicators so customers can be confident investing in a long-term partnership with SIG to deliver food and beverages to consumers in a safe, sustainable and affordable way. Customers choosing the company’s SIGNATURE packaging solutions will also get the additional environmental benefit of tethered caps made from polymers linked to 100% renewable, forest-based materials. “Our new tethered cap solutions build on SIG’s strong track record on sustainable innovation as we go Way Beyond Good for people and the planet,” said Ali Kaylan, SVP Innovation and VP Global Marketing at SIG. “By announcing the launch three years ahead of regulatory requirements, we are providing reassurance for customers as they prepare to comply with forthcoming EU regulations. Thanks to SIG’s flexible and adaptable systems, our tethered caps can be used with existing SIG filling lines and closure applicators, making our solutions The tethered domeTwist will be available for SIG’s way and without needing to hold down the cap with a secure investment for the long-term.” carton bottle combidome, as well as tethered their fingers. To close the pack, the cap is simply combiMaxx and tethered combiSwift options for lifted slightly before closing in the usual way. Meeting consumer and regulatory demand SIG’s core family-size carton portfolio. Together, There is no compromise in convenience when for sustainable packaging these account for around 90% of SIG’s European pouring or drinking from the pack, and tethering the Customers are facing increasing demand for closures by volume. cap to the pack adds convenience by avoiding the sustainable packaging from consumers and regula- The new tethered caps are designed to be used cap getting lost. The pack can be opened and closed tors, with a particular focus on single-use plastics to with existing SIG filling lines and closure applicators, easily as needed until it’s empty, then the cap and tackle today’s concerns about plastic waste leaking with no major capital expenditure required by the pack can be recycled together. into the environment, especially into the world’s customers. Indeed, compatibility with existing SIG oceans. filling lines and customers’ existing packaging Building on SIG’s industry-first sustainable innovations The tethered caps are the latest in a series of sustainable innovations from SIG. The tethered caps will also be offered with polymers linked to 100% renewable, forest-based raw materials (via a certified mass balance system) for customers choosing SIG’s SIGNATURE solutions that include these polymers in the packs themselves. SIG’s sustainable packaging innovations are part of the company’s commitment to go Way Beyond Good for society and the environment and deliver added value to customers. The European Union’s Single-Use Plastics Directive designs, secondary packaging and logistics was a includes a requirement for all single-use beverage key consideration in the design of SIG’s tethered containers to come with their caps attached by July caps. This demonstrates a flexibility and adaptability 2024 to help ensure the caps are disposed of and that enables customers to be confident in SIG’s recycled together with the rest of the pack. packaging and filling solutions as a secure invest- SIG has developed tethered caps ready for market ment for the future. launch well in advance of the 2024 deadline to reassure customers that SIG remains the right Maintaining high convenience levels partner to help them meet consumer demand for for consumers sustainable packaging and stay ahead of European SIG’s tethered caps use a robust double-hinge regulatory requirements. solution that proved highly suitable for consumers during market research. Integrating with existing solutions for a When the pack is opened for pouring, the cap can seamless customer experience be firmly fixed at the desired position by pressing it SIG’s tethered caps will be launched initially for the down until it clicks. This means the consumer can https://www.sig.biz/en/packaging/open- closures used with its most popular packs in Europe. pour from the pack without the cap getting in the ings/tethered-caps

www.innovationsfood.com May 2021 Innovations in Food Processing & Packaging 33 SAPPI-3:Layout 1 14/5/21 09:03 Page 2

Creating sustainable packaging solutions for confectionery goods

Sappi and the packaging technology manufacturer Syntegon Technology are joining forces for more sustainable solutions in the confectionery industry

he pressure on brand manufacturers and thus on the packaging industry from consumers, retail and legislators to offer environmentally friendly materials and processesT is very high. Companies’ own aspirations to implement sustainable solutions are also growing rapidly. Tooffer reliable and sustainable paper-based packaging solutions to predominantly large and medium-sized customers in the confectionery industry, the innovation leaders Sappi Europe and Syntegon Technology have entered into a strategic partnership.

• Synergies for greater sustainability in the packaging of branded goods • Guaranteed product safety for confectionery goods • Conversion of packaging machines

While a large portion of the packaging industry is still merely talking about sustainable pack- aging solutions, the innovation leader Sappi already has a wide range of barrier on the market. Sappi has considerable expertise in relation to the creation of safe, functional paper packaging in particular. This goes perfectly with the approach of Syntegon Technology. The provider of process and Sappi and Syntegon Technology are joining forces for more sustainable solutions in the confectionery industry packaging technology supports its customers with regard to sustainability through material tests, the ‘paper-ON-form’ retrofit kit from Syntegon on its water vapour, grease, flavourings and oil, and thus machine applications and innovative packaging existing fill-and-seal machines. ensure that the quality of foods and other goods is designs. Syntegon follows two approaches when it One benefit of the new partnership for maintained. The barrier papers also make any comes to sustainable packaging: customers in the confectionery industry is consult- additional unnecessary. This means that ‘Depending on the product protection ing expertise. A precise needs analysis with regard to the packaging materials that are made from renew- requirements, we enable the use of conventional product requirements for the packaging, as well as able raw materials, can be recycled in the existing multi-layer laminates through recyclable mono- comprehensive material tests subsequently ensure paper cycle. They also offer a high-quality appear- materials or paper – both on existing Syntegon smooth packaging processes. Furthermore, thanks ance thanks to the natural look and feel of the technology owned by our customers and on new to Syntegon’s innovative technology, customers are paper, as well as providing excellent printability technology,’ explains Christoph Langohr, Project perfectly positioned for packaging processes with performance. This allows confectionary manufac- Manager Sustainability Horizontal at Syntegon. So, paper-based materials. The ‘paper-ON-form’ retrofit turers to communicate the value they place on the what could make more sense than joining forces? kit ensures optimal shaping and sealing in the combination of quality and environmental respon- packaging process even at high speeds for cold-seal sibility, through the entire supply chain, from retailer Combined expertise for branded applications. This can optionally be integrated into to consumer, creating confidence in a more manufacturers new Syntegon technology, but can also be retrofit- positive, shared future. While Syntegon typically operates ted into older technology from Syntegon. This You can learn more about the collabora- independently of packaging material and Sappi means that production targets can be optimally met, tion between Sappi Europe and Syntegon Technol- independently of packaging machines, their as the switch does not result in any deterioration of ogy in this video: https://player.vimeo.com/ combined expertise now comes to the fore – to the packaging speed or overall equipment effectiveness. video/512430141 benefit of customers. Branded companies in the confectionery industry in particular can now benefit Securely packaged products: recyclable from sustainable paper solutions, thanks to the close and attractive cooperation between the two companies, enabling In the production and packaging of them to stand out from the crowd at the point of sensitive foods such as confectionery, it is not just sale by providing the perfect blend of product optimal processes that are important, but also using protection and sustainability performance for their the right material. ‘Product protection is always products. paramount and is an essential feature of any The first joint projects undertaken by the packaging solution,’ explains René Köhler, Head of two companies in relation to confectionery packag- New Business Development Packaging Solutions at ing for branded goods demonstrate that moving Sappi. ‘Factors such as ingredients and the shelf life to paper-based solutions can be implemented of the product play an important role in this.’ effectively and safely. For example, a well-known To guarantee comprehensive product chocolate manufacturer successfully changed the safety, brand manufacturers use certified barrier packaging of one of its products from conventional papers from Sappi. The food-safe, paper-based to paper-based material from Sappi, after installing solutions offer integrated barriers against oxygen, www.sappi.com

