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Tekplas – building new capabilities in quality packaging for NZ food manufacturers

Waikato-based Tekplas have been engineering specialist plastic moulding solutions for 25 years. Now, through a new purpose-built factory in Rolleston, and a second new factory soon to open in Hamilton, they are proud to offer the only facilities in New Zealand where the entire process from moulding to packaging is performed entirely within a clean room environment – certified ISO Class 7. As the only plastic moulders in New Zealand with a FSSC22000-Q certification, Tekplas have years of experience working alongside providers of infant formula products, ensuring the highest quality production of enclosures and scoops for this tightly regulated market. They understand the paramount importance of food safety, and their ability extends to products in animal health and agriculture. At the heart of the business is a team of highly skilled engineers, who truly appreciate the importance of best design for every different product and end consumer. Alongside is a Quality Management System that ensures all products meet the highest industry standards. In a world where consumers are demanding greater transparency in how their products are made, and where they come from, a focus on quality is licence to operate for any food manufacturer. Tekplas offer innovative solutions for companies that not only want confidence in the production of their packaging but are also looking for new ways to enhance branding and identification. In-mould branding, for example, is a useful new tool with a lot of potential. The new factory builds – one recently completed in Rolleston and the other due to complete early/mid 2021 in Hamilton – have been carefully designed with future innovation in mind. Not only does Tekplas offer the only certified, full service clean room environment in New Zealand (where products are moulded, inspected, and bagged all in the highly controlled hygienic environment), but the facilities […]

Only two in ten consumers say their food is safe to eat

On average less than 40% of food and beverage industry decision-makers place complete trust in the industry to ensure food and beverage safety Zebra Technologies Corporation , an innovator at the front line of business with solutions and partners that deliver a performance edge, today announced the results of its Food Safety Supply Chain Vision Study. The study highlights the views of consumers as well as food and beverage industry decision-makers worldwide from distribution and warehouses to grocery stores and restaurants around safety, traceability and transparency. Surveyed consumers reported their top food safety concerns include restaurant kitchen and wait staff hygiene, foodborne outbreaks, illness from contaminated food, and food and beverage recalls. Consumers can be quite unforgiving if they experience a food incident as approximately six in 10 reportedly would never eat at a restaurant again if they contracted a foodborne illness or food poisoning. Slightly more than 80% of surveyed consumers said companies have an important role to play in implementing food safety solutions and an ethical responsibility to ensure the safe handling of their food. Most consumers (70%) said it is important to know how their food and ingredients are manufactured, prepared, and handled, while 69% agreed knowing how their food is sourced is also important. Given the increased focus on health and wellness, it’s unsurprising both consumers and industry decision-makers are showing a great level of interest in the source, quality and safety of their food. However, a disconnect exists between what consumers believe and what industry decision-makers think. Almost seven in 10 (69%) decision-makers say the industry is prepared to manage food traceability and transparency, but only 35% of consumers agree. Furthermore, only 13% of consumers felt the industry was extremely prepared today to manage food traceability and be transparent about how food travels through the […]

Bringing RSE workers back the right move

BusinessNZ welcomes the announcement that New Zealand will welcome back 2,000 international workers under the Recognised Seasonal Employer scheme BusinessNZ Chief Executive Kirk Hope says the move is timely. “Our exports industries have weathered the Covid storm well to date, but it would have been devastating to let fruit rot on the ground and cause economic damage to regions if access to workers was constrained by border restrictions. “The relatively low unemployment rate is both a signal that New Zealand’s economic fundamentals are holding up well, and also a red flag that the prospect of skill shortages could create more hardship for companies than the impact of Covid and lockdowns. “International workers make a significant contribution to the New Zealand workforce and ensure companies are able to continue to operate and keep New Zealanders in work. Companies are also taking up opportunities to attract and upskill New Zealand workers for these roles and in some cases local workers have the opportunity to upskill alongside RSE workers. “We have a number of industries that need international skills and expertise to supplement the New Zealand workforce, and it is critical for the Government to work rapidly and constructively with industries to understand these workforce pressures and find the right solution, as horticulture, viticulture and the Government have done today.”

Demand surges for Evolution Dirt Remover

A UK manufacturer of vegetable harvesting equipment has seen a surge in demand for its unique vegetable handling machine from customers in New Zealand. Scotts Precision Manufacturing has this month sent its fourth Evolution Dirt Removers to Wyma, which has included the innovative separator in a cleaning line that will be used by a large scale potato packer in Canterbury. Faced with a high volume of soil in their crop, the potato packer approached Wyma, which in turn contacted Derek Scott, managing director of Scotts Precision Manufacturing. “We have a long-standing relationship with Wyma in Europe and have supplied them with several Evolution Dirt Removers over the years, and this is the fourth unit that has made its way to New Zealand,” says Derek. “We’ve seen interest in the Dirt Removers grow considerably over the last year, and it is fantastic that we now have a machine in use in Canterbury.” The Evolution Dirt Remover machine was launched in 2005, and the new generation of machines now uses patented polyurethane spiral rollers to ensure that clod, stones, haulm, vines and loose soils are separated from the potatoes (and other root vegetables) in a very gentle way. These spiral rollers feature large air chambers, a “foam pocket” section that improves the grip on root clusters to reduce blockages. The flexibility of the rollers means protection from stones is maintained while improving the machine’s self-cleaning function. The latest version of the Evolution Dirt Remover also features maintenance-free direct-drive motor and gearbox units on each extracting shaft which are reversible and have variable speed control. Additional to the standard main crop spiral rollers with a 10mm tread pattern, less aggressive spiral rollers with a 6mm tread pattern are now an option. The 6mm tread is designed for customers looking to clean small potatoes […]

