< Previous30 Food & Drink International www.fdiforum.net SORTING AND WEIGHING Getting with the times 30-33.qxp_Layout 1 19/12/2022 14:45 Page 1Food & Drink International 31 www.fdiforum.net SORTING AND WEIGHING C ompanies have an incredible balancing act to perform, with customer satisfaction on one end and protecting their bottom lines (and increasing profitability) on the other. Larger companies such as Amazon, Evri, and DHL have embraced automation, the process of introducing automatic equipment into existing processes. This has been to great effect, as now offering next day delivery is not only common, but also expected. For companies that utilise scales, it is especially important to keep up to date with changes in scale technology. Product weight impacts product storage and distribution, so inaccurate weighing processes could lead to additional transport costs, or even parcel damage. Thankfully, automation has hit the scale industry, allowing companies to weigh faster and obtain more accurate readings than ever. Allowing computers to take control of these basic tasks frees up personnel to focus on more complex and labour intensive work. This will speed up the entire sorting process. In scaling terms, one of the best automation options is the setpoint controller scale. These are best used in either manufacturing production lines, or as part of an automated sorting process. These allow you to program multiple weight values into the scale, which will then automatically update this information into a computer. These values will also be used in programmable logic controller functions, meaning that it can determine the next actions within the process depending on its weight. For example, when filling a container, 2 target setpoints could be programmed, one for near the target weight and one for actual weight, the controller will automate machinery to operate at full speed until the first setpoint is reached. The controller would then tell the machinery to slow down (possibly via a secondary source on a trickle function) until the second setpoint is reached. The scale will notify users when containers are nearing emptiness, meaning that production does not have to cease for refilling. To integrate into an automated sorting system, the setpoint controller can weigh an item which then activates a sorting system and sorts parcels into various lines depending on their weight. A benefit of these automated systems is the ability to analyse the data recorded. The scales log what has been weighed during a pre-determined period of time, and these can be uploaded to a computer for analysis. Scale data usually can be uploaded via a USB device into a computer USB port, or via WiFi connection for instant access and real-time updates. Analysis is something that companies are increasingly hot on, as it can help identify risks before they become issues, notify staff of any equipment breakdown, and provide easy insight into any inefficiencies in process. Scale data can now often be exported in a CSV format and uploaded into The nature of sorting is changing. Today’s world is faster paced than ever before and distribution centres need to handle increased volumes of packages, and a greater variety of shapes and sizes, all whilst aiming to slash delivery times and satiate eager customers. 32 Á 30-33.qxp_Layout 1 19/12/2022 14:45 Page 232 Food & Drink International www.fdiforum.net SORTING AND WEIGHING applications such as Excel or Access to run more in depth data analysis. For larger scale operations, a checkweigher may be more appropriate. Checkweighers are large scales, predominantly used as the last step in quality control. Products on a conveyer system are moved through the checkweigher machine, which weighs them before packing or shipping. These machines also have the ability to reject packages that do not meet pre set standards. A checkweigher operates by comparing product weight against a designated limit, specified by the company. This is usually determined by agreed product guidelines. For example, if a product should weigh 100 grams (with some allowances), a checkweigher will determine whether an item falls within the correct weight range or deviates from acceptable tolerances. Checkweighers are mainly used as the last step in quality control. This is especially useful within the food industry, where packaging and nutritional requirements rely on products falling within tight weight tolerances. As part of an automated process, the checkweigher will include a reject belt to move under or overweight products away from the main production line, avoiding these items from being processed. The majority of checkweighers will easily slot into existing production lines and conveyor systems. This means that implementation is straightforward, with little down time, and easy for staff to utilise. Furthermore, checkweighers can be interspersed at various stages of the production process for complete oversight. This includes pre-production, where you can ensure the correct amounts of materials are available to complete the process. Checkweighing © stock.adobe.com/vladimirnenezic 30-33.qxp_Layout 1 19/12/2022 14:45 Page 3Food & Drink International 33 www.fdiforum.net SORTING AND WEIGHING in-line production monitors