< Previous30 Food & Drink International www.fdiforum.net FUNCTIONAL INGREDIENTS Consumers are focusing more than ever on what additional benefits food and drink products can offer them, from immune support to stress relief. Though the adoption of functional ingredients in food and drink products has been on the rise for some time as people seek to gain extra benefits from what they consume, the COVID-19 pandemic has stimulated fresh demand for these goods as consumers become more focused on maintaining good health and taking control over diet to combat the virus - just as they are engaging in frequent hand washing, sanitising and social distancing. From ice cream to water, functional ingredients appear across the spectrum, obtained from a variety of sources. After the past year, preventative products featuring functional ingredients that support immune systems have become increasingly important to consumers as a proactive approach is taken to remain healthy. Research from Innova indicates that sixty per cent of first Function 32 Á 30-33.qxp_Layout 1 26/04/2021 12:16 Page 1Food & Drink International 31 www.fdiforum.net FUNCTIONAL INGREDIENTS © Shutterstock /Nitr 30-33.qxp_Layout 1 26/04/2021 12:16 Page 232 Food & Drink International www.fdiforum.net FUNCTIONAL INGREDIENTS global consumers are looking for products that promote immune health, while one in three state their concerns over immune health grew in 2020. Probiotics, turmeric, ginger, elderberry, and ginseng are ingredients gaining popularity. Probiotics also hold an important place, alongside prebiotics, as a functional ingredient that supports digestion and gut health, impacting the microbiome in the intestine and appearing in a whole host of products from cereal to coffee and baked goods. Research from Kerry highlights that for promoting digestive health, forty-eight per cent of consumers place yoghurt and yoghurt drinks as the most popular option, but there is also interest in fruit and vegetable juices (thirty-eight per cent), cereal, granola, and breakfast bars (thirty-five per cent), and hot drinks (twenty-eight per cent). When it comes to the latter, however, with tea and coffee for example, stability is a key challenge - a probiotic needs to survive manufacturing, shelf life of a product, © Shutterstock /Iakov Filimonov 30-33.qxp_Layout 1 26/04/2021 12:16 Page 3Food & Drink International 33 www.fdiforum.net FUNCTIONAL INGREDIENTS and exposure to boiling water in the prep of the product. Furthermore, with continued consideration for digestive health, a rise in high-fibre product launches is unsurprising. Inulin, derived from the chicory plant, is coming to the forefront as a natural form of fibre for its prebiotic effect. The ingredient has also been used to assist in sugar reduction. Protein also continues to be an area of consumer interest driving food choices, with protein-rich diets linked to managing and preventing chronic diseases, building and preventing loss of muscle. It can be seen clearly in sports and performance products, but protein-enriched goods are also growing in categories such as dairy, cereals, bakery, and snacks as manufacturers innovate while looking to create improved products that overcome the problems of off-notes and gritty textures when dealing with added proteins. Whey proteins, for example, have now penetrated shakes, iced teas, and indulgent bars, and newer alternative proteins like pea continue to expand in use. A novel area being addressed with functional ingredients is consumer desire to improve cognitive function, mental health, and reduce stress, and brain health claims are rising rapidly with new food and drink launches. Nootropics is a standout upcoming trend for this, particularly in the drinks space, as supplements that claim to boost mood, memory, motivation et al. The most common nootropic products - aka natural brain enhancers - are centred on focus and calming the mind. L-theanine for instance, which can be found in certain green and black tea leaves and certain mushroom species, is a calming ingredient thought to improve mood, sleep, and reduce stress and anxiety, which has become of real value in the pandemic. Other nootropics include caffeine, for alertness and attention, choline, a nutrient involved in brain and nervous system function, creatine, to fuel brain cells, and omega-3 fatty acids. Companies can also utilise natural foods and flavours with inherent nootropic qualities like dark chocolate, blueberries, and turmeric. Herbal teas and flavoured waters are big categories for nootropic experimentation. Nootropic foods meanwhile are in their infancy, though are entering the market in snack foods. From nutrition bars to ice cream, ingredients lists are being formulated to offer calming and relaxation effects. Simultaneously, well known ingredients associated with calming effects are being turned to such as chamomile, lavender, CBD, and botanical blends designed for stress relief. With the general boom in functional foods, there is also the opportunity to extend use of functional ingredients into food service. A report from Kerry notes that fortifying takeout food with probiotics could meet the growing consumer demand for functional ingredients that promote digestive and immune health and improve wellbeing. The report suggests that integrating functional ingredients could provide a new chance to capitalise on the wellness trend, differentiate, and come back from the pandemic stronger, while addressing health-focused consumers in a changed world. ‘Opportunities for Formulating With Probiotic Ingredients in Food Service’ indicates that sixty-five per cent of US consumers seek out added functional benefits from everyday food and drink, and seventy-eight