< Previous30 Food & Drink International www.fdiforum.net PROCESSING, CONTROL AND AUTOMATION Perfect efficiency may be an impossible dream, but settling for less than the best can be much more damaging. The automation industry is fast adapting, but not everyone is so quick on the adoption of it. E nvironmental pressures over the last decade have done much to shape the food and drink industry. The pandemic fundamentally changed the way business was done in many countries, and the two areas that it most influenced food were in the supply chain with difficulties getting foodstuffs to stores on time, and in factories – where labour shortages warred with hygiene requirements and staff off sick. While automation was always a factor in food and drink manufacturing, it Chasing maximum efficiency Chasing maximum efficiency Food & Drink International 31 www.fdiforum.net PROCESSING, CONTROL AND AUTOMATION was often seen as an expensive alternative to staff, but the lockdown showed the industry just how flawed that thinking was. Now, the processing and automation industry is taking over. Labour and staffing were difficult during the pandemic and the task hasn’t gotten any easier now. We, and many others, have advocated automation as a means to reduce the industry’s reliance on a heavy workforce for many years. Some, especially UK companies, were slow to adapt and invest in robotics, and sure enough those companies are struggling now with the Great Resignation. Investment in automation and touch-free processing is on the rise, and not just because it eases reliance on staff. The more a processing line avoids the human element, the more hygienic it can become. Being able to process goods faster, more accurately and without the risk of contamination ought to be reason enough for further investment, but if necessity is the only 32 Á © stock.adobe.com/ctrl+s photo© stock.adobe.com/Sergey Ryzhov32 Food & Drink International www.fdiforum.net PROCESSING, CONTROL AND AUTOMATION way to push change, then the shifting economic conditions across Europe will certainly do that anyway. Packaging is the most common area of manufacturing in which to find automation. A consistent and sterile environment needs to be maintained to preserve the safety of consumable products. Packaging machinery is easy to clean and lessens the chance of product contamination from unscrupulous handler hygiene practices. Furthermore, there is less down time from cleaning machinery, than from continual hand washing. Automating solutions are varied, with the most common in packaging being can sealing, pouch making, and pick up and drop off robots. Raw food items need to be handled carefully, as they are more prone to spoiling and contamination. Automatic raw food packing is available, which use paper or polythene as primary packaging (the materials that come in direct contact with the product). This does not react with the raw items, is cost-effective, and relatively easy to implement as raw foods tend to be processed separately, so installation can be achieved without affecting all products. These processes also reduce employee injury. For example, meat products need to be cut with sharp knives. Using cutting and packaging machines reduces the likelihood of injury due to sharp objects. They also provide a cleaner cut, thus giving a clean and appealing look to the meat product. Having items automatically packaged means that product output will be consistent. This means that no human error is involved, which could cause some packaging to be less secure than others. This increases the risk of the product inside spoiling or being damaged in the transportation and shelving process. Not only does this impact consumer enjoyment of the product, but companies can also literally lose millions in product wastage. On the subject of making best use of automation to limit wastage, it’s worth keeping in mind the age and reliability of any good piece of processing equipment. While manufacturers can make tools capable of lasting ten, twenty or thirty years, that doesn’t mean they should be used for that length of time. Technology is ever- expanding, and businesses compete not only against one another but against themselves. The same brand and same product may release a machine three times as efficient as one they release ten years prior and taking the attitude of wanting to “get the most out of your equipment” before buying new can be self-defeating. A McKinsey report found that the average food processing plant is more than two decades old. With the continuing market proliferation of smart technologies, companies risk making themselves obsolete. Investing in machinery and equipment that can deliver cost savings will, of course, be a motivation alongside efficiency gains, but part of the criteria also needs to be Tel: +44 (0)1707 331111 info@welwyntoolgroup.co.uk www.welwyntoolgroup.co.uk Hot Air delivered direct to the point of application HOTWINDMISTRALVULCAN © stock.adobe.com/agnormarkFood & Drink International 33 www.fdiforum.net PROCESSING, CONTROL