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The Top 100 Food and Drink Manufacturers in the UK and Ireland Advanced engineering and manufacturing Centre of Excellence to be built in Northamptonshire
Pfizer’s investment in Ireland exceeds €8 billion
WuXi Biologics’ new €325 million biopharmaceuticals contract manufacturing facility takes shape
Nestle Waters UK invests £31 million at Buxton Factory
COVID-19 Prevention Measures
C o n t e n t s
- 3 F OOD & D RINK
- 36 I NVESTMENT - B EVERAGES
The Top 100 Food and Drink Manufacturers in the UK and Ireland.
Nestlé Waters UK invests £31 million at Buxton Factory.
- 21 M ANUFACTURING
- 41 & 43 C OVID -19 P REVENTION M EASURES
UK manufacturers slash investment in fight for survival.
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Edmond Scanlon, CEO, Kerry Group.
P AGE 21
Stephen Phipson CBE, CEO, Make UK.
Safe Space - From challenge to opportunity. MyBio’s rapid antigen testing - Helping businesses in the fight against Covid-19. PAGE 29
- 25 A DVANCED M ANUFACTURING
R EGULAR D EPARTMENTS
Advanced engineering and manufacturing Centre of Excellence to be built in Northamptonshire.
Processing & Manufacturing . . . . . . . . 14-17, 32, 39 & 44
PAGE 7
- 29 & 31 -
P HARMACEUTICALS
Chris Kirke, President, Moy Park.
Information Technology . . . . . . . . . . . . . 19 Energy & Environment . . . . . . . . . . . . . . 20 Robotics & Automation . . . . . . . . . . . 22-24
Pfizer’s investment in Ireland exceeds €8 billion.
Materials & Packaging . . . . . . . . . . 26 & 27
Kuehne+Nagel Ireland invest in a dedicated Dublin-based facility for global partnership with West Pharmaceuticals.
Paul Reid, Managing Director, Pfizer Healthcare Ireland.
Storage & Logistics . . . . . . . . . . . . 31 & 37
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Brendan McGrath, Ireland Site Head & VP Manufacturing, WuXi Biologics.
Managing Director: Colin Murphy Editor: Mike Rohan
- 33 D ATA C ENTRES Irish Data Centre Industry to add 1,800+ jobs in next 12 months.
Group Operations & Awards Director: Sylvia McCarthy
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Audrey Baxter, CEO, Baxters Food Group.
Advertising: Rachel Howard, Keith O’Brien, Mark Hutchinson Production Manager: Sylvia McCarthy
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National Technologies to establish its EMEA Headquarters in Dublin.
Premier Publishing Limited can accept no responsibility for the accuracy of contributors’ articles or statements appearing in this magazine. Any views or opinions expressed are not necessarily those of Premier Publishing and its Directors. No responsibility for loss or distress occasioned to any person acting or refraining from acting as a result of the material in this publication can be accepted by the authors, contributors, editor and publisher. A reader should access separate advice when acting on specific editorial in this publication!
- 35 I NVESTMENT -B IOPHARMACEURICALS
WuXi Biologics’ new €325 million biopharmaceuticals contract manufacturing facility takes shape.
PAGE 12
Design, Origination and Separations by Fullpoint Design (086) 1573510
Alistair Darby, CEO, SA Brain & Co.
Printed by W&G Baird.
MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2
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I FOOD & DRINK
The Top 100 Food and Drink Manufacturers in the UK and Ireland Food and drink processing is the largest manufacturing sector in both the UK and Ireland. To reflect the importance of this sector to both economies, Manufacturing & Supply Chain presents a league table of the Top 100 Food & Drink Manufacturers in the UK & Ireland. anked according to their annual turnover figures, the top 100 companies range in scale from sales of about £18 billion down to £117 million. Unilever’s Foods & Refreshment business ranks 1st, with Welsh brewer and hospitality company, SA Brain & Co, placed 100th. The annual turnover figures used to compile the ranking are all pre-COVID19 in order to avoid imbalanced comparisons due to the distortions to business performances that the pandemic has created because of the differing dates of financial year-ends. Diageo (ranked 3rd) is the largest alcoholic drinks group. The biggest players in the meat, dairy and soft drinks sectors are respectively ABP Food Group (ranked 8th), Arla Foods UK (ranked 9th) and Coca-Cola European Partners GB (ranked 17th). Kerry Group (ranked 4th), the global taste, nutrition and consumer foods business, is the leading food ingredients manufacturer and also the largest Irish company. Companies with annual turnovers in excess of £1 billion occupy the top 37 places within the league table. The food and drink manufacturing
R
Hanneke Faber, President of Unilever’s Foods & Refreshment business (ranked 1st).
industries in the UK and Ireland are intricately linked. Many companies treat the two regions as a ‘single market’ and have established manufacturing operations in both. UK Food and Drink Industry With sales in the region of £86 billion, the UK food and drink processing industry accounts for over 15% of total manufacturing GVA. Prior to COVID-19
Edmond Scanlon, CEO of Kerry Group (ranked 4th), which is the largest Irish company in the Top 100.
MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2
growth was being fuelled by overseas business and UK food and drink exports were worth more than £23 billion annually. The EU remains the largest export market, accounting for about 60% of sales, while Ireland is the largest single destination, generating over 20% of total exports, followed by The Netherlands, France, the USA and Germany. However, the UK is the fourth largest food importer in the world and the second largest drinks importer. Indeed, food and drink imports are worth double the value of UK exports in this sector. With overseas sales of £4.9 billion in 2019, Scotch whisky contributes about 70% of all food and drink exports from Scotland and 21% of the UK total. COVID-19 has severely impacted the UK’s food and drink exports with sales down by 13.8% to £9.7 billion in the first half of 2020 compared to the corresponding period in 2019. Declines were reported among nine of the UK’s top ten products, with whisky, chocolate, cheese, salmon and gin seeing export value drops, according to the Food and Drink Federation (FDF) as sales to the majority of the UK's top markets declined. Ireland With a turnover of about Eur29 billion, 3
Ibrahim Najafi, CEO of Froneri (ranked 10th).
food and drink manufacturing is Ireland’s most important indigenous industry and will play a central role in the country’s economic recovery from COVID-19. Due to the relatively small size of the domestic market, exports are a crucial source of revenue to Irish food and drink manufacturers. The Irish food industry has traditionally been strong in meat processing and dairying but has also developed a sophisticated convenience food sector as well as an international expertise in food ingredients. Brewing and distilling are key strengths on the drinks side. Ireland’s food, drink and horticulture industry achieved record export sales of Eur13 billion in 2019 marking a decade of consistent and extraordinary growth. Exports have grown by 67%, or Eur5.5 billion, since 2010, and Irish food and drink products are now sold to over 180 countries worldwide following years of successful market diversification. EU markets accounted for 35% of exports in 2019 while international markets (the rest of the world) accounted for 31%. As Ireland’s nearest neighbour, the UK remains the largest single destination for Irish food and drink exports and accounted for 34% of the total last year. For example, about 50% of Ireland’s beef exports and over 20% of dairy products (including 40% for cheese and 25% for butter) are sold in the UK.
Siobhán Talbot, Group Managing Director of
However, the Irish food and drink industry has been steadily reducing its reliance on the UK, which accounted for 41% of exports in 2011, by consistently increasing sales to other markets. Ireland is also a major importer of food and drink products – such as potatoes, soft drinks, coffee, mineral water and wine - with this trade being valued at about Eur7.7 billion annually and almost half coming from the UK. Like the UK, Ireland’s food and drink exports have been adversely affected by COVID-19.
Changing Market Trends Of course, COVID-19 has forced UK and Irish food and drink manufacturers to reassess the way they conduct business as they adjust to rapidly changing market trends. The UK food and grocery market is set to grow by 10% - or by £19.1 billion to £211 billion - between 2019 and 2022, according to the latest market and channel forecast research from IGD. COVID-19 has accelerated the shift to online shopping and IGD expects this channel to mostly retain the loyalty of new customers gained during the pan-
TOP 100 Food and Drink Manufacturers in the UK and Ireland
Company 1 Unilever (Foods & Refreshment) 2 Associated British Foods 3 Diageo 4 Kerry Group 5 Total Produce 6 Boparan Holdings
Turnover
Ownership/Status
£17.78b £15.57b £12.87b £5.81b £4.44b £3.34b
7 Tate & Lyle 8 ABP Food Group 9 Arla Foods UK
£2.76b £2.55bE £2.54b
10 Froneri Ltd
£2.28b
11 Greene King 12 Muller UK & Ireland Group 13 Glanbia 14 Nomad Foods 15 Bakkavor Group 16 Ornua (formerly Irish Dairy Board) 17 Coca-Cola European Partners GB
£2.22b £2.10b £2.09b £1.91b £1.86b
plc plc plc Irish co-op/plc Irish plc Incorporating 2 Sisters Food Products – Independent plc Irish independent Arla Foods, Denmark/Sweden PAI Partners, France & Nestle CK Asset, Hong Kong Alois Muller, Germany Irish co-op/plc Nomad Foods Independent
£1.83b
Irish dairy co-ops
£1.83b
18 Dawn Meats Group 19 Mondelez UK
£1.76bE £1.66b
20 Hilton Food Group
£1.65b
Coca-Cola European Partners Irish independent Mondelez International, US plc
Glanbia (ranked 13th).
MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2
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12th MAY 2021
CITYWEST HOTEL, DUBLIN
Stefano Agostini, CEO of Nestlé UK (ranked 22nd).
demic. Discount will, however, become the fastest-growing channel in 2021 and 2022, as shoppers seek to economise due to rising unemployment. Fall in M&A Activity Merger and acquisition activity within the UK food and drink industry has remained subdued in the wake of COVID-19. New research from leading business and financial adviser Grant Thornton UK LLP has found that deal activity in the food and beverage sector fell in the first half of 2020, but that deals are still closing amidst the COVID19 pandemic. Trefor Griffith, Head of Food and Beverage at Grant Thornton UK LLP, explains: “It is no understatement that the second quarter of 2020 saw the most rapid change in consumer behaviour since the end of World War II. The surprise is not that deal volume was down on the previous quarter, but that the fall wasn’t sharper. The surviving transactions were either long term strategic deals or those that aligned with pandemicresistant trends, such as healthy eating. These deals give some comfort that M&A activity will continue, despite some parts of the sector facing an uncertain immediate future.” He elaborates: “While the food and beverage industry was nimble in reacting to the national lockdown – furloughing workers, reallocating resources, simplifying ranges, and switching up supply chains – it’s clear that uncertainties began to take hold in Q2, which turned out to be a case of survival of the fittest in terms of deals. The remainder of 2020 and beyond is likely to be a game of two halves. It will be a rocky road for those servicing restaurants, office canteens, cafes and coffee shops, while those supplying directly or indirectly to retailers are likely to boom.” Recent Deals The UK food and drink industry has
proved attractive for overseas investment in recent years. One of the latest new entrants to the market is CK Asset, which is one of the largest property developers in Hong Kong and an international investment group, following its £2.7 billion purchase of Greene King (ranked 11th). Greene King is the UK’s leading integrated brewer and pub retailer with an estate of over 2,700 pubs, restaurants and hotels across England, Wales and Scotland. Including debt, the enterprise value of the transaction was approximately £4.6 billion. US-based Pilgrim’s Pride Corporation, which already owns Moy Park (ranked 23rd), a leading poultry and prepared foods processor in the UK and Continental Europe, has increased its manufacturing presence with the acquisition of Tulip for £290 million in October 2019 from Danish Crown, which is Europe’s largest pork processor.