34 Innovations in Food Processing & Packaging May 2021 www.innovationsfood.com TOMRA SORTING:Layout 1 14/5/21 09:04 Page 3

TOMRA confirms excellent detection of V-Shapes sachets as polypropylene

Convenient single-dose packaging from V-Shapes, enabling dispensing of product with a single hand, is now proven more sustainable than ever

-Shapes, an innovative supplier of vertically integrated products and services for convenient, hygienic and sustainable single-dose packaging, and TOMRA, a Vproducer of customized sorting solutions, recently confirmed V-Shapes’ single-dose sachets as being constructed of polypropylene and easily detected in the waste stream for proper sorting. These unique sachets are constructed with material from a variety of sources, including V-Shapes-developed materials as well as substrate provided by Sihl GmbH that is specifically designed for recyclability and ideal for use with digital inkjet printing. The result is V-Shapes recyclable material that is also compatible with SIHL ARTYSIO recyclable functional flexible packaging films for aqueous inkjet printing, providing multiple choices for configuration. Sihl not only offers a special coating that works with water-based inkjet inks, but also a multifunctional top film that, in addition to excellent printability with aqueous inkjet, also has great sealing properties to provide the best protection during the shelf life period with barrier properties matched to the product being filled. In addition to the TOMRA verification of detectability, the independent auditing company Interseroh has confirmed the excellent recyclability solutions create the V-Shapes patented opening “For purposes of recycling, the V-Shapes of the V-Shapes ‘Made for Recycling’ polypropylene solution with a pre-cut of the semi-rigid material, sachets are considered rigid materials; industrial packaging used to create V-Shapes sachets. followed by exact dosing of product, sealing and recycling centers have difficulty recycling flexible “At V-Shapes, we offer a wide range of cutting to form customized filled sachets at up to materials,” said Sven Dobler, Senior Vice President of substrate types for our single-dose sachets, 300 units per minute. Sachets can also feature Orlandi, Inc., an early adopter of the V-Shapes depending on customer needs and the product branded printing on one or both sides. The solution. “We believe the ability to guarantee the type being filled,” said Jesper Gustavsson, Business compact footprint of this converting/filling equip- V-Shapes 100% polypropylene sachets as Development & Founding Partner, of V-Shapes. “We ment means it can be conveniently operated in detectable per the TOMRA tests will be a significant are especially pleased to be able to offer our spaces as small as 25 square meters, using a boost to our business and drive conversion from customers a recyclable polypropylene sachet based single operator, and deliver a robust return on flexible single-unit packaging to the V-Shapes on materials recently developed by V-Shapes which investment for packaging /fillers. The solution. The concern about waste and consumer have been shown to have excellent specific sachet materials tested by consciousness about sustainability are barriers to the industrial recyclability by a number TOMRA were constructed of a adoption of conventional flexible single-unit of certifying organizations, including V-Shapes developed semi-rigid packaging, and our high-end cosmetics brands are most recently sorting verification by material for use on the bottom of eager to include this packaging concept in their TOMRA and certification of the the sachet and a V-Shapes devel- offering for a more circular economy approach.” SIHL media by Interseroh.” oped flexible polypropylene mono- “Especially during the COVID-19 V-Shapes sachets are a polymer for use on the top layer pandemic, brands, retailers and operators of large- brand-new way to safely, affordably that includes a thin inner liner of audience venues such as sports arenas, airports and and sustainably deliver single-dose aluminium oxide to establish a theme parks have expressed a growing interest in a products, from hand sanitizer to barrier to prevent migration of more sustainable, hygienic and convenient way to honey and more that can be easily opened with contaminants into the contained product. Precut dispense products in precise single-dose measures,” only one hand. These recyclable single portion sheets, rather than assembled product, were used said Christian Burattini, CEO of V-Shapes. “These sachets can be printed on the top and/or bottom in the verification process. sachets, constructed of V-Shapes developed sides in multiple languages with customized brand “We were satisfied with the detectability of monopolymer polypropylene ‘designed for messaging and use instructions. They represent a V-Shapes sachets constructed from V-Shapes- recycling’ substrate, combined with the efficiency new and innovative way to distribute single-dose developed monopolymer polypropylene and the and cost savings associated with our vertically liquid and powdered products. Up to 98% of ability for the sachets to be accurately detected in integrated ALPHA and PRIME converting/filling units, packaged product can easily be dispensed using just the waste stream using our near infrared (NIR) light offer a revolutionary way of meeting those needs. ” one hand, resulting in little product waste and no detection system,” said Charlotte Glassneck, mess or spillage. V-Shapes provides its vertically Manager Plastics Applications, at TOMRA. “Even the For more information about products and integrated ALPHA and PRIME converting/filling smallest V-Shapes polypropylene sachets, which are services from V-Shapes, visit https://www. systems to converters/fillers/brand owners around available as small as 40 x 50 mm and 40 x 80 mm, v-shapes.com/. the globe who can then add these innovative are detectable as they are sorted in the waste For more information about testing, sachets to their offerings. Beginning with a roll of stream using our detection equipment and can be recycling, sorting and other products and services substrate, ALPHA and PRIME vertically integrated accurately sorted in the industrial recycling process.” from TOMRA, visit www.TOMRA.com

