< Previous20 Food & Drink International www.fdiforum.net CONTROL AND AUTOMATION C overing a multitude of technological advancements in streamlining manufacturing processes, factory automation is merely an umbrella term for a vast variety of possibilities. It can include the adoption of a whole spectrum of enhancements and replacements for human labour, ranging from partially manual operations to fully automated factories. By transitioning from partially manual processes to fully automated factories, food manufacturers can unlock benefits that will revolutionise their operational efficiency and competitive edge within the market – but it can be a costly process. Automated single machines, as a step along the way between manual operations and full automation, are equipped with advanced control systems that enable autonomous operation, reducing reliance on manual intervention. By automating discrete tasks within the production process, and decreasing the risk of human error, higher levels of precision and consistency are easier to achieve, which means more reliable product quality and reduced wastage. For some, end-to-end automated factories will represent the upper echelons of manufacturing excellence. From raw material handling to finished product packaging, full automation ensures machine accuracy, efficiency and quality, with no human intervention whatsoever. The common reference to these kinds of factories as ‘lights out’ or ‘dark’ facilities illustrates their capabilities. They can run constantly, day and night for 365 days a year, only needing maintenance and some cleaning efforts to Tel: +44 (0)1707 331111 info@welwyntoolgroup.co.uk www.welwyntoolgroup.co.uk Hot Air delivered direct to the point of application HOTWINDMISTRALVULCAN robots From single machines to fully integrated robotic systems, factory automation is revolutionising manufacturing processes and reshaping industry standards for efficiency and quality. 22 Á robots EmbracingFood & Drink International 21 www.fdiforum.net CONTROL AND AUTOMATION © stock.adobe.com/I Viewfinder 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 electronics22 Food & Drink International www.fdiforum.net CONTROL AND AUTOMATION carry out their work. The truth remains that most FMCG factories will need some level of human oversight. Partially manual processes are still common in the running of many factories for this reason. This balance allows the machine qualities of speed and data-informed consistency to be matched by human insight and adaptability, whether to adjust processes, or for the intuition certain quality checks require. Robotics cover by far the most cutting edge and exciting areas of factory automation and have the added bonus of being widely versatile in the tasks they can accomplish. Robots can be used to move essentials around the factory, transport raw materials to the production line, or bring finished products to the packaging area. But they can also be deft enough to manage the actual assembly and packaging of products, some having the fine motor skills to perform tasks such as labelling, packaging and handling end products. The beauty of automation extends beyond the simple actions robotic features can manage, bringing in sensors and software that fortify quality control measures. Embedded within the machinery itself, sensors can be vigilant for variables like temperature, swiftly adjusting parameters to maintain optimal conditions. Meanwhile, vision systems inspect products and instantly identify imperfections that might elude human detection. In maintenance, machinery wear and tear can also be managed through sensor technology. Scheduled maintenance, guided by data-driven insights, ensures uninterrupted production flow, reducing the costs of downtime. Additionally, robots lend their prowess to routine upkeep tasks, such as cleaning or oiling machinery, so the focus of human staff can go towards being the custodians of quality output. Perhaps the most alluring asset of automation is its ability to accelerate processes, driving productivity to new heights. However, automation’s impact transcends the factory floor and products themselves, exerting a profound influence on product BAG SEALING MACHINES RM Sealers remain a leading British manufacturer and supplier of high quality Bag Sealing Machines, also known as Rotary Band Sealers and Impulse Sealers. Call 01442 843387 to speak to a member of our team SEALERS © www.rmsealers.co.uk 24 ÁFood & Drink International 23 www.fdiforum.net CONTROL AND AUTOMATION BENCHTOP BAG SEALING MACHINE IMPULSE BAG SEALING MACHINE HORIZONTAL BAG SEALING MACHINE VERTICAL BAG SEALING MACHINE © stock.adobe.com/xiaoliangge24 Food & Drink International www.fdiforum.net CONTROL AND AUTOMATION quality and traceability. Sensors can track materials