Tulip (ranked 35th), which has now been renamed Pilgrim’s Pride, is the largest pig producer in the UK with 12 fresh and value-added operations and
Chris Kirke, President of Moy Park (ranked 23rd), which is Northern Ireland’s largest food company.
TOP 100 Food and Drink Manufacturers in the UK and Ireland
Company 21 Princes 22 Nestle UK 23 Moy Park 24 Britvic plc 25 Budweiser Brewing GroupUK&I (formerly AB InBev UK) 26 Greencore 27 Cranswick 28 MolsonCoors Brewing Company (UK) 29 C&C Group 30 William Grant & Sons 31 Chivas Brothers 32 Pladis Foods 33 Marston’s 34 Heineken UK 35 Tulip 36 Greggs 37 Samworth Bros 38 Dairygold Co-op 39 Mars Wrigley Confectionery UK 40 Premier Foods MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2
Turnover £1.62b £1.58b £1.51b £1.50b
Ownership/Status Mitsubishi, Japan Nestle, Switzerland Pilgrim’s Pride, US plc
£1.50b £1.49b £1.44b
Anheuser-Busch InBev, Belgium plc plc
£1.42b £1.39b £1.19b £1.16b £1.15b £1.14b £1.13b £1.06b £1.03b £1.02b £873.8m
Molson Coors Brewing, US Irish plc Independent Pernod Ricard, France Yildiz Holding, Turkey plc Heineken, Netherlands Pilgrim’s Pride, US plc Independent Irish co-op
£842.1m £824.3m
Mars, US plc 7
UK’s Northampton brewery, London Fields brewery, and national distribution centre; and Marston’s six national and regional breweries – Marston’s, Banks’s, Wychwood, Jennings, Ringwood and Eagle – and 11 distribution depots. Under the terms of the proposal, the joint venture will have access to the Marston’s pub estate for its beer portfolio through a long-term strategic partnership. The joint venture will also benefit from Marston’s Beer Company’s wide distribution network. The UK’s Competition and Markets Authority (CMA) has now approved the deal. £246 Million Sale of Fox’s Biscuits The latest major deal involving a Top 100 company is the sale of part of the Fox’s Biscuits business by 2 Sisters Food Group, Britain’s biggest food manufacturer and one of Europe’s largest poultry processors, to Ferrero Group, the Italian confectionery giant for £246 million. Part of Boparan Holdings (ranked 6th),
Patrick Coveney, CEO of Greencore Group (ranked 26th).
annual sales of £1 billion. The acquisition, following the $1.3 billion purchase of Moy Park in 2017, has consolidated Pilgrim’s Pride Corporation’s position in the UK and Europe. £780 Million Beer Merger The biggest domestic deal currently is the proposed merger by Carlsberg and Marston’s to form a joint venture beer company in the UK - Carlsberg Marston’s Brewing Company. Both companies plan to inject their brewing and distribution assets into the joint venture. In addition, at completion Carlsberg will pay up to £273 million to Marston’s to become the controlling shareholder, owning 60% of the joint venture and Marston’s owning 40%. The joint venture is valued at £780 million. The Carlsberg Marston’s Brewing Company will have a strong portfolio of international, national and regional beer brands. Its assets will include Carlsberg
Tom Atherton, President of Saputo Dairy UK (formerly Dairy Crest), which is ranked 51st.
TOP 100 Food and Drink Manufacturers in the UK and Ireland
Company 41 Kepak 42 Edrington Group 43 Lakeland Dairies 44 Karro Food Group 45 Valeo Food Group 46 Warburtons 1876 47 Young’s Seafood 48 McCain Foods GB 49 Dale Farm
Turnover £756mE £739.3m £713.2m £585.2m £558.4m £551.8m £523.3m £511.6m £509.4m
50 Heineken Ireland 51 Saputo Dairy UK (formerly Dairy Crest) 52 Carlsberg UK 53 Meadow Foods 54 Lucozade Ribena Suntory 55 Irish Distillers Group 56 Aurivo 57 Ferrero UK 58 Carbery Group 59 Foyle Food Group 60 JW Galloway (Scotbeef)
£470.8m
Ownership/Status Irish independent Independent Irish co-op CapVest, UK CapVest, UK Independent Karro Food Group McCain Foods, Canada United Dairy Farmers Group Heineken, Holland
£456.8m £456.2m £427.2m £418.4m £413.6mE £390.5m £383.5m £372.7m £352.0m £349.5m
Saputo, Canada Carlsberg, Denmark. Independent Suntory, Japan Pernod Ricard, France Irish co-operative Ferrero, Italy Irish co-operative Independent Independent
MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2
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2 Sisters is selling the Fox’s biscuit manufacturing sites at Batley and Kirkham in England, which primarily produce biscuits sold under the Fox’s brand. 2 Sisters will retain a third site at Uttoxeter which produces own-label biscuits for major retailers. The business being sold generated sales of approximately £157 million during the last 12 months. Ronald Kers, CEO of Boparan Holdings, comments: “This sale is in line with our strategy and is further good news as we build on two years of strong turnaround momentum and continue to focus on our core business. It strengthens our liquidity position and reduces our leverage ahead of our planned refinance of the business.” The transaction is subject to customary closing conditions and regulatory approvals and is expected to close in the next few months. 2 Sisters has been involved in a number of recent disposals as the group accelerated its transformation strategy. For example, 2 Sisters recently sold its Matthew Walker Christmas puddings business to Valeo Foods Group (ranked 45th), the fast-growing Dublin-based international ambient foods producer, for £67 million. International Front While COVID-19 has impacted the level of M&A activity domestically, strategic international acquisitions by Top 100 companies are still evident. For instance, Diageo recently announced the $610 million (£480 million) acquisition of Aviation American Gin along with its owner Davos Brands. Aviation American Gin is the second largest and one of the fastest growing brands within the super premium gin segment in the US. Fever-Tree (ranked 79th), the supplier of premium carbonated mixers, recently acquired Global Drinks Partnership, the tonic and mixer group’s sales agent in Germany. GDP is a well-established sales
Audrey Baxter, CEO of Baxters Food Group (ranked 62nd).
TOP 100 Food and Drink Manufacturers in the UK and Ireland
Company 61 KP Snacks 62 Baxters Food Group 63 Refresco Beverages UK 64 Asahi UK 65 Noble Foods Group 66 Innocent 67 Finsbury Food Group 68 Yeo Valley Group 69 Fullers Foods International 70 AG Barr 71 Addo Food Group 72 William Jackson & Son 73 Volac International 74 Seachill 75 Walkers Snack Foods 76 First Milk 77 McCormick UK 78 Weetabix Ltd 79 Fever-Tree 80 Burton’s Foods
Turnover £345.7m £337.9m £336.3m £335.6m £328.5m £325.6m £303.6m £294.6m 285.2m £279.0m £277.9m £270.7m £268.7m £261.3m £256.0m £252.7m £249.8m £241.8m £237.4m £232.8m
Conor McQuaid, Chairman and CEO of Irish
Ownership/Status Intersnack, Germany Independent Refresco, Netherlands Asahi Group, Japan Independent Coca-Cola, US plc Independent Plc plc LDC, UK Independent Independent Hilton Food Group PepsiCo, US Co-operative McCormick, US Post Holdings, US Independent Ontario Teachers' Pension Plan, Canada
Distillers (ranked 55th).
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agent and importer of premium drinks, with a strong track record of growing premium brands in a complex, fragmented market. The £9.5 million acquisition consolidates the strong partnership that Fever-Tree and GDP have developed over the last seven years in Germany. The German market, which is one of the largest mixer markets in Europe, represents a major opportunity for Fever-Tree. Brexit In addition to the longer-term impact of COVID-19 on consumer shopping habits, food and drink manufacturers will also have to adjust to the implications of Brexit as the trading relationships
between the UK and the EU change fundamentally on 1st January 2021. Given the close trading links in the food and drink sector between the UK and Ireland, companies involved in exporting and importing between the two jurisdictions will face new customs and logistics challenges. UK Business Confidence at Record Low The latest data from the Food and Drink Federation shows that net business confidence among British food and drink manufacturers reached a record low of 65.2% in the second quarter of 2020 due to COVID-19, uncertainty over Brexit
TOP 100 Food and Drink Manufacturers in the UK and Ireland
Company 81 Country Style Foods 82 Marlow Foods (Quorn Foods)
Turnover £209.8m
Ownership/Status Independent
£204.6m
83 Scottish Sea Farms 84 Lactalis McLelland 85 Linden Foods
£200.1m £199.9m £199.3m
86 Whyte & Mackay Group 87 Coca-Cola HBC Northern Ireland 88 Manderley Food Group (Tayto) 89 Zetar 90 Alpro UK 91 Natures Way Foods 92 Halewood International 93 St Austell Brewery 94 Shepherd Neame 95 Walkers Shortbread 96 Nichols 97 Lantmannen Unibake UK 98 Branston Group 99 Aston Manor 100 SA Brain & Co
£192.7m
Monde Nissin Corporation, Philippines Independent Lactalis, France Fane Valley Co-operative & ABP Food Group Emperador, Phillipines
£189.2m
Coca-Cola HBC, Greece
£185.3m £184.4m £183.4m £182.5m £181.7m £169.3m £156.6m £143.1m £142.0m £139.8m £133.5m £133.3m £116.9m
Independent Zertus, Germany Danone, France Independent Independent Independent plc independent Plc Lantmannen, Sweden Independent Agrial, France Independent
Source: Company accounts, DueDil, Irish Times. Eur = £0.88.
Sally Abbott, Managing Director of Weetabix (ranked 78th).
and closure of the hospitality and out-ofhome sectors. The industry has also had to contend with rising costs and a fall in exports. Despite a drop in confidence, manufacturers ranked increased domestic demand, increased export demand and access to new UK preferential trade agreements as well as planned investment in new machinery as key opportunities for the rest of 2020. Separately, Santander UK bank has carried out research into the impact of COVID-19 on SMEs. The results found that 24% of food and drink businesses expect to return to normal operating levels by the end of 2020. Ian Wright CBE, Chief Executive of the Food and Drink Federation, comments: “Manufacturers and hidden heroes working across the supply chain have ensured continued access to essential food and drink for UK consumers, diminishing the impacts of COVID-19 on industry. As the dust begins to settle, we can now see how the pandemic has had a seriously damaging impact on 2020’s overseas sales of UK food and
Alistair Darby, CEO of SA Brain & Co, the Welsh brewer and hospitality company, which is ranked 100th in the Top 100.
