< Previous30 Food & Drink International www.fdiforum.net FLOW MEASUREMENT AND CONTROL An excellent example of this is Coca-Cola Europacific Partners’ facility, the largest soft drinks factory in Europe by volume. The company partnered with Endress+Hauser to implement a network of Promass Coriolis flow meters across its syrup and sugar dosing lines. These meters feed data directly into the site’s SCADA system, allowing for precise control over ingredient ratios. The upgrade enhanced flavour consistency across product lines and led to a significant reduction in ingredient waste. One of the greatest demands placed on flow meters in food and beverage manufacturing is hygiene. Given the strict regulatory requirements around food safety, these instruments must be designed with cleanability at their core. Modern meters feature hygienic-grade stainless steel construction, minimal dead space, and CIP/SIP (Clean-in-Place / Sterilise-in-Place) compatibility to ensure thorough cleaning between product runs. In particular, manufacturers are now choosing meters specifically for their hygienic credentials. Bronkhorst’s ES-FLOW ultrasonic flow meters are a case in point. Used by Haas-Mondomix B.V., a company that builds mixing and aeration equipment for the confectionery industry, these devices help ensure highly accurate dosing of small quantities of additives such as colourings, acids, and flavourings. Their compact, crevice-free design and ability to measure low © stock.adobe.com/navintarFood & Drink International 31 www.fdiforum.net FLOW MEASUREMENT AND CONTROL © stock.adobe.com/Sergey Ryzhov flow rates of viscous fluids make them ideal for applications where hygiene and precision are non-negotiable. Flow meters are also helping manufacturers tackle one of the less obvious challenges in production: product build-up. Thick or sticky substances can accumulate inside pipelines and measuring instruments, compromising measurement accuracy and requiring more frequent maintenance. Intelligent flow meter designs now feature smooth bore geometries and real-time diagnostics that warn operators when cleaning is needed or when flow begins to deviate from expected patterns. Product build-up and inefficient cleaning processes can also have a major impact on sustainability metrics. This is where flow data becomes a powerful tool for change. Take, for example, Bath Ales brewery in Warmley, near Bristol. With support from Endress+Hauser, the brewery installed a series of flow meters to monitor water consumption across various stages of production. Integrated with a central data management platform (eSight), this setup allowed the brewery to track water use in real time and optimise its CIP cycles. Another compelling example is Northern Monk Brewery in Leeds. In collaboration with Brew Resourceful, the brewery undertook a comprehensive water usage audit that relied heavily on flow data. As a result of implementing the recommendations, Northern Monk saved over 7.6 million litres of water annually, amounting to an estimated cost saving of £41,000. Flow measurement provided the data-driven insights needed to identify inefficiencies and take corrective action. Today’s flow meters are active components in an intelligent production system. Many now feature built-in diagnostics, self-calibration capabilities, and the ability to measure additional parameters like density, temperature, or pressure. As the demands on food and drink manufacturers continue to grow, so too will the importance of flow measurement and control. The industry is moving towards a future where every drop counts.32 Food & Drink International www.fdiforum.net SNACK FOODS AND READY MEALS F or years, convenience and cost were the primary drivers in the snack food and ready meals manufacturing sector. However, today’s consumers are armed with more complex demands, seeking healthier options, diverse flavours, and products that align with their environmental values. This maturation of the market presents challenges and considerable opportunities for businesses operating in this dynamic arena. For snack food producers, the traditional reliance on simple formulations is giving way to a demand for innovation. While classic favourites still hold their appeal, supermarket shelves now boast an array of alternatives featuring novel ingredients and health-conscious claims. From vegetable-based crisps to snacks incorporating superfoods, manufacturers are responding to a more discerning consumer. A significant force behind this new wave of ingredients is the increasing influence of the biotech revolution on ingredient solutions for both snack Biotech and bold flavours reshape the future of snacks and ready meals As consumer demands shift toward health, sustainability, and quality, biotech innovations and advanced manufacturing are transforming the snack and ready meal industry from the inside out. 34 Á BAG SEALING MACHINES RM Sealers remain a leading British manufacturer and supplier of high quality Bag Sealing Machines, also known as Rotary Band Sealers and Impulse Sealers. Call 01442 843387 to speak to a member of our team SEALERS © www.rmsealers.co.ukFood & Drink International 33 www.fdiforum.net SNACK FOODS AND READY MEALS © stock.adobe.com/Tondone BENCHTOP BAG SEALING MACHINE IMPULSE BAG SEALING MACHINE HORIZONTAL BAG SEALING MACHINE VERTICAL BAG SEALING MACHINE34 Food & Drink International www.fdiforum.net SNACK FOODS AND READY MEALS ✓ Plug & Print ✓ Lowest TCO ✓ Outstanding print quality ✓ 5-year no-maintenance by design ✓ Focus on sustainability and durability foods and ready meals. Innovative bioprocessing techniques, particularly fermentation, are unlocking new possibilities for creating ingredients with enhanced functionality and sustainability. This method allows for the production of proteins and other components using microorganisms, offering a more resource-efficient alternative to traditional agriculture. For snack manufacturers, this opens doors to developing products with novel textures and improved nutritional profiles. Imagine crisps made with protein-rich, fermented ingredients or flavourings derived through sustainable bioprocesses. Similarly, in the realm of ready meals, biotech-derived ingredients can contribute to both quality and sustainability. Fermentation can produce specific proteins that enhance the texture and mouthfeel of meat