AND AUTOMATION environmental impact. Too many producers still rely on old machinery rather than investing in new or refurbished replacements. It’s a false economy and counterintuitive besides, yet worryingly commonplace in the UK, and in parts of Europe as well. In reality, the best adopters of automation appear to be in ASEAN countries, especially in China, where factories are capable of producing high quantities of good quality product at low prices, giving the country an economic edge over not only their neighbours, but a good portion of the world’s market. Our extensive product range includes: Innovative, system-compatible air heaters Powerful, robust blowers Compact, flexible hot-air blowers Comprehensive range of accessories 3 Heat output & air volume steplessly adjustable with potentiometers 3 Integrated temperature controls 3 Integrated temperature probes 3 Protection against heating elements or devices overheating 3 Brushless power motors 3 Integrated power electronics © stock.adobe.com/desinko34 Food & Drink International www.fdiforum.net HEALTH, SAFETY AND HYGIENE P and hygiene of any food production setting, that much everyone knows. But with the many facets to consider in cleanliness, from surfaces and utensils to basic personal hygiene, there are more openings for contamination than you might assume. Proper planning and procedure are needed at every stage when handling food in order to prevent foodborne illness, or simply to ensure the high quality and reputation of your product. The first step should always be to wash your hands, and to ensure that all staff and operatives do the same. It’s something we often do – or perhaps even skip – without thinking about why it’s important, but as a way of preventing the spread of bad bacteria or viruses, it’s invaluable first The crucial role of thorough cleaning and hygiene practices in food production settings ensures the prevention of contamination and the promotion of a safe and high-quality product. Food and Drink International explores how to establish effective cleaning procedures, prevent cross- contamination, and prioritise food storage for optimal safety and hygiene. first SafetyFood & Drink International 35 www.fdiforum.net HEALTH, SAFETY AND HYGIENE when done correctly. When we remember all the surfaces and objects we touch throughout the day in different settings, including outside before we enter the workplace, it’s far easier to imagine all the germs that could be taking a ride into food preparation areas on our hands. They can even be ideal incubators for illness-causing bacterial strains such as listeria, e. Coli and salmonella; regularly washing hands with soap for at least 20 seconds is the best and only way of stopping them in their tracks. Once hands have been taken care of, the next priorities for cleaning are the surfaces, utensils and machines used for food preparation. Here’s where proceedings can become intricate, complicated or even stressful, as every blade, countertop and operator panel is a potential contamination risk. Haphazard sterilisation is likely to be just as dangerous as not cleaning at all, since it’s all too easy for some areas to be overlooked by a flustered staff member. Beginning with a schedule of what needs to be cleaned and when will keep human error from rendering efforts useless. A cleaning plan can never be too detailed, as every piece of information made available to a nominated cleaner means fewer areas for confusion or error. Take the time to set out a systematic checklist of all necessary cleaning tasks, including floors and the outside surfaces of any machinery. 36 Á © stock.adobe.com/Parilov36 Food & Drink International www.fdiforum.net HEALTH, SAFETY AND HYGIENE These can then be scaled on a case-by- case basis in terms of how often they need to be performed, from monthly or weekly to after each use of a surface. When all tasks have been allotted a timescale, each one can be assigned to an individual or team according to their skills and availability. This flow of consideration will help create a schedule that covers all bases, while being realistic and as efficient as possible based on your business’s valuable resources. Communicate rotas to all relevant team members, keeping everyone up to speed on the tasks they’re responsible for. It’s also a good idea to arrange and provide for up-to-date training on proper cleaning techniques and procedures. Wherever possible, ensure staff are in the loop and feel comfortable expressing potential improvements, or changes that may be needed on a functional level. Remaining open to adjustments is a must in upholding hygiene, particularly when there may be changes to the layout of a factory floor, or additions or upgrades to machinery which require cleaning procedure to be reassessed. When you’re covered for cleansing each individual surface and piece of equipment with the right regularity, cross-contamination becomes the greatest adversary to food safety and hygiene. This is when ingredients themselves can be the worst