machinery update march 2015

The machinery only journal for processing & packaging | www.machineryupdate.co.uk

INSIDENEWS

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NEWS

PLUS

INSTALLATIONS

NEW MACHINERY

Issue 2, Volume XXVI, March/April 2015

The Prompt Payment Codeis all about encouraging andpromoting best practice between organisations and helping the supply chain torun smoothly but will it?

This years PPMA Show in September is set to be the largest event since 2008 -for further information [email protected]

A new generation ofsleeving machine has allowed a German mineral water brand to use specially shaped PET bottles with efficiency

A Cartesian palletiser hasbeen developed that takesup just 4.3m2 of floor space,delivering a 50% reductioncompared to some otherrobotic arm solutionsFind out more on page 16

Skin packs march onIn our special feature on meat, fish and other proteins, we report onhow more and more products are now packed in vacuum skin packs due to the retailer, processor and end user benefits that they bring

CAMA UK Ltd - [email protected] - Tel. +44 (0) 1793 831111

Much more than simple technology

Cologne

24 - 27 March

Hall 7.1

Stand B011-A010Sta

44 VISIONSeveral new launches this issue as well as installations to inspect beverages and automotive products

46 LABELLING, CODING & MARKINGLaunches include a converger equipped with an inline labeller 48 COMPONENTS Mitsubishi has expanded its iQ automation platform

52 REGULATIONS Assessing any risk is a continuous process when meeting the requirements of PUWER and should be a regular occurence

54 WHO WHAT WHEREPeople, events and diary dates

56 CLASSIFIEDMachinery and services 57 BUYERS GUIDES

www.machineryupdate.co.uk MARCH/APRIL 2015 MACHINERY UPDATE 3

March/April

EDITOR:Gail Hunt

SALES MANAGER:David Chadd

PUBLISHING MANAGER:Bill Lake

BUYERS GUIDE CO-ORDINATOR:Chris Valdes

ARTWORK CONTRIBUTOR:Barry Heath

HEAD OF MARKETING:Grant Collier

A PPMA PUBLICATIONPPMA Ltd,New Progress House,34 Stafford Road, Wallington,Surrey SM6 9AA

TEL: +44 (0) 20 8773 8111 FAX: +44 (0) 20 8773 0022

E-MAIL ADDRESSES:[email protected]@[email protected]

WEBSITE:www.machineryupdate.co.uk

APPLICATIONS FOR FREE COPIESof Machinery Update are considered from specifiers, managers and purchasers of processing and packaging machinery in the UK.

ANNUAL SUBSCRIPTION:35 (UK), 50 (Continental Europe), 65 (rest of world).

ISSN 0969-4145

PRINTED BY:Manor Group, 7-8 Edison Road, Highfield Industrial Estate, Hampden Park,Eastbourne BN23 6PT.Tel: +44 (0) 1323 514400

The Processing and Packaging Machinery Association assumes no responsibility for the statements or opinions, whether attributed or otherwise, in Machinery Update.

This publication is copyright under the Berne convention and the International copyright convention. Apart from any fair dealing for the purposes of research or private study, as permitted under the Copyright, Designs and Patents Act 1988, no part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means in any form without prior written permission of the publishers.Publishers: PPMA Ltd

Contents15

7 NEWSWe talk to the young engineer who was named the One to Watch by the PPMA last year

12 NEW MACHINERYSix pages of new options include a horizontal cartoner and a compact Cartesian palletiser

18 INSTALLATIONSEquipment installed for ice cream, biopharmaceutical drugs, mineral water and building blocks

28 SPECIAL FEATURE MEAT, FISH & PROTEINSThis 16 page feature reports on the latest trends and developments including the rise of vacuum skin packing in the sector as well as seal testing and fat content analysis

28REGULAR FEATURES

Learn more and discover what robots can do for you at: universal-robots.com

A complete range of collaborative robot arms ready for any application

Introducing the new UR3, the 3 kg rated robot from Universal Robots. With a reach of 500mm and a payload of up to 3 kg, its the perfect option for those looking to automate smaller processes.

The UR5 (5 kg, 850 mm) or the UR10 (10 kg, 1300 mm) are ideal if youre looking for a robot with a larger payload, increased reach or

www.universal-robots.com.

> Easy Programming> Fast Set Up> > Collaborative and Safe> Fastest Payback in the Industry

UR10UR5UR3

AVERAGEPAYBACKPERIOD

195DAYS

www.machineryupdate.co.uk MACHINERY UPDATE 5

PPMA matters

As we come out of recession, growth opportunities exist and efficiencies are needed so lets all invest. Thats the answer. Spend our money on investment, at the same time make more goods or machines, satisfy the demand, buy more raw materials, spend more on labour, advertise again, let them know were still here.

All good advice, all good practice, but where does our money come from and how do we all finance this growth and recovery? And how do we finance it if our biggest customers are not paying us SME suppliers very quickly?

Bank borrowing is one choice, take longer to pay your suppliers another and chasing your customers money in more quickly is another. The simple goal is to get more cash.

Grant Jamieson CHAIRMAN PPMA GROUP OF ASSOCIATIONS (INCORPORATING PPMA, BARA & UKIVA)

Low inflation means no price increases and so we all have

to become more efficientIn isolation this seems a sensible and reasonable approach.

But we dont function in isolation as we are part of the bigger picture. This bigger picture tells us we are having exactly these things done to us. Bank borrowing is expensive, our suppliers are chasing us more aggressively and our customers are deferring payment more aggressively. We, the SMEs, are often the piggy (or piggy bank) in the middle.

I am therefore delighted to see, and fully support, the Prompt Payment Code initiative being introduced and supported by politicians at the moment. A number of leading companies are signing up to a payment code of conduct openly declaring their terms and conditions of payment(with some notable exceptions).

It is not a perfect solution but it is definitely a first step in the right direction. The first requirement in any change initiative must be to recognise the need for change and to see the bigger picture.

Hopefully this initiative demonstrates that the recognition phase has begun. We need to spread the word and the deeds to fully establish this important topic.

It is down to all of us to create an honourable trading environment. We must ensure the supply chain that is fundamental to all companies, whatever their size remains intact and is there when it is needed. Like, for instance, now when recession is coming to an end and everyone sees growth and opportunity which they want and need to seize.

Seeing the bigger picture and working together is surely the only sensible way to succeed.

Paying on timehelps all of us to grow

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News www.machineryupdate.co.uk MARCH/APRIL 2015 MACHINERY UPDATE 7

News

Consultation ends onthe grossly unfairlate paying practices

The Department for Business, Innovation & Skills (BIS) is currently analysing the response to its discussion paper designed to determine policy on, amongst other things, grossly unfair terms and practices in terms of late payment and specifically the impact this has on SMEs.

Government is taking forward a suite of measures to tackle late and prompt payment at the moment. BIS is committed to achieve a cultural shift that will make it unacceptable for larger companies in positions of extreme bargaining imbalances to exploit smaller suppliers.

And through the Small Business, Enterprise and Education Bill, currently before Parliament, BIS is introducing a requirement for large companies to report on their payment practices and performance. Minister of State at BIS Matthew Hancock thinks this increased

transparency, through a tough and transparent new reporting requirement on all the UKs largest companies, will help us take significant steps to addressing the current imbalance in economic power between small and large contracting parties.

These moves have been welcomed by PPMA chairman Grant Jamieson who is delighted to see, and fully support, the Prompt Payment Code initiative being introduced (see page 5). We, the SMEs, are often the piggy (or piggy bank) in the middle between our suppliers and our customers, he says.

Meanwhile, many high profile companies have been actively ignoring these calls and putting more pressure on their supply chains.