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EasyPack Packaging Schwarzwaldmilch joins with V-Shapes first to opt for to drive new business with SIG’s innovative unique packaging combiMaxx concept closure -Shapes, an innovative supplier of vertically Vintegrated products and services for conven- ient, hygienic and sustainable single-dose packag- ing, has reported that South African company EasyPack Packaging has acquired a V-Shapes ALPHA vertically integrated machine for the manu- facture of single-dose sachets that can be opened with one gesture using one hand. In addition to producing hand sanitizer, the company also packages and exports food products, such as honey, peanut butter, grappa, olive oils – anything liquid to semi-solid. “I have known the Burattini family for many years,” Dr. Hennie du Plessis, CEO of EasyPack © SIG Packaging, states. “The Italians are the best at manufacturing packaging machines. So I turned to The first commercial launch of SIG’s innovative and highly convenient closure combiMaxx has taken place in partnership with well- the late Antonio and his son Christian in 2005 to known German dairy Schwarzwaldmilch. see if we could come up with a more convenient approach to a single-serve sachet. The need for this combiMaxx can generally be combined came to the fore after my wife broke a tooth trying he first commercial launch of SIG’s innovative with all existing mid- and large sized combibloc and to open a traditional small ketchup package!” Tand highly convenient closure combiMaxx has combifit carton packs from SIG, starting with du Plessis, formerly working as a rocket taken place in partnership with well-known German combiblocSlimline, combiblocMidi and combifit- scientist, has a background in chemical engineering dairy Schwarzwaldmilch. Midi. The upgrade to combiMaxx was possible with- and a doctorate in petrochemical chemistry. When Consumer demand for more convenience out significant investment by Schwarzwaldmilch, as Christian Burattini co-founded V-Shapes, inventing in packaging is constantly growing. SIG’s new wider the company was able to use its existing closure an innovative, patented and vertically integrated closure combiMaxx is a solution which takes applicator. packaging machine that produces single-dose convenience to a new level, while also ensuring Only a minor technical upgrade to the sachets, du Plessis was one of the first to jump on smooth and easy implementation on existing SIG existing closure applicator and sorter unit is required board. “We installed our ALPHA machine in 2018,” filling lines. via an upgrade kit and, once installed, customers he says, “we were the second in the world to have Schwarzwaldmilch now offers combiMaxx can run combiMaxx and SIG’s best-selling closure one. And it has been a huge boon to our business. on all its dairy products in SIG’s combiblocSlimline solution combiSwift on the same applicator. Just With this six-lane machine, we can produce close to 1,000ml carton packs. Due to its large opening with one small setting change is required by the machine 350.000 single-dose sachets per day, a huge a 25mm inner diameter, the new closure offers operator. improvement over any packaging machine I know optimal product flow, perfect stream controllability Frederic Faber, Marketing Manager D-A-CH of for single-dose products.” and easy handling. Other benefits include a tamper- at SIG: “Our combiMaxx closure is certainly a game The V-Shapes ALPHA machine has been a proof ring and the reassurance of resealable and changer for the food and beverage industry when significant growth driver for du Plessis with existing leak-proof storage. it comes to consumer convenience. Our close customers. “But almost more exciting,” he says, “is Andreas Schneider, Managing Director of cooperation with Schwarzwaldmilch has turned the the ability to attract new customers. We are very Schwarzwaldmilch: “Meeting the convenience challenge of meeting ongoing consumer needs into busy talking with overseas customers and foresee at needs of the consumer is important to us. Incorpo- a reality.” least one large customer that would keep two rating SIG’s new combiMaxx closure on our dairy The partnership between SIG and six-lane ALPHA machines busy full-time! That’s how packages offers outstanding performance for Schwarzwaldmilch offers true product innovation unique the offering is; and especially in this consumers, while also strengthening our brand and differentiation as part of SIG’s Value Proposi- pandemic time, brands are seeking better and more position. Our close cooperation with SIG enables us tion, which aims to deliver innovative product and hygienic ways to distribute their products.” to take consumer convenience to the next level packaging solutions that enable businesses to satisfy One other point du Plessis makes about without the need for a new closure applicator or any ever-changing needs. the V-Shapes sachets is that they can be completely major investment.” www.sig.biz filled, and the edges seal even if there is product contamination in the seal area. “The importance of complete filling not only ensures the exact dose is packaged, but it also eliminates the need for air head space required by other types of packaging,” he says. “Depending on the product, adding air to Smurfit Kappa announces €40 million the package can significantly reduce the shelf life and/or quality of the packaged product. You can investment in North Wales also pack the same volume in a smaller space than with traditional sachets. And, of course, there is murfit Kappa has approved transformational deliver unrivalled, innovative packaging solutions to much less weight and space consumption than Sinvestment plans for its Mold plant in North customers across the UK and Ireland. We are when using bottles. Plus, the floor space required Wales, that will further expand capacity at the determined to meet the future needs of our to operate ALPHA is minimal. One salad dressing facility, make it the largest box factory in the UK and customers in a sustainable way. It is vital that our customer said her current single-serve packaging allow the company to meet the growing demand investment has benefits for the local community process requires six times the space required by for sustainable packaging. and the environment.” ALPHA to produce the same amount of product!” The investment in state-of-the-art equip- The on-site Experience Centre offers du Plessis concludes, “the V-Shapes ment will reduce CO2 per tonne emissions by 15% customers the chance to come into the facility solution is in a class of its own, a different league. at the plant. to see the science, creativity and data used to There is nothing else out there in the market that Commenting on the announcement, innovate, customise and implement sustainable compares.” Smurfit Kappa UK and Ireland CEO, Eddie Fellows, packaging solutions. said, “This investment in North Wales will increase www.V-Shapes.com our capability, flexibility and speed of response to www.smurfitkappa.com

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AR Packaging New BOPP film with fibre-based barrier tray for fresh vegetables improved thermal resistance and fruit minimises nnovia Films is launching a new film in its aging films. CHS offers improved thermal resist- use of plastics IPropafilm™ range of transparent speciality pack ance and shrinkage properties compared to conventional polypropylene films. It has been resh vegetables and fruit are food categories designed to substitute traditional outer web films in Fwith high waste levels throughout the supply laminates for applications such as pouches and chain. To meet the move to packaging with less lidding in various food markets. plastics while not sacrificing product protection, AR Paul Watters, Product Development Packaging has introduced a barrier cartonboard tray Manager Packaging, Innovia Films explains “With with more than 95% fibre content, tailored barrier CHS, we have developed a BOPP film with and convenience features. enhanced functionality which allows the film to be The drive to minimise the use of plastics in used in new application areas. We have been packaging is a main topic for retailers and food particularly successful with the film’s performance producer. Solid plastic trays are commonly used for as the outer film of laminate structures used in fresh vegetables and fruits, and even if trays made applications. In this application area of renewable plastics have been introduced, there are a lot of mixed material laminates used and recyclable fibre trays are requested. AR Packaging because of the drive towards simplified structures it has therefore introduced a one-piece tray with a thin is important to offer alternatives to the traditional barrier coating. The tray is based on cartonboard films used and CHS is a part of this solution.” made of fibres from certified sustainably managed Watters continued “CHS will help our sources and a fibre content of up to 95% makes it customer on the journey towards developing new recyclable in the paper stream in most countries. structures based on mono-materials for better and “The majority of our product develop- more efficient recycling in the future.” ments are focused on packaging solutions made of CHS like many other Propafilm products renewable materials and which are recyclable. The has been classified as Made for Recycling by switch to fibre-based trays for fresh vegetables can Interseroh. Paul Watters, explains “The Interseroh be pretty easy with no investments in new produc- certification of CHS demonstrates that the film can tion equipment needed”, said Philipp Eissner, be recycled in countries where the infrastructure Business Development Manager at AR Packaging. exists to recycle polypropylene.” “These new trays are already in use in Germany and they are well suited for a wide range of products Propafilm™ CHS offers improved thermal resistance and If you want more information or to trial such as fresh vegetables & fruits, herbs, mushrooms, shrinkage properties compared to conventional polypropy- this new film for your products then contact seeds and much more.” lene films. packaging@innoviafilms.com www.ar-packaging.com Proseal takes the lead in sustainable tray formats

