< Previous30 Food & Drink International www.fdiforum.net PACKAGING SPOTLIGHT © Shutterstock /Adisa scheme could be most at risk. Naturally, older customers also had a higher risk of buying a copy by mistake. Although many brands will have a well-known and core identity, it’s never too late to change packaging or update it. The more complicated the design, the harder it is to imitate, and it is important to keep in mind that copycat brands will usually have less funds available than the original. Distinctive shapes are an option for drinks and some packaged goods, especially if it’s a dramatic change that could either be copyrighted, or one that would be too expensive to mimic. Sustainability There is a misconception for many that sustainable packaging is an expensive process, often using unusual and new materials such as plant-based fibre, which requires a complete overhaul of a manufacturer’s Protect your customers and your business with Brother food labelling solutions. The amendments to the Food Information Regulations have put food safety in the spotlight. Brother’s labelling solutions for food that’s pre-packed for daily sale (PPDS) make it easy and efficient to maintain the highest standards. Create highly legible, high-resolution labels with all the information customers need by linking to your existing database or tablets. Include ingredients, allergens, use-by-dates, prices, barcodes and even nutritional information, to ensure clarity is always on the menu. Discover our full range of food labelling solutions at brother.co.uk/food-labelling Create clearer pre-packed food labels with Brother 28-33.qxp_Layout 1 28/01/2020 12:32 Page 3Food & Drink International 31 www.fdiforum.net PACKAGING SPOTLIGHT UK aftersales spares and service support provided. www.robopac.co.uk Robopac, Unit 7 – 8 Highfield Parc, Highfield Road, Oakley, Bedfordshire, MK43 7TA Tel: 01234 825050 Fax: 01234 827070 Email: sales°ÕJÀL«>V°V Turntable Wrapping Machines Rotating Arm Wrapping Machines Case Sealers & Erectors Self-Propelled Robot Wrapping Machines Horizontal Wrapping Machines See us at Stand J60 processing line. All of this is not necessarily the case. While it can be, and those who wish to embrace it more fully than others certainly can look into unique packaging materials, it’s worth pointing out that there is another modifier which can influence the sustainability of the packaging process – efficiency. If a company’s packaging needs can be handled in a manner which reduces manpower, wastage or material used, then there is an environmental and sustainable benefit to that change. What’s more, there is a financial and manpower saving as well. Many packaging specialists have boosted their research and development departments to emphasise this new approach, and focus is now on packaging that minimises material or waste, as opposed to redesigning or retrofitting lines to accommodate a unique new packaging solution. Of course, there are other ways to improve the sustainability of food packaging, and although it is expensive, it’s hard to deny the benefits of the more esoteric methods. In development we can see milk-based packaging, packaging created from plant extract and even packaging which degrades itself. Edible and environmentally-friendly packaging options are another step in the right direction, but the next logical step is in creating fully biodegradable packaging for which to house and transport products. Using this method would help to create a closed-loop approach to packaging, where wasted and surplus food is used to create bio- packaging, which can then be turned into compost, potentially fertilising new fruit and vegetable products. Though undeniably expensive, companies who can keep themselves at the forefront of this innovation often experience unprecedented success. To many manufacturers, this is the realm of the giants – companies that can afford the risk. To them, however, it is not something done for frivolous purposes, but because they have identified an opportunity to pull further ahead and stake their claim in the market. Efficiency Considering the large quantities of finished products that go through a manufacturing facility in any given day, there is also a necessity for a flawless and efficiency system that can work with batches of well over 10,000 individual products. All of this with minimal downtime, efficient energy usage and unparalleled accuracy. This provides problems both within the manufacturing facility itself, but also the warehouse and distribution sector – specifically in end of line packaging. One solution to this is to automate the system as much as possible, but to adapt for varied product lines by having some form of off-line automation. By having a separate automation machine, as opposed to one that is part of a specified production line, changes can be made to settings based on what is needed at the time. This is particularly useful for pallet-wrapping in 33 Á 28-33.qxp_Layout 1 28/01/2020 12:32 Page 432 Food & Drink International www.fdiforum.net 26 & 27 February 2020 | NEC, Birmingham PACKAGING INNOVATIONS, ECOPACK, CONTRACT PACK & FULFILMENT, LABEL&PRINT AND EMPACK Explore the packaging supply chain “The UK is leading the edge on environmentally friendly