as they move through the production line, allowing for a detailed record of each step of the process and reducing the risk of recalls. Even when an error or flaw slips past detection, the trace established by data during production can remain linked so that faulty batches may be easily identified and pulled back from sale if necessary. Robots and other automations can complete all these tasks, and many others, much more quickly and efficiently than humans. Any level of automation will likely result in improved efficiency, because throughput will increase as production times decrease, leading to cost savings and growth in profitability. While robots can perform repetitive tasks at a constant speed without needing breaks, automation as a whole can manage and monitor production in up-to-the- moment real time, allowing for adjustments to be made quickly and efficiently. From solitary machines that stand in as masters of a specific task, to robotic-human collaboration and fully automated procedures, embracing automation heralds the future of thriving business operations. Selecting the best combination for a business’s unique needs can then unlock even further insights for future improvements, while safeguarding both quality and the wellbeing of workers. As businesses navigate this playground of innovation, one thing remains clear: the synergy of human ingenuity and technological prowess will be what continues to pave the way to success. ʴˈˇ˂ˀʴˇʸ ˀ˂ʼˆˇˈ˅ʸ ʶ˂ˁˇ˅˂ʿ %RI\GIWWSJQSMWXYVIGERLEZIPEVKIMQTEGXWSRJMREPTVSHYGX UYEPMX]TVSHYGXMSR IUYMTQIRXJYRGXMSR1SMWX8IGLƅWRIEV MRJVEVIHQSMWXYVIWIRWSVEPPS[WQERYJEGXYVIVWXLIEFMPMX]XSEHNYWX QSMWXYVIPIZIPWFEWIHSRVIEPXMQIMRJSVQEXMSRPS[IVMRKVE[ QEXIVMEPGSWXWERHSZIRYWEKITVSPSRKMRKIUYMTQIRXPMJIG]GPIERH MRGVIEWMRKTVSHYGXUYEPMX] TVSHYGXMSRIJJMGMIRG] ˪˪˪ʡˠˢ˜˦˧˧˘˖˛ʡ˖ˢˠ ʞʧʧʤʤʦʫʠʩʫʣʧʤʦ © stock.adobe.com/Parilovwww.fdiforum.net Plan your campaign with Food & Drink International… ...your competitors are! 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Contact us below for our 2024/2025 editorial schedule Call today on +44 [0] 1472 310310 or email: a.cooper@blmgroup.co.uk INTERNATIONAL INTERN NATION AL chal Ope lle tin l dchilled dcosur r F oozen and c fooods Caps and cl ain y upplS lyy cha spotlight INTERN NATI O N AL Sustainabl e pack kaging ngand n e practic Sustainab r Wa eehousin distribution b distribution ution e tur e contr ol practices emperTe a atur spotlight INTERN NATI O N Neewws hallenge Up to the Col c INTERN NATI O N AL I nno G re o v a ti nmena d I En vir onmen spotlight Contr ool and Impor rt and aut omation xpor d rt ation MINIMUM COST…MAXIMUM IMPACT! www.fdiforum.net 26 Food & Drink International www.fdiforum.net HPS PRODUCT RECOVERY SOLUTIONS Q&A Can you tell us a little about HPS and what you do? HPS provides Advanced Liquid Product Recovery Technology, often referred to as ‘pigging’, to companies that manufacture, pump or process liquids. The technology makes these companies more efficient and saves them significant amounts of money. The technology saves companies that transfer liquids through pipelines tens, often hundreds of thousands of $ Dollars, £ Pounds or € Euros every year, mainly by recovering product that would otherwise go to waste. It also improves process efficiency in several areas, speeding up batch changeovers, saving water, energy, and effluent, while helping environmental sustainability and reducing CO2e emissions. How does HPS’ liquid recovery technology help food and drink manufacturers? The initials “HPS” actually stand for “Hygienic Pigging Systems”. The technology has been around for nearly 30 years now and was originally developed for use in hygienic applications, in particular food and beverage production. Of course, HPS technology has developed quite a bit since the early days, particularly when it comes to automation and control. Pigging fundamentally helps food and drink manufacturers by increasing yields and capacity, reducing product waste, water use and effluent, speeding up batch changeovers, lowering contamination and cross- contamination risks, and increasing the efficiency and environmental sustainability of liquid transfer operations. HPS technology will typically recover 99.5% of product from full pipelines on each batch changeover. This is perfectly usable product which is bottled, canned, packed, stored or continued to be processed just like the main batch. The savings can be vast – a well-known soft drink brand saves 44,000 cans per week, and this is a pretty average result for HPS technology. Another benefit is that because there’s hardly any product left to rinse, changeovers and Clean-in-Place (CIP) processes are much faster, and save water and CIP chemicals. Flushes are much quicker and water efficient, and especially where hot flushes are