If you have any views on

this topic, please contact us at [email protected]

THE SIX MONTH PROJECT IS FOR SIXTH FORMERS

Vision projects for studentsContinuing Stemmer Imagings commitment to support engineering education in the UK, it has started its third vision project with students from Farnborough Sixth Form College. The six months of work involves the design and construction of a vision system to carry out automated packaging inspections on breakfast cereal boxes.

Automaton companyconfirms much bigger stand at PPMA ShowCompressed air automation technology expert SMC is returning to the PPMA Show this autumn (30 Sept 2 Oct) and will take a significantly larger stand than the 123sq metres it took at its last tenure at the NEC-based event.

We have a reputation for attending industry exhibitions with stands that get people talking and well be working hard between now and September to make sure this years stand builds on this reputation, explains Bob Hitner, SMCs UK marketing manager.

Exhibition manager David Harrison welcomes SMCs participation and tells Machinery Update that this years event is set to be the largest since 2008.

SMC at Drives & Controls in 2014

Japanese print giantbuys Domino forfuture strategic gain

Domino Printing Sciences has been bought by Japanese print giant Brother in a deal worth 1bn.

The deal is subject to the approval of Dominos shareholders but the company believes the deal would create a well-positioned business with a differentiated value proposition in industrial printing, an excellent product offering and strong capabilities in the development of new technologies.

The enlarged group will be able to invest in the future to better serve our customers, says Domino Printing Sciences chairman Peter Byrom.

Super growth award for a Sussex-basedlabelling company

Atwell Labellers has won a Sussex Super Growth Award gaining a top 30 spot as one of the fastest growing companies in the period from 2010-2013 from over 200,000 businesses based in the county.

Owners David and Helen Charlesworth attended an awards breakfast at The American Express Community Stadium in March to receive the certificate. Having sold their house and cars to fund the purchase of Atwell ten years ago, the couple are now reaping the rewards of taking that brave plunge.

The company exports its labellers to over 30 countries around the world and has recently invested in a dedicated plant to expand its contract labelling offer.

Dan-Palletiser is safety accredited

Atwells David Charlesworth (right)

Palletising company is safety accredited Palletising solutions manufacturer Dan-Palletiser has achieved accreditation from the third party Safecontractor scheme for its commitment to achieving excellence in health and safety. Under the scheme, businesses undergo a vetting process which examines health and safety procedures and their track record for safe practice.

News8 MACHINERY UPDATE MARCH/APRIL 2015 www.machineryupdate.co.uk

Latest apps give on-the-go infofor conduit and sensors ranges

Specifying cable protection is now possible wherever you are thanks to Flexicons new find-a-conduit app while Balluff has released a free catalogue app to give information on its range of sensors, industrial RFID and networking solutions.

Specifying the correct conduit system for cable protection depends on the hazards faced by the system, says Tim Creedon, sales and marketing director for Flexicon, Often this assessment is most easily done on site, so having a mobile tool that enables you to explore different solutions on your phone or tablet is a big benefit.

Accessible through the companys website www.flexicon.uk.com, the app prompts the user to answer a number of simple questions to ascertain what hazards the cabling is likely to face. It then details the specification based on these answers and provides different conduit solutions to choose from.

The resulting conduit system can then be forwarded to Flexicon as an enquiry or to create a bill of materials through the Flexicon website.

Meanwhile, the Balluff app can be downloaded in the Apple App Store and Google Play Store.

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Getting to students early is young engineers planWinner of the PPMAs One to Watch award last year Dan Stamp believes manufacturers must begin to appeal to the imagination of students and graduates early on in order to turn the next generation on to the benefits of a career in the manufacturing sector.

Having graduated from my degree in Science in Design Engineering, I joined Kliklok two years ago because I was impressed by the innovation and functionality of the machinery they produce, explains Stamp.

As a young engineer, it does worry me that so few young people are entering the packaging and processing industries, he says but he also acknowledges that manufacturers do understand that recruiting trained staff can be a challenge.

Stamp believes that to counter the impending skills shortage that many have forecast for the UK industry, manufacturers should be looking to launch project solving competitions

that utilise the creativity younger people can bring to the table. When I joined Kliklok two years ago, I was impressed by the innovation and functionality of the machinery they produced, he says. Within a couple of weeks of conceptualising something were able to see our innovations being put to work on the shop floor which is a continuing motivator for me as a design engineer.

Since joining, Kliklok has continued to support my further development by sponsoring my Masters in engineering, he continues. I chose modules that I felt would be relevant to my position within the company and have already been able to put these skills to use in a recent project which helped to reduce the time required to design a machines change part tooling by 80%, he says.

weQube is the perfect answer to your industrial needs: The new smart camera from wenglor combines numerous features on a powerful platform. Try it out and experience the fascination of industrial image processing.

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You need. weQube.

New partner brings benefits to Lantech case handling range

Contact Packaging is a new UK partner for Lantech case erectors following a conversation at last years PPMA Show. This is the first time the family run business has offered case erectors as part of its equipment offer that also includes stretch wrappers, strappers, shrink systems and case sealers from Taiwan-based Extend as well as case sealing equipment from Siat.

Any customer who looks to invest in case handling systems is looking for maximum uptime, says Andrew Saxton, sales manager at Contact Packaging. They want reliable machines that require little maintenance and minimal changeover time and for this we felt Lantech ticked all the boxes, he says. T 01772 694140W www.contact-machinery.co.uk

New UK partner for Lantech units

Young design engineer Dan Stamp has continued his studies while at Kliklok

News10 MACHINERY UPDATE MARCH/APRIL 2015 www.machineryupdate.co.uk

New premises bring operationalgains to bespoke mixer supplierBespoke mixer specialist Winkworth celebrated its relocation to a new facility with this celebratory cake sporting a photograph of the building.

As well as housing a smart, clean and well organised production area, the companys 30,000sq ft premises in Basingstoke also features an all new mixing test centre to offer a test, select and perform service to customers. This allows the opportunity for customers to test many mixers or blenders before making a purchase.

This centre houses a range

of mixers of varying sizes and types while the mixing chambers can be managed for heating, cooling and vacuum as required.

Winkworths equipment can also now be hired to carry out trials or test marketing, a service which is proving popular with contract manufacturers across many industry sectors.

The company produces equipment to meet the

needs of a diverse range of applications such as confectionery, pharmaceutical products and even bitumen.

Phone 01480 408 500 www.leuze.co.uk

SMARTER PRODUCT USABILITY

Rolf Brunner,

Head of

Product Center

Laser Scanners easy handling.

GUARDING WAS NEVER THIS GOOD. SAFETY LASERSCANNER RSL 400 With two autonomous protective functions, an operating range of 8.25 m and a scanning angle of 270, the RSL 400 sets new standards in safety sensor technology.

And it is this breadth of knowledge that is helping the company to grow year on year.

We expect double digit growth this year as we settle in to this new facility as it helps us work more efficiently, explains Grant Jamieson, managing director at Winkworth. We have retained all of our highly skilled staff in the move from Swallowfield and have now also recruited new people to the business, he says.T 01256 305600W www.mixer.co.uk

Photograph of new premises decorated the cake

New Machinery12 MACHINERY UPDATE MARCH/APRIL 2015 www.machineryupdate.co.uk

Inspection range bringseasy accuracy benefitsAnew generation of foreign object inspection units was the highlight of Heufts stand at Anuga FoodTec that took place in March.

Glass, metal and stones can be detected on the new generation top-down eXaminer inspector but this latest model has a bigger field of view than the previous version, so can inspect oversized products and can also inspect two lanes of product at the same time.

The highly automated, easy-to-use system has the lowest level of radiation and, says Phil Cooper, business development manager at Heuft UK, is impressive as it offers higher detection accuracy. Also, the teaching in procedure makes it possible to differentiate individually between harmless deviations and critical faults in order to minimise the proportion of false rejects.

