< PreviousCLEANING AND MAINTENANCE On the spot inspection 30 Food & Drink International P lanned maintenance checks have been the norm for many years, but while they do allow for companies to continue operating without interference, they’re by no means the most efficient method of catching problems before they occur. And as factory lines become ever more automated and ever more mechanised, the problems associated with poor maintenance continue to stack. Automation gives manufacturers of food and drink the ability to carry out complicated tasks quickly and easily. However, it also brings with it the possibility of excessive downtime when breakdowns and accidents occur – interruptions which many companies can ill-afford. Considering how many businesses are looking to recover and perhaps expand after the pandemic, accidents – be they of workers or hygiene related – could well strike the death knell for a manufacturer. It may be an unfortunate truth, but companies that carry out maintenance checks on a planned and routine basis are often left at the mercy of their machinery, unable to predict or react in time to any problems that occur. To stay ahead of the game, manufacturers need to implement constant on-the-spot inspections. Of course, proper cleaning of those same machines also helps to reduce build-up of material that may lead to issues or damage later down the line. Investing up-front in some of the more sophisticated technologies on the market could pay dividends in the long run. For example, Electrical Panel Thermography can be used to identify even the most imperceptible flaws in a piece of manufacturing equipment. By measuring the temperature of a piece of machinery or individual component, thermal imaging devices can catch minor electrical faults before they cause On the spot inspection With tighter working conditions and a heavier focus on worker safety and food hygiene, on the spot maintenance inspections may well become the norm. 30-33.qxp_Layout 1 25/04/2022 14:53 Page 1Food & Drink International 31 serious damage, which ultimately means less downtime is needed for maintenance. Companies can also carry out spectrographic oil analyses to keep their machines running smoothly. The oil used to lubricate manufacturing machinery needs to be uncontaminated in order to do its job properly, but the only sure-fire way to guarantee this is to use an ICP (inductively coupled plasma mass) spectrometer to identify and weed out unwanted particle compositions. Conducting oil sample analysis can help to prolong the lifespan of machinery 32 Á © stock.adobe.com/nordroden © stock.adobe.com/ekkaluck 30-33.qxp_Layout 1 25/04/2022 14:53 Page 232 Food & Drink International www.fdiforum.net and should be carried out on a routine basis. Acoustic vibration monitoring technology, which costs relatively little, can also be employed to check the condition of mechanical parts. Industrial rotors, for example, will emit higher- frequency sounds if they sustain any damage. By using an Acoustic Emission (AE) sensor to detect early signs of friction, companies can address problems before they cause production to grind to a halt. It is vital to keep machinery as clean as possible – especially in an environment where food and drink is being produced. Products such as milk and cheese can be difficult to remove from hard surfaces if they are allowed to burn, and caramelised build-ups will inevitably make machines and pipes less functional. In order to remove potentially hazardous blockages, manufacturers are investing in UHP pipe-cleaning technologies which employ water pressure to achieve a more powerful clean. The latest products on the market are able to clean lengths of piping over 1 km long, and because many of them feature sophisticated rotary heads that increase water propulsion, they are also able to clean around bends. But what about health and safety? According to the Health and Safety Executive of the UK, machinery causes nearly five hundred accidents per year in the food and drink industry, including over 30% of fatal injuries. Poorly maintained and/or supervised conveyors are the biggest culprits, but food mixers, thermoform machines and wrapping machines also account for a significant percentage of the total. These figures make grim reading, but, thankfully, most companies are beginning to implement well-thought- out measures to ensure the health and safety of their staff. Eliminating hazards at the design stage is by far the best way to prevent machine-related accidents, but this is not always viable, and no method of checking is 100% fool-proof. Therefore, where particularly dangerous, heavy machinery is being used, companies should institute a permit-to-work system to ensure that, a) only highly trained operatives have access to the machinery, and b) that no individual is required to use a piece of machinery for longer than is necessary. It is similarly vital that machines are positioned in unconfined spaces on the factory floor. This not only reduces the risk of getting trapped in the moving parts of machines, but it also lessens © stock.adobe.com/auremar 30-33.qxp_Layout 1 25/04/2022 14:53 Page 3the chances of an operative inhaling the dust that is an inevitable by-product of many foods’ manufacturing processes. Dust inhalation and other issues such as eye and skin irritation can also be prevented if companies provision their staff with the correct safety equipment and take the trouble to install high-quality exhaust ventilation systems. Clean air is, of course, important, but is also by now a factor that every manufacturer should be wholly aware of. That said, given the nature of dust particulates and how difficult it is to detect them, many companies fail to maintain their air filtration systems as stringently as they should. It’s tempting, perhaps even