that weight remains consistent across batches. Inconsistent weight is an indicator for product contamination, and this provides the opportunity to remove affected batches before further processing. As with the setpoint controllers, the information can be accessed and analysed in further detail. Integrating checkweighers into existing automated processes means this data can be fed into other computerised logs, building a detailed oversight into operations. Checkweighers also have wider benefits to manufacturing and sorting processes. They ensure uniformity of product, helping to meet high customer expectations and manage cost per product. This also improves the overall quality of the product. The rejection belt reduces the likelihood of subpar products reaching shoppers, helping to meet customer expectations and reducing product wastage. Whilst investing in scale technology may not be the height of excitement, recent developments mean that sorting, weighing and production processes could be faster than ever. To stand a chance of competing with the household names in manufacturing and distribution, processes need to be as fast and efficient as possible, allowing for services such as 48 hour or next day delivery. Nowadays, scales can do more than simple weighing. They can feed into an overarching automated system, providing up to date data on the efficiency of a company’s process. This kind of data not only helps to troubleshoot issues, but also provides insight into the most common products weights to be sorted. This could be crucial key product indicator information, allowing companies to make more informed decisions. © stock.adobe.com/Yakobchuk Olena 30-33.qxp_Layout 1 19/12/2022 14:45 Page 434 Food & Drink International www.fdiforum.net BAKERY AND CONFECTIONARY © stock.adobe.com/ JackF Spiralling production costs Spiralling pr oduction costs 34-37.qxp_Layout 1 19/12/2022 14:47 Page 1Food & Drink International 35 www.fdiforum.net BAKERY AND CONFECTIONARY T here has been a push in the bakery and confectionary industries toward healthier foods in recent years – not only for vegan, plant-based and gluten- free product, but also for food with functional or beneficial ingredients. Running tangentially to the confectionary industry, the health snacks industry was recorded at being worth $85 billion in 2021 and is expected to grow 6.6% year on year until 2030. The drive for healthier foods has existed for the better part of two decades, and yet the COVID pandemic accelerated the issue for many people. For the first time in decades people found themselves eating more at home, and thus being more aware of what they were eating. This heightened awareness led to a dynamic shift toward healthier alternatives, and while bread has been a staple of the human diet for thousands of years it has proven itself something of an unhealthy option for many due to its high carb content. Complicating matters are rising energy costs across the EU in the face of the war in Ukraine and sanctions placed on Russia. Bakeries – be they local or large factories – are notoriously power hungry, and the cost of energy has left many of them struggling with increasing production costs. This is pushing many smaller bakers out of The bakery and confectionary markets are expected to grow drastically in the coming years, but spiralling energy costs and inflation will leave many struggling to make ends meet even with high demand. 36 Á 34-37.qxp_Layout 1 19/12/2022 14:47 Page 236 Food & Drink International www.fdiforum.net BAKERY AND CONFECTIONARY business and putting a squeeze on larger ones at a time when they would have been looking to bounce back from the lockdown of 2021. In the case of those who can survive, the focus will be on reducing energy costs by investing in energy efficient machinery. This is something that has long been touted as the answer since 2010, and yet many have been slow to adapt to what they saw as an unnecessary expenditure. After all, energy was not so expensive back then. It’s this lack of foresight that has crippled many in the food and drink industry; the nature of food, and bread especially, seems so inescapably necessary to human life that many believe it an untouchable industry like banking. The reality is that the same protections are not in place, and with inflation expected to keep rising before coming back down – and even that being up in the air – the costs associated with running a large factory © stock.adobe.com/agnormark © stock.adobe.com/Valerii 34-37.qxp_Layout 1 19/12/2022 14:47 Page 3Food & Drink International 37 www.fdiforum.net BAKERY AND CONFECTIONARY are going to increase. This will lead to a consolidation of power by the larger baking companies that are able to survive, as they take on struggling rivals and absorb them, or let them fail and claim market share. Despite this, the bread market itself is expected to rise by a staggering $118 billion between 2023 and 2027, over a period of only four years. This dramatic increase speaks to the demand still being there, but high demand will mean little when production costs are so high. Those forced to shut down will be in the unenviable position of having to make the decision even when demand for their products is high. The focus must