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MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2
drink. These were worth over £23 billion in 2019. While that figure is certain to fall for this year, there are still plenty of opportunities in foreign markets for UK food and drink manufacturers to seize in what remains of this year and as we look to 2021.” Ian Wright cautions about the perils of a no-deal exit from the EU for food and drink manufacturing in Great Britain. “In the event of a no-deal Brexit, shoppers will - literally - pay a heavy price. Imported food and drink from the EU will face eye- watering tariffs averaging 18% kick starting price rises. At the same time border delays and disruption will bring further costs which will not be subsumed by industry. A no-deal outcome is bad for food and drink businesses, bad for food security, and bad for every household in Great Britain.” Irish Challenges In Ireland, COVID-19 has been ranked as the highest priority risk facing the food and drink producers, according to ‘Bord Bia’s Risk Readiness Radar’, the most robust and accurate risk assessment of the sector ever undertaken. The report, by the Irish Food Board, identifies the high level risks facing the industry across six key areas: Covid-19, Brexit, challenges to market diversification, sus-
The latest major deal involving a Top 100 company is the sale of part of the Fox’s Biscuits business by 2 Sisters Food Group, part of 6th ranked Boparan Holdings, to Ferrero Group for £246 million.
tainability pressures, consumer insights & innovation, and talent management. Some 91% of respondents scored the trade implications of COVID-19 as either a high or a very high priority. Export market diversification was ranked the second biggest focus area for the industry as a whole, with 71% of respondents actively seeking to expand into new markets in response to Brexit. Shane Hamill, Strategic Projects Manager at Bord Bia, comments: “The Irish food, drink and horticulture indus-
MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2
try has had to withstand many shocks over the years. While a disruptive event is always an immense challenge for any business, dealing with the consequences inevitably helps businesses to build resilience and be better prepared for the next event. As a result of Brexit preparations, valuable skills in risk management have been learned by the agri-food sector and there is evidence that the industry has been better able to manage the impact of COVID-19 because of the actions it had taken over the past three years.” J
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PROCESSING & MANUFACTURING
Why Data-driven Processing? Smart poultry processing gets the right products to the right customer If you manage a modern poultry processing plant, you need a complete, clear overview of all processes. You want to keep control of the product flow from incoming broilers to packed retail products. You need reliable data to drive your decision-making. Marel is ready to provide all tools for data collection, traceability and full-potential performance of all automated processes, enabling the highest levels of quality control and food safety. arel provides a doorway into data-driM ven culture for poultry processors across the globe, by providing them with a complete set of data-gathering tools and services. Sensors, product detectors, vision graders, weighers, X-rays, and laser scans collect an invaluable set of reliable data. This is the ideal starting point to create a data-driven environment. Digital journey
Processing lines need to convert raw material into high-quality products and deliver the right product to the right customer at the right time. Increased capacities – up to 15,000 bph – and increased automation go hand in hand with a a data-driven process. Processors are under constant pressure to make complex decisions, matching an enor-
mous amount of incoming goods to order requirements. Only highly accurate digital tools, such as the advanced Innova Food Processing Software platform, can take the pressure off processors, by providing data collection, traceability, production control, Quality Control and performance monitoring (OEE). Innova links together virtually all equipment in the plant, empowering processors to get the most out of their operations in their digital journey. Food safety requires software too
Food safety benefits from data-driven processing too. By collecting product data step by step and add it to each product while it travels through the lines, Marel offers processors a strong backbone of food safety information. This reliable way of data-dri-
ven processing enables full traceability throughout the processing plant. Data gathering works both ways
“The need for information and traceability has grown,” says Roger Claessens, EVP of Marel Poultry. “Consumers want to know all the details of what they‘re eating: the origin, the nutritional value and the safety. It is a challenge to achieve this with fresh products such as poultry meat.” Data-driven processing is not just useful for informing consumers about the origin of their food. Farmers, processors as well as supermarkets can profit too. Roger Claessens continues, “The data gathered makes processors work in a more efficient and targeted way while maximizing the value of their products and minimizing the waste of food. Like this, they can get good prices instead of offering discounts. In the near future, artificial intelligence will allow us to produce on Friday exactly what supermarkets need at the weekend during the barbecue season.” Convert data into operations
All of today’s demands have made it impossible to run a processing plant without having access to digital tools. Applying data-driven processes brings the processor peace of mind. Innova Food Processing Software is just the right overarching platform to get access to such data-driven processes. Innova knows how to convert precise data into precise operations throughout the plant. Tie it all together
Themes such as traceability, continuous improvement, yield and OEE optimization can best be handled as part of an operationswide data solution. Innova software technology has advanced to the point where cou14
MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2
PROCESSING & MANUFACTURING pling the big data of a processing plant is a practical reality. Innova MES (Manufacturing Execution Systems) is an example of an operations-wide solution. It links processes for internal logistics (packing and warehousing), planning&optimization, performance management and quality management. MES provides tracking and monitoring of just about every aspect of every process, from ingredients measurement to production reports. By tying it all together in detailed analysis, MES ensures product flow tracking and full traceability of the products during the production process. Save an airplane
The Internet of Things (IoT) opens new avenues for poultry processors to add even more value. It allows them to automate monitoring as well as diagnostic processes, delivering valuable insight into how to get the most out of machines. This is very useful when implementing smarter processing and predictive maintenance. Remote diagnosis using IoT makes maintenance work more efficient and sustainable while saving local labor too.
By using IoT, each and every day we can save one symbolic Boeing 737 airplane flying Marel engineers around the world. During the Covid-19 crisis, Marel showed to be prepared for remote service and support. Via modern communication means, Marel’s engineers, confined to Boxmeer and Aarhus, transmitted their digitized support
procedures around the world. Like this, they succeeded in remotely guiding local technicians to install new processing lines in Korea, Australia, Philippines, Vietnam, China and more. “Applying data-driven processes brings the processor peace of mind.” J
Closed Loop Demand Planning & Finite Scheduling System
till using spreadsheets with a large ERP S system? SFJ Systems Ltd’s team of dedicated engineers will configure their fully flexible and configurable web system linked to your ERP system. This will deliver an accurate demand planning and finite schedule taking account of your complex data sets to find and report back on management reports for daily use. This is designed and ideal for food production. Our analytic capabilities include: • Diagnosing and enhancing data quality • Identification of historic trends • Data visualisation • Creation and implementation of management information and business intelligence systems, dashboards, and reports. Intelligent Resourcing
Industry experts with 30 years of experience
in industrial engineering, complex algorithms generation. Being internet focused using the latest programming methods, user training Online and on site. Communication with all levels of management and shop floor.
EDIs • No limit on the shop floor data capture systems • Display schedule in all departments • Management reports on production. SFJ Systems were founded in 1995 and work in many sectors. Here the focus is on food systems that deliver a finite schedule that is quick to use and not manual intensive. The systems work in the following sectors, transport, stock control, forecasting, time recording, pressure testing. The systems are multi user and used as a service or installed on site. More information and Videos on the web site www.sfjsystems.co.uk. J
Solutions
Closed loop demand planning and finite scheduling system. Accurate demand and EDI orders converted into a master finite schedule then passed to the shop floor where they are updated changed to the actual progress then passed back to the master schedule for an accurate view of production, and KPIs. Some features listed below: • Designed for large factories and SMEs • Algorithm configuration system to suit your factory • Weekly and daily forecast updated with MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2
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PROCESSING & MANUFACTURING I PNEUMATIC TUBE SYSTEMS
Advanced Pneumatic Technology designing solutions to meet every customer’s unique requirements neumatic tube systems have been P around for almost over one hundred years. The aim has always been efficiency, to save time in not having people hand carry items from one part of a building to the next. Advanced Pneumatic Technology (APT) have adopted, designed, adapted, and developed Pneumatic tube systems for host of different facilities. Most people will be familiar with the cash tube system in retail stores. Going back to the mid-20th Century, we would still have people recall: “I remember seeing these in Clearys, zipping along the wire.” As they did in many grocery and general stores in Ireland and UK. Our SafelinK System is now considered by many retailers as being as necessary as air conditioning and alarms. People are also accustomed to seeing Pneumatic Tube Systems in hospitals where there are used to send patient samples from Wards or clinics directly to the Lab. APT now have our Aerocom AC3000 system in 40 Irish Hospitals and 95 in UK. It saves time, makes staff working hours more efficient (as they are carrying out other tasks) and patients can often get a quicker turnaround time on their results. This is the benefit we
want to transfer to the manufacturing industry!! Quality Control
One element that almost all manufacturing companies have in common is testing. Quality control is an integral part of any company to ensure standards are maintained. Biscuits, Flour, Alcohol, Soft drinks, Hardware goods, Tinned Goods, Factory parts, Pharmaceutical, Dairy, Assembly lines they all test samples! Aerocom AC3000 Pneumatic Tube Systems can transport these samples directly from production/assembly lines directly to the laboratory or quality control room. This process can save 1,000’s of hours of walking!! Case Study: Milk powder production
A prominent producer of milk powder has 3 main bagging lines and one central testing laboratory. And the raw material liquid milk is taken in, liquid sample is taken from the tanker and carried to the lab (4minute walk). Once the tanker is pumped out and production begins, there are several testing points through the production process as well as at the bagging lines. The main issue is that the production area (like all in food, drink and pharmaceutical production) is critical care or clean room standards of hygiene meaning staff wear protective clothing. When samples 16
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were being removed from the bagging lines, the staff would have to de-gown to bring the samples to the lab, and re-gown when going back in. 5 minutes changing time, twice as well as 5 minute walk to the lab. 15 minutes to bring a sample to the lab. This was done every 30 minutes!! The company installed an Aerocom AC3000 System with a station at each of the production lines and each of the bagging lines, and now samples can be taken, bagged, placed in a transport carrier, into the sending station and they are in the lab in around 3 minutes!! This is just one example in one type of Industry!! APT is 30 years in business and specialize in designing solutions to meet every customer’s unique requirements. The question is, if you or your staff spend any amount of time hand carrying items from one part of your premises to another (even outside or separate buildings) then APT have a solution for you. It will save you time, save you money, increase efficiency and the investment in a Pneumatic Tube System will pay for itself in a very short time. Call us today, and we can survey your premises in person or review via drawings remotely and design a system to meet your requirements. J
PROCESSING & MANUFACTURING I MEASUREMENT TECHNOLOGY
Customized calibration concepts ensure system availability Endress+Hauser’s calibration standards exceed compliance requirements to deliver unsurpassed measurement reliability. ndress+Hauser repeatedly raises the bar when it E comes to its products and services. The measurement technology specialist relies on globally proven, standardized processes to optimize its customers’ processes and improve their productivity and competitive position – regardless of the measurement parameter. Less product loss and superior quality
Calibrating measurement instruments on a regular basis is key to ensuring that predefined tolerances are being adhered to in quality-relevant processes. Using calibration, deviations can be highlighted at critical measurement points, which helps averts losses during production. “Endress+Hauser offers traceable, cost-effective and ISO 17025-compliant calibration services along the entire process, from on-site testing to fully accredited laboratory calibration,” says Gary Dreyer, Product Manager Services at Endress+Hauser. As a result the company makes a significant contribution to quality Using calibration, deviations can be highlighted at critical measurement points, which assurance. A comprehensive calibration certificate, helps averts losses during production. including a compliance declaration, verifies the accuracy of the measurement point and the process recording, and guaran- latory and operational needs that cover efficiency, quality and accuracy. Utilizing standard operating procedures (SOPs) and certified tees the reliability of the processes and the products. master measurement instruments, the company maintains a consisIndustry know-how brings success tently high-quality standard for both onsite and laboratory calibraWith all industries facing increasingly stringent legal requirements, tions. conforming to relevant local and international standards is an especially important factor. Thanks to in-depth industry know-how and Manufacturer-independent calibration experience, Endress+Hauser is able to fulfill customer specific regu- Production areas frequently have a high number of measurement points for quality assurance and metering applications. In most cases the measurement instruments are not limited to one manufacturer. Endress+Hauser helps customers maintain an overview of the entire installed base and analyzes the instruments to determine the right calibration process, thus guaranteeing seamless and traceable calibrations of any measurement instrument and system availability. The Endress+Hauser Group
Endress+Hauser calibrates flowmeters around the world in accordance with the same standards..
