< Previous30 Food & Drink International www.fdiforum.net ENGINEERING AND COMPONENTS W hile the food and drink industry continues to face rapid change, increasing demand, new trends, and higher consumer expectations for quality and freshness year-round, as well as the drive for sustainable packaging and operations, the sector is simultaneously working to reduce costs and optimise productivity. Advancing machines and facilities is Flexible In the wake of the pandemic and disruption it caused, food firms have accelerated discussions with engineers over automation, increasing flexibility and more, while engineers themselves have changed how they work with such companies. Flexible key, and engineering central to this, as equipment and infrastructure ages, and focus is put on performance of machines and environmental targets. Simply placing spick and span machines in facilities is not always the best approach, with deeper collaboration between equipment builders and food manufacturers critical to creating a factory fit for their future. Something such as mixing Food & Drink International 31 www.fdiforum.net ENGINEERING AND COMPONENTS © stock.adobe.com/Es sarawuth equipment for example can designed and manufactured in purpose-built factories to meet stringent customer standards and optimise specific individual processes. Discussions over enhanced automation and digitalisation remain high on the agenda for engineers working to innovate for food firms, and the pandemic, which saw food processing plants judged essential, only expanded the desire for these solutions. With workforces already in the middle of a staff shortage and hints of a recession in the future, many have been forced or incentivised to consider automation as a labour-saving method, to assist where there are not enough employees to run plants. Even prior to COVID-19, tech that could take people out of food processing was a future priority, with focus growing on robots, which do not take days off, are excellent in repetitive tasks, reduce virus transmission concerns, are improving with better vision systems and the ability to work safer alongside humans, and are being moved upstream to take on wider roles. Robots are also being developed to be smaller and lighter, to make the most of space in facilities, seeing smaller and more precisely engineered components too. 32 Á32 Food & Drink International www.fdiforum.net ENGINEERING AND COMPONENTS Of course an end-to-end automated system is not always affordable or achievable, meaning most are seeking solutions where humans and robots work together, complementing each other’s skills. Deciding which aspect of a plant should be automated will vary based on the product being made. For those with currently lower levels of automation, determining which solutions bring fast returns and offer quick implementation will help in this process. Recent months have seen a rapid rise in demand for more flexible processing and variable speed options, for the ramping up of production of both goods and packaging. The importance placed on flexibility builds on that already existent as smaller production runs and more frequent changes have become common. With heightened agility required, interest is turning to automated modular systems where lines can be reconfigured as necessary for a different product. Meanwhile, remote service support devices have been fitted by engineers to help with line improvements and diagnostics. While it is called on to further automate operations, engineering is key in the rising adoption of cloud- connected sensors and IoT-enabled machinery in food production, as food manufacturers and engineers look to measure, gain more knowledge about, and enhance machinery and processes. With engineering and the integration of real time sensors and analytics, producers can gain actionable data and full control of their process, uncover anomalies, highlight problems in production and correct these to optimise operations, heighten productivity, capacity, and yield, and cut waste. Furthermore, with equipment failure a common cause of downtime, potentially leading to missed deadlines, upset customers, and revenue losses, sensors are useful to engineers evaluating maintenance, offering a chance to continually and remotely monitor if a machine and components are working properly, while connected remote alarm software can raise any concerns. Machine learning can be applied to data collected here to warn of a breakdown or other issue, facilitating predictive maintenance, and allowing the devices that need maintenance to be specifically targeted. Moreover, with the right software plant engineers can acquire and analyse process data, uncover events in need of intervention, optimise processes, and gain insights about processes. As food plants have adapted and brought in new tech to stay afloat in the pandemic, so have engineering firms and equipment manufacturers themselves to be able to provide machines to the food industry, shifting how they interact with clients and how equipment changes and upgrades are completed. With many unable to travel, and distancing restrictions in place, remote design, engineering, and testing has come into play to keep facilities running, and engineers have welcomed the virtual world. The food industry has embraced