This feature is also offered on the new FinalView FO6 for continuous 360deg inspection of pack characteristics and the

Spectrum II VX for checking fill quantity in bottles and jars as well as the closure.

The 360deg inspection of food containers is achieved without blind areas due to high performance GigE cameras on several levels and reflection-free LED illumination. This ensures

that only correctly positioned labels are produced while scratched or dirty labels or minute printing and design faults are also identified. This new version is perfect for high value spirits or wines and champagnes.T 01827 255800 W www.heuft.com

This eXaminer machine has a bigger field of view than the previous version

Roller belt sorter is ideal for diverting a variety of items

Conveyor Systems has added a modular activated roller belt sorter to its sortation range that can sort up to 3,600 items an hour at speeds of 75 metres a minute, depending on size. The double activated roller belt sorter was recently installed as part of an integrated system supplied to an e-commerce company to provide optimised product flow, as well as high speed sortation of small as well as awkward sized products not suited to conventional conveyor solutions.

The sorter is compact with the capability to divert single or small numbers of products in a minimal footprint, while its versatile modular technology can effectively handle a wide range of products from CDs, books, mail, polybags, cartons and totes. T 01283 552255W www.conveyorsystemsltd.com

The modular unit is compact

www.machineryupdate.co.uk MACHINERY UPDATE 13

Protective gainsfor PET options

Optimum product protection for milk products and sensitive beverages was the key issue being presented at Anuga FoodTec by KHS.

Both linear and rotary aseptic machines for filling extended shelf life or ESL milk products into PET/HDPE containers are offered by KHS. The Innosept Asbofill ESL filling machine, for instance, offers a small aseptic zone to not only give operators maximum product safety at a low cost; but a container that is hygienically sealed directly after filling. Another plus point of the Innosept Asbofill ESL is its short format changeover time which is performed without affecting the aseptic conditions.

Containers ranging from 0.1 to 2 litres through various weights from lightweighting to the classic bottle with a number of different closures can be produced at outputs of 12,000 or 24,000 bottles an hour at low operating and maintenance costs.

To ensure a long shelf life for milk products, mixed milk beverages and juices which are not destined for the cold chain, the KHS Innosept ASR rotary aseptic machine can be supplied. This has a capacity of up to 36,000 bottles an hour.

As part of the Bottles &

Shapes programme, visitors saw a new lightweight system which has been specially developed for milk products and sensitive beverages as well as the Plasmax process. This process illustrates how the insides of PET bottles are coated with an ultra-thin layer of glass.

At the same time, a new display packer for large containers was demonstrated. This is designed to cut packaging costs and with its large-format tray, allows strong branding for consumers in store. The company believes that in a competitive environment such as that among discounters, this new feature is a convincing and attractive alternative to standard trays.T 0121 713 6900 W www.khs.com

Cost reductions for packaging materials coupled with flexible marketing

The worlds lightest 0.5 litre PET bottle has been developed

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Now with Vericoder - automatic barcode


UV laser allows for high speedmarks without product damage

In response to manufacturer needs to comply with increased serialisation regulations, Videojet has introduced the 7810 UV 2-Watt laser in addition to its existing CO2 and fibre laser units.

Providing permanent, high resolution marking on HDPE, LDPE and synthetic fibre materials, this system is ideal for pharmaceutical, medical and cosmetics manufacturers as the surface of the product remains undamaged during the process.

The proprietary 360deg C arc software compensates for products on curved lines of movement to help ensure consistent coding, irrespective of product orientation. As packs move down the production line, multiple concave mirrors deviate the uv beam so that every part of the pack can be clearly coded as needed. This also allows for full product traceability throughout the supply chain.

High speed inline marking at up to 250 products a minute can be achieved using the 7810 UV 2-Watt laser.

Medical device products utilising synthetic fibre materials for sealing blister packs can be handled easily by the unit. The uv laser properties ensure that the light amplification does not burn the fabric, preventing any code deterioration during the sterilisation process. T 0870 240 5542W www.videojet.co.uk

THE UV LASER SYSTEM INCLUDES PROPRIETARY

360deg arc compensation software to ensure consistent codes regardless of product position

11 Barton Lane, Abingdon, OX14 3NB Tel. No.:+44 (0) 1235 534404 Email: [email protected]

DER ANTRIEB RELIABLE VERSATILE GLOBAL

The NORDBLOC range of geared motors brings a new dimension of flexibility and modularity. Inline, right angle or parallel gearboxes can be coupled direct to electric motors or via IEC inputs. The NORD decentralised inverters provide variable speed but much more, closed loop performance, positioning, synchronising, on-board PLC and digital communications. Gearboxes, motors and drives can be supplied as smoothed bodied, protected to IP69K and with our NSD surface conversion system and therefore suitable for the severe wash down applications.


Horizontal cartoner providesfast and easy format changesBosch Packaging Technology launched the new horizontal cartoning machine CFC 2012 at Anuga FoodTec in March.

It has been developed for large scale secondary packaging formats used by the food industry with a width up to 12 inches. The development of the CFC 2012 is based on our experience with bag-in-box machines and infeed solutions, explains Daniel Sanwald, product manager at Bosch Packaging Technology. Thanks to optimised control and conveying technology, the cartoning machine ensures quick format changes as well as safe and reliable product handling, he says.

Due to a wide range of in-feed systems, the machine can be used for many different products such as bags with or without side gusseting, as well as stand-up bags with gable tops. Even with the largest folded carton and product formats such as for cereals, the machine achieves an output of up to 200 folded cartons a minute. While modern servo technology guarantees supported, fast and also reproducible format changes, says Sanwald.

Due to the insertion aid, the CFC 2012 is efficient and safe as products are reliably and gently inserted into the folded cartons, without damage. And as transportation is lubricant-free, no grease can compromise the product infeed.

Products are transported via a robust strap conveyor belt which can be expanded segmentally. Moreover, the CFC 2012 operates quietly and

requires little maintenance. A three-star rotor with dual drive enables the safe removal from the large stack of folded cartons, and ensures process safety throughout the entire format range.

Thanks to the especially compact design, the machine can be easily accessed, cleaned and maintained from the operator side. Together with the intuitive operation

with an integrated HMI (Human Machine Interface), the horizontal cartoning machine stands for maximum operator friendliness at minimum maintenance effort, says Sanwald.

Primary packaging solutions for dry food products were also demonstrated at the exhibition. T 01332 626262W www.boschpackaging.com

The cartoners compact design means it is easily accessible from the front, as well as easy to maintain and clean


Compact Cartesian palletiserbrings space saving benefitsPacepacker has developed a Cartesian palletising system which typically takes up just 4.3m2 of floor space delivering a 50% footprint reduction compared to a comparable robotic arm solution.

Over the years, production facilities have got increasingly congested, explains Paul Wilkinson, Pacepackers business development manager. Automation solutions for end of line palletising can be very bulky however the Cartesian unit is very space efficient.

Situated at the end of an existing product conveyor, the palletiser is ideal for handling retail and wholesale goods in clusters, such as shrink packs of flour and trays of jam jars, as well as boxes, cartons, shrinkwrapped trays and other retail goods.

Palletiser design is simple and comprises a robust frame straddling the end of line conveyor. A Cartesian mechanism supplied by Festo is built into the overhead area and an empty pallet is placed

neatly on the floor within the structure. As product feeds along the conveyor, it is picked up and placed onto the pallet.

The most appropriate end effector for each application is added to the Cartesian device, typically an electro-magnetic or vacuum gripper, giving packing facilities a standalone palletising solution for accurate and

efficient handling of materials. Throughput speed depends on the volume and type of product being handled in each movement, but is about 6 a minute for shrinkwrapped, flexible packs like bundles of flour, and 10 a minute for ridged boxes. These speeds can be increased if multi picking is an option.

