< Previous30 Food & Drink Internationalwww.fdiforum.netMANUFACTURINGTo this end, a number ofcompanies servicing themanufacturing sector, includingBosch Rexroth, Sick UK,Werma and Hurst GreenPlastic, have worked together tocreate the Lean WorkshopGroup. Together, theconsortium has set up ademonstration production cell atBosch Rexroth’s headquarters topromote the benefits of leanmanufacturing to UKcompanies.The Group is using the cell tohost workshops, which embodiesthe latest developments in leanmanufacturing technology andmanufactures real products –metal dollies of the type used inwarehousing operations. Theseare produced in a wide range ofvariants to show how effectivelylean manufacturing handlespresent-day requirements forhigh-mix production.Companies such as PCEAutomation work incombination with the BoschRexroth Manual ProductionSystem to develop the optimumsolution for their customers’requirements.Across the productionprocess, new standards are beingmet. In the field of packaging,for example, Kite has launched arange of heat shrink and sealmachines due to the increasingdemand of more professionallooking products from retailers.These machines shrinkwrap aproduct and seal the film tocreate a highly attractive packusing a shrink hood system, andan integrated seal mechanism.The machines have beendesigned for customers lookingto move away from heat shrinkguns as they can significantlyimprove speed in the operation,with Kite’s offering including asystem that can shrink and sealup to 1200 packs per hour.The challenge formanufacturers is now often tomeet the exacting standards oftheir customers. It’s definitelyworth ensuring that hygienerequirements are complied withat every stage. When it comes todeciding on the design of theproduction facility, for example,opting for a resin system for thefloor and wall finishes, such asthose provided by Resin SurfacesLtd, means companies cancomply with these strict industryguidelines on cleanliness andbest practice. The companysupplies are resin systems thatmeet non-taint requirements andhave been independentlycertified by Campden BRI. Thesystems also have good slipresistance ratings and are easy todecontaminate and maintain.Ensuring compliance withestablished and recognisedinternational standards are anobvious way of ensuringmanufacturers are well-placed tomeet the demands of theircustomers. To this end, BRCGlobal Standards haveannounced over three thousandorganisations from over 120countries have achievedcertification to its BRC GlobalStandard for Packaging andPackaging Materials.The BRC Packaging Standardcan be used by any manufacturerproducing packaging materialsfor all types of products, and hasbeen designed to helporganisations adopt goodmanufacturing practices andsupport quality managementsystems. This will help them todevelop and manufacture safe,legal packaging materials thatmeet the quality levels expectedby their customers.Joanna Griffiths, BRC GlobalStandards’ Packaging TechnicalManager, says, “The StandardSHUTTERSTOCK.COM/PHOTOWIND27-31_Layout 1 19/06/2015 14:53 Page 4Food & Drink International 31www.fdiforum.netMANUFACTURINGwas the first Packaging Standardto be benchmarked by GFSI,helping to increase recognitionfor all BRC certificated sites.We are seeing strong growthlevels in our emerging marketslike the US, China, and Indiawith continuing growth in manyof our more establishedEuropean markets. Reachingthree thousand sites is atestament to the strength of theStandard and the esteem inwhich it is held in the globalpackaging industry.”For many manufacturers, oneof the major issues in ensuringexcellence has been locating andidentifying high quality staff,and the importance of skills tothe industry cannot beoverestimated. That’s whyindustry skills body the NationalSkills Academy for Food &Drink in the UK is urging foodbusinesses to have their say onnew building block standardsdesigned to drive professionaljob performance in crucial foodtechnologist and foodengineering roles.The Academy has issued anopen invite for food firms to getinvolved in a summer-longreview of National OccupationalStandards. Business involvementwill ensure the benchmarkindustry standards ofperformance and knowledgekeep pace with changingindustry needs and effectiveworking practices.Justine Fosh, Academy CEO,says, “Advances in productiontechnology, demand for newproduct development andconstant prioritisation of foodsafety and quality has broughtchange and new requirementsinto Food Technologist roles.New NOS for FoodTechnologists will help plug gapsin apprenticeship training andbring qualification learning up todate while qualifications inEngineering specific to the foodindustry will be founded onNOS and need to continue toreflect the unique needs of thefood industry in changing times.