Aparima environment plans driving change

A new survey of farmers in Aparima, Southland, shows farms achieve better environmental results when they have Farm Environment Plans. Six hundred dairy, sheep and beef farmers work together in the Aparima Community Environment Project, which aims to improve the health of freshwater and reduce environmental footprint. A recent survey of 151 Aparima farmers showed 80 percent have Farm Environment Plans – an increase of 23 percent on last year. The survey also highlighted that farmers with environment plans are more likely to implement a range of good farming practices. “These survey results show how serious farmers are about taking care of the environment,” said Otautau dairy farmer Edwin Mabonga, from mid-Aparima. Of the farmers surveyed, 95 percent have excluded stock from waterways – up 4 percent on last year. Eighty-seven percent use nitrogen fertiliser strategically – up 4 percent (this means using fertiliser only as needed to maximise pasture uptake and only on certain parts of the farm). “Farm Environment Plans identify environmental risks and management options on the farm, and contribute to improving water quality and other environmental benefits,” said Edwin. “They are living, breathing documents that help farmers achieve better environmental outcomes.” Plans must include actions to reduce farm sediment and nutrient loss, outline how wintering rules will be implemented, and where to riparian plant and fence. The plans are reviewed annually. Thousands of farms already have a comprehensive Farm Environment Plan and sector groups are continuing to further develop them as an effective way to accelerate further improvements. Farmers in the Aparima Community Environment Project are making significant changes which illustrates the type of innovation and commitment needed to surpass good management practices and set farmers in good stead for future. Edwin said his Farm Environment Plan ensures all his team know and understand the way […]

Dairy sector already committed to climate change solutions

DairyNZ shares the government’s ambition to reduce climate change emissions and today’s declaration of a climate emergency will further highlight the issue’s importance. The dairy sector’s climate change commitments and research are geared at supporting farmers to reduce emissions, to help achieve national greenhouse gas targets. “Dairy farmers are taking climate change seriously and the sector is committed to playing our part in tackling climate change and reducing our overall footprint,” said DairyNZ chief executive, Dr Tim Mackle. “There are no silver bullets, it is about making incremental changes across the whole farm system. While many solutions are known, some are not, which is why DairyNZ and others are investing heavily in research. “It is critical the government supports farmers to make change over a generation and the pace of other regulation recognises the efforts being made by the dairy sector.” Internationally, New Zealand already stacks up well, as one of the most sustainable and emission efficient dairy producers in the world. “If all dairy producers were as efficient as New Zealand, more than half the global emissions from dairy could be removed. But we know we can be even better and the dairy sector is 100 percent committed to this,” said Dr Mackle. The primary sector has joined forces with government and iwi/ Māori in a world-first climate change partnership, He Waka Eke Noa, which will support farmers and growers to measure, manage and reduce emissions. He Waka Eke Noa is a five-year programme giving farmers and growers the information, tools and support to reduce emissions and adapt to a changing climate. It includes clear actions and timeframes for environmental improvements. This includes rolling out Farm Environment Plans for all farms by 2025 to ensure every farmer knows their emissions footprint, where those emissions come from and how to […]

New precision irrigation carriage reduces water and fertiliser consumption by 75%

A roller energy chain in a guidelite guide trough ensures safe guidance of the hoses and cables in the precision irrigation carriage. The aim of the precision irrigation carriage from Rathmakers Gartenbautechnik is to use water resources sensibly whilst protecting the groundwater at the same time. With the new automatic irrigation system, the water reaches exactly where it should: directly to the plants. For the safe and compact guidance of hoses and cables, the developers rely on an igus energy chain system consisting of roller chain and guide trough. Water shortage is a major problem worldwide, which is why solutions are needed, especially in agriculture, which bring water in a targeted manner to the plant. For this purpose, Rathmakers Gartenbautechnik has developed a precision irrigation carriage together with Landwirtschaftskammer NRW. Whereas conventional irrigation carriages with a continuous jet stream waste a lot of water, the precision watering carriage irrigates and fertilises in a stipulated way. The unique system is especially suitable for outdoor potted plant cultivation and ensures that water is delivered precisely into the middle of the plant’s growing pot. By using this new technology, savings of 50 to 75 per cent are possible in irrigation water, plant protection and fertiliser, depending on the pot size. This also reduces the nitrogen input into the groundwater. The precision irrigation carriage has a span of 40m and a travel of 208m. The cables and hoses for the water supply were pulled behind the carriages until now. A loop was created, which required about 2m of space between the carriage guide and the plants. A safe and space-saving hose with cable guidance was required. 343 sqm of more usable space The main advantage of the system: by guiding the hoses and cables, the usable area is increased by 343 square metres. It […]