packaging, which is showcased at the event.” Rob Cooke, Packaging Design, Google “Packaging Innovations is definitely bigger and busier than other similar trade shows that I’ve been to, it’s a great place to meet with our current suppliers as well as source new ones.” Michael McGrath, Operations Manager, Talon Manufacturing Ltd The UK’s leading packaging supplier to ƚŚĞĨŽŽĚĂŶĚĚƌŝŶŬŝŶĚƵƐƚƌLJ͕ŽīĞƌŝŶŐ a wide range of packaging products including: ŝƌƐŚŽĐŬďŽƩůĞƉĂĐŬƐ Pallet wrap & systems Thermal packaging Labels an employee-owned business kitepackaging.co.uk 28-33.qxp_Layout 1 28/01/2020 12:32 Page 5Lavazza Professional’s new KLIX Eco Cup™ is recyclable with paper waste Lavazza Professional has introduced the new KLIX Eco Cup™, a truly sustainable solution for hot drinks and the first of its kind in the vending industry. The cup is biodegradable and recyclable with normal paper waste, because it is constructed of a patented water-based dispersion barrier board, manufactured by Koktamills, and PEFC™ accredited paper, sourced from sustainably managed forests. The cup is produced by Benders. The KLIX Eco Cup™ can be recycled into paper waste up to seven times and a Life Cycle Assessment, conducted by WSP, states that using the new cup ’reduces environmental impacts by almost 2/3 compared to a standard paper cup’* Lavazza Professional’s range of KLIX® machines already leads the workplace drinks market with sustainability features such as low energy and standby modes and efficient boiler systems, which heat just enough water to precisely the right temperature. The machines are manufactured in the company’s ISO 14001-certified UK factory. “Completely dedicated to the workplace, and now with the new KLIX Eco Cup™, Lavazza Professional offers a truly sustainable, hassle-free vending system,” said Ashley Weller, UK Market Director, Lavazza Professional UK. “We have always been passionate about supporting our customers on their own individual sustainability journeys. We are therefore pioneering a breakthrough, sustainable solution in the vending world. Our commitment is clear but we hope that other businesses will also increasingly play an active role, because strength is in numbers. We encourage the big players in the market to explore similar solutions in order to boost the rate of recycling for this type of cup.” The new KLIX Eco Cup™ will be available from February 2020 in the KLIX® Momentum and Outlook machines, starting with some of the most popular drinks, followed by a progressive roll out plan across 2020, dramatically reducing Lavazza Professional’s use of plastic. To find out more, visit www.lavazzapro.co.uk. Food & Drink International 33 www.fdiforum.net PACKAGING SPOTLIGHT warehouses, as it allows pallets of different sizes to be accommodated. Machinery and equipment have transformed not just the food and drink industry, but all manufacturing sectors. Efficiency like never before has helped revitalise the UK car industry, while automated lines have allowed food © Shutterstock Robby Fontanesi manufacturers to increase their yields dramatically. Despite this, the UK still faces heavy competition from abroad, and Brexit hasn’t helped much in that regard. One reason as to why this is, is because our foreign competitors often have a better attitude towards machinery and equipment than we do. The UK food and drink industry is falling far behind other countries when it comes to automation and the adoption of robotics into the food industry. These were the findings of a recent study into robotics within the food and drink industry, which found that even within Europe, the UK is ranked 15th in terms of robotics usage. The bigger problem still is that the changes in robotic investment within the UK are some of the lowest in the bloc, with many food manufacturers not seeking to make changes and instead relying on outdated and expensive labour models. A big problem is that this phenomenon of the UK falling behind is actually quite limited to the food and drink industry. As an example, the UK is still highly competitive in the automotive industry, despite robust competition from other countries, and lo and behold, the UK automotive industry is a huge investor in robotics and automation equipment. With Brexit finally happening, it may be time for UK manufacturers to step up their game. The UK is unlikely to have the same bargaining power it once did, and while we may find new trade deals, the EU will now be a staunch competitor. 28-33.qxp_Layout 1 28/01/2020 12:32 Page 634 Food & Drink International www.fdiforum.net MICROBIOLOGY AND TESTING There are many reasons why operators in the food and beverage sector would utilise testing and microbiological services, from mapping allergens, foodborne illnesses and contaminates such as pesticides, yeasts and moulds, to environmental swabs of production lines, testing nutritional values for the labelling purposes, and DNA analysis and authenticity. Food makers already have many measures at their disposal which can be utilised in-house, such as ever more sensitive sensors that can be easily added into existing production lines. With advances in portable sensors, food makers are better able to detect the presence of foodborne pathogens such as E.coli, listeria and salmonella