“There is an industry skillsshortage in both of these areasand contributing to NOSdevelopment is a great way forbusinesses to be part of thewider solution. The best way tosecure these skills is to ‘growyour own’ by helping to confirmthe NOS that attractiveapprenticeships can then be builtaround.”These new standards will beused to underpin existingApprenticeships andqualifications, inform futurequalifications and ensurelearning content remains fit forpurpose – to the mutual benefitof employers and employeesalike. It illustrates the greatstrides being made in the sectorto ensure excellence.SHUTTERSTOCK.COM/BIKERIDERLONDONNew brewery raisesa glass to ResinResin Surfaces Limited has played a key role ingetting a new Manchester brewery ready for its biglaunch.For more information about RSL visitwww.resinsurfaces.co.uk or call 0161 483 1232.Cloudwater BrewCo chose RSL’sResuthane TG69flooring system forvital improvements,to ensure thePiccadilly TradingEstate site would bea safe environmentin time for theunveiling. Co-founders Paul Jonesand James Campbellwere concerned thatthe warehouse floorwas potentiallydangerous due to itspoor anti-slipperformance.RSL’S ResuthaneTG69 was installedin the 400 sq mfloor area byspecialistcontractors Kemtile. Theproduct is a heavy-dutypolyurethane screed with amatt-textured finish, and isparticularly suitable for areasrequiring slip resistance,durability and the higheststandards of hygiene.Paul Jones says, “RSL andKemtile gave us completeconfidence that we’d end upwith the flooring we needed. Wechose them because of theirsolid reputation for productquality and installationexpertise. The installation teamwas professional and helpfulthroughout. We are completelyhappy with the work.”Martin Wroe, CommercialDirector at RSL, says,“Customers expect productswhich provide superiordurability and the higheststandards of safety. TheResuthane TG69 system is fastbecoming the flooring of choicein the food and drink sectorbecause it combines outstandingwear, anti-slip properties in bothwet and dry conditions, and it’salso hygienic and easy to clean,making it the ideal choice forthis project.”27-31_Layout 1 19/06/2015 14:53 Page 5A freshapproachConsumer tastes have more or lessdemanded innovation, with a host of newideas being launched across a wholespectrum of choices – those that emphasisequality and indulgence and those that offera healthy alternative.One challenge for the dairy sector inrecent years, however, has been the need tocreate products that emphasise theirtraditional production methods and recipes,while also speeding up production andensuring exceptional hygiene. These areissues that seem to be contradictory but itThe unit supplied to Lyburn comprisesof five independently controlled stationswith a capacity of up to thirty cheesemoulds. The design of the press maintainsa constant pressure on the cheese whichcan be easily adjusted allowing individualcontrol of each station making each unitfully flexible. This is the second five-stationpress that WMH have supplied to Lyburnand will enable the dairy to increasecapacity to sixty 6kg cheeses per batch.The WMH cheese presses are designedto offer the highest level of hygiene withsloping surfaces and open edges tominimise entrapment of whey. As with allthe company’s presses they incorporateintegral drip trays and slot in containmentbars and are fully mobile, being mounted32 Food & Drink Internationalwww.fdiforum.netThe International Cheese Awards this month emphasise the hugeinnovation that is currently taking place in the dairy sector.A freshapproachFood-grade FANUC robots canpacking wedges of cheese, such asGouda, into deep trays reachingpacking speeds of 120 pieces perminuteis possible to alter the production processwithout losing the many things consumershave always enjoyed about the product.An example of this in action comes fromLyburn Cheese, who have seen an increasein demand for their artisan hand-madecheeses since they were featured on TVchef James Martin’s BBC series. In order tocope with the upturn in sales, they havemade use of a new five-station cheese pressfrom Western Mechanical Handling tohelp increase production capacity at theirNew Forest dairy.32-34_Layout 1 22/06/2015 10:40 Page 1Food & Drink International 33www.fdiforum.netDAIRY FOCUSon swivel and braked casters.Other companies