Self-Watering soil makes farming viable everywhere

Scientists from UT Austin’s Cockrell School of Engineering have developed a new type of soil that can pull water from the air and distribute it to plants. As novel as it sounds, this soil could help expand the map of ‘farmable’ land around the globe to previously inhospitable places, and reduce water usage in agriculture at a time of growing droughts. According to associate professor Guihua Yu, the team’s unique atmospheric water irrigation system uses super-moisture-absorbent gels to capture water from the air. When the soil is heated to a certain temperature, the gels release the water, making it available to plants. Moreover, when the soil distributes water, some of it goes back into the air, increasing humidity and making it easier to continue the harvesting cycle. According to Yu, each gram of soil can extract approximately 3-4 grams of water. Depending on the crops, approximately 0.1 to 1 kilogram of the soil can provide enough water to irrigate about a square meter of farmland. The gels in the soil pull water out of the air during cooler, more humid periods at night. Solar heat during the day activates the water-containing gels to release their contents into soil. During a four-week experiment, the team found that its soil retained approximately 40% of the water quantity it started with. In contrast, sandy soil had only 20% of its water left after just one week. In another experiment, the team planted radishes in both types of soil. The radishes in the hydrogel soil all survived a 14-day period without any irrigation beyond an initial round to make sure the plants took hold. On the other hand, radishes in the sandy soil were irrigated several times during the first four days of the experiment – but none of them survived more than two days after […]

The power of traceability for food and medical manufacturers

– Reinaldo Silva, Head of Digital Manufacturing and Automation at Facteon As food and medical manufacturers face stringent regulations, an ability to trace the movement of raw materials and finished product both within your facility and beyond is demanded throughout industry by manufacturers of all sizes. A variety of forces have highlighted the need for food and medical manufacturers to gain greater traceability of both raw materials and finished products within their facility and beyond. Risk One: Increasingly Globalised Supply Chains As it becomes more cost-effective and simpler to source raw materials from suppliers across the globe, manufacturers are relying on increasingly globalised supply chains. While this brings a range of benefits, such as proximity to raw materials, cost competitiveness and improved quality of raw materials, there are significant risks as the supply chain becomes increasingly complex. As a result, traceability requirements expand significantly. Simplistic supply chain approaches that focus on “one step back and one step forward” traceability become increasingly complicated and impractical when manufacturers are drawing on a globalised supply chain. Risk Two: Product Recalls Tyson Foods famously recalled 39,000 pounds of frozen chicken patties which were potentially contaminated with foreign matter in mid-2019. From business interruption and eroded profit margins to long-term damage to your brand, a product recall has the potential to harm consumers and cost manufacturers dearly. Research has also found that a mere 21% of food recalls across USA, UK and Ireland were detected by the manufacturer. In fact, regulatory bodies discovered 68% during routine or spot testing. This highlights the potential competitive advantage that can be unlocked by manufacturers taking a proactive approach to both raw material and product traceability. Medical device manufacturers are also at risk of product recalls. Research has found that a significant challenge for medical manufacturers in the event of a product recall is tracing each […]

ClearTech® set to deliver massive water savings for dairy farming

The ClearTech effluent treatment system at Lincoln University Dairy Farm (LUDF) has saved over 600,000 litres of freshwater in its first full month of operation. The quantity of freshwater saved equates to the average daily water use of about 3,000 people, or the amount of water that an individual person would use in eight years. With steeply-rising farmer demand for ClearTech, the new effluent treatment technology will potentially save billions of litres of freshwater a year if used across the New Zealand dairy industry. LUDF Farm Manager Peter Hancox says the impact of the ClearTech system on the farm’s operations has been a revelation. “Our ClearTech plant has been fully operational since the start of our milking season, and already the amount of freshwater we’ve saved is remarkable. We’re saving at least 50% of the water used to wash the yard. “If we continue along this trend, and we fully expect to, then over the whole 10-month season we’ll achieve a total saving of 6,000,000 litres of freshwater.” Hancox says the costs of set-up and ongoing maintenance are relatively modest, and far outweighed by the benefits that will accrue to farms and the wider community. And as the ClearTech system works away in the background, its benefits are delivered with no extra effort on behalf of the farmer. “It’s a win/win for farmers and the communities they’re part of, as every litre of wastewater recycled is a litre of freshwater saved.” The breakthrough technology, developed by Lincoln University Soil Science Professors Keith Cameron and Hong Di, in conjunction with commercial partner Ravensdown, won the Science & Research Award at the inaugural Primary Industries Awards in July 2019, and the South Island Agricultural Fieldays Agri-Innovation Award, as well as a Highly Commended at the 2019 National Fieldays Innovation Awards. The ClearTech […]

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