< Previous20 Food & Drink International www.fdiforum.net SUSTAINABLE PACKAGING packaging worldwide focus on plastics - with a total of 147 measures identified, with the European Union and Asia having the highest number of regulations centred on plastics. McKinsey & Company also note that regulations worldwide have a relatively higher focus on beverage packaging than other categories. There are regional differences, though, with the European Union and North America concentrating more on beverages, with 50 to 60% of their regulatory measures having a specific end-product scope targeting beverages, while Latin America and the Middle East zero in on food packaging. Furthermore in the European Union and Asia, an emerging trend aims to tackle packaging across multiple product categories - a holistic approach. Mapping from McKinsey & Company reveals that financial penalties, versus subsidies, are the main and preferred regulatory method for sustainability change in the packaging industry, with around 45% of legal measures implying a defined financial fallout referring to penalties, generally related to taxes, fines, and fees. France is highlighted for using incentives the most to encourage change in packaging sustainability, for instance through indirect premiums or indirect subsidies/funding. Today there are a wide variety of sustainable packaging options. ‘Simpler’ © stock.adobe.com/ jchizhe 18-23.qxp_Layout 1 27/05/2022 14:44 Page 3Food & Drink International 21 www.fdiforum.net SUSTAINABLE PACKAGING info@macpac.co.uk Tel: 0161 442 1642 www.macpac.co.uk THERMOFORMED PACKAGING SPECIALISTS We design, produce tooling and manufacture packaging all under one roof, at our AA grade BRC accredited factory. We use responsible manufacturing processes and raw materials with up to 100% recycled content as well as being 100% recyclable. UP TO 100% RECYCLED 100% RECYCLABLE Innovative, Economical & Responsible. UK MANUFACTURER actions might involve reducing size and weight of packaging, improving design for better material recovery, or switching to already well- established, greener forms of packaging including cardboard and aluminium cans. Meanwhile increasing use of recycled materials, like rPET, in the production of packaging, along with ensuring the packaging remains recyclable, is a top priority, and utilising biodegradable or compostable packaging is an aim for many. With plastic the dominant food packaging material, minimising consumption of virgin plastics obtained from our limited fossil fuel supply is key to heighten the sustainability of packaging, seeing alternatives from moulded sugarcane and hemp, to paper and recycled plastic turned to. Approximately 36% of all plastics produced are used in packaging, including single-use plastic products for food and beverage containers, approximately 85% of which ends up in landfills or as unregulated waste, according to UNEP. In addition, 98% of single-use plastic products are produced from fossil fuel (virgin feedstock). 22 Á DataLase awarded Innovate UK Smart Grant for label-free plastic bottle project DataLase, the global leader in Photonic Printing Solutions, has been awarded funding from Innovate UK for their label-free plastic bottle project. Innovate UK Smart Grants are available for game-changing and disruptive ideas from businesses, through a regular competitive application process. DataLase’s grant funded project aims to present an alternative technology that could provide a label-free solution that can decorate and inform, is readily recyclable, and does not contribute to plastic waste. Given that one leading soft drink brand produces around 3 million tonnes of plastic packaging a year and plans to continue to use plastic bottles, within a global label printing market of $40bn, the potential value of this disruptive innovation is huge. Ally Grant, DataLase’s chief technology officer, said: “To win funding from Innovate UK is a fantastic boost for DataLase, particularly as our unique technology went head-to-head against hundreds of other competitor applications. The funding will allow us to conduct further R&D, develop engineering systems and to continue a truly ground-breaking technology that could have enormous impact on plastic waste globally, by eliminating plastic labels.” 18-23.qxp_Layout 1 27/05/2022 14:44 Page 422 Food & Drink International www.fdiforum.net SUSTAINABLE PACKAGING Looking forwards, moulded fibre materials are anticipated to grow in popularity, particularly for creating fully recyclable trays, while in the dairy industry some food and drink producers have switched to paperboard cartons and paper yoghurt cups, paper bottles are being investigated by brands, and plastic packaging suppliers are improving sustainability by utilising more recycled content and bioplastic materials. Examples amongst brands have seen milk producer Anchor develop a plant-based, 2-litre milk bottle made from renewable and sustainably sourced sugarcane, The Vegetarian Butcher now use a chilled retail tray made from 100% recycled plastic and seek out a recyclable, monomaterial top film that seals the packaging, while Notpla has made biodegradable and edible food packaging produced from seaweed and plants for drinks and sauces, and condiment maker HEINZ is developing a paper-based, renewable and recyclable bottle made from 100% sustainably sourced wood pulp, innovating its ketchup bottle. Other innovations have seen scientists from Harvard T.H. Chan School of Public Health and Nanyang Technological University, Singapore develop a ‘smart’ food packaging material that is biodegradable, sustainable and kills microbes that are harmful to humans. It could also extend the shelf-life of fresh fruit by two to three days. The natural food packaging is made from a type of corn protein called zein, starch and other naturally derived biopolymers, infused with a cocktail of natural antimicrobial compounds. These include oil from thyme and citric acid. In an experiment, strawberries that were wrapped in the packaging stayed fresh for seven days before developing mould, compared to counterparts that were kept