themselves. Although some food companies, especially major global operators, will maintain their own in- house laboratory facilities for food testing, the majority can’t afford that expense, don’t have the space to spare, and it’s simply not feasible for all companies in the food chain. Enter specialist food testing companies. Ensuring food safety and regulatory compliance during the discovery of a pathogen is already a protracted process, but with added wait times between testing, it only draws the process out which could be difficult for food makers to mitigate in an increasingly competitive market. Advances in rapid diagnostics, however, have led to ever more efficient, accurate and swifter tests being developed to detect pathogens and contaminants and validate authenticity. Turnaround times are quicker, downtime for food producers and operators is reduced, and companies can implement recall plans and investigations quicker and more efficiently. This helps to protect customers, curb potential litigious action and reputational damage, and keep costs down. If a pathogen is detected in the test sample, then undoubtedly the batch that sample was taken from will be destroyed. Detecting that pathogen as early as possible means that the source can be more swiftly identified. Once that’s discovered, the source can be better ascertained. If, for example, environmental swab testing reveals that the conveyor system was the source of the contamination, steps can be taken to ensure it is thoroughly cleaned or replaced and tested again to confirm whether production can resume. There will of course be production downtime during this process, but steps can be taken to ensure that no further batches pass through the same conveyor. Though testing is used during investigations in existing outbreaks, many food chain operators use it as a precautionary measure. It’s not that food makers are hoping to find contaminates or pathogens in their products, but rather want the peace of mind of knowing their products are safe. Should a pathogen then be found, they’re already in a better 36 Á The ins and outs of testing As well as complying with food safety regulations, testing helps to keep consumers safe and protects company reputation. As we’ll explore, the cost of failing in safety can be devastating for food companies. 34-37.qxp_Layout 1 28/01/2020 12:28 Page 1Food & Drink International 35 www.fdiforum.net MICROBIOLOGY AND TESTING © Shutterstock /anyaivanova 34-37.qxp_Layout 1 28/01/2020 12:28 Page 236 Food & Drink International www.fdiforum.net MICROBIOLOGY AND TESTING BOTTTLE& BAGGGEDEDIA Manufacturer of prepared culture media and associated products for microbiology. Find out more at www.sglab.com BESPOKKE MEEDIA MANUFAACTURE PLAATE MEDIAA CONVENIENCE YOU CAN TRUST. position to act. Routine testing is therefore advised, not only for ingredients and finished products, but for the premises and production lines themselves. Swabs can be taken of the entire production environment, from equipment, machinery and trucks, to the growers of raw ingredients. Testing is a key preventative measure for food makers, but it also has a valuable role to play in new product development. With the testing of ingredients and prototypes, companies can undertake shelf life determination and, as previously mentioned, discover nutritional information for labelling. Products are recalled for a variety of reasons, though most commonly because of the presence of undeclared allergens such as soya, peanuts and gluten. Rigorous testing before products hit shelves can help to prevent future recalls and the cost they incur. The cost of contamination There are myriad sources where contamination can occur, whether that’s raw materials coming into contact from soil, sewage and live animals, in the slaughterhouse where meat is concerned, or in transit where food is improperly cooled or heated. Improper storage temperatures are doubly concerning for high risk foods such as dairy products, seafood, cooked rice, meat and poultry and prepared fruits and vegetables. Contamination also occurs during production, where chemicals used to maintain machinery can mix with foods, or pathogens can develop on improperly cleaned machinery. A recent high-profile example of a microbiology outbreak ended in January this year after the US Centres for Disease Control and Prevention (CDC) announced it was safe to eat romaine lettuce from Salinas Valley in California, declaring the three-month outbreak over. Between September to December 2019, 167 people from twenty-seven states were sickened with E. coli after eating contaminated romaine lettuce, resulting in eighty-five hospitalisations nationwide. Though no deaths were reported, fifteen of those sickened developed a type of kidney failure. This most recent outbreak followed a similar one in 2018 from the same strain of E. coli from the Salinas growing region, and another the year before it. The issue arose because leafy greens like lettuce can become easily contaminated in the field by soil, water, animals and improperly composted manure. Contamination can also occur during handling, storage and transportation and after all that, consumers typically © Shutterstock /Sirirat 34-37.qxp_Layout 1 28/01/2020 12:28 Page 