Endress+Hauser is a global leader in measurement instrumentation, services and solutions for industrial process engineering. With dedicated sales centers and a strong network of partners, Endress+Hauser guarantees competent worldwide support. Endress+Hauser provides sensors, instruments, systems and services for level, flow, pressure and temperature measurement as well as analytics and data acquisition. The company supports customers with automation engineering, logistics and IT services and solutions. Their products set standards in quality and technology. For further information, please visit www.eh.digital/3m56uwO. J
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INFORMATION TECHNOLOGY I REAL TIME MONITORING
WISE Factory and Business Software Systems How do you see your Factory? How are your Business Processes ensured and Quality assured repeatedly, and in real time? or Food & Beverage Manufacturing, F Liquids and Powders Management, MedTech & Data Security Services Systems, Metals Manufacturing, and Aquaculture Track & Trace: WISE design & develop software applications & integration solutions for Factory Floor Scheduling, Data Acquisition & Exchange, KPI, Product Identification, Labelling, Traceability, Automation Integrations, Laboratory QA, and Warehouse Management. Traceability, Management, and Integrations are the WISE MES set of solutions used to record the critical key aspects of your Production and to monitor your processes and production, in real time. Key Manufacturing Functionality
Traceability & Labelling: our set of solutions to record the manufacturing process of a specific Product or a specific Batch together with a marking and labelling system, including the management of Raw Materials, Semi-Finished Goods and Finished Product. Batch and Recipe Management: For your industry Operations Management, WISE MES modules help to manage batch execution more efficiently, allocating equipment, downloading parameters, automating recipe procedures and enforcing quality processes in real time. It also coordinates with the plant control systems, interfaces with the operators and directs batch activity, material flow and production records to a central MES database and to your ERP. Batch events trigger electronic workflows for quality sign-off procedures or real time corrective actions in case of alarms or nonconformance. Production Scheduling & Performance Monitoring: WISE MES introduces quality
in production planning and execution, enabling optimisation of production tasks and reliable control of production progress. Reliable real-time data derived by WISE MES and WISE Line Manager directly from the production process, for operators, team leaders, machinery, maintenance technicians, quality controllers and logistics, enables a site to have a Production Schedule updated every second. Interfaces and Integration Management: for Automation, ERP Systems, Management Teams, Team Leaders and Operators, Automated Operations Interfaces, and Overall Business Interactivity. Production Area Digitalisation: In order to move your Production Plant to a significantly higher level of organisation, WISE MES also includes a module to help your
achieved. The ability to reference a specific Production Batch in a trace-back scenario, further allows for subsequent Production or Quality decisions and Customer Feedback Management. Beverage Production
Including the above, WISE Beverage Production Modules also manage Pallet and Keg Labelling and multi-line Production, including the management of multi container & bagged concentrate components. Liquid Ingredients Management
Production Plant implement a migration from paper records on production lines and to digitise the daily management process. Your key-point checklists get digitised, and each linked to the correct Production Order and Quality checks of the current run.
WISE MES Silos & Tankers Module manages Supplier Lot Tracking and Internal Silo Batch Allocation, as well as each Silo vessel of your site’s Silo landscape in real time, plus PO call-off and Quality Testing. Tanker Registration and Grouping, Weighbridge integration, Grade and Potency Management are some of the key features, including the management of smaller liquid vessels such as canisters and barrels, and such activity as Inline Dosing. Powders and Ingredients Management
WISE Manufacturing Modules manage your Production across multiple Production Lines, covering Production Planning, Production Orders, Production, Packing, Materials Handling, Picking, Dispatch, Delivery, WMS, Quality Assurance, and Automation Integrations. By driving the correct process workflows and business rules in the course of actual operations, and in real-time, this ensures both production efficiency and the guarantee that quality of process and data is
WISE MES Bulk Production and Ingredients Preparation Modules manage your Small Batch Manufacturing activities scalable right up to Bulk Batch Manufacturing. Internal Batch Allocation and traceability of all key activities and quality checks ensure that processes are executed to repeatable standard in real time. WISE MES has been implemented in the areas of Infant Milk formula, Dairy Sector, Ingredients Producers, Beverage Sector, Snack Foods, and Aquaculture. WISE has been in Business for over 30 years.J
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Food & Life Sciences Production
ENERGY & ENVIRONMENT I REAL TIME MONITORING
European retail giants reduce operational costs by €1 million with EFT Energy ith an incredibly challenging economic W environment ahead, EFT Energy’s General Manager Reuben Keogh, observed: “Companies are now recognising they must reduce their energy consumption and increase production efficiency to maintain their competitive edge. To facilitate this, energy and production data must be measured. If you can’t see it you can’t measure it, and if you can’t measure it, you can’t affect positive change.” EFT Energy’s EnergyManager™ platform has helped to reduce operational costs by more than €1 million and increased
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energy efficiency in a yearlong partnership with a major European grocer and clothing retailer. Since onboarding Energy Manager™ in 2018, 90% of its stores saw up to a 45% reduction in energy consumption. The target for this retailer as a business was to hit a 20% reduction against their 2017 energy usage. These data results represent a global reduction of 5GWH for the retailer. EnergyManager™ platform empowers its customers to make informed business decisions by providing precise, data-driven, actionable insights into energy spending, consumption and productivity. More importantly, EnergyManager™ is a solution that bridges basic energy monitoring and Industry 4.0, ensuring that EFT Energy customers are as successful and profitable as possible in their future operations. EnergyManager™ creates value by forecasting energy demand, alerting to anomalous usage and leveraging analytics to nor-
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malize for weather, production rates and commodity costs. “At EFT Energy, we work hard to provide the most effective solutions for our customers to realize their full potential. By leveraging data and advanced analytics solutions through capabilities like EnergyManager™, we are successfully doing this," added Reuben Keogh. “We're excited to continue our important role in this partnership and working with all our customers to better improve their operations, increase energy efficiency, and ultimately leading to cost savings.” J
I MANUFACTURING
UK manufacturers slash investment in fight for survival Britain’s manufacturers have slashed investment in a battle to stay afloat despite improvements in output and orders from the historic lows of the last quarter, according to a major survey published by Make UK and business advisory firm BDO. ccording to the Make UK/BDO Manufacturing Outlook Q3 survey the balance on investment intentions fell to -32% from -26% in the last quarter. Whilst not reaching the levels of cutbacks seen during the financial crisis as yet, the trend downwards is following a similar pattern to that seen at the end of 2008 and beginning of 2009.
A
three years of political uncertainty at the end of last year, increasing talk of a final ‘no deal’ exit from the EU would be a final nail in the coffin for many companies. If we are to avoid this and, the avalanche of job losses that would follow in already hard hit areas and sectors, it is essential that the first step towards a fuller recovery is provided by a comprehensive trade agreement with the EU.” Financial Challenges
Stephen Phipson CBE, Chief Executive of Make UK.
By way of an indicator as to how far investment has been cut back this year the balance in the first quarter was +20% as industry bathed in what seemed greater political certainty following the general election. The biggest cutbacks were in Yorkshire & Humber, Wales and Scotland. Uncertainty
Make UK also warned that given the uncertainty surrounding the Brexit negotiations and the very real possibility of ‘no deal’, the combination of that outcome with the continued impact of the pandemic could cause further damage to investment prospects in the latter part of the year. “Manufacturing has begun to climb away from the abyss that it stared into earlier in the year. But, make no mistake it is going to be a long haul back towards normal trading conditions, with talk of a V shaped recovery nothing more than fanciful,” says Stephen Phipson CBE, Chief Executive of Make UK. He continues: “Having emerged from
“No-one is in any doubt about the financial challenges facing manufacturers, but turning the investment taps off now will have serious medium to long term implications,” points out Tom Lawton, Head of Manufacturing at BDO. “The Government must be alive to this risk and provide the support required to help UK manufacturers through this transition period and beyond. Other countries (perhaps in particular Germany) do provide good examples of consistent long term support to their manufacturing sectors. The UK should look to adopt a similar approach.” According to the survey the balances on output improved to -36% from -56% in the last quarter which was the lowest balance ever recorded in the 30 year history of the survey. UK and export orders also improved from similarly historic lows to 36% and -34% respectively. More encouragingly, companies expect the prospects for industry to continue moving in an upward direction with the balance forecast for output for the next three months improving to -7%. Whilst still negative this would represent a significant improvement from the -56% balance recorded in Q2. By sector there were marked differences with Basic Metals reporting a shockingly bad balance of -75% as demand for steel dried up from the automotive and aerospace sectors. By contrast, other sectors such as electronics, machinery equipment and electrical equipment all improved in line with the UK averages with the forecasts for the next three months showing a continued improvement. MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2
Employment
Despite the improvement in business conditions since the start of the crisis however the employment balance weakened since the last quarter, falling to -29% from 22%. This would indicate that manufacturers are cutting back on staff, though whether it means companies are adapting to the new environment by improving productivity with fewer staff remains to be seen. In line with other recent economic indicators of an improvement in business conditions almost a fifth of companies are now at full operating levels (17.6%) while a further 28% are operating between three quarters and full capacity. Looking forward over a quarter (27%) expect to be at full capacity at the start of 2021 while a further third (35.4%) expect to be between three quarters and full capacity. Given the impact on the sector Make UK is now forecasting that manufacturing output will fall by almost 11% (10.9%) while it has downgraded its forecast for recovery in 2021 by more than a full percentage point from 6.2% to 5.1%. GDP is forecast to fall by -8.5% this year before recovering by +10.1% in 2021. J
Tom Lawton, Head of Manufacturing, BDO.