in mainstream fruit plastic boxes, which stayed fresh for four days. Meanwhile researchers from São Paulo State University have produced a bioplastic from type B bovine gelatine, which will make the new plastic edible and eco- friendly. Nanoclay was added to the mixture to make it more consistent, increasing its tensile strength to almost double a conventional polyethylene packaging’s tensile strength, and a nano emulsion made from black pepper essential oil was added to the mixture to give the packaging a better flavour and odour. There are further aspects of packaging that must be considered, past that which is in direct contact with foodstuffs, however, such as switching to biodegradable packaging peanuts and corrugated bubble wrap in logistics packaging. Moreover, using eco-friendly inks is important, with the raw materials used in product packaging not the only things hurting the environment. As a result petroleum-based inks are being replaced with soy-based or vegetable inks that are biodegradable and less likely to release toxic chemicals when manufactured or disposed of. As new regulation for packaging picks up pace and a growing number of consumers seek out environmentally friendly products, making use of sustainable food and drink packaging will allow brands to remain compliant, reflect consumer values and ethics, and develop strong loyalty among consumers. • Plain / Printed Labels • Thermal Transfer Ribbons • Lasersheets • Fanfolded Labels • Barcode Labels © stock.adobe.com/svetlana_cherruty 18-23.qxp_Layout 1 27/05/2022 14:44 Page 521_0149 When are you planning to reduce the plastic content in your packaging? Delipac can The time is now. Delipac - the sustainable, food safe and plastic free packaging solution. Available now. STOP Kicking the Can! www.denmaur.com/delipac z&DQLWEHYHULƪHGDVSODVWLFIUHH including micro plastics? z Can it be completely and universally recycled? z Can it completely bio-degrade? z Can it compost completely - either at home or industrially? z Can it still sell and deliver your products and be convenient? z&DQLWEHQRZLQVWHDGRIRU" 18-23.qxp_Layout 1 27/05/2022 14:44 Page 624 Food & Drink International www.fdiforum.net WAREHOUSING AND DISTRIBUTION E fficiency and cost-reduction has traditionally been the most important factor in running a warehouse or distribution centre. The balance between minimising costs and maximising throughput, isolating and identifying factors that cause delays or problems becomes increasingly important. Now, however, maintaining levels of hygiene and social distancing have become the latest standard after the pandemic, and while that has finally come and gone, fresh pressure from rising fuel prices, inflation and a lack of staffing has led to a whole new raft of issues. Given the new and unpredictable world we live in, perhaps it’s time to spend less time worrying about how to squeeze the most out of your warehouse, but more on how to keep it running no matter what hits. Resilience, more than efficiency, may be the industry’s latest keyword. It might come across as though these outward pressures are being touted as beneficial for the industry, and they’re really not. Adaptation rarely comes willingly, or happily, but the optimisations that will result from them can serve the sector well, and the lessons learned should not be forgotten. The largest of which now is inflation surrounding workforces, with low unemployment and wages combining to make warehouse workers in high demand. For those companies who cannot afford to offer exceptionally attractive packages to maintain and attract staff – and this approach isn’t very sustainable long- term anyway – the alternative is to look at ways to minimise the reliance on staff. We’ve long since touted the benefits of automation here, and the lockdown may be offering yet one more reason to look for automated centres for the future. It’s worth noting that automated warehouses don’t truly attempt to live in a world where humans don’t exist. There is likely to be a team monitoring an automated warehouse from another location, ensuring that everything runs efficiently and running the warehouse. Even then, however, it would be a much smaller team, enabling social distancing and more space between employees, and even allowing the possibility of several key members of staff to work remotely and cover several warehouses. By cutting out manpower there is less risk for accidents or mistakes. While `to err may be human` is all well and good, it’s not something that will placate major customers who haven’t received their shipment on time, or who now have lost or damaged stock. Automated systems reduce the chance of human error. Of course they do not completely remove the potential for accidents, Resisting outward pressures Lean, efficient, resilient. With the pandemic behind us and a fuel crisis currently being experienced, perhaps “resilience” will become a more important feature than efficiency for warehousing. 24-27.qxp_Layout 1 27/05/2022 14:45 Page 1Food & Drink International 25 www.fdiforum.net WAREHOUSING AND DISTRIBUTION such as a wooden pallet splintering – a fully automated system also cannot be injured by the resultant mess. Space is another benefit to an automated system. Walkways and mezzanine floors can be unnecessary if a distribution centre is set out properly. Aisles could theoretically be removed entirely if a warehouse was to use roof- mounted shuttles or cranes to move goods about. But even if a company preferred to use remote-operated forklifts, there would be less requirements in terms of the width of aisle – a remote forklift unit of course not needing to be as wide as a normal one, due to its lack of a driver cabin. Software, specifically Supply Chain Management Software, can also help in this regard, especially with accurate summation of stock incoming and outgoing, but also where it is stored 26 Á © stock.adobe.com/Petinovs 24-27.qxp_Layout 1 27/05/2022 14:45 Page 226 Food & Drink International www.fdiforum.net WAREHOUSING AND DISTRIBUTION Celebrating our 45th Anniversary and what employees will be available at