cost-efficient, to focus on inspecting and repairing machinery directly related to profit- making, i.e. the manufacturing line, but this attitude is self- defeating in the long run. All machinery breaks eventually and catching it before it goes bad will save a company more in terms of money and time in the long run, hence the importance of spot inspections. Food & Drink International 33 www.fdiforum.net CLEANING AND MAINTENANCE FOLLOW US WHEN YOU SEE THE PERFORMANCE WHEN YOU SEE THE PRICE WW Versatile thanks to a wide performance range, intuitive and flexible user guidance, low-pulsation dosing, and energy-efficient during operation - all at an attractive initial cost. The new iSTEP XS offers XL performance at XS price ! iSTEP XS Now available iSTEPXS.sera-web.com More info: sales.uk@sera-web.com Tel. 01283 753400 © stock.adobe.com/spyarm According to the Health and Safety Executive of the UK, machinery causes nearly five hundred accidents per year in the food and drink industry, including over 30% of fatal injuries. 30-33.qxp_Layout 1 25/04/2022 14:53 Page 434 Food & Drink International www.fdiforum.net PACKAGING INNOVATIONS AND EMPACK Packaging Innovations and Empack 2022, the UK’s leading packaging event, will reunite the food and drink industry when it returns to NEC Birmingham on 25 and 26 May. The event will feature a range of suppliers from across the entire packaging spectrum, from design and product development through to packing, filling, and fulfilment. Visitors can use the event to get up close to an array of newly launched food and drinks solutions, and discover the latest industry developments, innovations, and cutting-edge technologies. Innovation on Show With the event’s exhibition spaces sold out, many attending exhibitors will be launching their latest innovations specifically for the food and drink industry. The Label Makers will display its range of sustainable label solutions, including those for recyclable bottles. The bespoke service is aimed at delivering the strongest on-pack message, to ensure maximum shelf stand-out. Lactips will launch its Plastic Free Paper. The coating provides a barrier to oxygen, fats, and mineral oils, and represents a fully recyclable and compostable solution for industrial food applications. Expac will promote its wide range of bottles, tubes, jars, and glassware, designed for use in the personal care and household sectors. The company has invested in its sustainability credentials, by developing a range of bag-in-box refill products which house a variety of common food products, such as oils, emulsions, and liquids. New Vision Packaging will showcase its range of novelty, seasonal, and limited-edition packaging solutions designed to add additional consumer value to limited-life products. Colorlites will promote its latest range of glass bottles and jars. The products can be used to package a variety of foods including spices, oils, and preserves. Damati Plastic will present its range of recyclable and reusable plastic food takeaway containers, including two and three partition containers and bowls, as well as hinged varieties. Curated Insights Designed specifically for professionals working in the food and beverage industries, the Packaging Innovations and Empack seminar programme will Food and drink exhibitors flock to Packaging Innovations and Empack 2022 36 Á 34-38.qxp_Layout 1 25/04/2022 14:56 Page 1 !"#$% &' ()*$)+( VISIT US AT PACKAGING INNOVATIONS STAND B20 34-38.qxp_Layout 1 25/04/2022 14:56 Page 236 Food & Drink International www.fdiforum.net PACKAGING INNOVATIONS AND EMPACK ShredPak FSC CERTIFIED powered by employee share-ownership 01672 564333 SUSTAINABLE SHREDDED PAPERS Visit Us - Stand G70 PACKAGING SOLUTIONS CARBON NEUTRAL COMPANY RECYCLABLE & BIODEGRADABLE ZigZag Part of the kite packaging group Tissue Paper Corrugated SleeveFlexi-Hex® ,ŝǀĞĮůů run across three stages, signifying commitment to address the plethora of issues and pressing topics across the industry. The Empack Technology stage will feature content curated specifically for manufacturing, processing, and logistics professionals. The Innovation and Design stage and the Ecopack stage will focus on the latest developments in packaging technology, with a specific focus on sustainability. Further to this, and in association with OPRL, the Ecopack Challenge will make its long-anticipated return, with innovators pitching their cutting-edge solutions to a panel of judges including Ocado and Pret A Manger. Also, The Big Debate makes its NEC debut, tackling the latest challenges in packaging regulations and assessing whether the guidelines will have the desired impact of reducing waste and improving recyclability. Renan Joel, Easyfairs’ Divisional Director, concludes: “Our event features a huge range of food and drink exhibitors, many of whom are at the forefront of the most impressive industry developments. Our industry- leading seminar programme we have planned will further provide visitors with actionable, takeaway advice that they can apply to their latest packaging project. Nothing beats doing business face to face, and it will be amazing to be back in Birmingham after so long away. We can’t wait for the event to begin!” For any further information, please visit www.packagingbirmingham.com or contact the show team on +44 (0)20 196 4300 or PackagingUK@easyfairs.com. 34-38.qxp_Layout 1 25/04/2022 14:56 Page 321_0224 When are you planning to reduce the plastic content in your packaging? Delipac can The time is now. Delipac - the sustainable, food safe and plastic free packaging solution. Available now. STOP Kicking the Can! www.denmaur.com/delipac z&DQLWEHYHULƪHGDVSODVWLFIUHH including micro plastics? z Can it be completely and universally recycled? z Can it completely bio-degrade? z Can it compost completely - either at home or