be on reduction of costs where possible. Though investing when times are hard is difficult enough already, there may be no point waiting to see if things clear up. Energy costs are likely to keep rising before they get better, and technology has advanced drastically in the past few years, leading to more energy-efficient machines than ever before. Be it in production, automation or packaging, there will always be savings to be made for those prepared to look for them. Given that the highest energy usage in a bakery is likely to be the ovens, it might be better to look at offsetting those high costs by streamlining the equipment outside of it. Mixers, conveyors, depositors and packaging machinery should be a major point of focus. The year ahead will be one of contrasts for many in the industry – for those who can weather the energy costs, the future is bright, with high demand and a lot of competitors struggling. For those who did not plan ahead, or who did not save money – and cannot raise more – to invest in energy efficient changes, it might be a problematic year. www.kanegrade.com Tel: +44 (0) 1438 742242 Email: info@kanegrade.com NATURAL FOOD INGREDIENTS 34-37.qxp_Layout 1 19/12/2022 14:47 Page 438 Food & Drink International www.fdiforum.net NEW YEAR - NEW SUPPLIERS T he new year is a time for new beginnings, and for many in the food and drink industry it’s a time to explore new suppliers. When managing food production, making changes to your supplier base is necessary to adapt to shifting market conditions, consumer tastes, growing or contracting demand, and regulatory requirements, and to remain competitive. Though some are hesitant to move away from what they know due to a sense of loyalty or to avoid any snags that might arise in the process, the reasons for doing so, or at least assessing your options are aplenty. You may have noticed your suppliers are no longer meeting your expectations, perhaps they can’t control their costs, their quality has dipped, they don’t have the infrastructure to meet the scale up in production you require, or lack communication, transparency, and a commitment to traceability that are essential in safe and efficient food manufacturing. Then there’s the need to respond to myriad global challenges and crises which continue to expand and expose vulnerabilities in supply chains. In such complex times, conducting supply chain risk assessments is key, to identify failure points, and over reliance on certain suppliers. Dependence on one supplier can quickly threaten production when this supplier is unable to operate, as has been seen over the past few years with the COVID-19 pandemic disrupting manpower, movement of supplies and causing a surge in demand, Brexit causing transport delays and additional costs, and Russia’s invasion of Ukraine last year seeing significant damage to supply chains, with many countries across the world reliant on wheat from Ukraine and Russia - accounting together for almost 30 per cent of global wheat exports. With the war, companies have been pushed to adapt rapidly, finding alternative suppliers and sources where able, and reformulating products, switching ingredients such as sunflower oil to alternatives like coconut oil to keep products in stock. Manufacturers, then, would be wise to begin sourcing from multiple suppliers to mitigate risk of disruption, reduce costs, maintain availability, and become more responsive to global changes. The climate crisis is also calling on firms to reassess their suppliers, whether that be raw material, New beginnings Exploring new suppliers is vital to ensuring the best products are being produced and to remain resilient in the face of global crises. New beginnings Exploring new suppliers is vital to ensuring the best products are being produced and to remain resilient in the face of global crises. 38-40.qxp_Layout 1 19/12/2022 14:49 Page 1Food & Drink International 39 www.fdiforum.net NEW YEAR - NEW SUPPLIERS packaging, or machinery suppliers. Following COP27, featuring the first Food Systems Pavilion, sustainability is at the forefront of customers’ and consumers’ minds, and expectations are increasing for manufacturers to provide more environmentally friendly and ethically sourced products, and move away from any suppliers that jeopardise this. Brands themselves are setting stringent sustainability and Net Zero targets, and thus suppliers are required that hold the same CSR goals and stick to best practices, such as those that are not involved in deforestation, have systems in place to help tackle waste, and produce ingredients with regenerative farming practices in mind. A food manufacturer may additionally seek a machinery supplier that can deliver equipment lowering energy use and that can help create a greener factory. Energy providers offering renewable choices might also be switched to, to minimise an operation’s emissions, while a new packaging provider may be crucial to supporting eco EXPLORE OPPORTUNITIES Get Halal Certified Tel: +44 (0)1707 331111 info@welwyntoolgroup.co.uk | www.welwyntoolgroup.com RECYCLING HOT AIR EASY CONNECTION ECONOMICAL COMPATIBLE NOZZLES HIGH AIR VOLUME OVERHEATING PROTECTION $ 40 Á © stock.adobe.com/NARONG 38-40.qxp_Layout 1 19/12/2022 14:49 Page 2Next >