technologies required for remote factory acceptance tests, demos, troubleshooting, diagnostics as well as augmented reality tech like smart glasses, and the combination of local engineers with digitally present engineers for installation. Of course when acquiring new equipment, financing and calculating total cost of ownership are vital considerations. When deciding on whether to invest in new solutions, then, one will need to assess running costs, including maintenance and sanitation, service and spare parts costs, machinery performance and impact on labour, risk of downtime, quality of equipment, and life expectancy. © stock.adobe.com/I ViewfinderFood & Drink International 33 www.fdiforum.net MEET THE EXPERTS I t’s easy to define an expert as an individual skilled in a given area but doing so eclipses the journey involved in reaching that point. Indeed, experts begin their careers in exactly the opposite end of the spectrum – as bright-eyed novices. From here, they accumulate understanding and experience, honing their skills through practical learning until, years later, they can be labelled as experts. Suffice it to say, when you take their advice, you’re getting decades worth of know-how in every single answer. In this regard, it’s always better to invest in experts in their specific fields, rather than those who claim to adept across all fields. One can’t help but think of the adage of the ‘jack of all trades, master of none’. Expertise is something that is difficult to quantify. Do we call someone an expert for the length of time they have worked in an industry, or for the success stories they have from it? Or better yet, is an expert little more than an individual with a collection of qualifications and letters after their name? The answer is never quite simple. In a sense, an expert could be said to be a combination of all three, but at the same time every single person is – or ought to be – an expert in their own craft. Someone who runs a expertise Defining Someone who dedicates all their time to a particular task or role is undoubtedly an expert, but how do you decide who or what firm is the right expert for your needs? The challenge is in finding someone who is an expert in their chosen field, but who can also become an expert in your company as well. © stock.adobe.com/littlewolf1989 34 Á34 Food & Drink International www.fdiforum.net MEET THE EXPERTS packaging company is bound to be an expert in packaging, the same for food manufacturing or recruitment agencies. The challenge is in finding someone who is an expert in their chosen field, but who can also become an expert in yours as well. There are many people who are experts in a given craft – be it designing a processing line or working on rebranding for packaging, marketing or brand logos – but expertise is meaningless if a company isn’t able to apply it to your own, and therein lays the challenge. This is where so many people find issue with experts; they hire someone who prescribes themselves expert, and they may well be, but find the advice given to be either incompatible with their company or not tailored to it. It only serves to follow that someone who has dedicated their professional life to a specific part of a sector would have much more valuable experience and insight than someone who has only delved superficially across a plethora of different sectors. After all, PhDs aren’t awarded to those students turning their hand to as wide array of topics as possible, but the ones who dedicated their time and energies to a specific niche. ‘From field to fork’ is a buzzword beloved of the media for its apparent ability to capture the length and breadth of the food and drink supply chain in one term. While undoubtedly easily applicable, the phrase does the industry a disservice, downplaying the complexity of the supply chain and the massive number of players working within it. There are many moving parts tessellating together to ensure that the journey from field to plate is as smooth, safe and efficient as possible. That’s why our ‘meet the experts’ pages look to highlight all the players that enable the supply chain to function and have them share their expertise and insight. © stock.adobe.com/Martin Barraud/KOTO Labfacility are the UK’s leading manufacturer of Temperature Sensors, Thermocouple Connectors and associated Temperature Instrumentation and stockists of Thermocouple Cables. In addition to the stocked items, Labfacility also offers bespoke Temperature Sensors. Quality and Service are key elements in the continued growth of Labfacility. Labfacility manufacture a wide range of temperature sensors to suit your application. A large range of Thermocouples in IEC, ANSI and JIS calibration, PRT’s, Detectors, Environmental Sensors and Hand-Held Sensors/ Thermometers are available to buy online. We are Europe’s largest manufacturer of thermocouple connectors and accessories in IEC, ANSI and JIS Colour codes. The full range of connectors is available from stock for immediate despatch. Traceable to ISO17025 (UKAS) calibration standards, Labfacility offers a choice of a 3 or 5 point traceable calibration: using our in-house calibration facility, you can select any temperature points between-10°C & +200°C. www.labfacility.com • Email: Sales@labfacility.com Telephone: +44 (0)1243 871280 HYGIENIC ENGINEERING, SYSTEMS AND COMPONENTS Axium Process is a leading UK based, hygienic engineering company. Our focus is on technically demanding process operations where knowledge, compliance, documentation, and quality assurance become indispensable. Inhouse services include hygienic fabrication, precision machining and innovative solutions for filtration and liquid separation applications. Product profile Our comprehensive range of products include, process skids, frames, CIP systems, tanks and vessels, pilot scale equipment and heat exchangers. We have developed a complete range of hygienic stainless-steel filters consisting of sintered mesh, wedge wire and perforated screen options. Food & Drink International 35 www.fdiforum.net The LHS 210 / 410 Air Heater Series Leister’s new series of compact and powerful LHS 210 / 410 air heaters are suitable for installation in industrial plants where space is limited or tubular air systems such as furnaces for heat curing processes, due to their compact design and ease of integration. With a choice of eight air heaters with single (SF) or dual flanges (DF), the innovative design allows for easy electrical connection, with connection housing separated from the airstream, which allows unhindered air flows through the air heater with minimal loss in pressure. The connection housing is also protected against overheating, making it possible to work with an air inlet temperature up to 350 degrees Celsius. The SF-R and DF-R air heaters are equipped with an extension on the housing connection. The ceramic inside this extension ensures that the electrical connection on the tubular air heaters is sealed off and protected from high temperatures or backflowing hot air. One of the distinguishing features of the SF and SF-R models is that they are compatible with Leister’s extensive line of nozzles and are suitable for countless industrial applications. For example, the air flow can be extended with a wide slot nozzle or distributed over a larger area. Whilst the Leister LHS 210 series produce an air volume of 80-250 l/min, the 410 range generates a larger air volume of 160-420 l/min, with all air heaters supplying hot air up to a maximum 650 degrees Celsius. For further information and technical advice for equipment in this field, please contact Welwyn Tool Group on 0800 856 0057, email info@welwyntoolgroup.com, or visit www.welwyntoolgroup.com. Microsearch Laboratories Ltd are a provider of UKAS accredited food safety testing services. Based in west Yorkshire, Microsearch has extensive expertise in the areas of Microbiology, Chemistry & Nutritional as well as Allergen & species testing. The company has been providing services to food manufacturers for over 40 years. Providing the best service possible to our clients is key to our success. We provide a broad range of accredited services along with expert technical support. Microbiology ‒ Pathogen detection, food spoilage organisms, shelf-life analysis, challenge testing, rapid pathogen screening ▶ Chemistry & Nutritional ‒ Group 1, Group 2, Meat content, Hydroxyproline, Mycotoxins, LIDL prelisting reports ▶ Allergen and Species - All 14 UK allergens, 8 meat species screen, GMO services, fish speciation ▶ Added Value ‒ Bespoke IT systems for submission and reporting, Technical support across all services, training, and advice ▶ 01422 405678 sales@micro-search.co.uk PART OF PRODUCT PROFILECOMPANY PROFILE HAVE ANY QUESTIONS? CONTACT OUR EXPERT Danny Franklin Managing Director For further information call +44 (0) 1792 883 882, email info@axiumprocess.com, or visit www.axiumprocess.com HYGIENIC & PRECISION ENGINEERING EXCELLENCE FSC Construction & Maintenance FSC delivers specialist construction and maintenance services within the food and drinks production industry. We operate throughout the UK, and our experienced team constructs refurbishes and repairs industrial facilities to ensure manufacturers maintain optimal operational efficiencies. Our extensive services include but aren’t limited to: Construction & Maintenance •Construction, renovation and refurbishment of new and existing industrial facilities. These factories, warehousing, cold storage, office & staff facilities and external works. • 24/7 industrial maintenance services. Mechanical Services Our gas-safe registered team delivers commercial and industrial gas and plumbing services: • Appliance installation, servicing and repair. • Plumbing & pipework installation and repair (steam, condensate, compressed air, cooling water and oil) • Gas Safety and Purging. • Annual inspection and testing of pipework to comply with legislation. Flooring Services The FSC Flooring Division works with clients to supply and install a range of floor coverings including resin, concrete, carpet tiles, LVT and vinyl safety flooring. For further information call +44 1472 355454, email office@fscl.co.uk, or visit www.fscl.co.uk36 Food & Drink International www.fdiforum.net DAIRY INDUSTRY With the dairy industry frequently in the headlines for its environmental impact, strides are being made throughout the supply chain to embrace new technology to offset carbon impact. D espite the popularity of its products, the dairy industry continues to be thrust into the spotlight for its negative