What weve done is create a practical and cost efficient

palletising alternative, says Wilkinson. Like many of our systems, a 12 month ROI is entirely feasible.

The first model was recently commissioned by a family-run flour farm and installed in January. Estimated timescales from order to delivery for the new palletiser are currently about 12 weeks.T 01371 811544 W www.pacepacker.com

The most appropriate end-effector for each application is added to the Cartesian device for efficient materials handling

Unique vacuum pick up frame Ergonomic magazine for easy filling of case blanks Small footprint Easy size change from one format to another Supplied as a hot melt glue option or adhesive tape Colour operator touch screen panel Can be a stand-alone machine or integrated into

other machinery Installed and commissioned with after sales support

C1000/2000case erector

from Lantech

Lantech modular case erector capableof up to 30 erected cases per minute

17 Elizabeth Court, St Neots, Cambridgeshire, PE19 8PF

T: 01480 382739 M: 07764 772965 E: [email protected] www.maters.co.uk


FOOD PRODUCTS CAN BE COOLED UP TO

10times faster than systems based on forced convection or natural convection cooling

Ambient and chilled air coolingsystem offers speed advantages

If diversitys what youre looking for: the Varioline packaging system from krones. www.krones.com

By utilising patented ambient air impingement technology, the Foodesign cryo-jet 5 cools food products up to ten times faster than systems based on forced convection or natural convection cooling. This reduces pre-packaging and pre-freezing cooling times while maintaining product quality.

Suitable for applications including baked goods, snacks, bars, confectionery and fried foods, the cryo-jet 5 offers rapid in-line cooling in a compact system that cuts the floor space required by long cooling conveyor systems including spiral belt cooling options. As well as reducing the total footprint, this maximises production line yield, says the company.

Using hundreds of high velocity jets of ambient air, the cryo-jet technology rapidly strips heat from the product while maintaining critical properties such as appearance, taste and shape.

It is available as a standalone unit for mounting on existing conveyors or as a complete cooling system together with a Foodesign wire mesh or plastic belt conveyor. Available in a variety of sizes, it can be integrated easily into a production line.

Constructed in heavy duty stainless steel, the cryo-jet 5 can be provided with an air filter.T 0121 628 8900W www.foodesign.com

Installation News18 MACHINERY UPDATE MARCH/APRIL 2015 www.machineryupdate.co.uk

Award-winning drugs facilityis the largest single line order

A61 metre long system installed at the Biberach site of Boehringer Ingelheim is the largest single line order to date for Bosch Packaging Technologys pharmaceutical product division. Indeed, the project has spanned several years and last year, it was awarded the Facility of the Year Award (FOYA) in the equipment innovation category by the International Society for Pharmaceutical Engineering.

Boehringer Ingelheim wanted to increase the flexibility and capacity at the Biberach site, and so decided to expand and

Isolator segments of the FLC 4080 filling machine from Bosch ensure aseptic conditions during the filling and closing process at the Biberach site

modernise its production of biopharmaceutical drugs. After two years of concept development and design studies, the Aseptic Area 5 and Combi Line project started which involved the construction of two ultramodern filling lines with a common connection to two freeze dryers in an existing production building. Our goal was to create a flexible production area for the manufacturing of all important biopharmaceutical dosage forms, which would meet todays and future requirements for aseptic processing while allowing

transparent and flexible production, explains Dr. Friedrich Haefele, vice president BP Fill & Finish Germany at Boehringer Ingelheim.

PROJECT PARTNERProject partner Bosch Packaging Technology developed and installed two complete filling lines with the corresponding isolator technology, consisting of an FLC line as well as an MLD combi line for filling liquid and freeze-dried products into vials. The MLD combi line also processes single and double-chamber cartridges. In the latter, one chamber is for the freeze-dried active ingredient and one for the solvent.

Bosch provided the technology we needed for a flexible aseptic production in the form of five separate isolators from a single source and at a competitive price, explains Joachim Schweizer, project leader at Boehringer Ingelheim. The combi line enables us to conveniently switch between different container types and optimally adjust production to meet our needs and those of our customers, he continues.

Thanks to their compact design, we also reduced cleanroom footprint while integrating the systems into our premises.

Additional components were provided by the Bosch subsidiaries Pharmatec and Moeller & Devicon.

Pharmatec manufactured several sterile filtration modules to filter the product immediately before filling, as well as two mobile CIP (Clean in Place) systems. These are used to prepare the cleaning media for the filling systems of the filling machines. Moeller & Devicon automated the transport and removal of the cartridges with several handling units.

FIRST PHASEThe first project phase began with the construction of the vial line in production building F113 in Biberach. Its centerpiece is the FLC 4080 which enables the company to fill and close up to 400 containers a minute. Before being filled, the vials are washed in a Bosch RRN 3084 washing machine and then sterilised in a Bosch HQL 4360S tunnel.

The Bosch filling line allows up to 400 containers a minute to be filled by the company, ranging from vials to single and double-chamber cartridges


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fast and flexible response to production requirements at maximum operating times. To offer the greatest possible transparency, they are located in modern, glass-walled cleanrooms, making them visible to visitors and customers. T 01332 626262W www.boschpackaging.com

The FLC 4080 vial line is completed by a VRK 6160B capping machine

Four separate isolator segments ensure aseptic conditions during the filling and closing process and the loading of the freeze dryers. Glove ports for operating the system and separate HVAC and decontamination systems ensure an optimal protection of both staff and product.

This vial line is completed by a VRK 6160B capping machine from Bosch with a capping capacity of 600 containers a minute. The 61 metre long system is the largest single line order to date for Bosch Packaging

Technologys pharmaceutical product division.

While the vial line was undergoing the qualification process, installation of the second project for the facility began with the combi line from the Bosch site in Crailsheim, Germany. The MLD 3081 is also equipped with isolator technology and can, besides vials, fill and close up to 300 single and double-chamber cartridges per minute. The combi line further consists of two RRN 3083 washing machines one for vials and one for cartridges as well as an HQL 4680S sterilisation tunnel.

FLEXIBLE TRANSPORTDepending on the product, a trayloading unit is used for cartridges and a VRK 3080 capping machine for vials. The combi line also features a connection to the freeze dryer. What is special about the system configuration

is its flexible transport concept, which uses the same fully automatic loading and unloading system of the freeze dryer for double-chamber cartridges that is used for vial processing.

The manufacturing lines that received the FOYA are organised in a U-shaped configuration, thus enabling

The 61 metre long system is the single largest order to date for Bosch


Bottles are all dressed up inperfectly fitting, snug outfitsMineral water bottler Gerolsteiner has dressed its special shaped 0.75 litre PET bottle in a snugly contoured outfit thanks to the installation of the new generation Sleevematic ES machine from Krones.

The German mineral water giant was the first beverage company to install this machine that was first seen at interpack 2011. It is used in conjunction with the new TripleS film from CCL Industries which delivers extremely high stretch capability. Stretch at a level that a shrink tunnel is no longer required.

Gerolsteiner installed the Sleevematic ES downstream of two stretch blowmoulding machines, allowing the labeller to be fed with bottles from either of the two blowmoulders. After this, the prelabelled containers are passed on to one of the two fillers in the two lines as needed.

However, demand for the special shaped 0.75 litre bottle has been so huge that the Sleevematic ES is being run in three shifts. The company is therefore planning to have a second Sleevematic ES installed, and to have it integrated directly downstream of the filler in one of the two bottling lines.