per cent of consumers want restaurants to host more options with functional ingredients. As consumers look for products that offer something more, and take their time to read labels, food and drink firms will need to develop products that do not only present great taste, texture, and eye-catching packaging, but goods with functional ingredients - from minerals and vitamins to probiotics and fibres - and health benefits. Of course, when working with functional ingredients food and drink companies will need to hold proof of claims made. 30-33.qxp_Layout 1 26/04/2021 12:16 Page 434 Food & Drink International www.fdiforum.net CLEANING AND MAINTENANCE Companies that carry out maintenance checks on a planned basis often fail to meet their targets. On-the-spot inspections often provide more comprehensive results, and a competitive edge. Automation gives manufacturers of food and drink the ability to carry out complicated tasks quickly and easily. However, it also brings with it the possibility of excessive downtime when breakdowns and accidents occur – interruptions which many companies can ill-afford. Considering how many businesses are going to be looking to recover and perhaps expand after the pandemic, accidents – be they of workers or hygiene related – could well strike the death knell for a manufacturer. It may be an unfortunate truth, but companies that carry out maintenance checks on a planned basis (i.e. at set times of the year) often fail to meet their targets. To stay ahead of the game, manufacturers should look to implement constant on-the-spot inspections. Problems with machinery should be addressed as they arise, not months down the line. The best way to increase productivity is to ensure that every piece of machinery runs as smoothly as possible. Ahead of the game 36 Á 34-37.qxp_Layout 1 26/04/2021 12:19 Page 1Food & Drink International 35 www.fdiforum.net CLEANING AND MAINTENANCE © Shutterstock /franz12 34-37.qxp_Layout 1 26/04/2021 12:19 Page 236 Food & Drink International www.fdiforum.net CLEANING AND MAINTENANCE Of course, proper cleaning of those same machines also helps to reduce build-up of material that may lead to issues or damage later down the line. Investing up-front in some of the more sophisticated technologies on the market could pay dividends in the long run. For example, Electrical Panel Thermography can be used to identify even the most imperceptible flaws in a piece of manufacturing equipment. By measuring the temperature of a piece of machinery or individual component, thermal imaging devices can catch minor electrical faults before they cause serious damage, which ultimately means less downtime is needed for maintenance. Companies can also carry out spectrographic oil analyses to keep their machines running smoothly. The oil used to lubricate manufacturing machinery needs to be uncontaminated in order to do its job properly, but the only sure-fire way to guarantee this is to use an ICP (inductively coupled plasma mass) spectrometer to identify and weed out unwanted particle compositions. Conducting oil sample analysis can help to prolong the lifespan of machinery and should be carried out on a routine basis. Acoustic vibration monitoring technology, which costs relatively little, can also be employed to check the condition of mechanical parts. Industrial rotors, for example, will emit higher-frequency sounds if they sustain any damage. By using an Acoustic Emission (AE) sensor to detect early signs of friction, companies can address problems before they become cause production to grind to a halt. It is vital to keep machinery as clean as possible – especially in an environment where food and drink is being produced. Products such as milk and cheese can be difficult to remove from hard surfaces if they are allowed to burn, and caramelised build-ups will inevitably make machines and pipes less functional. In order to remove potentially hazardous blockages, manufacturers are investing in UHP pipe-cleaning technologies which employ water pressure to achieve a more powerful clean. The latest products on the market are able to clean lengths of piping over 1 km long, and because many of them feature sophisticated rotary heads that increase water propulsion, they are also able to clean around bends. But what about health and safety? According to the Health and Safety Executive of the UK, machinery causes nearly five hundred accidents per year in the food and drink industry, including over thirty per cent of fatal injuries. Poorly maintained and/or supervised conveyors are the biggest culprits, but food mixers, thermoform machines and wrapping machines also account for a significant percentage of the total. These figures make grim reading, but, thankfully, most companies are © Shutterstock /Kzenon 34-37.qxp_Layout 1 26/04/2021 12:19 Page 3FOLLOW US WHEN YOU SEE THE PERFORMANCE WHEN YOU SEE THE PRICE WW Versatile thanks to a wide performance range, intuitive and flexible user guidance, low-pulsation dosing, and energy-efficient during operation - all at an attractive initial cost. The new iSTEP XS offers XL performance at XS price! iSTEP XS Now available Food & Drink International 37 www.fdiforum.net CLEANING AND MAINTENANCE beginning to implement well-thought-out measures to ensure the health and safety of their staff. Eliminating hazards at the design stage is by far the best way to prevent machine-related accidents, but this is not always viable, and no method of checking is one- hundred per cent fool-proof. Therefore, where particularly dangerous, heavy machinery is being used, companies should institute a permit-to-work system to ensure that, a) only highly trained operatives have access to the machinery, and b) that no individual is