are alsoexpanding and making use ofnew technology to reducedowntime. A-ware Food Group’sNetherlands facility in Zeewolde,for example, recently installed asecond lane fitted with super-fastFANUC robots to boost itscheese palletising output further.They have over 42 packing linesat the facility, which opened lastyear. Five FANUC robots arepositioned at three stages of A-ware’s new production line,which operates seven days aweek to meet growing consumerdemands. Packing wedges ofcheese, such as Gouda, into deeptrays are two food-gradeFANUC M3iA/6S robots,reaching packing speeds of 120pieces of cheese per minute andminimising the time between theprocess of cutting the wholecheese rounds and placing theminto packs for sealing. Ratherthan being standalone devices,both robots are fully integratedinto the new double linepackaging machines as thisenables more complexmovements, as well assafeguarding workers.For case loading, Robertpackcreated a bespoke solution usingtwo FANUC M3A/6S robots,performing multiple tasks,including box loading, under-boxerector, tray edge closer and a lidsetter. At the end of the line sitsa space saving standaloneFANUC M-710C/70, which cantypically palletise up to 720 traysan hour. One of the intentionsof the process is to ensure themachines talk to each other toensure efficiency across theproduction line.These processes improveefficiency but for consumers thequality of the product is allimportant – and this is an issuethat has become especiallyimportant with an increasedemphasis on low fat and fat-freeproducts. This means thickeningand stabilising agents are calledupon to replace the mouthfeelthe removed ingredientsprovided, which themselvesprovide challenges while mixingand blending the products.Companies such as Silverson areassisting in this regard – theirnew Flashmix mixers, forexample, can incorporate higherconcentrations of difficultpowders including thickeners,maintaining a high pumping rateand powder incorporation rateas viscosity rises.This is vitally important as thepotential for product build-up isvery great and this can lead toextensive downtime whilecleaning takes place. Packagingis another aspect where hygieneis important and Penn Packagingwork with SN German Pouch-Pack Technology to assist anumber of companies in thedairy industry with thepackaging of fresh liquid dairyproducts, such as yogurt drinks,in pouches.The ULTRA-CLEAN FILLHFFS machines of the LMSseries are CIP and SIPcompatible, and all machineparts, including the filling area,can be cleaned and sterilisedwithout dismantling. The SNULTRA-CLEAN technologymeets all internationalrequirements for clean filling offresh, liquid dairy products intopouches and is acknowledgedand certified by 3A Dairy as thefirst and only machine of thiskind.At the recent Anuga FoodTecevent visitors were able to seethe new SN FFS machine, theFM 060, for the production ofcontour pouches, where allrelevant machine parts are madecompletely of stainless steel andhence washdown is particularlyeasy.As well as improvements intechnology in manufacturing,the sector is also innovating inthe products themselves.Microbiologists at Oregon StateUniversity, for example, havediscovered and helpedcommercialise a new type ofdairy or food thickener, which34 Ácould add probioticcharacteristics to the products inwhich its used.This new product appears togive fermented foods a smooth,thick, creamy property, and mayLyburn Cheese have madeuse of a new five-stationcheese press from WesternMechanical Handling to helpincrease production capacityat their New Forest dairyPenn PackagingHarkstead Hall Barn, Harkstead,Ipswich IP9 1DBTel: +44 (0)1473 893990Email: email@penn-packaging.co.ukwww.penn-packaging.co.ukCompany ProfilePenn Packaging supply awide range of primary andsecondary packagingequipment to many industrialmarkets. SN MaschinenbauGmbH specialise inmanufacturing high qualitypouch packing systems for 3or 4 side seal pouches, doypacks, stand-up pouches, shaped pouches and more.Product ProfileBesides precise filling and high speed production, sterility and storagelife are the major challenges when filling fresh, liquid dairy products intopouches. By integrating ULTRA-CLEAN technology into the multi-stationmachines LMS 120 LP and LMS 424 LP, SN tackles this challenge withtypical German efficiency.All standard pouch formats and contents between 70ml and 350ml canbe produced on the LMS 120 LP and LMS 424 LP machines. All machineparts, including the filling area, can be cleaned and sterilised withoutdismantling.The SN ULTRA-CLEAN technology