The second Sleevematic ES is scheduled to go into operation this summer. The line accommodating it will then become a dedicated line filling the special shaped 0.75 litre bottle, thus obviating the need for any changeovers. This bottle will be filled with both mineral water and sweet beverages.

The TripleS films being used offer a stretching capability of up to 55%. The biggest advantages provided

Since the material is stretched rather than shrunk onto the container, the starting material can be a lot smaller

by the use of self-recovering shrinkfilms are that no shrink tunnel is needed, resulting in savings in investment costs, energy costs during ongoing operation plus space savings. No gluing is required and the sleeve separates easily from the bottle for recycling.

One crucial point was to match the labels surface quality even more efficaciously to the materials processing behaviour in the machine, explains Ulrich Rust, one of the three managing directors at Gerolsteiner and

responsible for technology/supply chain management/quality. Thanks to the development work carried out jointly with CCL and Krones, we fully succeeded in achieving that, a result that is not to be sneezed at, he says. Labelling efficiency now comes to 98 %, due not least to the machines smooth running, adds Harald Jakoby, head of technical planning at the bottler. This means a high level of availability.

The second important issue was label material wastage,

which is now less than 0.2 per cent. Weve arrived at where we had to go and this is a level we can build on, says Rust.

The special shaped 0.75 litre bottle sports a three-quarter-sleeve, extending from just above the bottles base to a point over the waist in the bottles middle. The sleeve shrinkage required for the container is 15% which is achieved easily by the TripleS film.

Due to limitations imposed by the existing blowmoulder, the Sleevematic ES is currently dressing only 19,000 bottles an hour but it can run at up to 22,000 containers an hour.

The Sleevematic ES has taken us a giant step forward as far as dress quality is concerned, because weve further improved the bottles visual appeal, emphasises Rust. Weve now got a perfectly dressed container which satisfies our customers and ourselves.

Weve been given exactly what wed hoped the machine would give us, he says. T 01942 845000 W www.krones.comThe special shaped 0.75 litre bottle is dressed in a three-quarter-sleeve

www.balluff.com

IT'S A GOOD FEELING TO ALWAYS KNOW WHAT YOU CAN RELY ON.

Sensors. Systems. Network technology.

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Contact us today to fi nd out how Kensal Handling Systems can increase line effi ciency, reduce costs and optimise productivity.


Strapping heads handleheavy blocks with easeGordian Strapping has supplied three OMS pallet strapping machines to heavy duty building products manufacturer William Rainford in Aintree.

The Group has interests in aggregates, concrete products, timber and renewable energy and last year, it increased production capacity at William Rainford with the addition of a new KVM block making line. The three strapping machines an 08RP twin head vertical strapper, an 08RP single head vertical strapper and an 06RP horizontal strapper operate on this new line. Both the vertical machines are equipped with side shift technology.

The OMS TR19HT and TR14HD strapping heads are designed for use with PET strapping, and are proven in the toughest working environments within the building products industry, explains Daren Spice, sales & marketing director at Gordian. The heat seal technology in

these heads means that a full service is only required every 200,000 cycles.

The heads are compatible with a variety of different strap grades and feature auto strap loading, auto strap re-feed, strap in place signal and automatic heater blade cleaning.

We were impressed

with the build quality and performance of the OMS machines, explains Graham Atkinson, group production manager. Gordians ability to support the machines with local service engineers was also an important factor in our decision making process.T 01256 394400 W www.gordianstrapping.com

Three OMS pallet strappers have been installed at William Rainford

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Exceptional Sales Company Growth

Integrated coding and labelling makesproduction simpleA producer of high quality sleeved meat products is reaping the benefits of an integrated coding and labelling system installed by offline coding company PrintSafe.

The standalone system is applying promotional labels and also printing date codes on a range of sleeves for own label and retail branded products. Each sleeve is coded and labelled, as required, ready for production.

In operation, the udaFORMAXX feeder moves the sleeves from stack to stack past the label applicator and thermal inkjet printer. It can comfortably handle about 300 sleeves a minute.

PrintSafe says the flexibility of the udaFORMAXX made integrating the customers choice of coding and labelling equipment a simple task. T 01962 761761W www.printsafe.co.uk

Integrated system brings gains


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700plus mobile stacking delivery system for the finishing area

Print finishing capabilities areboosted with folding machines

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Tough, reliable, and not afraid of getting wet.

The A520i is a versatile performer even in the harshest of environments it maintains its sleek operation, delivering seamless performance.

Whatever the wash-down routine outside, its robust, 316 grade stainless steel casing protects all the intelligence inside.

The unique plenum airflow cooling system keeps the printer cool and the electronics sealed.

And with the Domino service-free i-Tech ink management system, the A520i minimises planned downtime, while reducing your solvent footprint driving down the overall cost of ownership. Ink jet printing that does more for you.

Clean inside and out

JThomson Colour Printers has installed two MBO folding machines a K8/4 S-KTZ Perfection Combi and a T800.1/642 Perfection to correct the imbalance between speeds achieved in its printing operation and its finishing capabilities. Both were supplied by agent Friedheim International

Although we had added speed and capacity to our printing operation, we had not done the same with our finishing capabilities, and realised we needed to correct this imbalance, explains Kevin Creechan, managing director at the printer. Technology has progressed significantly since our last purchase but it was apparent that the range of capabilities provided by the MBO folders was ideal for our business.

The family owned business handles a lot of section work and because of this, chose the K8 RS in particular because its speeds of up to 275m a minute can match the speed of its offset presses.

Also, by making such a significant investment with the two MBO folders we will be more competitive on larger projects which up until now we have probably not been able to consider, continues Creechan.

As part of this investment the company also purchased a Palamides Alpha 700plus mobile stacking delivery system supplied by Friedheim. T 01442 206100W www.friedheim.co.uk

TRANS Rail based Transmodules are the central element of a Schubert packaging system. These transport robots autonomously guide your products through all areas of the

The Transmodul in action

youtu.be/Pu6597wHncs

Schubert UK Ltd Villiers Court, Meriden Business ParkCopse Drive, Coventry CV5 9RN, Great BritainPhone +44 1676 525825, Fax +44 1676 521541

www.gerhard-schubert.co.uk

MODULpackaging system ensuring positive control through the entire process. Thus they open up new dimensions: for flexibility and safety, for operating comfort and efficiency.

Kliklok has sold three more automatic packaging lines to R&R Ice Cream in the UK for its Northallerton factory to accommodate increased production capacity for its popular Nobbly Bobbly, Fruit Split and FAB ice lollies.

R&R again chose to install the Kliklok MSR (medium speed rotary) end load cartoner. Two machines with 12 pitch flight centres and one machine with 15 flight centres were supplied to cater for the twelve different varieties of carton sizes required.

Standard features on the MSR include a sturdy, stainless steel construction, patented rotary carton feeder, large capacity carton


Loma Systems has completed one of its first installations of an X5 SpaceSaver x-ray inspection unit to savoury pastry products manufacturer The Welsh Pantry.

The company, which already has Loma metal detectors and checkweighers, is using the compact system to inspect its pie products for glass, ceramic and stainless steel contaminants.

Measuring only one metre in length, the reduced size of the x-ray system enables

users to reclaim valuable floor space and was one of the key reasons for The Welsh Pantrys purchase.

Like many food production facilities, space is at a premium so the launch of the super compact X5 x-ray with significantly smaller footprint was great timing, says Alan Shaw, technical manager at The Welsh Pantry. The systems market leading detection performance is also helping to further strengthen our strict

quality control and food safety procedures.

While the X5 SpaceSaver installed at the pastry products producer is currently operating at speeds up to 35m a minute, the system is capable of running up to 75m a minute.