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ROBOTICS & AUTOMATION
Rockwell Automation releases PlantPAx 5.0 ockwell Automation has released the R PlantPAx® 5.0 distributed control system (DCS). This latest DCS version from Rockwell Automation helps industrial producers positively impact the lifecycle of their plant operations with plantwide and scalable systems to drive digital transformation and operational excellence. New system capabilities help digitally transform operations by introducing process functionality native to the controller, improving the availability of system assets driving compliance in regulated industries, while enabling the adoption of analytics at all levels of the enterprise. Intuitive workflows and the use of industry-leading cybersecurity standards will help teams design, deploy, and support a DCS infrastructure which reduces timeto-market and helps plants realize profit at a faster rate. “We’re excited to bring PlantPAx DCS 5.0 to our customers,” says Jim Winter, Global Process Director, Rockwell Automation. “New system features are step changes in helping our customers lower the overall costs to design and commission. The functionality improves the overall effort to integrate the process control layer to the enterprise. By reducing the lifecycle cost of the system and lowering operational risks, we are continuing to find innovative ways to bring more value to end-users.” Process end users desire a system that offers the benefits of a modern experience without the burdens that come with a traditional DCS. The new 5.0 release innovates the modern DCS in the following areas: * Reduced Footprint - This release introduces new process controllers and
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extends the Logix family with cuttingedge processing power and capacity to reduce the complexity of PlantPAx architectures. This footprint reduction reduces total cost of ownership of the system throughout the lifecycle. * Project Consistency - With native process instructions embedded in the controller firmware, project teams can adopt approaches to control strategies that drive consistency for individual projects or multi-site deployments. Consistency simplifies the lifecycle management of deployed systems as teams modernize their automation infrastructure. Consistency lowers total cost of ownership (TCO). * Streamlined Workflows - PlantPAx 5.0 provides improved design and operational user experiences. Development teams will realize savings in the configuration of instrumentation, alarms and diagnostic system elements. Operators will have the extended ability to view underlying control logic in a safe and secured manner. Maintenance will have controlled view access MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2
for troubleshooting. * TÜV (Certified for Cybersecurity) - To operate at peak performance and minimize cybersecurity threats, PlantPAx 5.0 system architectures are TÜV certified to the international standard ISA99/IEC 62443-3-3 which provides guidance on the implementation of an electronically secured system. * Analytics Enabled - Process end-users recognize the value of analytics as an essential strategy to realize profit in their process operations. The PlantPAx 5.0 release has purpose-built frameworks that easily connect live and historical data from the DCS into reporting and analytical tools. It enables extended experiences, such as Augmented Reality, using workflows aligned with process strategies controlling plant operations. Furthermore, its allows extensible scalable analytic packages leveraging predictive and prescriptive models for process applications such as soft sensors, anomaly detection, or model predictive control. As producers continue their digital transformation journey, the advances from this system release will help them unlock value and reduce overall costs at all phases of the plant lifecycle. For more information about PlantPAx DCS 5.0, please visit rok.auto/plantpax. J
ROBOTICS & AUTOMATION
Cobots.ie making big strides in automation obots.ie entered the automation market C in 2018 as a distributor of the collaborative robot, manufactured and engineered by the reputable Danish company Universal Robots. Since then they have been making big strides in the automation sector in Ireland. Cobots.ie have formed partnerships with some of the biggest names in robotic accessories including PickIT, Robotiq and OnRobot for vision systems and a large variety of end-of-arm tooling. Although, Cobots.ie was only set up in 2018, it brings with it a wealth of experience in both engi-
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neering and automation technologies with their sister company I.T.S. being in operation in the automation sector since 1993. It has been a busy year so far for the thriving East Cork robotics company. Earlier this year Cobots.ie took part in the annual Manufacturing and Supply chain exhibition in Dublin, where they launched their new dedicated UR training academy, the only UR training facility in Ireland. Martin Buckley, CTO at Cobots.ie says: “We wanted to offer people the chance to get hands on experience in real life practical applications that add real value to a company’s ability to capitalise on their automation investment”. They also launched CoMig, their first cobots branded dynamic welding solution accessory for the Universal Robot. Cobots.ie formed a new partnership with Asyril SA and is proud to introduce their series of high- performance flexible feeding solutions for parts and components to the Irish market. In March of this year the company announced their new Leasing program in
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collaboration with Universal Robots for the UR line of collaborative robots. “In the current climate, we are aware that companies are being more cautious in terms of capital investment. Our latest service option lowers the financial barriers for manufacturers to invest in automation,” states Dan Buckley, Managing Director at Cobots.ie. The new financial leasing options are a response to the growing need for flexible automation implementations and allows companies to remain competitive despite economic pressures. J
I ADVANCED MANUFACTURING
Advanced engineering and manufacturing Centre of Excellence to be built in Northamptonshire Daventry in Northamptonshire has been unveiled as the new home for an advanced engineering and manufacturing Centre of Excellence. RM, a company founded in 2007 and famed for its international success on the racetrack, has received funding from South East Midlands Local Enterprise Partnership (SEMLEP) to extend and remodel one of its existing sites in Daventry. Staff have already started to migrate into the new centre, a DMG Mori 3D printer (a first in the UK) has recently been installed and building work is set to begin on what will become the UK’s Centre of Excellence (CoE) for Low-carbon Automotive Technologies.
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Market Leader
JRM Managing Director Jason King says: "Our new Centre of Excellence will make us a market leader. We will become a company able not just to design and manufacture products but also test and approve them in our Quality Control department. This means we will bring together under one roof all our capabilities as an advanced engineering company and at the same time bring in new ones – for industries locally and oversees.
JRM Racing's Bentley GT3.
ously spread across three sites – one in Bicester and two in Daventry – to consolidate and create one state-of-the-art centre in the town’s Rutherford Way. Hilary Chipping, Chief Executive of SEMLEP, says: "This new Centre of Excellence will reinforce our reputation in the South East Midlands for innovative technical testing and automotive expertise. Our area’s strengths in this will become increasingly important as we work to enhance efficiencies in both speeding up adoption of new technologies and contributing towards achieving a net zero-carbon economy. We are delighted work has already started and confident this will be a centre that will not just benefit Daventry and Northamptonshire but also the UK as a whole. " Facilities
Jason King, Managing Director of JRM.
"Historically we have worked in the automotive sector with the likes of Jaguar, Subaru and Nissan. Moving forward though we see no reason we can’t also break into the aerospace and medical sectors." It is a grant of more than £1.6 million from SEMLEP’s Local Growth Fund that has enabled the company, which was previ-
JRM’s new Centre of Excellence will include: • A 3D printer, which has already been installed. This is currently the only one in the country and can swap quickly between several different materials, including titanium, aluminium, and steel. The printer will create low volume, high complexity items, such as a prototype for a Formula 1 car or an item for a classic car that cannot be bought elsewhere in the world. • A High Frequency Driver in The Loop (HFDITL) rig, which will be in place by April next year. This is being built to Formula 1 standards, enabling manufacturers to investigate, and engineer new MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2
vehicle concepts and systems, as well as allow drivers to hone their racing skills in the e-world. • The Chassis Rig, for testing and developing full vehicle kinematic and compliance behaviour. The aim is to bring the first rig model to market in 2021. It will initially be available as a JRM test facility resource and later will be made available for other companies to purchase. These rigs will bring a high level of precision and accuracy, whilst being quiet, cost competitive and eliminating the need for environmentally unfriendly power sources such as hydraulics, which is currently favoured by traditional rigs. • JRM will also continue to work on their new ‘Celebration Car’ at the Centre of Excellence, taking the Nissan GTR GT3 but completely re-engineering it to produce a short run and making it road legal. Jason King adds: "We will launch as a low volume vehicle manufacturer for the first time. We want to show that we are not just a race team, but that we are an expert all round engineering company." The Centre of Excellence will also include additional commercial incubation space for small and large businesses and the centre will be fitted with solar panels to provide at least 75% of the energy needs for the site. JRM’s new premises will include electrical charging points, a 350kW solar farm and will retain the flexible hours that have become a new norm during COVID-19, to reduce petrol consumption. J
The current JRM building.
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MATERIALS & PACKAGING
MSO to grow Belfast factory with £5 million investment and 35 new jobs ast Belfast-based packaging company E MSO Cleland Ltd is to tap further into growing demand for sustainable packaging by making a £5 million investment in its business and creating 35 jobs. MSO specialises in complete packaging solutions from design through to delivery of cartonboard packaging and labels for the food and drink, and pharmaceutical sectors. Joanna Calixto, Managing Director of MSO Cleland, said: “Since taking over MSO in 2013, we have significantly restructured our business and worked hard to rebuild an impressive reputation in the packaging industry across the UK, ROI and increasingly into Europe. “We have just installed a new state-ofthe-art Heidelberg Lithographic printing press and over the next two months will be taking delivery from Bobst of Die Cutting and Gluing machinery. Invest NI’s support has been invaluable in helping us make this investment.” In 2018, the company benefitted from a Knowledge Transfer Partnership with Ulster University, which helped it to
Pictured (L-R): Kevin Holland, CEO of Invest NI, with Joanna Calixto, Managing Director of MSO Cleland.
increase its technical knowledge and move into the manufacturing of sustainable packaging. Joanna Calixto added: “With COVID19, it may seem a strange time to many to make this investment, but we’ve been laying the foundations for the last number of years. This has included creating our
growth strategy and setting up our Apprenticeship scheme, focusing on the right skills set and business culture for our workforce in preparation for this next phase. This investment gives us the latest capabilities, enabling us to continue to innovate and add value to our customers’ packaging.” J
Quinn Rebrands to Mannok as 2019 results show company in strongest position since acquisition Mannok’ is the new identity for Quinn ‘company’s Industrial Holdings, a name which the familiar brands ‘Quinn Building Products’ and ‘Quinn Packaging’ will now transition to. The rebrand coincides with details of the company’s 2019 financial results, which show it to be in the strongest position since its acquisition in 2014, with a fifth consecutive year of increased earnings (EBITDA). Rebranding to Mannok marks the culmination of a 5-year transformation and investment programme that has repositioned the
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business as a provider of increasingly sophisticated and sustainable building and packaging solutions, supporting an increase in sales of over 30 per cent during the period. The new brand name derives from Fear Manach, the origin of ‘Fermanagh’, reflecting the company’s pride in their roots in the Fermanagh and Cavan region, and their commitment to the people and communities which are the lifeblood of the organisation’s success. The new identity resonates well with domestic and international stakeholders, an important consideration given the company’s increasing export focus. An overview of Quinn Industrial Holdings’ operating performance for the 12 months ended 31 December 2019 shows another increase in earnings (EBITDA Earnings Before Interest, Tax Depreciation & Amortisation) to €26.6 million, with an investment MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2
increase to €11.5 million. This marks the fifth successive year of increased earnings and shows a robust performance despite the challenges of Brexit and price decreases in certain markets. A 2.5% dip in turnover from €240 million in 2018 to €234 million in 2019 reflects lower pricing in line with market trends, with overall volumes comparable to 2018 levels. Investment of €11.5 million in the period brings total company investment to €60 million since acquisition in 2014. The 2019 outturn demonstrates the strong underlying performance of the business, despite a very challenging latter part of the year as a result of the continuing BREXIT uncertainty. 2019 saw heavy investment in both Quinn Building Products and Quinn Packaging, which included fleet and mobile plant replenishment, as well as investment in fixed plant augmentation projects expected to yield significant profitability over the years ahead. J
MATERIALS & PACKAGING I RECYCLING
Nestle partners with Plastic Energy in first steps for recycling facility in the UK Nestlé UK and Ireland has joined forces with Plastic Energy, a major chemical recycling company, with the aim of developing a plant in the UK. he two companies will T come together to explore the scope for the first- com-
source of high quality recyclate to use in Nestlé products.
mercial large-scale facility of its kind in the UK. Plastic Energy, which already has two similar recycling plants in Spain, uses and develops specialist recycling technology to transform traditionally hard-to-recycle plastic waste, such as confectionery wrappers, dry pet food pouches and breakfast cereal bags, into recycled oils called TACOIL. These can then be used as a replacement for fossil oils to make food-grade plastics.
