< Previous30 Food & Drink International www.fdiforum.net FROZEN AND CHILLED FOODS Fresh thinking in frozen and chilled markets A multi-billion pound global market is seeing the frozen and chilled food industries expand, fuelled by factors beyond just cost, including premiumisation, sustainability, and technological advancements.Food & Drink International 31 www.fdiforum.net FROZEN AND CHILLED FOODS T wo seemingly disparate sectors – frozen and chilled foods – are finding fertile ground for expansion, underpinned by a global market projected to reach a staggering USD 638.6 billion by 2034, growing at a robust CAGR of 5.7% from 2024. While frozen’s inherent affordability offers a compelling narrative in leaner times, the story of both these industries is far richer, woven with threads of innovation, convenience, and a keen understanding of evolving business and consumer needs. The allure of frozen is undeniable, particularly when margins are under scrutiny. The ability to secure consistent quality at a potentially lower cost, coupled with the dramatic reduction in food waste, presents a compelling financial argument. Frozen vegetables, meats, and even prepared elements offer a stability that fresh produce sometimes can’t guarantee. This predictability is about building resilient and efficient supply chains in a global market where even the US frozen food market is projected to grow at a healthy 4.9% CAGR through 2034. A quiet revolution has been underway in freezers across the land. Today, “frozen” can mean gourmet ready meals boasting restaurant-quality ingredients, sustainably sourced seafood frozen at its peak freshness (a segment predicted to see a 4.0% CAGR by 2034 globally), and vibrant, flavourful fruit purees perfect for the burgeoning smoothie market. This premiumisation trend speaks to a sophisticated demand, both from businesses seeking to offer high-end options without the perishability pressures, and consumers unwilling to compromise on quality, even when seeking convenience. Meanwhile, the chilled sector continues its own compelling growth trajectory, mirroring the frozen sector’s focus on convenience. This translates to a hunger for ready-to-use components that streamline kitchen operations. Pre-portioned chilled sauces, prepared salads, and ready-to-assemble meal © stock.adobe.com/Juan 32 Á32 Food & Drink International www.fdiforum.net FROZEN AND CHILLED FOODS kits are becoming indispensable for time- pressed chefs and caterers. The ability to reduce labour costs and ensure consistency is a powerful driver, particularly in a world where changing lifestyles and busy schedules are prompting consumers to seek convenient meal solutions. This convenience is clearly reflected in the market dominance of ready-to-eat frozen foods, capturing a noteworthy market share exceeding 25%. It isn’t just about saving time, but also about meeting the evolving needs of a modern workforce and consumer base, particularly millennials who are increasingly drawn to the ease and single-serving options that frozen foods offer. The health and wellness movement has spurred innovation in both frozen and chilled aisles. Businesses are increasingly seeking out options that cater to specific dietary requirements – plant-based alternatives are a significant growth area within frozen, reflecting shifting consumer preferences. Suppliers who can offer a diverse range of healthy frozen and chilled ingredients are finding themselves in a strong position. Underpinning this expansion is a growing awareness of sustainability and ethical sourcing. Businesses are under increasing pressure to demonstrate their environmental credentials, and this extends to their food procurement. Frozen and chilled suppliers who can offer transparent supply chains, minimise waste, and adhere to sustainable practices are gaining a competitive edge. For instance, the Marine Stewardship Council (MSC) certification for seafood provides assurance of sustainable fishing practices, a crucial factor for businesses sourcing frozen fish. Whether it’s MSC-certified frozen fish or chilled products in recyclable packaging, these considerations are moving from the periphery to the core of purchasing decisions. © stock.adobe.com/Yuparet Improving the reliability of temperature monitoring through magnets Magnet thermocouples are specialised temperature sensors used in environments where traditional thermocouples face challenges. The use of magnets facilitates easier installation and positioning, improving the versatility and reliability of temperature monitoring systems. Magnet thermocouples offer an innovative solution for demanding temperature measurement requirements. Magnets with pull strengths ranging from 0.7kg to 11.8kg offer a wide range of applications across various industries. The pull strength of a magnet refers to the force required to pull it away from a ferrous surface. The