required to use a piece of machinery for longer than is absolutely necessary. It is similarly vital that machines are positioned in unconfined spaces on the factory floor. This not only reduces the risk of getting trapped in the moving parts of machine, but it also lessens the chances of an operative inhaling the dust that is an inevitable by- product of many food manufacturing processes. Dust inhalation and other issues such as eye and skin irritation can also be prevented if companies provision their staff with the correct safety equipment and take the trouble to install high-quality exhaust ventilation systems. With automation on the rise, plant maintenance has never been more important to food and drinks manufacturers. Taking the right steps now could mean increased profits in the long run. © Shutterstock /Phovoir CHEMICAL DOSING iSTEPXS.sera-web.com More info: sales.uk@sera-web.com Tel. 01283 753400 34-37.qxp_Layout 1 26/04/2021 12:19 Page 438 Food & Drink International www.fdiforum.net COLD STORAGE Since March 2020, COVID-19 has placed extra strain on cold storage, with the pandemic pushing consumers to buy frozen goods and take part in more online food shopping and creating backlogs of products due to border/export/port complications. Moreover, with many restaurants across the globe closed, the pandemic has left suppliers scouring for alternative customers and locations to store excess food, while some food processors, running out of storage, are being forced to cut output. The role of cold storage is indispensable in the food and drinks industry with temperatures too far one way or the other leading to product degradation, spoilage and wasted goods – all of which eats into profits. A prudent example of this importance in action is frozen vegetables. In order to preserve the maximum flavour, nutritional content and product integrity, vegetables must be frozen as quick to being picked as possible. Indeed, this has become a selling point for many frozen food producers looking to market their goods as every bit as healthy as their fresh counterparts and less wasteful. However, this means frozen vegetables must move from the freezing process, through to packaging and, finally, be transported into retailers, whilst all the while remaining at a constant temperature. So how exactly can this be accomplished in the supply chain? The first part of this chilled logistics journey typically occurs in-house, such as a production line in an enclosed warehouse or other such facility. Though there are myriad options open to manufacturers when it comes to keeping a consistently cold production line or storage facility, it’s counterproductive to invest in subpar technologies. Even tiny changes in temperature can lead to micro-thawing and the crystallisation of frozen goods. This makes insulation crucial in maintaining a cooler temperature as the heat outside a facility will be constantly trying to make its way inside. The nature of heat means it can work its way through even the smallest breaches in a manufacturer’s temperature defences, be that a wall, window or door. One of the biggest threats to frozen foods lies in the changeover from one facility to another, such as a manufacturing line to a distribution centre. Manufacturers will likely have temperature controlled loading bays to ensure a constant temperature is carried across and maintained from production and packing. Curtain walls will help to maintain this consistency, creating a barrier to ensure that cold air stays inside its designated area whilst also allowing workers, loaders and forklift trucks to easily pass through. Yet there’s no getting around the fact Cold front The demand for cold storage within the food and drink industry has skyrocketed, driven by changing consumer habits craving fresh food and seafood, expanding supply chains, escalating concern over food waste, and a general increase in the amount of goods that are cold-stored. 38-40.qxp_Layout 1 26/04/2021 12:33 Page 1Food & Drink International 39 www.fdiforum.net COLD STORAGE that loading bays are literal openings into the outside world and so could therefore scupper this carefully controlled chilled environment. To compensate for this, and to maintain the cold integrity, manufacturers and logistics operators rely on hoods around the bay door opening. In practice, this means a truck or lorry can back into a bay and open its doors, thereby creating a seal and ensuring that the cold air isn’t diffused and compromised by the warm. Frozen and chilled foods can then be loaded without fear of their thawing or warming up. Though many of the precautious observed in the cold chain might seem obvious, there are other subtler dangers that must be considered. Now that we’re in the thick of summer, it’s important that manufacturers understand how the performance of their temperature controlled systems can be affected by the heat and what they can do to counteract those negative effects. Electrical equipment of all kinds generate heat, and these temperatures have been attributed to electronic components tripping or failing outright altogether. Moreover, temperatures can get so high inside a panel that fire risks become a clear and present danger. While cold storage has been slow to embrace innovation, change has arrived in the sector. A plethora of technologies have been implemented to improve cold chain and storage management. Automation and, though not fully integrated like in traditional warehouses, robotics are on the rise, replacing manual workers and processes to speed up the movement of food to efficiently fulfil orders. This is prompting taller, high density and 40 Á © Shutterstock /Sorn340 Studio Images 38-40.qxp_Layout 1 26/04/2021 12:33 Page 2Next >