Packaging Waste
Preliminary Study
A preliminary study with the aim of developing the new plant in the UK will be conducted by Plastic Energy, partially funded by Nestlé UK and Ireland. This will start in early November and will take around six months to complete. Nestlé continues to explore new ways to
both recycle packaging and increase foodgrade recycled content within it. Plastic Energy’s recycling technology offers both a sustainable solution for hard-to-recycle plastic packaging that would otherwise go to landfill or incineration, and an innovative
Group Packaging Manager at Nestlé UK and Ireland, Alison Bramfitt says: “The issue of packaging waste is one where we all have a role to play, to not only cut our use of virgin plastic, but also make sure the plastic in our packaging has a second life. We are working hard to create a circular life span for our packaging so it can have multiple lives and uses, and partnering with Plastic Energy is just one of the ways we are taking steps forward on this journey. “We want to increase the amount of recycled plastic we use but there are currently real challenges in the supply of recycled content for food packaging in the UK. That’s why we are excited about the potential of this partnership with Plastic Energy. We hope the outcome of the feasibility study will help offer more insight into the options for supporting the infrastructure in recycling capability in this country.” Circular Economy
Carlos Monreal, Founder and CEO of Plastic Energy, says: “We are excited to partner with Nestlé on this project which we hope will pave the way for brands to start incorporating more recycled content into their products. Our goal at Plastic Energy is to support a circular economy for plastics by recycling end-of-life plastics that would otherwise go to landfill or incineration. The recycled oils that we produce from our process replace fossil oils to create new virgin-quality plastics that can be used for food-grade packaging.” J MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2
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I PHARMACEUTICALS
Pfizer’s investment in Ireland exceeds €8 billion From an initial investment of €10 million in 1969, Pfizer’s total investment in Ireland now stands at over €8 billion. fizer is the world’s largest biopharma company and its Irish operations contribute over Eur2 billion to the local economy annually. The first pharmaceutical manufacturing multinational company to locate in Ireland, Pfizer currently operates six sites across the country at Ringaskiddy and Little Island in County Cork, at Newbridge in County Kildare, and at Grange Castle, Ringsend and City West in Dublin. Pfizer’s operations in Ireland encompass manufacturing, shared (finan-
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tical manufacturing and R&D hub and the world’s third largest exporter of pharmaceutical products. Key Milestones
Pfizer’s decision in 1969 to locate its first Irish site in Ringaskiddy laid the foundation stone for the company’s successful evolution in Ireland. When Pfizer first moved to Ireland, 51 years ago, Jack Lynch was Taoiseach and Margaret Thatcher became Prime Minister in the UK. The Ringaskiddy site began by man-
Paul Reid, Managing Director of Pfizer Healthcare Ireland and President of the Irish Pharmaceutical Healthcare Association (IPHA).
Pfizer’s Irish operations contribute over €2 billion to the local economy annually.
cial) services, scientific research and development (R&D) and commercial operations. Pfizer’s Irish operations play a central role in delivering innovative medicines to patients in over 100 countries around the world. On the manufacturing side, the Irish facilities are involved in the production of active pharmaceutical ingredients, solid dose pharmaceuticals, sterile injectables, vaccines and biopharmaceuticals. Part of Pfizer's Worldwide Research & Development (WR&D) is also based in Ireland - the Global Biotherapeutics Technology group at Grange Castle was established in 2006 and is part of a worldleading protein drug discovery unit within Pfizer Worldwide R&D. Indeed, Pfizer’s growth in Ireland during the past five decades reflects the country’s development as a global pharmaceu-
ufacturing citric acid but Pfizer now manufactures complex medicines for cancer, infectious disease, inflammation and stroke prevention from its Irish sites. Pfizer initially employed 16 people in Ireland. The global pharmaceutical giant now has an Irish workforce of 4,000 people with more than 600 people employed at Ringaskiddy. Pfizer opened its site at Little Island in 1978 followed by a new manufacturing plant at Newbridge in 1992. Pfizer further
increased its Irish manufacturing capacity with the acquisition of Warner Lambert in 2000. In 2003, Pfizer’s European shared services centre in Dublin came on stream and extra Irish manufacturing capacity was added through the acquisition of Pharmacia. Pfizer’s Irish presence was also increased in 2009 with the $68 billion acquisition of Wyeth to create the world’s premier biopharmaceutical company. Pfizer invested $444 million in expanding the future production capacity of its Newbridge site in 2006. Grange Castle Biotechnology Facility
The Grange Castle campus represents Pfizer’s largest single investment in Ireland. Construction of the biotechnology facility commenced in 2000 and the site was licensed and officially opened in 2005 following investment of $2.2 billion. A further $200 million was spent at Grange Castle in 2011 and $100 million
Pfizer’s priority is researching and developing medicines and vaccines that will transform patient’s lives.
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in 2013 to increase the site’s manufacturing capacity for vaccines and therapeutic proteins respectively. Located on a 90 acre site, Grange Castle in one of the largest integrated biotechnology plants in the world and is part of the Pfizer Specialty Biotech manufacturing network. Principal manufacturing technologies include large-scale mammalian cell culture, protein purification, vaccines conjugation, and aseptic syringe filling.
of potential new therapies. Science-based
Investment in R&D
Pfizer’s priority is researching and developing medicines and vaccines that will transform patient’s lives. In addition to the medicines currently being manufactured, Pfizer maintains a strong pipeline of potential new treatments, with more than 90 projects presently at different stages of the clinical trial journey. Pfizer has invested heavily in establishing a strong R&D infrastructure in Ireland. In 2007, it spent $60 million in R&D at Grange Castle and Newbridge. In 2009, Pfizer spent $14 million in a new R&D facility at Ringaskiddy fol-
Pfizer lab at Grange Castle.
lowed by a $30 million investment in the New Product Technology Laboratory (NPTL) at the site in 2014. Also in 2014, Pfizer entered a public-private partnership with Science Foundation Ireland (SFI) to encourage the discovery
“At Pfizer, science is at the centre of everything we do and we employ thousands of scientists globally, some of these are based in Ireland,” explains Paul Reid, Managing Director of Pfizer Healthcare Ireland. “The story of bringing a medicine to life is one of innovation, imagination, and perseverance in the face of obstacles both expected and unforeseen. It takes over 10 years of research starting in the laboratory and including clinical trials before a molecule becomes a medicine and only 1 in 10,000 molecules ever becomes a medicine. This is a high-risk costly endeavour and we invest $7-8 billion annually in drug discovery. Pfizer is working to pioneer gene therapy breakthroughs that change patients’ lives. We hope to unlock the promise of gene therapy for patients worldwide living with rare genetic diseases.” Paul Reid was recently named President of the Irish Pharmaceutical Healthcare Association (IPHA), the representative body for the international originator biopharmaceutical industry. J
STORAGE & LOGISTICS
Kuehne+Nagel Ireland invest in a dedicated Dublin-based facility for global partnership with West Pharmaceuticals uehne+Nagel Ireland has signed a multi-year contract with K West Pharmaceuticals, a leading global manufacturer in the design and production of technologically advanced systems for the world’s top pharmaceutical and biotechnology companies. Furthermore, Kuehne+Nagel Ireland has invested in a custombuilt facility dedicated to the management of West Pharmaceutical’s contract logistics and road logistics services. The bespoke warehouse boasts racking for 30,000 pallets and has a full temperature controlled system to accommodate the unique requirements pertaining to West Pharmaceutical’s complex operation.
global partnership for both contract logistics and overland transportation. We’ve specifically engaged with Kuehne+Nagel Ireland’s leadership team and benefited from their expertise and personalised customer-focused approach, while at the same time leveraging the breadth and depth of the global Kuehne+Nagel team – it’s a winning approach. Particularly, we worked closely with the Kuehne+Nagel Ireland team on the strategy to secure land, build and manage a dedicated warehouse, allowing our West Pharmaceuticals operations in Dublin to focus and deliver on its core technical and manufacturing competency,” confirms Michael Moes. J
Bespoke Solutions
“When engaging with customers, we have a collaborative method, working in partnership to derive bespoke solutions that will work for our customer’s needs,” says Pamela Quinn, Managing Director of Kuehne+Nagel Ireland. “The set-up of complex supply chain solutions for a large company like West Pharmaceuticals can often take a long time. From the very beginning of our relationship with West Pharmaceuticals, we were committed to investing the time to understand their full logistical requirements. Our strength lies in our ability to offer innovative solutions to customers on a wide range of logistical services.” Ireland is one of the largest exporters of pharmaceutical products globally and the commitment from Kuehne+Nagel Ireland stretches further than the dedicated West Pharmaceuticals facility, with a further nine locations in Ireland also devoted to the pharmaceutical and medtech industries. Michael Moes, Vice President Global Supply Management of West Pharmaceuticals says that the customer-focused approach of Kuehne+Nagel Ireland was an appealing strategy that offered many benefits. “West and Kuehne+Nagel have embarked on a critical and
Pamela Quinn, National Manager, Kuehne + Nagel Ireland (front, centre); Tom Clarke, Site Director, West Pharmaceuticals (front, right); Martina Doyle, Business Development Director, West Pharmaceuticals (back, right); Larry Travers, Materials & Logistics Manager, West Pharmaceuticals (back, left); Adam O’Sullivan, Head of Pharma & Healthcare, Kuehne + Nagel Ireland (front, left).
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PROCESSING & MANUFACTURING
Data Rich Processing – The growing necessity of R&D to GMP Manufacture mproved diagnosis is driving precision in Iulation treatment, accompanied by increasing regstringencies from the likes of the MHRA and FDA. This, in turn, ensures processes as well as the products themselves, are fully understood during every step of the manufacturing process. The requirement for both the R&D and manufacturing processes to be ‘data-rich’ has become a pre-requisite for drug product manufacturers, and purchasers of drug products, alike; a phenomenon driven not only when things go well, but where an irregularity might have occurred, even when confirmed to be within the validated ‘Design Space’ parameters. Where the products are usually very expensive to manufacture, manufacturers are always keen to use the data to prove, even if an irregularity took place, the batch can still be released rather than simply quarantined and/ or rejected. From a regulatory perspective, the above method of data interpretation and auditing for corroborating a product is safe for release, is also hugely beneficial. From Theory to Practice
US based, SP Scientific, has put data necessity at the forefront of its breakthrough suite of new lyo/freeze drying technologies named Line of SightTM, supported in the UK, Ireland, and France, by Biopharma Group. Line of SightTM encompasses process analytical technologies (PAT), designed to assist pharmaceutical developers/ manufacturers in achieving drug commercialisation objectives, whether for scale-up or scaledown. All aspects of the range are designed for use at R&D scale, but capable of use at full GMP production too.
patible at manufacturing scale. ControLyo® Nucleation Technology o Precise control of the freezing point in all vials simultane ously, including vials with a thermocouples o Increasing nucleation tempera ture, lowering supercooling, saving time and money o Larger ice crystals – giving a reduced cycle time and faster reconstitution times o To discover more about the improvement in cake appear ance, reduced protein aggregation, skin formation, and vial cracking, watch a short video https://youtu.be/JM00HTm8XaU This allows scientists to know from the outset of an R&D programme that the technology can be scaled up successfully – it is imperative technology can work at the commercial scale, as well as R&D. Some of the most significant freeze drying data interpretation tools for key data post-processing are: AutoMTM/SMART™ Freeze Dryer Technology This is a primary drying cycle optimization tool for in depth product information to determine: o The ice interface temperature o Product resistance (Rp) o Cycle optimisation LyoFlux® TDLAS Sensors Available for use at any scale for the accurate measurement of vapor mass flow in the calculation of critical product attributes such as: • Primary and secondary endpoints • Average product temperature & resistance • Heat transfer coefficients, such as Kv • Assists with engineering freeze dryer performance qualification Tempris® Wireless Sensors All Line of SightTM freeze dryers are compatible for use with Tempris probes. Wireless probes allow the same probe type to be used for R&D and production, whereas wired probes used for R&D are not com-
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LyoCapsule™ This freeze dryer enables accelerated freeze drying cycle development with as few as 7 vials and has all of the functionality listed above which is particularly beneficial when small scale development is required due to: • High costs of the product being trialled • Low availability of the product itself – allowing R&D to occur with very small sample volumes, creating data that can be used efficiently at larger scale. As can be seen from the importance of PAT at the heart of Line of SightTM, whilst the science of freeze drying remains King in the production of viable product, it is apparent that one of the most necessary/ critical elements of processing is the availability of auditable data, which, no matter how good your product looks and performs post-process, generates both regulatory and consumer confidence in the product and subsequently the manufacturer. To discover more about PAT and Line of SightTM, speak to a Biopharma Group specialist http://bit.ly/BPS Contact or see freeze drying equipment via www.bpscrowthorne.ie. J
I DATA CENTRES
Irish Data Centre Industry to add 1,800+ jobs in next 12 months new survey released from Host in A Ireland finds an optimistic business outlook over the next twelve months for the Irish data centre industry. Ninety-six percent (96%) of companies surveyed are positive or very positive about business opportunities within the data centre and hosting service industry. Eightyfour percent (84%) of these companies also expect their employee base to grow in the next 12 months, potentially creating more than 1800 new jobs. The survey was conducted with a sample of 50 companies in the data centre ecosystem in Ireland,
including Host in Ireland partners and other invited participants. 2020 has been an unexpected year, fundamentally changing how we live, work and play. Technology has been adopted at rates previously unimagined and data processing and storage have exploded. While the COVID-19 pandemic has had a devastating impact on many industries worldwide, the data centre industry shows signs of long-term growth and stability. Data centres have been one of the top performing asset classes in global real estate investment in 2020 due to the increased demand for digital infrastructure created by the pandemic. CAPEX Spend
Garry Connolly, President and Founder of Host in Ireland.