availability of magnets with pull strengths spanning this range allows for precise selection based on the specific requirements of each application, ensuring optimal performance and reliability, particularly within temperature- controlled environments. Labfacility’s thermocouples are staples within the food and drink industry, and are available from their global suppliers, DigiKey and Farnell and direct from www.labfacility.comFood & Drink International 33 www.fdiforum.net FROZEN AND CHILLED FOODS This progress is significantly enabled by technological leaps in food preservation. Innovation in freezing and chilling technologies is playing a crucial role in the industry’s expansion. Companies like SPATULA highlight the power of rapid freezing, or flash freezing, which swiftly locks in nutrients, flavour, and quality by preventing large ice crystal formation, a significant improvement over conventional methods that can damage food structure and lead to dehydration. Similarly, advancements in chilled storage and transportation are extending the shelf life of fresh and minimally processed foods, opening up new market opportunities. The rise of e-commerce has further disrupted traditional models, creating direct- to-consumer opportunities for both frozen and chilled food businesses. This bypasses traditional retail constraints and allows for greater control over branding and customer relationships, particularly for niche or premium offerings. Notably, supermarkets and hypermarkets remain the most preferred distribution channel for frozen food products, commanding a substantial market share of around 40%, highlighting the continued importance of traditional retail in reaching consumers. Looking at specific markets, the UK is projected to see a healthy CAGR of 5.2% in its frozen food market, demonstrating the strength of this sector within our domestic landscape. This growth mirrors trends observed globally, driven by factors like increasing urbanisation and the demand for convenient, on-the-go options. For businesses, understanding these dynamics isn’t just about navigating the present but also bout capitalising on the substantial opportunities that lie ahead in this dynamic and increasingly vital part of the food landscape. The chill winds of the economy, it seems, are actually helping these sectors to flourish on a global scale. © stock.adobe.com/ChrisTYCat34 Food & Drink International www.fdiforum.net CLEANING AND MAINTENANCE I n the relentless churn of a food processing facility, the spotlight often shines on production targets and output volumes. Yet, lurking beneath the gleaming stainless steel and complex machinery lies a critical element that underpins product quality and operational efficiency: meticulous cleaning and maintenance. Food and beverage professionals understand that their sector operates under unique pressures. As products are for human consumption, any lapse in strict control can lead to contaminated goods, with the potential for serious outbreaks, illnesses, and costly legal battles. While the fundamental need for a clean environment might seem self-evident, the reality within a food processing plant is far more intricate than a quick once-over with a mop. The very nature of the industry creates a perfect breeding ground for bacteria, allergens, and other contaminants. Failure to address these microbial and physical hazards can have devastating consequences, ranging from costly product recalls and reputational damage to, in the most severe cases, putting consumer health at risk. Food scientists at Cornell University have highlighted the limitations of relying solely on visual inspection to assess cleaning effectiveness. Their research points to the use of rapid-testing adenosine triphosphate (ATP) swabs as a more reliable method. These swabs, when exposed to microorganisms, produce a light, much like a firefly’s glow, indicating the presence of organic matter. Recent history is peppered with stark reminders of what happens when hygiene standards slip. Investigations into foodborne illness outbreaks often trace their origins back to inadequately cleaned equipment, where biofilms can stubbornly cling to surfaces, resisting standard cleaning protocols. These incidents not only erode consumer trust but also trigger stringent regulatory scrutiny and Clean factories, safe food From microscopic threats to stringent regulations, maintaining hygienic food processing environments requires a multifaceted approach, embracing both traditional methods and innovative solutions. New Crisis Management Course from Verner Wheelock Imagine waking up to find that your company is splashed all over social media because a listeriosis outbreak has been linked to one of your products. Would you know what to do? How you manage a situation such as this is key in retaining your company’s good reputation, mitigating any financial losses and minimising