environmental associations. From the land it takes to raise dairy cows and grow their feed, to impacts on water quality and greenhouse gas (GHG) emissions, consumers are becoming more savvy to the influence the sector has, causing greater thought into their selections whilst grocery shopping. But strides are being made to improve the dairy industry, often going unseen, and commitments are being made to environmental sustainability and reaching carbon neutrality. In the US, the dairy industry has committed to the 2050 Environmental Stewardship Goals, addressing areas where the industry can have the greatest effect, including achieving GHG neutrality, optimising water use while maximising recycling, and improving water quality by optimising utilisation of manure and nutrients. Following this, the US Dairy Net Zero Initiative (NZI) was launched to help farms cut their environmental impact, supporting dairy farms to adopt new technologies, practices, and create new markets and products. There are a plethora of specific actions businesses across the dairy industry are taking to improve their environmental impact. Within facilities LED lighting is being installed, green energy is being switched to as well as produced, and waste reduction practices implemented. New and 38 ÁFood & Drink International 37 www.fdiforum.net DAIRY INDUSTRY © stock.adobe.com/Kadmy38 Food & Drink International www.fdiforum.net DAIRY INDUSTRY efficient technology and equipment are also being invested in, from that that minimise electricity consumption to high-efficiency refrigeration used to instantly chill milk at the farm, more efficient machinery and trucks, and sound waste heat recovery systems in plants. Managing wastewater is also key, with water playing a major role in dairy manufacturing and processing, with facilities working to ensure it gets reused and recycled back into processes, while upgraded pumps and piping circulating water to evaporative cooling towers for example are cutting energy use. When it comes to addressing water use, even fixing leaky pipes can be impactful, while placing phase separation sensors at transfer points to make sure only minimal amounts of product, water and detergent are wasted in changeovers and in cleaning in place is effective, whereas larger projects in wastewater treatment can prevent damage to the environment through groundwater and rivers and provide potable water for use. Furthermore, sustainable water management is also vital at the farm, requiring responsible farming and irrigation practices and modern technology. Water can be managed on every level. Addressing waste more widely, many dairy companies are no longer simply discarding waste, sending it to landfill. As everything from cardboard to plastic to whey and water is recycled and repurposed, those in the dairy industry are also turning inedible waste into renewable energy via anaerobic digesters, seeing microorganisms disintegrate organic waste to create gasses, decreasing fossil fuel use and finding a new source of income. One of the main sources of methane at dairy farms, manure, can be wielded by dairy © stock.adobe.com/Syda Productionswww.halalfoodauthority.com - info@halalfoodauthority.com - 0044 (0) 20 8446 7127 Meat, Food Processing, cosmetics, logistics, chemicals, additives & aromas, cleaning substances, packaging, pharmaceutical, ingredients GETHALALCERTIFIED GOBEYONDBORDERS Food & Drink International 39 www.fdiforum.net DAIRY INDUSTRY farmers in anaerobic digesters to reduce their impact while providing a biogas with energy rich potential. The captured biomethane can then be used to power vehicles and fit into a system of cows eating feed grown in fields and producing milk and manure, for the milk to be delivered in trucks fuelled with biogas coming from manure. Moreover, biogas produced could also be employed to power manufacturing facilities, while the by-product from the biogas system can be used to increase crop yield. Major companies like Shell are developing renewable natural gas production facilities located within dairies, using cow manure as feedstock, though it must be noted the upfront capital cost of installing these systems is a significant obstacle. Further actions are being taken at farms, from focusing on regenerative agriculture to achieve benefits of carbon sequestration, water retention and improved soil health, to ensuring to use deforestation-free soy in cattle feed as well as looking to food waste and food processing by-products for feed to decrease resources needed to create feed from crops. Concurrently, genetics projects are helping to breed more environmentally friendly cows. Advancements in technology have played a vital role in the move towards sustainable farming practices. There has been a greater emphasis on integrating automation and data-driven systems into dairy farming operations. Robotic milking systems have gained traction, offering benefits such as increased efficiency, thus using less energy to operate. Robotic milking systems individually milk the quarters, significantly reducing overmilking, thus improving the teat health of the cow. Reducing the risk to the animal also reduces the amount of antibiotics required, thus allaying public fear of antibiotic resistance. © stock.adobe.com/ Денис БабушкинNext >