According to Anthony McDermott, director and co-founder of construction consultants Mitchell McDermott: “We expect to see CAPEX spend for Irish data centres reduced by only 0-5% due to COVID-19 in 2020. This compares very favourably to some sectors in the construction industry which will see larger decreases.” “The role of the data centre in keeping our economy moving in the last few months has reinforced the critical nature of our industry. We have a real opportunity to attract, develop and retain new talent as we
look to keep pace with the growing business demand,” says Hannah Ormondroyd, Head of People, Data Centre Solutions, CBRE. “There is also the possibility we can help recently furloughed employees find a new home and transfer their skill sets to a new industry.” Digital Factories
“Data centres are the digital factories of today and have been one of the few completely open for business during the pandemic. As significant portions of our lives shifted to an online world, the industry has felt a great sense of purpose as essential workers being on the digital frontline,” says Garry Connolly, President and Founder of Host in Ireland. “The positive outlook and enthusiasm is understandable. When you take that, plus the renewable energy resources Ireland has at its disposal, there is a real opportunity to build and maintain Ireland's leading position in the global digital datasphere.” J
National Technologies to establish its EMEA Headquarters in Dublin ational Technologies (NTI), the US N company that provides fibre optic and data centre installation services, has announced the opening of its EMEA HQ in Park West, Dublin. This is National Technologies first international operations outside of the US and will see 52 high-quality roles created over the next three years. Founded in 2009 and headquartered in
Chicago, NTI has expanded into nine offices across the US. The announcement shows National Technologies Ireland’s commitment to better serve its customers across the Europe, Middle East, and Africa (EMEA) region. Leading the new Irish operations, Eddie Gleeson will be responsible for all NTI business activities across the EMEA region, including developing a highly skilled team to carry out a full design, delivery, and installation services for fibre optic and data centre networks. The Irish team's initial focus is to hire various key positions, including management, finance, technicians, project managers, and office administrators. Eddie Gleeson, Managing Director EMEA, says: “We are delighted to be opening our first international operations. Dublin is the perfect location for National Technologies to grow and better serve our customer base across the EMEA region,
with its abundance of talented workforce and pro-business environment.” J
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Eddie Gleeson, Managing Director EMEA at National Technologies.
I INVESTMENT – BIOPHARMACEUTICALS
WuXi Biologics’ new €325 million biopharmaceuticals contract manufacturing facility takes shape WuXi Biologics, China’s leading biologics medicine manufacturer, is investing €325 million in developing a new biopharmaceuticals contract manufacturing facility at Dundalk in Ireland.
WuXi Biologics is investing €325 million in developing a new biopharmaceuticals contract manufacturing facility at Dundalk in Ireland.
hen completed, the new WuXi Biologics Ireland campus at Dundalk will house the world’s largest facility using single-use bioreactor technology, and will produce medicines for patients globally. The bioreactors will be used to manufacture biologics drug substances on a round-the-clock basis, with the ability to quickly switch product lines in response to customer requirements.
W
Factory of the Future
The design of the new facility reflects bestin-class industry practice and marks a stepchange towards the ‘Factory of the Future’ concept. The factory will incorporate single-use disposable reactors, scale-up and scale-out systems and perfusion technology. Using large volume, single-use bioreactors greatly enhances commercial manufacturing potential by allowing not only scaleout of capacity but also scale-up and flexibility for supplying multiple products and customers. In addition to the flexibility and time to market benefits of single-use manufacturing, clients gain economies of scale which can address their full range of biolog-
ics supply needs, from kilograms to tons, according to WuXi Biologics. The venture represents WuXi Biologics’ first ever manufacturing investment in Europe and marks the Hong Kong-listed company’s first investment of this scale anywhere outside of China. Unique
WuXi Biologics is unique in that it operates the world’s only open-access biologics technology production platform. This offers end-to-end solutions to partner organisations which use it to discover, develop and manufacture biologics medicines from initial concept through to commercial manufacturing. As a fully-integrated contract manufacturing platform company, WuXi Biologics provides its partners with the advanced capabilities, cutting-edge technologies and comprehensive solutions to enable them to develop innovative biologics medicine. Biotechnology is now central to the development of the emerging innovative diagnostics and therapies which are changing how disMANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2
eases are prevented and treated. However, with the advent of personalised medicines, manufacturing quantities for individual drugs are becoming smaller. “The growing sophistication in the development of highly specialised biologics medicines often involves the manufacturing of relatively small quantities of highly specialised drugs,” points out Brendan McGrath, Ireland Site Head and VP Manufacturing at WuXi Biologics. “Generally, it is neither practical nor economic to manufacture small volumes of specialist biologics medicines in traditional large-scale biopharma facilities. Instead the scale-out technology and processes which WuXi Biologics will operate in its new Dundalk campus will allow for cost-effective scale-out of biologics production from small to large volumes as required.” Rapid Progress
Construction of the main building of the new biologics manufacturing site in Dundalk was completed within ten months of construction commencing in February 2019. The facility is designed to adopt both large scale commercial manufacturing using disposable bioreactors and next-generation continuous bioprocessing manufacturing technology and will have a total bioreactor capacity of 6,000 litres perfusion (MFG6) and 48,000 litres fed-batch (MFG7) after full completion. Global Hub
The decision by WuXi Biologics to locate in Dundalk illustrates the continuing success of Ireland’s formula for attracting leading biopharma investment and consolidates
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the country’s reputation as a global hub for biologics production. “This is a huge vote of confidence in this country,” says Brendan McGrath. “Among the reasons for the decision were the availability of a highly educated and talented workforce, the existence of an established cluster of world-leading biopharmaceutical companies, a world-class research base and the availability of a shovel-ready greenfield site in Dundalk, which will enable the facility to be ready for production during 2021.” Continued Global Expansion
The investment in Dundalk marks the start of WuXi Biologics global biomanufacturing network. The Chinese group has since acquired a manufacturing facility in Germany and also expanded its labs, clinical and manufacturing facilities in US, allowing
Brendan McGrath, Ireland Site Head and VP Manufacturing at WuXi Biologics.
When completed, the new WuXi Biologics Ireland campus at Dundalk will house the world’s largest facility using single-use bioreactor technology, and will produce medicines for patients globally.
it to further implement its ‘Global Dual Sourcing within WuXi Bio’ strategy of offering quality services to global customers and serving patients through a robust supply chain. The acquisition of Bayer’s final drug product manufacturing facility at Leverkusen in Germany is the group’s second manufacturing facility in Europe. The expansion of its global capacity presence in Europe and the US has allowed WuXi Biologics to quickly respond to customers’ demands and cope with the market demands raised by the unexpected challenges caused by COVID-19. “By leveraging the group’s world leading technology and excellent, highly-trained talent pool, the group continues to shorten the R&D timeline and reduce manufacturing costs for customers,” points out Dr Chris
Chen, CEO of WuXi Biologics. “The disruptions caused by this pandemic have highlighted the need for extensive manufacturing capacities throughout the world and a robust global supply chain. Our strategy of establishing dual manufacturing sites worldwide in the past three years puts our customers in the most favourable situation during this unexpected crisis.” Dr Chris Chen continues: “Together, we can turn challenges into opportunities. Our capacity expansions in the US and Europe will enable the group to capture new opportunities, meet increasing demands from existing clients and attract potential business partners. Our integrated platform has been well accepted by our global customers who, by giving us new projects, demonstrates their faith in our ability to execute and deliver.” J
I INVESTMENT – BEVERAGES
Nestlé Waters UK invests £31 million at Buxton Factory major investment of around £31 million is flowing into the A Nestlé Waters factory at Buxton in England to increase capacity, improve distribution and reduce carbon emissions. This investment further cements the long-term future of Nestlé Waters in Buxton. Work is already underway on a £26 million extension to the factory’s warehouse facility to create a state-of-the-art logistics operation that significantly reduces the need for external storage. Bringing distribution in-house, with the investment in the new 14000 sq m facility, will significantly reduce the need for Nestlé Waters products to be transported from the Buxton bottling plant to external warehouses by road. It is estimated that the new investment will cut CO2 emissions by around 480T every year based on current volumes. A further £5 million is being spent on the construction of a new pipeline from an additional, nearby, natural mineral water source. The Rockhead spring at Cowdale Quarry in the village of Cowdale, was acquired by Nestlé Waters at the end of 2018. The source is being connected to the existing factory through a 4.6 km pipeline running underground from the source to the bottling facility on Waterswallows road on the outskirts of Buxton. Both projects are designed to boost efficiency and optimise capacity at the site whilst creating opportunities for growth in a sustainable way into the future. This will be achieved through careful 36
management of the water sources, storage and transportation which will deliver a reduction in carbon emissions. It is expected that both projects will be completed in the spring of 2021. The Buxton factory was opened in 2012 and designed with sustainability in mind. The site features a heat recovery system, sends zero waste to landfill and 100% of the site’s grid supplied electricity is renewable. J
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STORAGE & LOGISTICS
Supply chain: How to improve it and make it agile and resilient to change - The advantages of automation t is no coincidence that Igrowing automation has kept over the last 10 years. Specifically, thanks to automation, in warehouses we have shifted from the “person to goods” to the “goods to person” approach, which offers significant advantages. There are many automated solutions available for automatic storage and picking, but vertical storage systems certainly outpace other solutions with their remarkable flexibility. Their most obvious advantages are: • Higher productivity and efficiency • Fewer picking errors • Lower production costs. By integrating picking assistance systems in automatic storage solutions, operators are guided in the selection of the items to pick, considerably reducing the margin of error and order preparation times. The double bay also improves efficiency: while one tray is in the bay for a picking operation, the lift prepares the next tray for the successive one. This ensures an increase in productivity and ever greater efficiency within the warehouse.
Picking, in particular, is the heart of the warehouse and for this reason is one of the priorities when it comes to optimizing warehouse activities. In fact, picking is the process during which individual items are collected from shelves, pallets or more simply from material storage areas. Anthropomorphic robots, autonomous mobile robots and cobots: all these systems are able to improve and automate the picking phase. However, the greatest advantages are obtained when they are installed in combination, for example with an automatic vertical storage system, because they make the picking and placing process very agile. Automatic picking technology operates at speeds and efficiency rates that manual picking can never match. While it is true that there are ways to improve manual picking, automatic systems are more efficient, especially in situations with many different items where it is necessary to operate quickly and without mistakes (especially when orders are concentrated in specific time frames). J
Automated picking, the perfect ally for agile logistics
Transparency and communication must help supply chain managers to optimize all logistics processes, especially warehouse management and all related activities.