any legal costs. Crisis Management, a brand-new course by Verner Wheelock has been designed specifically to give food industry professionals the skills to navigate a crisis effectively and bring it under control. Taking place on Tuesday 3rd June, the one-day course can be attended in person at Verner Wheelock’s training centre in Skipton, North Yorkshire, or remotely via Zoom. Subjects covered include: crisis categorisation; situational awareness; escalation procedures; information management; internal and external communication channels; who needs to do what – and when; and consequences, needs and expectations. For more information visit vwa.co.uk Food & Drink International 35 www.fdiforum.net CLEANING AND MAINTENANCE © stock.adobe.com/utaem2022 hefty fines. For businesses operating in such a tightly regulated environment, a proactive and robust cleaning regime isn’t just best practice; it’s a non-negotiable necessity. Today’s food processing plants are fitted with a complex array of highly sensitive equipment, from peeling machines to intricate packing lines and refrigeration units. Each component demands constant, specialised attention within a fast-moving production environment. The challenge, of course, lies in the complexity of modern food processing machinery. Unlike a factory floor that can be swept and scrubbed, the intricate network of pipes, conveyors, mixing vessels, and filling heads presents a far more demanding cleaning proposition. Residues can accumulate in hard-to-reach crevices, and the internal workings of equipment can become breeding grounds for unseen contaminants. Traditional cleaning methods, while essential, may not always be sufficient to ensure thorough hygiene throughout the entire system. This is where innovation and technology are stepping up to the plate. The industry is witnessing a surge in advanced cleaning solutions designed to tackle these very challenges. Automated Clean-In-Place (CIP) systems, for instance, have become increasingly sophisticated, employing precisely controlled cycles of rinsing, detergent application, and sanitisation to clean the internal surfaces of pipes and tanks without the need for extensive manual dismantling. These systems save time and labour and offer a more consistent and verifiable level of hygiene. The Cornell study, 36 Á36 Food & Drink International www.fdiforum.net CLEANING AND MAINTENANCE conducted in a commercial tofu manufacturing facility, demonstrated that targeted cleaning, guided by ATP monitoring and verified by microbiological tests, significantly improved environmental hygiene and product quality. This approach allows for the identification of microbial ‘niches’ that might be missed by standard cleaning protocols. Beyond CIP, other cutting-edge technologies are emerging. Inline inspection cameras, often with robotic capabilities, allow for the visual assessment of internal pipework and equipment, identifying areas where residues may be building up. This proactive approach enables targeted cleaning interventions before contamination becomes a problem. Furthermore, advancements in antimicrobial surface coatings and novel cleaning agents are offering additional layers of protection against microbial growth. In the UK, food and drink processors are rigorously regulated by bodies such as the Food Standards Agency, which has the authority to conduct unannounced inspections. Key areas of focus include general cleaning practices, machine safety – with tragic cases like the 2014 incident at Heinz highlighting the severe consequences of neglecting machinery safeguards – food safety standards (ensuring correct temperatures and preventing rust), and effective pest control. One of the key advantages of ATP monitoring, as noted by Professor Randy Worobo, a senior author of the study, is its objectivity. Unlike subjective visual assessments, a luminometer provides quantifiable data, removing potential bias in evaluating cleaning crew performance and empowering them to see the results of their work directly. The urgency of effective cleaning is further underscored by statistics from the U.S. Centers for Disease Control and Prevention, which estimate that over 48 million Americans contract foodborne illnesses annually, leading to thousands of deaths. Robust hygiene monitoring, such as ATP testing, plays a crucial role in mitigating these risks. Maintaining an extremely hygienic workplace goes beyond simple tidiness. Food and beverage manufacturers must enforce stringent practices encompassing pest control (with careful consideration of chemical use), constant cleaning and disinfection to prevent contamination and even worker injuries from slips, strict personal hygiene protocols including PPE, prompt waste management, proactive overall maintenance, and comprehensive staff training. The Health and Safety Executive identifies wet floors alone as a significant cause