ray sealing specialist Proseal says it is perfectly Modified Atmosphere Packaging (MAP) tray. suitability of plastic vs cardboard for trays will Tpositioned to help food producers explore Produced with renewable or recycled cardboard, continue for years to come and that there is room ptions for alternative packaging materials. The HALOPACK® combines a strong environmental for both materials in the market. Recycling and company has worked closely with both tray and film profile with high barrier properties that maintain reusing both types of packaging has proved to be suppliers to stay ahead of the demand from product quality and extend shelf-life. The patented the most effective way to minimise carbon footprint retailers and consumers for environmentally friendly design is fully sealable for efficient in-line produc- and protect the environment. solutions and has a proven track record with many tion and Proseal can supply a machine that erects The adoption of top sealing instead of alternative formats now available in the market and assembles the packs. and clip-on lids in the soft fruit sector, for following the work Proseal has done. At the same time, Proseal acknowledges example, reduces packaging materials by as much In particular, Proseal’s entire range of tray the important role that plastic packaging plays in the as 45%. This equates to a saving of 10 tonnes of sealing machines already have the capabilities to food sector, particularly its ability to help reduce plastic for every one million trays that are top sealed. handle different materials such as board and pulp food waste, which is widely acknowledged as a Similarly, Proseal can assist tray manufacturers in the with no modifications necessary. This enables food significant environmental problem. Protein produc- development of lighter weight trays that still have manufacturers to switch more easily to new pack ers have now switched from PE lined PP trays to the strength and robustness to produce tight, high formats without an additional and costly investment. mono APET, which can be recycled. quality seals in its tray sealers. Proseal’s innovative ProPosition™ auto- Proseal believes the arguments over the “Environmental concerns are becoming matically identifies the best position for an increasingly important part of trays, to ensure perfect alignment every consumers’ food purchasing decisions, time. Its advanced technology provides but they are still seeking quality and food manufacturers and processors freshness from their products,” with a simple one-step tool-set-up and comments Tony Burgess, Sales Direc- removes the time consuming and tor of Proseal. potentially wasteful process of running “Our developmental work is test trays. focused on ensuring that new pack The company’s unique Test formats remain functional and fit-for- Kitchen facilities are also available to purpose and do not compromise on allow suppliers of alternative packaging protection or shelf-life while still deliver- materials to carry out extensive trials. ing sustainability benefits.” This ensures that any potential tray Founded in 1998, Proseal design is conducive to tray sealing, able designs and manufactures high quality to deliver the required levels of tray sealing machines, conveyor product protection and extend shelf- systems and sealing tools for food life, and that on the shelf presentation industry markets worldwide. Proseal is can be successfully commercialised. part of the JBT family, and together they In addition, Proseal is the tray remain committed to continually sealing partner for the HALOPACK® supporting customers’ needs. tray, the first fully gas-tight cardboard Alternative Materials Proseal Test Kitchen www.proseal.com

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VAC 95+ for recycling at the highest level

t's new, it's sustainable, it's fully recyclable: VAC ately visible at a glance for every user and consumer. I95+ is the name of the new innovative vacuum VAC 95+ was developed in the company's own bag from allfo, Germany, that brings a plus in laboratory and application technology centre located sustainability to the retail trade and thus revolution- in Germany. izes processes in the food and packaging industry. Like no other vacuum bag, the new VAC 95+ Powerful sustainability combines outstanding barrier properties with great The sustainable product protection is as performance in product presentation and the best effective as ever. It has even better barrier properties environmental compatibility. than the classic PA/PE vacuum bags and keeps The innovation consists of more than 95% food fresh and appetizing to the highest degree. The polypropylene (PP) and a thin high barrier. There- high barrier properties protect the packed products fore, the name VAC 95+, too. In contrast to the against water vapour (H2O) and oxygen (O2) and original combination of (PE) and thus ensure a long shelf-life of foodstuffs and other polyamide (PA), PP can be easily recycled material- sensitive products. Due to its very good sealability, based. The innovative PP bags with a thin high the VAC 95+ can be used on all common vacuum barrier can be identified and sorted out in modern chamber machines. This makes it the ideal sorting facilities and then be reprocessed into environmentally friendly bag for sensitive foods such high-purity recyclates. These can then be used to as meat, sausage, fish or seafood. But cheese, manufacture new products. potatoes, ready-to-eat meals and vegetables also stay fresh longer in the VAC 95+ and are safely Excellent recyclability protected from spoilage during transport and on the The excellent recyclability has now also sales shelves. The hygienic preservation of food- been officially confirmed: For the latest PP bag stuffs is ensured by the tight fit of the vacuum bags generation, allfo, the European market leader for on the product as well as the stable gas and oxygen from 2022 this must be as high as 63%. With our high-quality vacuum packaging, received EU-wide barrier. VAC 95+ produced in Germany, companies can certification from the cyclos-HTP institute in the achieve the required high recycling rates - today and category "recycling class AAA". allfo is thus the first With VAC95+, the company allfo achieves the in the future," says Gessinger. and only manufacturer of vacuum bags to receive recycling rate the highest recyclability class for its product. The innovation from allfo helps companies Vacuum bags for a reduced CO2 footprint “With the VAC 95+, we’ve hit the nail on achieve the recycling quota required by the EU. The Not only its recyclable materials but also the head and are offering an innovative and European Packaging Directive (94/62/EC), already the high level of quality of the PP bag are of sustainable solution just at the right time. Because published in 2018, affects all member states and benefit to the environment. Because the CO2 the pressure on food producers and the packaging requires a recycling quota of 50% for plastics within footprint that occurs during food production is industry is becoming ever greater. More than ever the next five years. By the end of 2030, the quota significantly higher than that in the manufacturing before, ecological alternatives to the conventional is expected to rise even further – in fact, to 55%. process of the vacuum bags. Thus, every vacuum vacuum bags in PA/PE are being sought. With our The European Commission even speaks out in bag provides the foodstuff with protection against VAC 95+, we deliver exactly this alternative that is favour of all plastic packaging on the EU market spoiling, a contribution to greater sustainability. Even also expected by consumers at the point of sale” being recyclable by this point in time. more environmentally friendly if the product explained Harald Gessinger. The plus in sustainabil- "In Germany, these stricter requirements protection can also be completely recycled, as with ity is visible to everyone – namely via the imprint already apply. Our national packaging law currently the latest innovation from allfo. “100% recyclable”. So, the recyclability is immedi- requires a recycling rate of 58.5% for plastics, and www.allfo.de

i2r enjoys strong connection with iconic pie brand

eading tray manufacturers, i2r to surge. nation’s favourite. LPackaging Solutions, supply the UK’s number Iconic food manufacturer, Pukka, has been Focusing on new product development, one hot pie brand¹, Pukka Pies. A long standing making and baking its award-winning pies in Sys- i2r’s association with the pie brand has evolved supplier relationship, i2r’s strong connection with ton, Leicester for over 57 years. The company is a since 2015 and they currently supply both plain and Pukka is down to being innovative and anticipating privately owned family business and employs over coloured aluminium trays for Pukka’s grocery range. new trends - a trait particularly important in the 360 people, producing over 180,000 pies per day The trays, which support a variety of recipes, are burgeoning convenience food sector, where the in the UK and overseas. Winners of The Grocer’s produced in a number of colour variations including demand for quick and easy meal options continues Brand of the Year in 2020, Pukka pies are the black, red, gold, green, grey, blue and silver, all of which are fully recyclable. Pukka’s pies are stocked in fish & chip shops across the county, as well as more than 4,000 grocery outlets nationwide, including Tesco, Asda, Morrisons, Sainsbury’s and Co-op, as well as a range of smaller convenience stores. “We really enjoy working alongside i2r, and have been working with them for a number of years now”, said Pukka’s Gary McCall. “Their excellent service, product quality and help with NPD in particular, are all key attributes in making our supply chain as efficient as possible.” i2r’s Commercial Director, Jon West, added: “Our relationship with Pukka goes from strength to strength. They trust us to deliver, maintain a streamlined supply chain and provide outstanding customer support; in doing so, we are able to fully anticipate their needs and ensure we fully support Pukka’s development program as well as well as complementing their sustainability ethos.”