meets all international requirementsfor clean filling and is acknowledged and certified by FDA, USDA and 3ADairy. Format changeovers are easily done by exchanging completebuilding groups and by using central adjustments.32-34_Layout 1 22/06/2015 10:40 Page 234 Food & Drink Internationalwww.fdiforum.netDAIRY FOCUSTaking thecomplexityout of mixingThe new Silverson Flashmix takes a revolutionaryapproach to powder / liquid mixingUnlike manymixers, which usevacuum to pull inpowders, theFlashmix uses aspecially modifiedpumping rotor toliterally force powder intothe liquid stream – there’sno venturi, no vacuum. Thisnot only allows it to disperseand hydrate large volumes ofpowders, it means it can beused at higher temperaturesand with higher viscosity mixes– offering the advantages of highshear mixing to a manyapplications that were previously notpossible. The wider capability of this mixer also means it can incorporatehigher concentrations of difficult powders such as gums andthickeners, maintaining a high pumping rate and powderincorporation rate as viscosity rises. There are three models in the new range, each offering severalhopper and valve configurations to suit the widest variety ofapplications. Powder incorporation rates in excess of 15,000kg/hourcan be achieved using the FMX 75, the largest model in the series.A key factor in the development process for this new mixer wasbuilding up an extensive database of actual powder/liquid mixingapplications. Practical testing of dozens of grades of gums andthickening agents, dairy proteins and other powders has been carriedout, across a range of batch sizes and varying concentrations. This information on mixer performance will enable Silverson’srepresentatives and agents to specify the appropriate model andconfiguration for a wide range of applications, streamlining theproduct development process for many clients. For more information, visit www.silverson.co.ukinitially find uses in sour cream,yogurt, kefir, buttermilk, creamcheese and artisan soft cheeses.Composed of naturalcompounds, it offers a slightlysweet property and mayimprove the sensorycharacteristics of low fat or fat-free foods and, unlike otherpolymers commonly used asthickeners, it may add probioticcharacteristics to foods, withassociated health benefits.Janine Trempy, an OSUmicrobiologist, says, “There areactually very few new, non-disease-causing bacterial strainsthat produce unique polymerswith characteristics desirableand safe for food products. Inthe case of a dairy thickener, forinstance, a bacterium such asRopy 352 ferments the sugar inthe milk and produces asubstance that changes themilk’s properties.”Arla Foods Ingredients,meanwhile, have developed aninnovative protein-basedsolution so dairies operating aset yoghurt production line canuse their existing equipment tomake drinking yoghurt. TheNutrilac protein ingredient isadded to the manufacturingprocess at the beginning of theproduction cycle andsubsequently prevents theyoghurt from setting, resultingin a liquid yoghurt drink with aprotein level of up to 5% –without requiring theinstallation of a new productionline.Set yoghurt is particularlypopular in South East Asia andthe Middle East and is alsowidely consumed in parts ofEurope, the US and Russia.Colours, flavours, sugars andsweeteners can be added at thebeginning of the manufacturingprocess as usual, along withhealthy ingredients forfortification such as calcium,fibre and probiotic bacteria.Torben Jensen, CategoryManager for Fresh DairyProducts at Arla FoodsIngredients, says, “Our Nutrilacprotein offers an easy way fordairies to add another productrange to their portfolio, and tomake much better use of theirexisting production line. This isan ingredient solution that canbe used by dairies of all sizes.However, we expect it to beparticularly interesting tosmaller companies without thespace to install a second line,but who wish to capitalise onthe great opportunity offered byprotein-rich drinking yoghurts.Dairies that are already makingset yoghurt can tap into thisdemand quickly and easily witha minimum of hassle and cost.”These innovations iningredients, production andpackaging have all improved thequality and variety of dairyproducts on the shelves – butwithout losing the traditionalrecipes and methods that havemade them so popular.Microbiologists at OregonState University havediscovered a new type ofdairy thickener whichcould add probioticcharacteristics to theproducts in which its used32-34_Layout 1 22/06/2015 10:40 Page 3Food & Drink International 