the time that it is required to be shifted. Any delays at the distribution part of the supply chain, especially if caused by not having the correct SCM in place can be catastrophic, as it is distribution centres which commonly deal with directly with the final client – introducing that age-old risk of failing to satisfy and thus losing a key contract. With the food and drink retail market dominated by a few very powerful retailers, manufacturers can ill- afford to suffer any lost confidence with these major clients. So, what is holding companies back? Costs remain an important factor, with a fully automated warehouse system requiring not only specialist machinery and software, but also a lot of planning and preparation. For existing warehouses, it might mean alteration, or removal of all existing systems, which would lead to a lot of wastage. While for new builds, there is already such high investment being utilised for distribution centres that adding another facet to the mix in what is already a tough economic climate, simply isn’t desirable. Return on investment tends to be a little slower with fully automated systems, despite high labour costs. Naturally, all this is compounded thanks to the uncertainty of factors like the war in Ukraine, inflation and the cost of living. On top of that there are also concerns about the flexibility of automated systems vs their more standard counterparts. When creating a new warehouse there is always the possibility that sales fall, or the space is not fully utilised in some way. In the event that a warehouse suddenly finds itself only operating at 50% capacity for instance, it is a relatively simple affair to move the racking around, designate the space to a different sector, rent out the space – or even just cut down on the size of the workforce to save costs. With a fully automated system this just 24-27.qxp_Layout 1 27/05/2022 14:45 Page 3Food & Drink International 27 www.fdiforum.net WAREHOUSING AND DISTRIBUTION NewCold grows again Europe’s largest ‘deep freeze’, on former steelworks land in Corby, is months away from completion. Automated cold storage specialist, NewCold, started work on the development in late 2020 to meet growing demand from the food manufacturing sector. Ross Hunter, supply chain director, explains: “The company already has a strong demand for its services at its Wakefield site and sees Corby as a prime location in the logistics ‘golden triangle’, with proximity to frozen distribution centres of large retail and food service customers. This will enable NewCold to help our customers reduce food miles and cut costs.” When fully operational the site will employ more than 250 people, but industry-leading automation will play a key part in the facility’s operation for NewCold, which has headquarters in the Netherlands and operates from fourteen locations on three continents. Ross Hunter adds: “Since opening our first UK site in Wakefield seven years ago, we have seen an increase in demand for our warehouse and transport services and although the Wakefield facility is the largest of its kind in the country, handling 4,000,000 pallets annually and storing 143,000 at any given time, demand has outstripped supply.” isn’t quite so simple. Excess equipment could be sold for some quick capital, but that just leaves the warehouse unable to pick back up if sales increase, while leaving half of the warehouse inoperable will only result in marginal savings in terms of energy costs. Automated systems that are locked in place are not as easy to move around as workers, and even if a company was able to rent the space out to another – software systems and operating procedures would need to be adapted to the new products, causing further © stock.adobe.com/warloka79 © stock.adobe.com/panuwat confusion. Ultimately, many companies are forced to adapt some kind of balance, reaping the benefits of automated systems where they can, while also keeping a certain degree of manual labour in place to work around it. 24-27.qxp_Layout 1 27/05/2022 14:45 Page 428 Food & Drink International www.fdiforum.net FLOW MEASUREMENT AND CONTROL There’s a myriad of flow meters available to food and drink producers depending on the product and requirement. As well as exploring these options, we break down the advantages and disadvantages and some of the challenges to overcome. F low measurement is critical right across the food and drink supply chain, fulfilling applications from aeration of food and measuring ingredient quantities, to carbonating and packaging. As well as this manufacturing context, it is also prevalent in retail and hospitality settings – with cafés, bars and restaurants relying on flow meters in coffee machines and other dispensaries – as well as in the processing of wastewater. Flow your own way Flow your own way 28-31.qxp_Layout 1 27/05/2022 15:44 Page 1Food & Drink International 29 www.fdiforum.net FLOW MEASUREMENT AND CONTROL © stock.adobe.com/279photo As with any other equipment that comes into contact with food and drink products, it’s important to consider how flow meters can affect taste quality. An issue which should be of particular concern to products with a mild flavour or those with none at all – such as bottled water. For such products, it is strongly advised to use non-metallic wetted components which won’t affect the taste of foods or beverages. There’s more than flavour at stake, however, with subpar meters potentially rendering a product unfit for human consumption. Avoiding such outcomes can be significantly diminished by selecting flow meters made with anti-corrosion and anti-rust materials as standard. Typically, meters are made from a shell of stainless steel with movement parts incorporating special food grade materials with optimised design. Whatever the application, the importance of health and safety can’t be overstated and so to avoid contamination, inline devices must be hermetically sealed. Moving parts, meanwhile, must be structurally sound and clean of lubricants. Moreover, meters should be easy to clean when 30 Á 28-31.qxp_Layout 1 27/05/2022 15:44 Page 2Next >