www.i2rps.com

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The bad, the ugly and the good - New consumer research highlights packaging frustrations and delights

ow attitudes to packaging and its functionality Hhave changed over the past seven years, based on a detailed survey of 1,000 UK consumers, is the subject of a new White Paper from leading packaging tapes provider Essentra Tapes. The full results were first revealed at a recent ThePackHub webinar, where Essentra Tape’s head of marketing & development, Ian Beresford, unveiled consumers’ latest opinions and compared them to previous research in 2013. While the survey showed a 15% decrease in consumer packaging frustrations during this time, at 70% the figure remained high, with difficulty in opening packs still a major gripe among respon- dents. However, environmental concerns and the “Such additional benefits can help to huge growth of e-commerce have had a significant reinforce positive perceptions about a product and influence on consumer opinions, and overpackag- support brand image and positioning.” ing is now seen as the number one frustration. Key findings from the survey included: Not surprisingly, the Covid-19 pandemic • Too much packaging is now the number one has also had an impact, with the hygienic benefits frustration with 58% of consumers highlighting this of packaging becoming more important. issue, an increase from 49% in 2013. Age was still a key factor, and the research • 57% of those surveyed cited ‘Difficult to open’ as confirmed that ease of access continued to be a their top frustration and 48% said that they had particular problem for the over 55s. Access was also to use knives or other tools to get into packs. This the deciding factor behind consumers’ most and compares to 61% and 69% in 2013. least favourite pack styles. The three most frustrating • 56% of respondents said there was too much Glass jar packs all lacked opening devices with the hard packaging in home delivered goods and 40% plastic clamshell retaining its top spot from 2013, highlighted the amount of waste this generates. while juice cartons with screw caps and cans with • Over 50% of consumers are very or extremely sealing ring pulls were the number one and two most concerned about the hygiene of goods in super- pleasing packs. markets and takeaway food deliveries as a result of In addition, consumers highlighted the the pandemic. research puts importance of sustainability within packaging and • The top ten most frustrating and pleasing packs ranked recyclability as their number one issue. Packs were: Selig on top

new series of independent tests carried out to Adiscover the best way to seal glass jars has put Selig’s GlassFuze on top. The research was commissioned by a peanut butter producer follow- ing complaints from customers relating to product spoilage. A new solution had to be found to seal the jars, as the company’s brand reputation was being put at risk. High oil content products, such as peanut butter, can be challenging to package as the oil makes it difficult to achieve a 100% between the liner and the jar . With this in mind, that are easy to recycle are what consumers care Essentra Tapes is continuing to promote a packaging engineer tested five sealing methods about and providing simple, clear instructions and ‘Packaging with Purpose’ that not only enables on glass jars, using a 4-minute -300 mBar pressure the necessary infrastructure to help with this is key. brand owners to satisfy the need for functionality test on a laboratory Pack-Vac leak detector. It also appears that consumers are starting to expect but also delivers additional benefits that will help The sealing solutions tested on 100g glass packs to be designed to be more sustainable, with to strengthen a brand’s relationship with its jars included a plastic screw cap and an induction only a third saying they would be prepared to pay consumers. seal liner, a plastic screw cap and a foam liner, a more for sustainable packaging. “Packaging is the key medium by which to metal screw cap and a flowed-in seal and a metal “Our latest research shows that the image communicate the brand, and our research shows twist cap and a flowed-in seal. of packaging among consumers has improved that consumers respond positively to packs that Overall, the screw caps were shown to be somewhat since 2013 but there is clearly still work serve a clear purpose,” concluded Beresford. superior to the twist caps in terms of leakage to do,” commented Beresford. “In particular, it “When packaging works, it makes people prevention, but the leak test results showed that underlines the need for packaging manufacturers to feel good about the product; conversely, a poor only one solution provided consistent, secure continue to adapt their solutions in line with current pack can have a deeply negative effect on their sealing that showed no leakage. This was the jar market trends and consumer attitudes to sustain- perception of the brand, affecting re-purchase sealed using Selig’s induction heat seal liner with ability, making it easier for them to make the right decisions. GlassFuze™ heat seal. choice. “Packaging solutions that focus on open- Darren Dodd, Marketing and Service “It is also clear that the need to meet this ing, closing, informing and protecting can resolve Director at Selig says, “With more than two years of wide variety of consumer needs means that packs many of the typical consumer pack frustrations and research, we’re proud that the capabilities of often have to be multi-functional. For example, a at the same time deliver added value and enhance GlassFuze™ have received independent endorse- for easy-opening can also provide a means brand image, to the extent of becoming an integral ment. Oily products are notoriously difficult to seal of communication between a brand and its part of the brand experience.” securely, and this small solution can make a big consumers; a resealable pack can combine user- difference to product reliability and a brand’s convenience with product protection, portion The Essentra white paper is available to download reputation.” control and the minimisation of food waste. free at www.essentra.com/en/capabilities/tapes. www.seligsealing.com

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Brupac chooses new disposable, Mondi’s new yet recyclable, in-cup drinks packaging packaging solution for Bell