Despite all the advanced features offered by the X5, they all combine to make it extremely simple to use, says Shaw.T 01252 893300 W www.loma.com

End load cartoners aremeeting lolly demands

Making lightwork ofheavy loadsAstec Conveyors designed and manufactured a further heavy duty modular flat belt conveyor system for a leading corrugated cardboard manufacturer to transport stacks of corrugated cardboard weighing up to 1,000kg each.

The use of plastic modular belting is an alternative to conventional roller conveyor and provides solid support for transportation, dramatically improving stack stability, explains Astec. The heavy duty conveyor side frames are constructed from powder coated mild steel or stainless steel to suit the environment to give a solid and robust structure. The frame was designed with a very low profile to ensure that the height of the conveyor was compatible with an existing trolley car and the downstream equipment.

This heavy duty modular belt is blue with yellow inserts on the edge to easily identify when the conveyor is moving and is powered by a geared motor unit with inverter control to ensure the smooth movement of loads.

Meanwhile, Astec has supplied a bespoke conveyor system for a North London depot of a parcels company which it manufactured, delivered and installed in eight weeks. It included a new sortation carousel comprising over 100m of wide belt conveyors with lift up access gates and delivery chutes on both sides. T 01283 210333W www.astecconveyors.com

Compact x-ray inspection system allowspastry products to meet safety demands

Klikloks MSR end load cartoner offers easy size change and pre-programmed menus

The heavy duty modular conveyor

powered hopper, plus the benefits of easy size change and pre-programmed menus for flexible production requirements. In addition, the MSRs intelligent carton abort sensing feature avoids product damage and ensures minimum carton waste for R&R.

Klikloks relationship with R&R spans 12 years, having installed several cartoning machines at its Crossgates and Northallerton plants to pack ice lollies and ice cream bars, and also at its factory in Osnabrck, Germany.T 01275 836131 W www.kliklok-int.com


HOME DECOR GB BOUGHT THE COMPLEX MACHINE IN

2012 for wrapping sliding doors and Frontline Packaging has been supporting the installation

Service agreement signed for alarge, complex shrink wrapperSheffield-based Home Decor GB has signed a regular service agreement with Frontline Packaging to support its large, specially modified shrink wrapper. The agreement includes regular servicing and out-of-hours support for the company.

The shrink wrapping machine was purchased by Home Decor in 2012 for wrapping large sliding doors, which require a completely enclosed seal on all four sides. It is a large, complex and technically challenging application and when Frontline Packaging took over the distributorship for the product range, it continued to offer a high level of support to Home Decor to ensure the machine kept working.

Tony and the team at Frontline have supported us every step of the way with an excellent service, explains Andrew Bowen, supply chain director at Home Decor. It hasnt always been easy but Frontline have always been willing and able to step in and help whenever we needed it, he continues.

Frontline has helped Home Decor out with machine modifications, parts and further equipment and it has worked hard to ensure that the original equipment manufacturer also provided technical support when necessary. T 01763 249255W www.frontlinepackaging.com

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Feature: Meat, fish & other proteins28 MACHINERY UPDATE MARCH/APRIL 2015 www.machineryupdate.co.uk

Vacuum skin packaging (VSP) is the biggest trend in fresh proteins right now and the benefits for processors, retailers and end users are huge, says Matthew Jackson, sales director at Multivac UK.

Extending shelf life, reducing packaging weight, shelf ready presentation options and no drip loss all combine to make this pack format attractive. It is also possible to process meat or fish with premade trays or on a thermoformer and our Multifresh technology also offers easy open options, says Jackson.

The VSP format guarantees hygiene, maximises shelf life and is deemed an appetising way to display products as consumers have come to understand that the darker colour of beef (as opposed to the red, high oxygen MAP packed product) is wholly acceptable, says Jackson.

Multivacs R 575 MF Pro thermoforming packaging machine produces skin packs for products with heights of up to 120mm.

This thermoforming packaging machine has been optimised for packaging tall products. Unlike standard thermoforming packaging machines producing skin packs, an upper web preforming station has also been integrated into this model. It forms the upper web before it is conveyed to the sealing die. The thermoformed film is heated again, in the dome of the sealing die, before it is placed around the goods to be packaged.

This intermediate step is designed to increase the process reliability of the skin packaging process.

This process also ensures that the upper web in the sealing die has the shape of the product to be packaged. The additional heating makes the film malleable enough to fit snugly and smoothly

Showing offwith tight fit

Our MF Pro machine has the smallest footprint to product ratio on the market, says Matthew Jackson

around the packaged goods. As the malleability of the film also ensures the optimal sealing of the upper and lower web, it provides maximum packaging reliability.

Perfect for tall products such as joints of meat and even whole roasts, the upper web in the sealing die has to cover a longer path during

The VSP format maximises shelf life and is deemed an appetising way to display products as consumers have come to understand that the darker colour of beef (as opposed to the red, high oxygen MAP packed product) is acceptable

Machinery Update talks to Multivac about the latest trends and developments in fresh proteins packaging

their packaging. On contact with the packaged goods the temperature usually decreases and, consequently, the plasticity of the film, which endangers the quality of the packaging.

The thermoforming packaging technology of the R 575 MF Pro is also superior to the tray packaging usually

used for tall packaged goods, from an economic perspective, claims Multivac. Film from a roll significantly reduces the cost of the packaging material and reduces the effort involved in handling and storage.

A supplier to Waitrose is currently using this solution for joints of meat.

Meanwhile, Waitrose replaced its traditional tray packaging for its steaks three years ago and as well as saving 30 tonnes of packaging a year and increasing shelf life by three days, Waitrose claimed at the time that the new packs would make the

meat more succulent and tender. Waitrose told The Grocer that the packaging technology was allowing it to offer customers a better quality product while cutting down on waste. Its lightweight but robust nature was also saving space in the fridge or freezer.

As Jackson explains, there is a real benefit to the retailer in adopting skin packaging as it obtains nine days life for some products such as beef joints/muscle cuts. This means two weekends when these products are predominantly purchased, he says. We are also seeing some frozen products moving to VSP to improve presentation and save on printed cartons.

Further fresh products such as mince is moving to VSP as well as processed products such as burgers, coated protein and kebabs.

FUTURE TRENDSFuture trends for processors include the need for quick changeovers and flexible machine options due to short contract commitments from retailers. We can achieve changeovers in less than ten minutes on both thermoformers and traysealers, says Jackson. Smaller pack sizes along with tear and share/eat me keep me options are also becoming more popular which can both be achieved with VSP.

Multivac developed VSP over 20 years ago and in the UK it has been the package of choice for smoked fish and cured products such as gammon for some time. Its recent adoption for fresh products sees no abating which is why Multivac offers equipment from entry


THIS FEATURECONTINUES OVER

14 pages

level trayskin machines and thermoformers up to equipment that runs multiple formats with functions such as automatic depth

adjustment and automatic pack size change.

The range also includes the E-Concept machines which as well as focusing on reducing

material consumption also reduces electricity, water and compressed air usage.T 01793 425800 W www.multivac.co.uk

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According to heat sealing specialist Proseal, the growth in popularity of skin packs and other new formats for meat, poultry and fish products is creating additional challenges for equipment suppliers.

Skin packs feature a special film that seals to all surfaces of a tray rim, sidewalls and base to tightly cover the entire contents. The packs were first adopted primarily for fish products but are now being used increasingly for other types of foods such as ready to cook meals, game, meat and sausage products, and mini joints.

Many meat and fish processors are experimenting with pack formats, particularly for new product developments, explains Tony Burgess, Proseals head of sales and control systems.

At the same time it is imperative that, while exploring these options, they are still able to maintain current production.