offenders, especially when it comes to products of animal origin. Meat in particular is a high-risk factor because it may contain those dreaded traces of salmonella and other illness-causing bacteria. When meat is raw, that risk is even higher. Because meat requires a lot of handling during preparation, bacteria can easily spread from hands to blades and surfaces. This isn’t always restricted to direct contact either, as these products can release juices and fluids which also contain bacteria. Every surface that’s touched by raw meat or its juices must be carefully taken note of, then cleaned to eliminate the chance of contamination further along the production line. One of the worst scenarios to risk is cross-contamination between different food products. If not kept separate, raw meat and its juices can come into contact with any other product currently in production. Having specific equipment for raw animal products, including poultry, seafood and eggs, is the most effective way to prevent this risk, along with ensuring separate preparation areas are used for raw and © stock.adobe.com/littlewolf1989Food & Drink International 37 www.fdiforum.net HEALTH, SAFETY AND HYGIENE cooked foods. Then it’s time to go back to that cleaning rota you drew up so carefully for the task of sanitising every surface these animal products have touched. Even before any processing of raw products of animal origin can take place, storage must be factored in to keep them away from other foods, and prevent any bacteria already present from multiplying or causing spoilage. Perishable items like these should be kept frozen, or refrigerated between -2 and 2 degrees Celsius, and kept at a stable temperature until they’re needed for processing and cooking. You may also use a first in, first out or FIFO technique and use the oldest products in storage first. Not only will this prevent food waste, but it will also ensure no products are left to become a greater contamination risk as they move through the production line. Preparation and planning are key to keeping a healthy and safe environment for your food and drink products. However, the good news is that once these are taken care of, it’s much easier for hygiene and cleaning tasks themselves to be carried out with minimal hassle. Any rotas and guidelines you can put in place and make available to staff will up focus and attention on every specific task, in your employees’ assurance of their responsibilities and plan of action. Beyond that, as long as equipment, hands and spills are frequently cleaned, continued consideration to best practice will be what keeps your factory, staff and customers safe. Allergen Services, Meat and Fish Species Detection, GMO Screening, Nutritional Values, Acrylamide, Pesticides, Heavy Metals, Vitamins and Minerals, Mycotoxins, Authenticity and Isotopic Analysis, Challenge Testing, Microbiological Assessment, Rapid (24hr) Pathogen Detection. UKASAccreditedServices UKAS accredited food, swab and water analytical services • A range of turnaround times available DAKKS accredited services available through our group Laboratory, IFP Labs Unit 1b Moderna Business Park, Mytholmroyd, HX7 5QQ Tel: 01422 405678 Email: sales@micro-search.co.uk Part of IFP Laboratories Group TESTING WITH RESPONSIBILITY © stock.adobe.com/amorn38 Food & Drink International www.fdiforum.net EIT INTERNATIONAL Q&A Tell us a little about EIT International and its products. EIT International is a leader in the development and supply of environmentally friendly preventative controls & detection systems for the food, dairy & beverage/ brewing production, pharmaceutical and nutraceutical industries. We achieve success by working closely with our regional distributors and customers throughout the world, by increasing efficiencies and reducing down-time for preventative maintenance programmes in production facilities and helping to eliminate expensive market recall through proven technical expertise. EIT Internationals’ proprietary scanning and detection systems include: * Bactiscan TM , BactiscanPRO TM , and BactiscopeTM biofilm & bacteria scanners * Gappscan TM heat exchanger integrity detection & quantification systems * Magnerscan MAG3TM surface integrity & crack detection scanners * PasfloTM pasteurisation residence & flow validation systems We have also partnered with an approved group of resellers which allows us to service customers across the European, North American, Asian, and African continents. What is the Magnerscan MAG3TM and how does it work? The Magnerscan MAG3 TM is a handheld surface integrity and crack detection scanner which has been developed for the real-time examination of spray dryers, holding, mixing, and blending tanks and vessels. A battery powered unit generates a magnetic field while in use and utilizes an array of close contact in-line sensors to provide fast and accurate crack detection testing. The MAG3TM detects surface and subsurface defects, incomplete weld fusion, corrosion cavities, and porosity electronically without the use of harmful