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PROCESSING & MANUFACTURING I ASSEMBLY TECHNOLOGIES
EMC and Bosch Rexroth – A Partnership Profile First introduced over 30 years ago, Bosch Rexroth’s high-performance aluminium system offers industry the most comprehensive range of products using its unique T-slot design. he idea is appealingly simple, the system is based on aluminium TTheir profiles with an "endless" longitudinal slot. modular system today encompasses well over 1,500 parts consisting of economical light profiles, heavy-duty standard profiles, closed slot profiles for better cleanliness and the Bosch Ecoshape system offer easy connections between square and round profiles. The robust and corrosion-resistant Rexroth profile allows you to realise components such as ergonomic work tables, flow racks, Covid-19 screens or protective fences within a short time and without having to spend great effort on planning. COVID-19 Screen
Free Design Software
Easy to assemble, flexible and positionable, they can be used for a whole host of applications. Transparent partition walls, counter attachments, protective conversation walls or other setups can be realised in countless forms with the Rexroth modular profile system. Combined with the right plastic sheets, suitable solutions can be created to protect employees, customers or patients from the transmission of pathogens. The elements of the protective device can easily be adjusted or converted later to create new applications for changed needs. Sustainability is thus guaranteed!
Bosch Rexroth’s powerful design tool MTpro with Layout designer software assists designers every step of the way from selection, to configuration, through to order generation. The software allows customers plan and construct complete Covid-19 guards, frames, workstations, flow rack systems without the need for a CAD system, automatically generating a bill of materials. MTpro is now available for free download at www.boschrexroth.com/MTPRO
One Construction Profile – Plenty of Room For Ideas
The new function-integrated profiles (FIP) from Rexroth offer a large usable interior and finally create more space for your design ideas: the completely internal cable guide allows for the safe and space-saving laying of cables, data lines and hoses – and thanks to the new profile junctions, they can even be laid through profile connectors for the first time. This simplifies and speeds up not only the design process, but also assembly and installation.
Function-integrated profiles – including cable guide.
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Local Support and Service
Electrical Mechanical Controls (EMC) Ltd, based in Galway, are proud to add Bosch Rexroth to its growing list of agencies. It further enhances the product range they offer to its customers in the Medical Device, Pharmaceutical, Food, Plastics and General Manufacturing industries. Bosch Rexroth Ireland provide EMC and their clients technical and product support and assist with the generation of design concepts. EMC as well as holding stock of Aluminium Extrusion and Accessories, support the needs of its customers by providing a profile cutting service & Installation of finished frames. For more info please feel free to contact EMC at 091 483651 or Eddie Kelly 087 7700723 or email sales@emcs.ie. J 39
I COVID-19 PREVENTION MEASURES
Safe Space – From challenge to opportunity esponsible employers and business owners are rising to the challenge of providing Covid-secure spaces, but most are still unsure of what is ultimately required. There is a seemingly endless list of measures which may be taken, some of which are touched on below, and key to designing your solution is selecting and integrating those which will work best for you. Moreover, in this necessary exercise, there are several defining aspects which can transform this challenge into valuable opportunity. Firstly, the impact on those who will be experiencing this adapted environment. Solution design must consider dignity as much as compliance. An opportunity presents itself to foster a culture of safety, care and trust, in keeping with the much talked of ‘reset’ and the obvious benefits of wellbeing as a powerful driver of morale, health and productivity.
R
sonnel now, to protect your business from accusation in the future. Space safe, conscience clear. Solutions
To create Covid-secure spaces and realise these opportunities a wide range of solutions can be deployed. These commonly include occupancy control, temperature screening and contactless delivery of safety rules and hand sanitation before entering your venue. Contactless kiosks at entrances can provide instant temperature screen- Kiosk access control induction – ‘Automation benefits’. ing while avoiding queues, allowing social distancing, and providing was understood. analytics for insight and monitoring. In the A contactless path into workplaces or incident of a failed temperature test, venues can be continued with voice or seninstruction can be delivered sor activated lifts. Maximum occupancy on-screen, by phone mes- can be controlled by use of heat sensors sage (SMS, WhatsApp, inside the elevator and programming of Bluetooth) or vocally number/pickup/set-down as appropriate. depending on appropriate Access control systems can extend to discretion. deliver occupancy control with occupancy The system can be con- determined by size of room and social disnected to LED lights on tancing limitations within the room. This the entrance, programmed can be deployed with monitors at each to show red until system room entrance and can also administer a allows access via voice one-way system, particularly important in instruction and/or sig- venues that are smaller in size. Starting times for employees can be stagnalling green or connection Production workstations with screens – ‘Safe space. Conscience clear’. to automatic doors or gates. gered to minimise people arriving at one Secondly, the opportunity for cost savDigital signage can display specific time, as well as shifts and breaks to minimise ings in what at first appears to be simply hygiene rules, thus delivering information numbers in break rooms. Within workcosts. The use of automation for tasks such while avoiding face-to-face contact. The places, desks and workstations can be sepaas access checklists and virtual inductions device can be programmed to deliver rated by clear screens, allowing communicawill provide cost savings in reduced labour, inductions and pose questions which can tion but reducing airborne contact. Mobile increased reliability and ease of record be answered vocally to ensure information phone apps can show location of available spaces within a building and for keeping. venues such as restaurants and bars Thirdly, with the documenting and can be used to place orders and controls needed to ensure safe spaces process payments. comes new information streams, preMaterials like copper that are less senting opportunity for new and hospitable to germs can be used, and valuable insights as evidenced in optireconfigured ventilation systems. misation through i4.0 analytics in the Fast-paced growth, brainstorming manufacturing sector. and increased collaboration happens Finally, and on a cautionary note, in real life, in real groups. Businesses as employers and business owners we need this to grow, and for the econoare and will be, accountable for my to make a comeback. And for this, actions taken to ensure safety. This safe spaces are needed. The pandemic duty of care is now more important has forced upon us a paradigm shift than ever, and it may be a wise why not use it as a leap forward? J investment to protect public and per- Face/automation analytics chart – ‘i4.0 analytics’. MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2
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I COVID-19 PREVENTION MEASURES
MyBio’s rapid antigen testing – Helping businesses in the fight against Covid-19 By Dr Linda Nolan, Managing Director of MyBio The plan for living with the Covid-19 virus over the next nine months was announced in September by the Irish Government. This strategy relies heavily on a centralized laboratory-based testing model, which can take 5 or more days for test results. While you wait, you quarantine, and it’s a significant disruption to business, travel and life in Ireland. he people who are being tested under this strategy are symptomatic, meaning they already don’t feel well or are showing the classic symptoms Covid-19. There are also other people who are asymptomatic (meaning that they have Covid-19, but they don’t have symptoms that they are sick, and can be unknowingly passing the virus to others). The model proposed does not account for asymptomatic testing and businesses need assurance that their employees are Covid free, they need to stay open and profitable, they cannot afford to close down.
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Emerging Trend
An emerging trend has been the use of a newer decentralized test, specifically one performed at the patient location (does not require a laboratory), and one that provides results in just 15 minutes at a significantly reduced cost. This is called a rapid Antigen test, and MyBio is already providing these professional use tests to Ireland. Antigen testing looks for pieces of proteins that make up the SARS-CoV-2 virus, enabling detection of an active Covid-19 infection. At the end of September, the HSE’s Chief Clinical Officer, Colm Henry, said that an evaluation on the use of rapid antigen testing to speed up the Covid-19 testing process is ‘imminent’. Soon after, and echoing many similar announcements, MyBio published a whitepaper entitled “The role of antigen testing in the plan for living with COVID-19”; it is freely available at www.mybio.ie/blogs/news/antigenwhitepaper. Customers
Our customers already include food manufacturers, first responders, nursing homes, manufacturing companies, healthcare distributors, construction & engineering companies, hotels and similar corporates. There is a common theme from all of these clients -- the desire for a rapid diagnostic assessment of an employee to determine if they are currently infected with Covid-19. Leading Harvard epidemiologist Dr Michael Mina concludes that while the use of clinical PCR testing (lab-based testing) is necessary for testing symptomatic people, antigen testing provides a faster and more cost-effective solution for monitoring the asymptomatic spread of Covid-19 in the workplace. The clear advantage of Antigen testing is that it is low-cost and can be delivered on site, with no need to send samples off to labs. In just 15 minutes, a positive test result means the employee should quarantine, seek advice from their physician, and follow HSE guidelines. A negative test result means they can continue to work alongside their colleagues, with confidence, keeping the business open and profitable. Simple and Fast
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PROCESSING & MANUFACTURING I PRECISION ENGINEERING
Cork company rolls with it to combat Covid-19 he agility of Cork-based company – MTD Precision Engineering - has T allowed them to rapidly adapt to circumstances arising from the COVID-19 pandemic. As one of Ireland’s leading precision engineering companies, MTD houses stateof-the-art technologies, specialising in the design and manufacture of equipment for clients in the biopharmaceutical and medical device sectors. Under the direction of Sean Hayes, business focus was adjusted at the beginning of
The Hansans roll-on hand sanitiser.
the COVID-19 outbreak in order to participate in the HSE’s search for ventilators and Personal Protective Equipment. It was during this time that Sean Hayes identified a shortage of small hand sanitiser bottles. “After an initial downturn in our traditional engineering design and manufacturing business, we felt compelled to take action and innovate while contributing to the combined efforts of those combating COVID-19,” he explained. The MTD team worked tirelessly from home, in order to develop and design both the hand-sanitiser product itself and the special-purpose filling line which would fill, label and pack the final product. “The result is a brilliant little bottle; safe, durable and easy to use as a personal, on the go, hand sanitiser,” he added: “The roll-on design has enabled an anti-spill function which dispenses just the right amount of sanitiser to the hands without fear of leakage or waste while stored in a pocket or bag.” “Distributors of Hansans have reported an amazing response from the back-to-
Sean Hayes with the Hansans roll-on hand sanitiser.
work, sport and school markets.” MTD’s ability to alter business focus in order to combat the issue of hand-sanitiser shortage, while simultaneously enlisting the use of local businesses to create a product capable of competing at a global level, reveals: “what can be achieved through cooperation, resilience and a ‘can-do’ mindset by the SME sector when in a crisis,” he said. For further information visit www.hansans.ie. J
MyBio’s rapid antigen testing – Helping businesses in the fight against Covid-19 - Continued from page 43
equipment, there are no lab delays. A nurse takes a simple nasopharyngeal swab to quickly collect the sample, after a brief sample extraction, the sample is then added to the test cartridge. Within 15 minutes, the test cartridge shows a positive or negative result. In a clinical study comparing the our Covid-19 Rapid Antigen Test to laboratory PCR testing, our test produced exceptional results. Our Antigen test is the most accurate antigen test on the market with
accuracy of 99.0%, sensitivity of 97.3%, and greater than 99.99% specificity. No other rapid antigen test can match these figures. Our test is inexpensive, meaning it can become part of your business strategy to stay open by routinely monitoring employee health to keep Covid-19 out of your place of employment. Rapid Antigen testing is becoming an essential tool to quickly and accurately track, trace and limit the spread of Covid-19 in Ireland. We can help you to stay open, keeping your employees safe in the fight against Covid-19. Contact us at: MyBio Ltd, Kilkenny Innovation and Research Centre, St. Kieran's College, Co. Kilkenny, R95 TP64. Website: www.mybio.ie; E-mail: info@mybio.ie; Tel (056) 770 0868. J 44
MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 2