35www.fdiforum.netINGREDIENTSSaying ingredients is important in themanufacturing process of food and drinkproducts might seem obvious. Everyoneinvolved in food, from the youngest chef tothe oldest Director of a manufacturingplant, knows that without qualityingredients there can be no decentproduct. However going back a few years,it was possible to say that consumers weremore concerned with the overall taste,texture and appearance of the product,than they were its individual ingredients.This is no longer the case.Consumers are more knowledgeablethan ever when it comes to what isincluded in the things we eat. Packagingnow requires ingredients to be clearlylisted, and it is not unusual to see someonein a supermarket aisle studiouslyinspecting the labelling on various cans orpackets. There is no doubt this has created someSHUTTERSTOCK.COM/MARILYN BARBONETaste remains a strong factor in food sales, but the functionality of the finishedproduct is more important than ever.36 ÁFunctionover form35-39_Layout 1 19/06/2015 14:56 Page 1difficulties for the industry, forcing companies to be careful on what they allowinto their food lest it be perceived as undesirable. However, it has also createdmany new opportunities for the food and drink industry. There is now the ability to rapidly differentiate products, that may look verysimilar, based on the quality, or benefits of the ingredients. Because consumersare now not so easily swayed by packaging or promotions, businesses canchoose to invest in their ingredients to ensure they have an actualcompetitive edge on rivals. While this has always existed in theory, pastconsumer tendencies to pay no real attention to labelling meant thathigher quality products might be ignored on the basis of price alone. The trend has also opened up the market to the value ofdiversity, enabling products that once competed in a fairly linearmarket to differentiate themselves on other points, such ascalorie count, local ingredients or real fruit juice. The health market continues to grow exponentially, with anincreased focus on vitamin and protein levels in food products.So it should come as no surprise that functional healthingredients have become popular with manufacturers.Another market growing in power is the weight loss,weight-control or diet industry. With current figures showing60% of UK adults are now overweight or obese, it is perhapsobvious why for many companies, having calorific or weight-loss benefits is the quick way to increase turnover. In manycases, the more scientific or specific the benefit, the better, asunlike with vitamins and minerals, consumers still struggle tounderstand the nuances of what helps them lose weight.One such new development in this industry is BENEO’sOraftiSynergy1 chicory root fibre, which in a recent studyexamining its effects on 42 overweight and obese children, wasshown to improve appetite regulation, by increasing theirfeeling of satiety, and fullness. Developing and including ingredients like this in foodproducts enables businesses to market themselves towardsspecific consumer groups, as well as draw attention fromorganisations or collectives that can promote their goods,such as large weight-loss forums and groups. The trick in the industry is to push the weight-loss aspectof the product, while maintaining the taste and texture of theoriginal offering. Even health conscious consumers have beenfound to move away from healthy products that are notpalatable to them, and in an industry so competitive businessescannot afford to have any weaknesses. INGREDIENTSSHUTTERSTOCK.COM/QUANTHEM36 Food & Drink Internationalwww.fdiforum.net38 Á35-39_Layout 1 19/06/2015 14:56 Page 2 Innovation. Knowledge. Expertise. It’s What’s Inside. Ingredients make up the food we eat, the beverages we drink, and the supplements we take. But what makes some ingredients fresher, tastier, and safer than others? It’s what’s inside that matters. Open the door to DuPont Nutrition & Health and you’ll see a team of solvers, providing the most innovative solutions in the food industry. We start with an ingredient portfolio that’s wider and deeper than most, but what truly sets us apart are the ingredients you can’t see – our consumer insights, breadth of research, and scientific capabilities. Want to see what else we can bring to the table? Come find out what’s really inside DuPont Nutrition & Health. Visit dupont.com/itswhatsinside to learn more. Welcome to the Global Collaboratory.