or non-food- safe chemicals. The technology is therefore environmentally friendly and does not require pre-test preparation. All the operator has to do is wipe the MAG3TM across the surface to be tested, and any areas of concern will be immediately indicated on the display. For harder to reach areas such as corners, welded joints, and pipe attachments the MAG3TM also has a single channel probe system which can be attached to the unit. This comprehensive scanning capability ensures the detection of both surface and sub-surface defects, allowing thorough examinations, and because it can detect subsurface issues, it is also be an important and useful part of preventive maintenance. The Magnerscan MAG3 TM tests surface and subsurface integrity, how does the proprietary technology compare to traditional storage vessel testing techniques? The technology behind the Magnerscan MAG3 TM is radically different to that used in dye penetrant and eddy current testing. The proprietary system of close contact in- line sensors create a magnetic field which can detect surface and sub- surface issues which offers several major advantages over traditional methods including immediate results, minimal downtime and safety for users and products. Dye penetrant testing necessitates the vessel to be taken out of operation, Q&A EIT International This month we speak with EIT International to learn more about the EIT Magnerscan MAG3 TM and the benefits it brings to crack detection in storage vessels.Food & Drink International 39 www.fdiforum.net EIT INTERNATIONAL Q&A cleaned and then prepared with chemical dyes which then need to be thoroughly cleaned from the vessels before being put back into service. This results in significant production downtime and the risk of introducing chemical contaminants into the product path. Dye test will also only locate surface cracks not subsurface issues. Eddy current testing can be slow and can produce false readings where there are welds and often will not detect defects that are parallel to the test object’s surface. Overall, Magnerscan MAG3 TM technology offers a safer, faster, and more cost-effective alternative to traditional storage vessel testing techniques, ensuring the integrity and quality of the finished product while minimizing production disruptions and environmental impact. How does the Magnerscan MAG3TM scanner head recognize the construction material of the vessel being tested? The Magnerscan MAG3TM works on many conductive materials including stainless steel, aluminium, copper, and brass to name a few. Calibrating the device to the surface being examined therefore, is a vital step. The scanner heads must be placed on the surface for the system to recognise the construction material of the vessel, then calibrating the MAG3 only takes a few seconds, and the setting can be saved on the device. Saving a calibration on the device allows for uniformity when testing metals that are the same, saving the operator time. How can the Magnerscan MAG3 TM help with GMP production, HACCP compliant programs and pathogen monitoring? These processes/ programmes are essential in regulated industries such food production (HACCP) and pharmaceuticals (GMP), and the Magnerscan MAG3TM can help in a number of ways. The Magnerscan MAG3 TM enables full on-site testing within hours, minimizing downtime in production which is fundamentally important to such facilities. By simply swiping the device across the metal surface, a surface integrity scan is completed, allowing for immediate results and prompt corrective action to be planned. This helps prevent quality deviations, ensures compliance with industry regulations or standard guidelines, and reduces environmental risks. The Magnerscan MAG3 TM aligns with sustainability programs by using environmentally friendly technology. It doesn’t require harmful dyes, chemicals, gases, or gels for testing, reducing environmental impact, both in the work environment for employees and the environment overall, and as it employs non-invasive integrity testing technology, it eliminates the need for pre-test preparation. This saves time and resources during inspections. The device can be calibrated within seconds and the calibration settings can be saved on the device. This allows for uniformity when testing metals of the same type, streamlining the inspection process, and improving efficiency. With six alarm settings and six frequency levels, providing a total of 36 different variations for detection the MAG3 allows the user to tailor the device to specific metals, ensuring accurate detection of defects. By incorporating the Magnerscan MAG3TM into their GMP and HACCP programs, manufacturers can enhance their quality control efforts, reduce risks, and maintain compliance with industry standards. The device’s efficiency, accuracy, and ease of use make it a valuable tool in ensuring the integrity of conductive materials used in manufacturing processes. To discover more, visit www.eit-international.com or contact us to discuss your requirements. Next >