In addition, the proliferation of new products means many manufacturers now have to be able to handle a variety of different packs on their lines, he says

For this reason, the Proseal GT range of tray sealers has been enhanced in order to have the flexibility to handle all pack types including normal tray sealing, MAP packs, and skin packs on the same machine. Equally important, the different pack types can be sealed using the same tooling.

This gives manufacturers the flexibility to switch easily between packs during normal production, or to run trial packs, explains Burgess.

He believes that future-proofing of equipment is an essential requirement for equipment suppliers.

The market is very fast-moving and competitive, he tells Machinery Update. Of course, manufacturers want

Skin tight isall the rage

Meat and fish processors are experimenting with pack formats but production must be maintained

reliability and efficiency from their machines but this is of little use if the machine itself quickly becomes outdated or superseded by an improved model later on.

Our GT platform is therefore designed to be able to be completely adaptable in order to incorporate latest developments, he continues. Therefore, for every feature

With its new TraySkin xplus vacuum packaging system, Sealpac has allowed bulky products such as larger pieces of meat or even whole roasts to be packed reliably in trays, even with significant protrusion

Machinery Update reports on how the latest skin tight packs are creating additional challenges in the market

that we develop for our new models, we ensure that it has the capability to be retrofitted to existing machines so that they can also help customers keep up-to-date with latest packaging trends.

Meat, fish and other protein suppliers are all keen on presenting their products in an attractive way which is why Sealpac has further developed

its TraySkin system to allow even larger products to be securely packed.

With TraySkin xplus, bulky products such as larger pieces of meat or even whole roasts can be skin packed reliably in trays, even with significant product protrusion. The preformed tray provides stability to the product, therefore allowing a protrusion of up to 90mm above the tray edge.

Here, says the company, the TraySkin xplus system also contributes to sustainability, as the solution allows for the use of flatter trays for such tall products, hence providing

a more economical use of consumables.

The tight and transparent skin film provides a full view of the product to consumers, along with an accurate product contour. They can therefore feel the product contour easily and safely in this type of pack.

TraySkin xplus packs can be sealed trouble-free on any of Sealpacs A-series traysealers, after which they are labelled or upgraded with a cardboard sleeve. Well protected yet highly visible for retail arenas, says Sealpac.

The TraySkin xplus system can be applied to numerous pack formats, from standard to speciality and can use a variety of different materials such as PP, CPET or aluminium. In addition, TraySkin xplus, depending on the application, is available in a number of variations, such as TenderPac.

FRESH RED MEATThis two-compartment vacuum packaging system, primarily for fresh red meat, separates the product from the drip-loss that occurs during maturation by means of the special ActiveStick. As such, appearance, shelf life and flavour of the meat are improved. Another variation of TraySkin xplus packaging is a special skin film that allows self-venting. Here, the valve functionality of the film enables gentle steam cooking of the contents.

In this case, the heating of the product under elevated but controlled pressure allows for short cooking times.

Sealpac says its proven TraySkin solution offers numerous benefits to users. The product is vacuum packed


PROTRUSIONS OF

90mmabove the tray edge can now be accommodated

directly in the tray by means of a tight film that fits the contours of the product like a second skin. This skin film provides excellent barrier protection

during the products entire life cycle. The result is an extended shelf life and often improved product properties, as the food maintains its

quality and consistency, while convincing customers with an optimal taste.W www.prosealuk.com W www.sealpac-uk.com

X-Ray Inspection forfood manufacturers

Sparc House, Merebrook Industrial Estate, Hanley Road, Malvern, Worcestershire, WR13 6NP England

T: +44 (0)1684 310000 E: [email protected] www.sparc-systems.co.uk

Cyclops 420

Use the Cyclops 420 range ofX-Ray inspection systems to safely,

reliably and accurately inspect100% of your products for

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1mm stainless in leg joint

Eclairs

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Sliced bread

Large cottagepie 1.0mm

stainless steel

Ham joint inroasting Tin


Italian manufacturer PFM has announced a new version of its Mistral flow wrapper, specially tailored to handle whole fresh chickens in ovenable film for roast-in-the-bag presentation, now being adopted by major retailers.

Equipped with a special long-dwell D-cam sealing system, and capable of modified atmosphere packaging, the machine provides an hermetically sealed pack that eliminates any need for consumers to handle raw chicken.

This limits any potential spread of bacteria and provides additional ease and convenience while sealing in chicken juices and flavour.

The Mistral flow wrapper is built in stainless steel to food industry standards and is designed on a balcony basis for ease of washdown. Feed belts, including the powered infeed to the sealing section, are removable for deep cleansing, off-machine.

In addition to standard flow wrapping, the Mistral can be equipped to create gussets in the film for a neater appearance for various products. T 0113 239 3401W www.pfmuk.com

Wrapper handlesovenable film forchicken in a bag

Mistral flow wrapper can handle whole chickens Bag feeding isquick and easy

Hot and cold smoked seafood producer Macrae Edinburgh approached Partners in Packaging (Machine Systems) to devise a way of handling

the flexible bags into which its premium smoked Scottish salmon is packed for retail.

Partners devised a system that feeds the bags onto a vacuum belt, where a date code is applied, and then bags are re-stacked using a shingling conveyor. The system comprises a Streamfeeder Model V2000 universal friction feeder which takes the bags from a stack loaded to the magazine and singulates them, feeding them onto a variable speed vacuum belt. This holds the bags stable while transporting them under the Videojet ink jet coder.

Bags are then transferred to the shingling belt to make it easy for an operator to pick up stacks of bags

which are then taken to the packing operation.

After the salmon is smoked, it is sliced and vacuum packed into pouches destined for Waitrose stores. It is important that these pouches are flat when the date codes are applied to ensure consistency and quality of print. This is why this process is completed off-line, says Partners.

What we liked about the off-line feeding system is the ease and simplicity of size changing, together with the flexibility of the Streamfeeder V2000 feeder, explains Steven McLean, engineering manager at the Livingston site. To change the bag size we use a single operator adjustment which opens up the magazine side guides, and the system is capable of handling bags up to 500mm in length.T 01706 369000 W www.partnersinpackaging.com

Macrae Edinburgh likes the ease and simplicity of size changing on the off-line feeding system

3 Pendleside, Lomeshaye Ind Estate, Nelson, Lancs, BB9 6RY Tel: 01282 601444 Fax: 01282 612201 [email protected]

Adpak Machinery Systems are proud toannounce we are now the distributor for the United Kingdom

SMI designs and manufactures a wide range of bottling systems & packaging machines for theindustry of food & beverage, household cleaning and personal hygiene products and chemical andpharmaceutical products, able to meet production requirements up to 50,000 bottles per hour.

www.adpak.co.uk

PPMA 2015

Hall 5Stand C74

Our checkweighers meet the highest requirements. Based on our machine building set, individually engineered solu-tions with a wide range of sophisticated technical features are waiting for your application. Developed and man u-factured under one roof.

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Our solutions combine speed and accuracy in a perfect way. Put-ting together a metal detector and our checkweigher will result in an outstanding space saving solution. The machinery will be able to withstand high care washdown requirements and will be fully supermarket compliant. Customisable as required.

CHECKWEIGHINGM e t a l D e t e c t i o n

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15th Jun - 19th Jun


Family-owned whitefish processor Kirwin Brothers has installed Fortress Phantom metal detectors to fulfil the production requirements of a new customer.

The company is experiencing ever-increasing demand from retailers UK wide for its range of wet and smoked fish fillets and portions, and it turned to Fortress Technology to develop a bespoke metal detection inspection unit for a new production line.

Installed at the end of the new processing line, the bespoke metal detector unit inspects wet fish fillets sold by weight or count in bulk and packed under a covering of ice. Whenever a product is prepared using a cutting or slicing method, for example fish filleting, there is a potential for contaminants to enter the food chain, explains Fortress managing director Sarah Ketchin. The bulk Phantom metal inspection system can detect particles as small as 1.5mm giving processors and their customers peace of mind that foods are contaminant free and fit for consumption.