K in-cup drinks specialist Brupac has moved the same size. The cup is wrapped with a cardboard Germany's Uover to using Greiner Packaging’s K3® card- outer layer, which can be produced with virgin or board-plastic packaging solution for its 12oz in-cup recycled board produced from sustainably managed ‘Abraham’ drinks range. forests. Brupac Drinks & Machine Company Greiner Packaging made the change to a Director Tim Worthington talks about why the new more environmentally-friendly packaging ham range change was made and the advantages it brings. solution really easy. We work with major well-known Due to Covid-19, the market for in-cup brands from Douwe Egberts and Café Direct to requires drinks has changed, with traditional markets such as PG Tips and Cadbury’s, so everything about the stadiums and large venues closed. However, now drinking experience has to be perfect. The K3® pack 37% less that the ‘roadmap for lifting lockdown’ has been keeps the ingredients safe until use and is great to announced, there is an increasing interest for in-cup drink from. It’s a huge bonus that the pack is also drinks in offices and catering establishments. fully and easily recyclable – which enhances our material and saves At a time when business owners and company’s and our brand partner’s reputation. facilities managers have safety and hygiene at the Until now, in respect of the recycling and 35 tonnes of plastic top of their agenda, disposable in-cup drinks have end-of-life of drinks cups, RECOUP has provided an many advantages. The alternative is to use crockery, answer, but the system relies on volume, and on spoons and containers, which can be handled by efficient collection. We are more confident in our ondi, a global leader in packaging and paper, multiple people and which require collection and sustainability position through choosing a pack that Mhas produced recyclable packaging for Bell dishwashing. Disposable in-cup drinks packaging can be easily recycled by each individual end-user. Germany’s ‘Abraham’ range of thinly sliced gourmet represents a safer, more hygienic, more cost effec- Working with well-known brands, we are ham that ensures perfect conformity with existing tive and more convenient solution. beginning to investigate opportunities to use the recycling guidelines. Brupac takes its environmental sustain- ability to print on the reverse of the cardboard wrap Bell Germany is launching a mono- ability responsibility very seriously and we needed to to not only communicate the recycling message, but material recyclable WalletPack in March for over 30 know that our disposable products could be easily also for brand promotions and consumer competi- products including Seranno, Prosciutto and Savoy and efficiently recycled. That’s why we chose tions. Greiner Packaging’s K3® isn’t just a step sliced ham. The new solution will replace a multi- Greiner Packaging’s K3® plastic-carboard solution. forward in terms of sustainability, it also presents a material non-recyclable plastic solution, using 37% The K3® light-weight thermoformed fantastic ‘free’ marketing opportunity! less material compared to standard modified uses up to 33% less polypropylene (PP) than a atmosphere packaging. This switch will also reduce conventional direct-printed, thermoformed cup of www.greiner-gpi.com plastic waste for Bell Germany by 35 tonnes per year thanks to the lightweight solution. It will also lower waste disposal fees for Bell Germany and meets the design for recycling guidelines of leading retailers.1 Created after two years of development, the new Mondi WalletPack operates as a folder, which the consumer opens to unpack the product. It features a re-close function on the backside to prevent food spoilage, provides excellent protection for thinly sliced deli meats, and has been verified by the German institute cyclos-HTP as 93% recyclable. © Greiner Packaging “Our aim is to create packaging that is Brupac’s 12oz in-cup drinks are now served in Greiner Packaging’s K3® plastic-cardboard solution sustainable by design. It should be better for the environment, while protecting the food, and stand- ing out on shelves to represent the Abraham brand. Our unique EcoSolutions approach takes all these elements into consideration: we worked closely with Bell Germany at every stage to ensure that this Performa Light™ by Stora Enso for high was the best solution for all their products”. says Thomas Kahl, EcoSolutions project Manager, Mondi. performance lightweight packaging Jessica Trautmann, Senior Product Manager, Bell Deutschland adds: “As with all food erforma Light is a GC2 folding boxboard that is unlimited scope in terms of the visual aesthetics that packaging, the priority is to protect the contents, Plight in weight but high in bulk and stiffness, can be achieved. however it has been our aim for some time to offering a robustness that enables brands to create Performa Light is manufactured at Fors Mill improve the recyclability of our packaging as we strong and firm packaging with less weight. in Sweden, with carbon neutral production using look to make all parts of our business more Combining excellent smoothness, high brightness patented fibre treatment technology to save energy sustainable. Mondi has been a valuable partner in and whiteness, Performa Light has an exceptional and raw materials without compromising packaging the creation of this solution and we are delighted to visual appearance. A triple pigment coated top side performance. be launching this new packaging that is recyclable, delivers excellent print results while the white Steve Chappell, Graphical Board Develop- while being functional and attractive on the shelf.” uncoated reverse side is industry leading. ment Manager at Antalis, says “Lighter weight The new packaging was launched with It’s a combination of features that lends boards mean reduced environmental impact and a German retailers from March 2021. itself to the creation of an array of premium pack- reduced carbon footprint at every stage of the pack- 1 Figures on savings calculated by Bell Germany aging applications, including cosmetics, beauty and aging life cycle. However, Performa Light maintains www.mondigroup.com healthcare as well as other graphical applications. improved strength due to microfibrillated cellulose Food contact approved and taste and odour neutral, in the structure. Lightweighting boards results in less Performa Light is also the ideal choice for packaging end waste and lower CO2 emissions in transport, chocolate, snacks and confectionery. all of which helps to make Performa Light a Send your news to It is compatible with a range of printing responsible, sustainable choice.” techniques, including offset, flexo, rotogravure and Performa Light is stocked in the UK & [email protected] digital and is ideal for finishing techniques such as Ireland by Antalis in a range of sizes and weights. embossing and hot foil stamping, ensuring almost www.antalis.co.uk

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New Sealed Air shrink packaging is designed-for-recycling for circular economy

ealed Air has developed a market leading Sdesigned for recycling shrink-packaging solution to support food companies increasingly move to a circular economy. The new CRYOVAC® brand Designed-for- Recycling Standard Presentation Shrink Bag and Shrinkable Rollstock are the world’s first RIC4 coded heat-sealable food packaging materials, meaning they are 100% recyclable* to help food processors and retailers further improve sustainability. Enhanced efficiencies and environmental performance can also be realised through the have been tested in accordance with protocols compatible with Horizontal Form Fill Seal technol- range’s thinner, lighter EVOH barrier and excellent set-out by the Association of Plastics Recyclers ogy and a range of other loaders. mechanical resistance. These features can help to (APR) and Plastics Recyclers Europe (PRE), with the Ed concluded: “To build a circular reduce packaging material usage and overall carbon 100% recyclability certified by Institut Cyclos-HTP. economy, we need materials and processes that footprint by up to 60%, compared to widely used Ed added: “As well as meeting growing take a holistic view of sustainability. This approach is packaging systems. demands for increased sustainability, the Designed- at the core of the new Designed-for-Recycling Ed Roberts, Global Sustainability Leader for-Recycling packaging also satisfies other packaging, with advances in recyclability achieved at Sealed Air, commented: “The Designed-for- important consumer requirements. The sealed as part of a solution delivering improved efficiencies Recycling Standard Presentation Shrink Bag and packs are easy opening, glossy with reduced haze and lower waste throughout the food supply chain, Shrinkable Rollstock have been designed to offer a and avoid discoloration of meats. Together, these beyond the end-of-packaging-life stage.” total packaging approach to improving sustainability. performance properties help drive sales, which is *The degree of recyclability of the final The recyclability is complemented by high shrink, another step towards less food waste and better package depends on the specific product configu- abuse resistance and barrier properties to reduce resourcefulness.” ration or components intended for recycling and the food waste, while also lowering sealing tempera- Operators can run the Standard Presenta- scope and availability of appropriate local recycling tures and energy usage during packaging.” tion Shrink Bags with a wide variety of heat-sealing facilities. The new Designed-for-Recycling Standard equipment including CRYOVAC® brand VR and VS Presentation Shrink Bag and Shrinkable Rollstock vacuum lines, while the Shrinkable Rollstock is www.sealedair.com ‘Project Snap’ ensures a sustainable future for PP yogurt multi-packs