™hh.DuPontNutrition & HealthCopyright © 2015 DuPont or its affiliates. All Rights Reserved. The DuPont Oval Logo, DuPont™ and all products denoted with ® or ™ are registered trademarks or trademarks of E.I. du Pont de Nemours and Company or its affiliated companies. 35-39_Layout 1 19/06/2015 14:56 Page 338 Food & Drink Internationalwww.fdiforum.netINGREDIENTSIn terms of markets, the US and EUremain profitable for the weight lossindustry, due to the high levels of obesityin key countries, particularly the US, UKand some Western European countries.These markets are, however, saturatedwith products on offer – so the rapidlyincreasing middle class in China might bea growing opportunity. Functional foods comprise a little of thehealth and weight loss benefits, but do sonot by reducing calories, but more throughthe addition of functional ingredients suchas probiotics, prebiotics or stanols andsterols. These are most commonly used in foodand drink products designed specifically forthe health market, for instance probioticdrinks that a consumer takes once to twicea day, while the more common healthingredients could be taken as often asdesired. Popular examples of these kind ofingredients in use consist of Benecol,Yakult, and the other one-a-day breakfastdrinks, or cholesterol-lowering spreads. Typically these contain stanols andsterols, plant extracts which occurnaturally in the world and that are thoughtto have a cholesterol lowering effect.Probiotics, on the other hand, refers to thebacteria which can confer a health benefitwhen taken in sufficient quantities,whereas prebiotics promote the growth ofbacteria in the large intestine that arebeneficial to intestinal health. There has been a recent move towardswhat is known as clean-label healthingredients, most often consideredbotanicals and bio-actives with naturalextracts. This is a step away from the morechemical and pharmaceutical-basedingredients which can achieve similareffects, and should be kept in mind for thefuture. When it comes to functional ingredientsit’s worth looking at what markets areperforming well for them, and which havealready been established for some time. Interms of Compound Annual Growth Rate,the US and Europe is expected to onlyincrease between 1-2% in the coming year,which makes it a steady market, but notone attractive to new entrants.There are however, five markets whichhave been predicted over 10% CAGR inthe coming years, including Turkey,Vietnam and India. The Middle East isalso a growing market which could beattractive to many in the industry. As a whole the ingredients industryremains as strong as it has ever been,though the emphasis has shifted slightlytowards food products which offer morethan just taste or satisfaction. This is notonly reflected in consumer trends, but alsoin world-wide politics, as the US FDAhave determined that all trans fats must beremoved from US food products by theyear 2018. Long having been considered acontributor towards heart disease andother coronary problems, there has beenSHUTTERSTOCK.COM/MAREKULIASZ35-39_Layout 1 19/06/2015 14:56 Page 4SHUTTEERSTOCK.COM/NATALIA KLENOVAFood & Drink International 39www.fdiforum.netINGREDIENTSFi EuropeFi AsiaFi RussiaFi VietnamFi South AmericaFi IndiaFi Asia-ChinaFi IstanbulHi EuropeHalal AsiaRegister at ZZZÀHXURSHHX)X'@Fi_GlobalSearch for Food ingredientsThe trusted route to market since 1986Visit Fi Europe, the world’s most important gathering of ingredients suppliers, distributors and buyers for the food & beverage industry. Don't miss the chance to meet 27,000 senior industry professionals from across the world, all in 3 days, under one roof. Fi Europe & Ni 2015, the perfect recipe for success 'HFHPEHUParis, France constant legislation limiting the amounts that can beput in US food, but the decision to force their removalentirely came as a surprise to many. In their statementthe FDA said “The FDA’s action on this major sourceof artificial trans-fat demonstrates the agency’scommitment to the heart health of all Americans. Thisaction is expected to reduce coronary heart disease andprevent thousands of fatal heart attacks every year.” This was a step following the decisions of numerousEU countries to ban, or limit, trans-fats in foodproducts in previous years, and shows the importanceof staying a step ahead of the curve when it comes tohealthy and natural ingredients, and the necessity ofusing them. At the end of the day, it can either be anadvantage to be leveraged by a company, or anopportunity missed – and something businesses areforced to comply with anyway, further down the line. 35-39_Layout 1 19/06/2015 14:56 Page 5Next >