Manufactured in the UK, Phantom metal detectors are built to perform within the harshest production environments, operating consistently in temperatures as low as minus 10 degC. Ideal for inspecting raw fish, the IP69K-certified system is fitted with a water resistant epoxy chute. In the last 12 months sales of Fortress IP69K metal detection systems have increased by 15%, says Ketchin. As well as complying with HACCP regulatory principles, processors must demonstrate a robust production process in order to satisfy food safety audits and retain retailer contracts.

To assist the workforce and help protect them from sustaining back injuries, Fortress custom-designed the inspection system to fit on a low level line rather than at a standard

Quality andyield boost

Food safety audits need a robust production process to be demonstrated

operating height. This makes it easier for operatives to transport the heavy containers from the conveyor belt to the cold store.

So impressed was Kirwin Brothers by this first installation, just four months later it purchased a second metal detector to help keep pace with the growing volume of supermarket orders for new pre-packed products.

We opted for Fortress metal detectors because the company came highly recommended by one of our suppliers, explains Paul Robinson from Kirwin Brothers.

The Grimsby-based whitefish processor has been so impressed with the detector that a second unit was purchased four months later

Kirwin Brothersinstall detectors tomeet new demands

We were aware that its equipment is considered the best in the industry by many food processors.

The product and service provided by Fortress was exceptional, he continues. Both metal detectors were delivered on schedule and have proved to be robust, reliable and very easy to use.

The second metal detector in particular has helped increase the efficiency of our packing operation by eliminating double handling and transferring product between lines.

The Phantom machine utilises the latest digital signal processing technology to detect and reject ferrous and non-ferrous metals including stainless steel. It is designed to offer speed, accuracy and ease of use.T 01295 256266W www.fortresstechnology.co.uk

The stainless steel containment specialist

Choice of containment types & fi nishes

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Large stock availability

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www.lasnek.com [email protected]

Lasnek Ltd, 1 President Way, Luton, Bedfordshire LU2 9NRTel: +44 (0) 1582 425 777

Feature: Name hereFeature: Meat, fish & other proteins36 MACHINERY UPDATE MARCH/ARPIL 2015 www.machineryupdate.co.uk

The D-wrap labeller at Albert Darnell is labelling sal

Labelling trayswith precision

ALTech UK has recently installed two machine types designed specifically for vacuum skin trays: one is labelling in a traditional narrow edge leading C-wrap

format and the other is creating a wide edge leading label sleeve in a D-wrap format.

Due to the often variable shape and size of the product and flexibility of the trays, vacuum skin packs are typically more challenging to label. For example, when labelling black puddings for Macsweens of Edinburgh, the C-wrap labelling machine had a bespoke solution of driving the pack from above, rather than the side to ensure precise transfer and drive of the product.

This configuration was supported by ALTechs standard label flag functionality, which splits the feed of the label into two parts and allows the dispensing peeler to be positioned closer to the product for greater label control, accuracy and reliability.

ALTechs D-wrap labelling solution

typically applies wide edge leading labels (but can also be offered in narrow edge format), providing the option to replicate the finished application properties of a sleeve, if demanded by a customer. It can be used with either a standard fully adhesive label or thicker card label.

If card is used, the adhesive is deadened and perforations are made at the fold points to give the appearance of a sleeved product with defined adhesive contact points.

The D-wrap labelling solution incorporates ALTechs proven standard module components, configured specifically for vacuum skin packs. Key features include a floating top holding belt which applies minimal pressure on the product, ensuring it is not damaged or bruised in any way (particularly relevant with skin pack products which tend to vary in height). Further components are 3D printing technology to profile the exact shape of the tray and a high speed rotary adaption system

ALTech UK is meeting the challenge of labellingvariable-sized vacuum skin trays with accuracy

SHRINK WRAPPING solutions you can TRUSTYorkshire Packaging Systems exclusive distributors for the rangeof high speed shrink wrappers

YPS will offer full spares andservice backup to existing

UK and Ireland basedHugo Beck installations.

High Speed Side Sealers

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Woodkirk Freight Terminal, Quarry Lane, Woodkirk, Dewsbury, West Yorkshire, WF12 7JJ, UKT: +44(0)1924 441355 F: +44(0)1924 440686 E: [email protected] www.yps.co.uk

CUSTOMER SERVICE


mon trays created on a Multivac Darfresh machine

capable of operating at more than 100 trays a minute depending on product size and frequency.

ALTechs latest D-wrap labelling installation is for Albert Darnell and is labelling salmon trays created by a Multivac Darfresh machine. This product is extremely variable in size which

frequently causes the packs to mis-shape. However, due to the machines adaptability, these variations are easily accommodated.

The machine also incorporated an ICE intermittent printer for country of origin and use by information, suitable for both card sleeve type and standard labels.

ALTech believes that this potential to act as either a label or a sleeve applicator makes this automatic machine an attractive option.

Albert Darnell, for instance, has recently ordered a C-wrap machine to accompany its D-wrap solution and Macsween, Scotlands premier supplier of Haggis, has several ALTech machines within its production lines, including two specialist horizontal labelling units to label haggis chubs.T 0800 612 6205 W www.altech-uk.com

Vacuum skin packs can be printed at speed

Horizontal units are labelling haggis chubs

Offering the potential to act as either a label or a sleeve applicator allows for reduced machine capital cost


In recent years, there has been a visible shift towards real-time analytical methods on the meat processing and production floor and for processors and manufacturers of both raw and processed meat products, fat content is one of the most important parameters to control.

As profit margins become tighter, manufacturers need to keep costs to a minimum, requiring accurate fat analysis methods to determine the measurement of Chemical Lean (CL), ie the lean to fat ratio as specified by their customers, explains Mike Stuart EMEA product specialist fat analysis at Eagle Product Inspection.

A dual energy x-ray absorptiometry (DEXA) system is a non-invasive, fully automated method to precisely measure the fat levels in meat by using two x-ray energy spectra to discriminate between tissue types of different densities. A high precision form of fat analysis, it works by measuring the amount of x-ray energy absorbed by the fat in the meat as it passes through the system thereby accurately measuring to within 1CL at high throughput. For meat manufacturers this means reduced product waste, increased production uptime and optimised product quality.

Last year, Eagle Product Inspection launched its FA3, an in-line fat, moisture and protein analysis system for fresh and frozen meat products. In addition to calculating fat, moisture and protein content it simultaneously

provides contaminant detection and weight measurement, facilitating high throughput rates for meat manufacturers keen to optimise productivity. This is a third generation refinement of a reliable, proven design, developed to meet producers needs for efficiency and also multi-functionality. Eagles in-line fat analysis technology inspects 100% of products passing through the production line, using DEXA.

The FA3 incorporates Eagles SimulTask image analysis software, which provides CL measurement, over varying meat thicknesses, enabling manufacturers to ensure a high quality product for end consumers. Its UPSHOT compact x-ray imaging geometry, further allows the scanning of the meat from its base, with detectors located above the belt.

The closer placement of the x-ray source to the product enhances the detection sensitivity for foreign bodies such as calcified bone, wire and other metal fragments, glass, stone, rubber and plastics, addressing manufacturers food

safety concerns and allowing them to meet regulatory demands, says Stuart.

Its sanitary design can withstand the harshest of wash down regimes, maximising durability and reliability for meat producers and manufacturers, he tells Machinery Update.

The FA3 system is designed for both packaged and unpackaged meats: the FA3/C and FA3/B. The FA3/C measures the CL values of raw meat such as beef, por

machinery update march 2015

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