ver the past two years, following requests from forefront of these developments and worked with OUK retailers, Greiner Packaging has replaced us quickly to re-engineer the PP multi-pack to give yogurt multi-packs made from polystyrene (PS) with it the same ‘snap’ quality of PS. polypropylene (PP) and ‘Project Snap’ has now successfully recreated the ‘snap’ which consumers A timeline of continuous investment love. Multi-pack development from PS to PP Yogurt multi-packs have traditionally been has taken considerable investment, but has been made from polystyrene (PS), but there is currently achieved faster than originally expected, with ‘Project no PS recycling stream in the UK and supermarkets Snap’ delivering the final part of the story. have focused on removing all PS products. Seeking “Over the past two and a half years, to deliver a sustainable alternative, in February 2018 Greiner Packaging Dungannon has invested heavily Greiner Packaging’s factory in Dungannon, in delivering these multi-packs made from PP Northern Ireland, began trials using polypropylene and then further engineering to give the same (PP), and was first in the UK to recreate a functional satisfying ‘snap’ as their predecessors,” says Greiner multi-pack in PP Packaging UK & Ireland CEO Philip Woolsey. © Greiner Packaging One of the advantages of PS was its Working with international thermoforming ability to deliver a really effective ‘break’ which was specialist Kiefel, thermoform machine maker Illig, New ‘Project Snap’ PP multipack yogurt packs from Greiner initially difficult to achieve with PP. Leading UK and filling and sealing specialists Trepko and Packaging ensure a sustainable future for this well-loved pack retailer Tesco was one of the first customers to Clondalkin, in February 2018, Greiner Packaging format. move from PS multi-packs to PP multi-packs, but began the development of a 4-pack PP multi-pack consumers were disappointed that packs made that could be easily separated. Production tooling particular food approvals. from the new material did not ‘snap’ in the same followed and by September 2018, filling and “The next step, for PP yogurt multi-packs way as the previous PS packs. sealing trials were underway at a UK dairy company. will be to manufacture them using recycled PP,” In July 2020, Greiner Packaging began By August 2019 all production trials were complete, Philip Woolsey concludes. “Mechanically recycled ‘Project Snap’ to develop and improve PP multi- and by the end of 2019 the new PP multi-packs PP can currently only be used for non-food pack breakability. By October 2020, the first were launched in the retail sector. Thanks to ‘Project packaging, however a food approval is now in successful filling trials of the latest PP 4-pack had Snap’, the new, improved multi-packs are now in preparation. Chemically recycled PP is suitable for begun, and the new improved yogurt 100g 4-packs retail. food contact, but not readily available as there are are now on-shelf. Greiner Packaging is currently heavily no large-scale recycling streams for PP. Greiner “We needed to remove PS from our involved in work on the use of recycled materials Packaging is currently involved in a project that aims packaging and Greiner Packaging helped us with such as r-PET, r-PS, and r-PP for the food industry, to obtain food approval for r-PP from mechanical the move to PP,” said Tesco Senior Packaging with a view to utilising greater quantities of recycled recycling. Ultimately, we will have succeeded in Manager Denise Mathieson. “However, our material in the manufacture of its plastic products helping retailers move to using a material which customers were always accustomed to the easy in the future. A holistic approach, together with the genuinely delivers on our circular economy ‘snap’ of the old PS yogurt multi-packs and we search for different material options, should lead to commitments, while still keep the fun element in needed to further develop this feature with the new quick results, irrespective of whether an issue relates place for consumers.” recyclable PP packaging. Greiner has been at the to new material-specific process innovations or https://www.greiner-gpi.com

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Amcor partners with Nestlé to bring sustainable packaging to shelves

mcor has leveraged its global R&D resources Ato help Nestlé put enviro-conscious consumers first, by making Smarties the first confectionery brand to move to recyclable paper packaging in Australia. The new packaging is made from sustain- ably sourced thermoformable paper and is dynamic enough to be printed on with either flexographic or gravure technology and finished with a heat or cold-seal adhesive. Reflex launch Pack Plus: Working closely with Nestlé, Amcor has developed this next generation packaging solution which performs when it comes to sustainability and consumer convenience, while also maintaining the A more sustainable highest levels of product protection. The new packaging technology with its various applications is used across the Smarties packaging solution Chocolate Block and Bar product range, is fully- recyclable and can go in home recycling bins, reaffirming Amcor’s commitment to more sustain- K based packaging company Reflex Group meet the requirements for recycling, which in turn able packaging today and for the future. Uhave launched a lined board division to helps to deliver the circular economy. Simon Roy, Vice President and General complement its existing packaging offering, and to The launch follows Reflex’s biggest ever Manager, Amcor Flexibles Australia & New Zealand provide a more environmentally friendly alternative single investment into two new state-of-the-art commented “As a diversified packaging company, to plastic packaging. bespoke lined-board printing presses totalling over we’re focused on delivering the most sustainable Grouped under the newly-formed Pack £5 million, which offer innovative printing capabili- packaging possible – whilst also ensuring product Plus division, the lined board products are suitable ties such as 7 colour front/reverse print, in-line foil protection and customer convenience – to help our for a wide variety of sectors including, MFP (Meat, capability and a combination of board, film and customers meet end consumer needs. This new Fish & Poultry), food-to-go, fresh produce, bakery paper lamination possibilities. range of packaging reaffirms our commitment and horticulture. The Pack Plus division is headed up by to ensuring all our packaging is designed to be Product variants include skillets, trays, fruit Jamie Gordon, who has 25-years’ experience in recyclable or reusable by 2025.” punnets, flat boards, slide seam sleeves, cartons, the packaging industry. Jamie began his career in crash-lock cartons and wrap boxes. production, moving to technical sales and account Main features of Reflex Pack Plus: management. Jamie later became a category • An environmentally responsible alternative to specialist in MFP and has been a Director in sales for Parkside’s Cré plastic trays, using up to 90% less plastic (includ- 8 years. ing skin film reduction) The Pack Plus products themselves have • Competitively priced and cost-effective been created by Innovations Manager Kevin Accreditation • 100% recyclable board and film when separated Dudman, who has been working in the packaging • Compostable adhesive for EN13432 packaging & retail industry for the past 40 years and is demonstrates best • Multicoloured 2-sided print and foiling passionate about discovering new, innovative and • Multiple lamination construction options using sustainable packaging solutions for Reflex’s growing practice for board, film & paper in innovative solutions portfolio of clients. • Unique board structure that’s both lightweight and Jamie Gordon said: “Reflex seeks to be on compostables rigid the forefront of innovation and is dedicated to • Environmentally & Vegan-friendly water-based inks providing sustainable and cost-effective packaging infrastructure and board adhesive solutions solutions for our clients. With many businesses • FSC & PEFC certified boards setting print sustainability and environmental pecialist packaging converter, Parkside Flexibles, • High-barrier lined for maintained shelf-life demands high on their agendas for 2021, we’re Sis well known for producing sustainable flexible • Emboss and de-boss technology excited to launch the Pack Plus range of products packaging. Their own range of laminates, • Alternative “dispersion coated” board options for that offer a realistic, sustainable and cost-effective Park2Nature™, is fully certified compostable. plastic-free sealing later alternative to a huge range of sectors” Parkside is a valued customer of Futamura’s The sustainable lined board options use Now operating out of 18 production sites NatureFlex™ renewable and compostable packag- FSC & PEFC accredited carton board, and more across the UK, Reflex Group produce a varied and ing films that provide an essential barrier layer for importantly its proprietary zero migration water- wide range of products from self-adhesive labels, many of the Park2Nature laminates. based inks and adhesives which are the hallmarks linerless labels, flexible packaging, labelling systems NatureFlex films are produced from of this truly revolutionary technological advance- & software, artwork & design, and more. sustainable wood pulp harvested from responsibly ment in recyclable packaging. As members of OPRL, managed plantations and are certified to both EU Reflex are able to align packaging specifications to www.reflexlabels.co.uk (EN13432) and US (ASTM D6400) composting standards. In addition to industrial composting, the product has also reached the T V Austria OK Compost Home standard. Ű Recently, Parkside has received Ireland’s Cré Accreditation for compostability and anaerobic digestion (AD) for their innovative paper triplex, containing NatureFlex as its barrier layer. The triplex is a high-performance flexible packaging structure for products such as coffee, confectionery, snacks, Please send your news items to and dried foods. The Cré accreditation means that the packaging can easily be identified by both consumer and collection facility as certified for [email protected] composting / AD processing with household food waste collection (in accordance with EN13432) and that those facilities are regulated to a high standard.