of injury in this sector, underscoring the importance of thorough cleaning. Moreover, effective cleaning is inextricably linked to proactive maintenance. Well- NEW AIR HEATER SERIES LHS 210 / 410 COMPACT & POWERFUL © stock.adobe.com/ultramanskFood & Drink International 37 www.fdiforum.net CLEANING AND MAINTENANCE Tel: +44 (0)1707 331111 info@welwyntoolgroup.co.uk www.welwyntoolgroup.com EASY CONNECTION HOT AIR RECYCLING ECONOMICALCOMPATIBLE NOZZLES HIGH AIR VOLUME OVERHEATING PROTECTION WNV unveils patented Internal Trailer Wash British company WNV Systems has just unveiled a patented Internal Trailer Wash that uses advanced technology to break new ground in trailer and container sanitation. A standalone, portable unit, the new Internal Trailer Wash (ITW) is engineered to be faster, safer, quicker, cheaper, and more effective than traditional cleansing methods. The improved hygiene standards it offers mean that companies can more easily meet Food Standard Agency (FSA) guidelines. Darren Bright, WNV’s sales director explained: “WNV is a pioneer in commercial vehicle cleaning tech, and we were approached by Morrisons to see if we could come up with a solution for automatic internal cleansing too. The FTA states that vehicles and containers used to transport food must be cleaned to a high standard, as food can easily become contaminated. If they have been used for transporting anything else as well, it’s vital that effective cleaning is carried out between loads to avoid the risk of contamination. Our new ITW system can do that quickly and cost-effectively, meaning the trucks can be back on the road again in hardly any time at all.” For more information visit www.wnv-systems.com © stock.adobe.com/Yakov maintained equipment is inherently easier to clean. Worn seals, corroded surfaces, and malfunctioning components can create harborage points for bacteria and make thorough cleaning significantly more difficult. A joined-up approach, where cleaning and maintenance teams work in tandem, is essential for optimising both hygiene and operational efficiency. A shift towards proactive strategies like preventive, predictive, or reliability-centred maintenance is not just advisable, it’s essential for minimising downtime and revenue loss. To effectively manage these multifaceted challenges, many food processors are turning to Computerised Maintenance Management Systems (CMMS). These systems are designed to schedule, monitor, and automate proactive maintenance work, providing crucial control over maintenance operations and contributing to a cleaner, longer-lasting, and more efficient plant. and so it’s paramount that manufacturers regularly change, sharpen and replace their cutting tools. It’s as much to do with hygiene, with a dull blade more likely to harbour matter and risk contaminating other products. Dull blades can also damage products, crushing, denting or bruising them. In any case, a manufacturer can be left with entire batches compromised and/or an expensive clean-up bill. Better to regularly replace and service cutting tools than risk extended periods of downtime. Hygiene is critical right across the supply chain but is of particular concern in the production line where products are directly exposed to conveyor belts, weighers and, of course, cutting tools. As we’ve already explored, the tools themselves must meet stringent 38 Food & Drink International www.fdiforum.net SLICING, DICING AND CUTTING C onsumers expect uniform quality across all brands now, going so far as to see unusually shaped foodstuffs as lower quality and discount. In fact, while some brands make names of themselves specifically for selling “wonky” fruits and vegetables, it remains that most consumers prefer perfectly sliced food. Moreover, a shift away from convenience food and toward healthy eating has seen a rise in sales of pre-cut vegetables. People want to cook more at home to avoid the ultra- processed label, and yet also don’t want to have to cut every bit of veg themselves. Pre- cut vegetables are proving to be a successful mix of fresh and convenient. The growing demand for pre-cut packaged foods and convenience meals containing sliced and diced foods have significantly increased the demand for cutting machines. In order to meet this demand, manufacturers have to turn to automation and other innovative options to maintain product integrity whilst also scaling up output. Consumers have come to expect uniformity in the food and beverage products they buy. Consistency of cuts and portion size is largely dependent on the sharpness of a cutting tool. Regular use renders any blade dull over time, Uniform cuts Uniformity is seen as a marker of quality, and the methods by which food is sliced, diced and cut during processing is more important than ever. 40 ÁFood & Drink International 39 www.fdiforum.net SLICING, DICING AND CUTTING © stock.adobe.com/GrafvisionNext >