involved, the technology also saves a lot of energy. A rule of thumb is that, for a typical water flush process, HPS technology will reduce both water consumption and rinse time by around 20%. I suppose one of the most important numbers is bottom line profit and the majority of HPS projects pay for themselves in around 12 months. That’s a fantastic ROI for most companies and everything after that is nearly all profit. What makes this different from traditional methods? It depends on what you mean by traditional methods. If you’re comparing pigging to a standard rinse, then with the rinse you lose significant amounts of product by flushing it down the drain. You also have high water consumption, long changeover times, and effluent, which has Q&A HPS Product Recovery Solutions We speak to HPS Product Recovery Solutions, specialists in liquid product recovery, to find out how they are helping food and drink manufacturers save hundreds of thousands each year with their advanced 'Pigging' technology. Peter Elgar, Executive Chairman at HPSFood & Drink International 27 www.fdiforum.net HPS PRODUCT RECOVERY SOLUTIONS Q&A to be treated, transported, or stored. Some companies try and blow product out during changeovers, which is initially low-cost but ends up getting expensive because it’s time consuming and inefficient. With air blow methods you’re looking at 50% product recovery at the very best, so you’ll still need a long flush and will waste a lot of product. Some companies use dedicated lines. But one of the big advantages of pigging is that it’s extremely quick and makes using shared lines a realistic and efficient option that increases flexibility and productivity. What are mistakes or things to avoid when implementing pigging technology? Some companies will use crude, manually operated pigging technology. HPS rarely provides anything other than automated systems, which are extremely efficient, fast, productive, and safe. With automated systems, there’s very little for operatives to think about, so the sequence gets done every time it needs to be, and the process is optimised. You also need to think carefully about your choice of pig. Generally, avoid any which have fins or complex profiles, as these can break, tear, or cause cleaning and hygiene issues. I also recommend avoiding pigs that contain solid magnets or powdered magnetic material. Magnetisation is essential for pig detection and system automation however, introducing solid magnets (which can break, shatter and escape from the pig) or magnetic powders are both a safety and contamination risk. One thing I would say to anyone considering liquid product recovery technology is this: the principle of pigging – which is basically propelling a specialist projectile through a line to recover all the product – may sound simple but it’s not as easy as you may think. I’ve heard some real horror stories over the years from people who’ve tried to do it themselves, and things have gone badly wrong. At best, they’ve not had the increase in productivity or efficiency that they’d expected. At worse, people have told me first-hand about “DIY pigging systems” that have not worked at all. Even worse, people have told me about DIY systems that have been outright dangerous because they hadn’t factored in various safety considerations that every single pigging system should incorporate. This is one of the reasons that, unlike other pigging system providers, HPS will not simply sell you the components for a pigging system. To provide components only is, in my opinion, unsafe and unethical. Instead, HPS will work with you on the design, provision, equipment supply, automation, commissioning, and training, backed up with ongoing customer support and advice as and when you may need it. How difficult is it to incorporate liquid recovery technology, and how does a company get started? HPS technology is one of the easiest, quickest, and most effective technologies food and beverage manufacturers can introduce and has a major impact on efficiency, productivity, and sustainability. We retrofit systems for existing facilities as well as working with our clients in designing solutions for brand new factories or facilities. One thing I recommend if you are building a new facility is to contact HPS early on in your project. Of course, there will be some disruption. How much exactly depends on the nature of the project but we will always keep this to a minimum. Ideally, we’ll get things commissioned during weekends or shutdown periods. All factories are different, and so are all HPS systems. Each one is custom designed around each of our clients’ individual aims, objectives, and factory layouts. HPS systems are safe, reliable, proven and extremely effective because we provide a complete solution, not just a crate