3Food & Drink International 37 www.fdiforum.net MICROBIOLOGY AND TESTING Rotronic Instruments (UK) Ltd Crompton Fields, Crompton Way, Crawley, West Sussex RH10 9EE. Tel: +44(0) 1293 571000 Email: instruments@rotronic.co.uk Web: www.rotronic.co.uk Company profile: Rotronic is a global company manufacturing instruments for the precise measurement of water activity, humidity, moisture, temperature, CO2 and differential pressure. Rotronic devices are specified throughout the food and other industries. Experienced engineers can provide measurement solutions for any application. Rotronic has UKAS / ISO 17025 accreditation for Temperature, Humidity and Dew Point calibration. Product profile: Rotronic manufactures water activity analysers to determine the free moisture within food products - a good indicator of product stability and shelf life. Controlling the moisture present improves product quality. Analysers provide measurements in typically less than five minutes. The wide product range includes the AwTherm analyser with full temperature sample control; the HygroLab C1 laboratory analyser for up to four probes, handhelds for making spot-checks and a PC-based solution which is ideal when visiting suppliers’ sites. The sensors can be calibrated to confirm performance. Full technical product information is available on the website. WATER ACTIVITY eat it raw and while washing at home removes some bacteria, it does not eliminate E. coli. Last year also saw the outbreak of listeriosis in Spain, the biggest in the country’s history. In all, more than two- hundred people were taken ill, of which three died, after eating branded chilled roasted pork. Though the outbreak began in mid-August, and was declared over in October, arrests were made after the Spanish Civil Guard and law enforcement agency Europol found individuals were aware since December 2018 that some food products contained listeria but did not inform authorities and continue to sell them. Last summer, six people died from listeria infection after eating pre-packaged chicken sandwiches in hospitals in England. Through thorough testing, meat from a distributor North County Cooked Meats was discovered to contain the outbreak strain of listeria. Along with sandwich producer The Good Food Chain, North County Cooked Meats went into liquidation and ceased trading. For the former, it was because the impact of suspending production during an inquiry was too great for it to remain viable, demonstrating the potentially huge costs that companies can face during outbreaks. Testing of any kind is no silver bullet, but rather one important part of a wider efforts to ensure consumer safety and regulatory compliance. By regularly testing their suppliers, distributors, production line and products, companies can help to ensure they remain on top of any potential contamination and are better prepared to act should an outbreak occur. © Shutterstock /Alexander Raths 34-37.qxp_Layout 1 28/01/2020 12:28 Page 438 Food & Drink International www.fdiforum.net CLEAN AIR SOLUTIONS The unseen issue As air fulfils multiple functions from farm to fork, it’s critical that every part of the supply chain ensure they have clean air solutions in place. 38-41.qxp_Layout 1 28/01/2020 12:12 Page 1Food & Drink International 39 www.fdiforum.net CLEAN AIR SOLUTIONS © Shutterstock /Burdun Iliya I t’s almost inconceivable that a food manufacturer would shun or shirk a thorough washdown routine across their production line. Although much attention is rightly applied to contact surfaces and processing equipment, one of the most pervasive hygiene threats in the supply chain can’t be dealt with in the same way. That’s down to the fact that air is used in a variety of ways during production and processing. As well as helping to power certain pieces of equipment, it is also used to texturize some products, is frequently used in meat packing and in the production of plastic bottles. During these stages, contaminates can enter airflow and adversely affect a product or batch prompting a product recall further down the line. Even if no consumers are sickened, the reputational damage – not the mention the cost of a recall itself – can leave a company dealing with a costly fallout. According to the Food Marketing Institute and the Grocery Manufacturers Association in the US, food recalls cost companies an average of $10 million in direct costs alone. There are many ways for food makers to minimise contaminated air flows, safeguarding their ingredients, end products and consumers. Careful planning is required for both plant layout as a whole and on the production line in order to maximise clean air solutions. Chief among them are air filters which, as one can deduce, filter toxins and contaminates from the air. But it’s far from a one-size-fits-all approach, with industry specific needs and regulations to take into consideration. For food-processing purposes and to safeguard an environment dedicated to food production needs, barrier type air filters are most commonly used. These filters capture and retain most microbes and dust particles. As these contaminates are trapped inside, it’s critical that the filters are replaced and cleaned regularly. 40 Á 38-41.qxp_Layout 1 28/01/2020 12:12 Page 2Next >