42 Innovations in Food Processing & Packaging May 2021 www.innovationsfood.com PACKAGING:Layout 1 14/5/21 09:14 Page 9

UK start-up, The Magical Mushroom Company, announces large-scale production of its plastic-free packaging made from mushrooms he Magical Mushroom Company (MMC), has UNITED CAPS announces Tannounced the launch of large-scale production of its mushroom-derived biodegradable packaging, a plastic-free alternative that can be broken up to biodegrade on a home compost heap or flowerbed. new products during Uniquely, this new packaging offers the same performance, at comparable cost, to traditional polystyrene, and is already being used to protect Interactive Virtual Event goods ranging from cookers, to cosmetics and a huge variety of everyday consumer products, including Diageo’s non-alcoholic gin brand, Seedlip. NITED CAPS, an international manufacturer of a white paper, which can be downloaded at This extraordinary packaging is made Ucaps and closures, has reported that, despite https://www.unitedcaps.com/company/united- possible through mycelium composite technology, the challenges of the pandemic, the company caps/uctc-report/. “It is our hope that wide distribu- pioneered and patented by US firm Ecovative continues to harvest from its rich product pipeline, tion of this white paper will encourage customers Design LLC. The process takes the post-processing developing and launching new products that will to engage with us on converting to these mandated waste from agricultural products such as hemp, help its customers be more productive and have closures as early as possible to avoid unnecessary hops, corn and timber and combines them with more sustainable packaging. These announce- non-compliance risks,” Henckes stated. mycelium – the root system of the mushroom. This ments were publicly made during UNITED living material is then grown to shape using 3D VIRTUALLY, an interactive virtual event held in lieu R&D efforts drive both product updates and moulds of the packaging design. These moulds are of the many industry in-person events that have new product development baked, hardening the material and preventing any been cancelled or postponed during the pandemic. New to the UNITED CAPS product further growth. The full process, from design to “While all of us are taking necessary steps portfolio is its 29 FLIP ON edible oils closure which prototype takes just 14 days. to control and ultimately put down this awful enables fast, clean pouring of liquids with drip MMC Holding International LTD, trading pandemic, at the same time, we must continue to control. It is easy to open and features a non- as The Magical Mushroom Company, has the move forward as an industry to ensure that products detachable tamper evident band that makes the exclusive EU, UK and Ireland licence to produce reach consumers in a safe and timely manner, and product more sustainable. A variety of branding Mushroom® Packaging. Its first facility, in Esher, that jobs are protected as much as possible,” said options and colours are available. Keeping the TE Surrey, began production in August 2020 and has Benoit Henckes, CEO of UNITED CAPS. “In light of band and closure intact boosts opportunities for capacity to produce more than a million packaging that objective, we at UNITED CAPS have continued recycling. units per year. to invest in our research and development efforts One example of UNITED CAPS’ dedication The business will open a second UK plant with the resulting announcements we are making at to continuous improvement is to continually update in 2021, increasing total production to more than UNITED VIRTUALLY, where we shared this news in already successful products to make them even three million units per year. This will be followed by seminars to ensure full understanding of their better is the launch of PROLINE 2, a closure for still the opening of plants in Bulgaria and Italy, which benefits among attendees.” beverages. This closure, which weighs just 3 grams, together will provide production capacity for the EU One area of discussion during UNITED performs like a much heavier closure and is of more than six million units annually. A third VIRTUALLYwas the first look at the progress UNITED suitable for use on aseptic lines. It is available in a continental European plant (in Germany) will open CAPS has made toward enabling customers to recycled material, improving its sustainability foot- in 2022. meet the EU regulations regarding tethered print, but can also be produced in more traditional With polystyrene causing immense closures. “At UNITED CAPS we talk about being materials upon request. As with many UNITED environmental harm, a commercially viable and BETTER UNITED,” Henckes added. “That obviously CAPS products, PROLINE 2 is available in a wide practical alternative is essential. Packaging produced is a reference to our quality, but it also speaks to our variety of colours for a premium look and on-shelf by MMC is 100% biodegradable at home and understanding that collaboration is a core compo- standout. Its venting feature improves end-user breaks down in soil within 40 days. It also fully nent of our success. Our development process for safety, venting pressure in the case of spoiled breaks down in water in just 180 days, meaning it tethered closures included extensive feedback from contents, and its advanced design offers exceptional has the long-term potential to significantly reduce both our customers and consumers which greatly grip. This innovative solution offers increased the level of plastic waste in our oceans. enhanced the end result.” efficiency and improved productivity in the filling of Paul Gilligan, Founder and CEO, UNITED CAPS views the EU directive sensitive beverages, such as juices and milks. commented: “We called ourselves the Magical regarding tethered closures as an industry-wide UNITED CAPS also presented its robust Mushroom company for a reason. Mycelium’s challenge that requires a holistic industry-wide line of caps and closures for Edible Oils & Vinegars unique qualities really are magical, enabling us to solution that would have as little impact as possible that offer Everything You Need, Nothing You Don’t, produce a hard-wearing, cost effective and totally on bottling lines and other parts of the supply chain. including its award-winning DOUBLEFLOW and a sustainable alternative to polystyrene packaging that To that end, the company spearheaded the forma- family of closure solutions for 26mm necks that biodegrades in the back garden in under 40 days. tion of the Alliance for Closure Tethering (ACT) to provide lightweight options without compromising “We’re thrilled to be open for business and bring together segment leaders in the packaging performance. The company continues to enhance excited by how quickly we’re scaling up our industry to conduct an impact assessment of this product portfolio as well as part of its R&D production and securing ever bigger contracts. various tethering solutions on existing finishes and efforts. Customer feedback has been universally positive to determine finishing changes that might be “We are pleased to be able to bring these and our earliest customers are all – without excep- required. The goal was to come to agreement on new and improved products to market during this tion – now coming back for more.” the best industry-wide approaches to tethered caps difficult time,” Henckes concluded, “to help the “With over a decade of experience and closures and to support better integration into industry continue to move forward and to stay in producing mycelium materials at scale, Ecovative is the supply chain with a united, rather than stand- compliance with important government regulations. thrilled to see consumers and brands around the alone, solution. But we are not stopping here. Stay tuned over the world adopt Mushroom® Packaging,” said Gavin The result is a broad portfolio of UNITED next weeks and months for additional innovation McIntyre, Co-founder and Director of Business CAPS tethered closures (UCTC) that were born news from UNITED CAPS as our talented R&D Development at Ecovative Design. “We are excited ready for the market, meet the new EU regulatory team continues its important work.” to be working with Magical Mushroom Company to requirements, and have been widely accepted by further scale this technology and look forward to UNITED CAPS customers. The company has For more information about UNITED providing more brands with this breakthrough published an informative white paper on its collab- VIRTUALLY and other information from UNITED packaging solution.” orative approach to developing tethered closures in CAPS, please visit www.unitedcaps.com.

www.innovationsfood.com May 2021 Innovations in Food Processing & Packaging 43 IN ASSOCIATION WITH

Where the processing, packaging & logistics sectors meet Informing, inspiring and connecting the industry

We look forward to the summer when the industry reunites and reconnects safely at the UK Food & Drink Shows, encompassing Foodex, National Convenience Show, Food & Drink Expo, Farm Shop & Deli Show, The Ingredients Show and The Forecourt Show. Register now at foodex.co.uk This is a trade event. No under-18s will be admitted.

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