of components. If you’re thinking of introducing the technology the best way to get started is to contact HPS via email, website, or telephone. info@hps-pigging.com www.hps-pigging.com +44 (0) 115 925 4700 28 Food & Drink International www.fdiforum.net LABELLING, CODING AND TRACEABILITY T raceability is defined as the ability to track foodstuffs, right through production, processing, and distribution. When food processing, this should extend to the source of all food inputs, such as additives, packaging, raw materials and other ingredients. Traceability is important because it encourages responsibility within the food chain. Corrective actions (such as product recall) can be undertaken quickly and efficiently. This is important during food safety concerns, as when a potential problem is identified, the traceability system can help to isolate potential contaminants and prevent affected products from reaching the retail shelves. Most recently, an outbreak of E. Coli in sandwiches and wraps (thought to be from contaminated lettuce) showed how prevalent recalls are in our industry. This is inclusive of importation and retail. When products are still within the supply chain, an efficient traceability system should be able to trace movements one step backwards and one step forwards. This allows businesses to target any affected products with minimal disruption to the trade, as it can be easily identified wherein the chain the issue occurred. Efficient traceability systems allow for pre-emptive actions to be taken, meaning that issues can be resolved before panic-inducing corrective actions are required. This both limits the amount of production time lost, but also the potential damage to business reputation that can be caused by multiple, or serious, recalls. So, how do you know if your traceability system is effective? A key element is as mentioned above, being able to trace one step forward and one step back at any point within the supply chain. This means that the system needs to include procedures for identifying all producers, suppliers, customers, and products. This should include name and address of suppliers and customers (and a description of the products or inputs supplied), a date of transaction or deliver, a batch identification (or similar markings), the quantity or volume of the product supplied or received and any other relevant production records (such as other materials utilised within the product or to utilise it) As discussed above, traceability allows for accountability. This extends into product labelling, which details the ingredients in food, and by law should highlight any relevant allergens. The law was updated on this a few years back, colloquially known as “Natasha’s law”. This follows from the tragic death of teenager Natasha Ednan-Laperouse, who suffered an allergic reaction to a Pret a Manger baguette. As it was prepared on the premises, Pret a Manger was not obliged to provide a full list of ingredients and allergens on the packaging. The law was changed last year, requiring businesses to include a full list of ingredients on pre-packaged for direct sale foods. This means that even small businesses (such as cafes and sandwich shops) who package sandwiches and salads to be sold later that day, must adhere to this law. To 30 Á Increased Scandals, allergen scares and recent contaminations have all set the stage for increased demand in labelling and traceability. traceability traceabilityFood & Drink International 29 www.fdiforum.net LABELLING, CODING AND TRACEABILITY Labfacility Case Study: Custom Duplex RTD Pt100 Temperature Sensor Solution for British Defence Labfacility specialises in designing and manufacturing high-quality temperature sensors tailored to customer needs. This case study outlines our custom Duplex RTD Pt100 sensor solution for a British defence client. The client required eight sensors for a critical test rig, combining two sensors for data recording and indication in one assembly. The challenge was to integrate both sensors without compromising performance or ease of use. After detailed consultations, we developed a duplex RTD Pt100 sensor with a dome-top terminal head for easy wiring and future replacements. Using 1/10 DIN RTDs, stainless steel parts, and a 1/2 BSP process thread, we ensured accuracy and durability. The sensors were designed, manufactured, and tested within two weeks. The sensors exceeded expectations, providing precise temperature measurements and easy installation. The client praised our efficient process and product performance. This project highlights Labfacility’s expertise in delivering custom sensor solutions, supporting the stringent requirements of the British defence industry. For more information visit www.labfacility.com © stock.adobe.com/Brian JacksonNext >