industrially? z Can it still sell and deliver your products and be convenient? z&DQLWEHQRZLQVWHDGRIRU" SEE US AT THE NEC Hall 1, Stand B74, 16th and 17th Feb 2022 Hall 1, Stand B74, 2 5 th and 26th M a y 2022 34-38.qxp_Layout 1 25/04/2022 14:56 Page 438 Food & Drink International www.fdiforum.net PACKAGING INNOVATIONS AND EMPACK Labelling with HERMA UK at Packaging Innovations With the event organiser’s, Easyfairs, launch of ‘The Sustainability Trail’ at this year’s Packaging Innovations and Empack 2022 exhibition, innovative green solutions are top of the agenda within the packaging industry. To support this drive, HERMA UK have created a portfolio of solutions to meet customer’s needs, should that be to produce less waste, work smarter with existing packaging, or to incorporate the use of more recyclable material. The HERMA UK labelling systems division will be showcasing some of these solutions at the forthcoming show, including the award winning InNo-liner system which eliminates the need for wasteful backing paper. If you would like further information, visit HERMA in the Empack Section at Packaging Innovations on stand B14, they are looking forward to meeting you there. Tel: 01440 763366 Email: sales@herma.co.uk Website: www.herma.co.uk Sealed Air demonstrates sustainability benefits of food packaging solutions at Empack 2022 Global packaging provider Sealed Air will be showcasing their range of food packaging solutions on stand C10 at this year’s Packaging Innovations & Empack show. Sealed Air will also welcome to the stand newly acquired Foxpak Flexibles Ltd, a pioneer in digital and graphics packaging. Food packaging solutions on display include CRYOVAC® brand Darfresh® family of vacuum skin packaging, demonstrating a reduction in plastic use and longer shelf life. In addition will be CRYOVAC® brand shrink bags which can use 50% less plastic than thermoformable packaging alternatives. By also extending shelf life, the excellent shrink bag barrier helps to minimise food waste. Shrink bags and automation go together perfectly. Systems can streamline product flows, increase packaging speeds, handle larger volumes and eliminate manual errors. For ultra-thin packaging film which matches high performance with sustainability, visitors can explore CRYOVAC® rBDFTM food packaging film, which includes 30% food-grade recycled content. www.sealedair.com/uk Reduce the carbon footprint of your packaging with BOPP films Innovia Films is focused on producing new BOPP flexible films that aid the reduction of the carbon footprint of packaging, while providing technical performance, simplifying structures, and maintaining full recyclability. At Packaging Innovations, Innovia will be presenting examples of their solutions to: * Reduce the use of fossil resources * Enable on pack recycling label * Extend shelf-life – less food waste * Simplify pack structures * Facilitate material substitution * Contain post-consumer recycled waste * Maintain food contact compliance Stephen Langstaff, Business Development Manager, Packaging at Innovia Films highlights: “Last year’s COP26 summit reminded us of the importance of reducing our carbon footprint. Food production is a major contributor to global warming and resource efficient packaging plays a vital role in reducing the carbon impact by reducing waste and extending shelf life. The carbon footprint of packaging is usually comparatively small when compared to the product it is wrapping. This is one of the big advantages of flexible packaging. Due to its light weight, it is far more resource efficient than cans, bottles, tubs, or trays.” The misconception that flexible packaging cannot be recycled is leading some to poor environmental choices, fortunately, things are changing. Come to Stand F82 in Hall 1 to discuss your current packaging challenges. Tel: +44 (0) 16973 42281 Email: filmsinfo@innoviafilms.com. Website: www.innoviafilms.com Encore REF30cn is a carbon neutral BOPP film that also provides the required technical performance for this application INTERNATIONAL Make the right Marketing decision! 34-38.qxp_Layout 1 25/04/2022 14:56 Page 5Food & Drink International 39 www.fdiforum.net SLICING, DICING AND CUTTING T he growing demand for pre-cut packaged foods and convenience meals containing sliced and diced foods have significantly increased the demand for cutting machines. In order to meet this demand, manufacturers have to turn to automation and other innovative options to maintain product integrity whilst also scaling up output. Consumers have come to expect uniformity in the food and beverage products they buy. A product they purchase from a store should be identical to one purchased in a different branch on the other side of the country. This is as true for the finished products and their packages, as the ingredients and goods inside. If there are varying sizes of meat or vegetables within a product mix, or if a blade isn’t adequately cutting, it risks contradicting the weight printed on its packaging. This can result in costly recalls, the fallout from which manufacturers can suffer from for years. Consistency of cuts and portion size is largely dependent on the sharpness of a cutting tool. Regular use renders any blade dull over time, and so it’s paramount that manufacturers regularly change, sharpen and replace their cutting tools. It’s as much to do with hygiene, with a dull blade more likely to harbour matter and risk contaminating other products. Dull blades can also damage products, crushing, denting or bruising them. In any case, a manufacturer can be left with entire 40 Á The right slice © stock.adobe.com/Sergey Ryzhov In a world where clear packaging is used to reveal the quality of the food inside, getting the right cut is paramount to a visually appealing meal. 39-41.qxp_Layout 1 25/04/2022 14:57 Page 1Next >