alternatives, or create novel fats that improve flavour while reducing reliance on less desirable ingredients like palm oil. Precision fermentation even allows for the production of individual dairy or egg proteins, offering opportunities for tailored nutritional benefits and unique textures in ready-to-eat dishes. While still in its scaling phase, this biotech approach promises a more controlled and modular ingredient supply chain, reducing vulnerability to traditional agricultural challenges. As production costs decrease with technological advancements, these novel ingredients are poised to become more economically viable for mainstream production. This transformation is also supported by advancements in ingredient solutions and sophisticated machinery that enable the creation of complex products at scale, with precise seasoning and consistent textures. The machinery employed in the production of both snack foods and ready meals is becoming increasingly advanced. Automated systems ensure precision in slicing, shaping, and seasoning, while sophisticated cooking technologies are being adopted to enhance the quality of ready-to-eat meals. This technological progress allows manufacturers to meet the demand for both high volumes and consistent quality. The journey from production to the consumer’s hand is also a critical factor influencing how these impulse buy products are made. Packaging plays a pivotal role, needing to be visually appealing for snacks to capture immediate attention and functional for ready meals to maintain freshness and facilitate heating. In the ready-to-eat sector, microwave packaging has become a crucial element, engineered for quick and efficient heating, aligning perfectly with modern consumption patterns driven by convenience. The growing emphasis on sustainability is driving a demand for innovative and environmentally friendly packaging solutions, presenting both a challenge and an © stock.adobe.com/Hafizwww.fdiforum.net SNACK FOODS AND READY MEALS opportunity for manufacturers to invest in new materials and technologies. This includes advancements in materials like biodegradable and recyclable options, addressing growing environmental concerns. Microwave packaging itself is evolving, with two main categories: microwave-active and microwave-transparent. Microwave-active packaging often incorporates susceptors to aid in toasting or crisping, mimicking traditional cooking methods. Microwave- transparent materials, on the other hand, allow microwaves to pass through for even heating. These designs are not only vital for food safety during heating but also contribute to improved taste and texture. Leading companies are heavily investing in innovation in this area to meet consumer and regulatory demands. Distribution networks must be efficient and reliable, particularly for temperature-sensitive ready meals. The conditions under which these products are stored and displayed in retail environments also directly impact their appeal and shelf life, influencing packaging choices and production considerations. For snacks, effective point- of-sale displays are crucial for driving those impulse purchases. Furthermore, smart packaging technologies, such as QR codes providing heating instructions or nutritional information, are enhancing user experience and brand engagement. The ready meal sector has witnessed a significant evolution in consumer perception. No longer solely a fall-back option, ready meals are increasingly seen as a convenient alternative to home cooking, with a growing demand for premium options featuring high-quality ingredients and sophisticated recipes. Manufacturers are responding by adopting production techniques that preserve flavour and texture, and by sourcing higher-quality components, including those emerging from the biotech sector. © stock.adobe.com/Stockistock W ithourHalalcertificate,youcansend products,beverages,cosmetics,andconfectionery productsMiddleEast,Malaysia,Indonesia, Türkiye,Singapore,Europe,andtherestoftheworld. W ithourHalalce products,bevera productstothe Türkiye,Singapo ertificate,youcansendmeat,meat ages,cosmetics,andconfectionery MiddleEast,Malaysia,Indonesia, re,Europe,andtherestoftheworld. www.halalfoodauthority.comwwwwwwwwwwh.h.hahahaha.ha.hlalalalallalfooofoofoodadadadaauaudadauaudadttthottrititittttiyyy.cy.cy.cy.cy.cy.cooomom info@@hhhhhalaaaalllllffffffoooooooooddddaaaaauthoriiiiiiitttttttyyyyy.ccccomm 0044(0)20888844444444667711227736 Food & Drink International www.fdiforum.net WAREHOUSING AND DISTRIBUTION Warehouse innovation © stock.adobe.com/KOTO Warehouse innovation Food & Drink International 37 www.fdiforum.net WAREHOUSING AND DISTRIBUTION F rom farm to fork, food makes many stops on its way to the plate, with the warehouse a crucial point in the journey. Food warehouses must keep products fresh, safe, and ready to be delivered, ensuring precise temperature management, preventing contamination, keeping close control of inventory and shelf life, and optimising distribution to meet strict delivery schedules. Without tight controls in these busy facilities — where products are entering and leaving in constant flux to meet the needs of the fast-paced food industry — slip-ups are inevitable, creating potential for spoilage, degradation of quality, health and safety issues, and financial loss. With warehouses across industries becoming the subject of optimisation and innovation, now is the time for the food sector to jump on board and shed its historic reputation of a reluctance to invest in novel technological advances such as heightened automation. If food firms are to meet growing pressure and demand from consumers, prevent costly errors, and create efficient operations that can speed up supply chains, leveraging modern technology in warehousing is key. At the core of the modern warehouse are Warehouse Management Systems (WMS), helping companies control warehouse operations from the entry of goods until the moment they leave, assisting in the management of inventory, workers, and automating order processing to streamline every aspect of a warehouse from one interface. These systems provide vital assistance in the form of real-time visibility of inventory and its movements, particularly when partnered with RFID tags or sensors, enabling accurate stock levels to be maintained, stockouts to be predicted, and demand fluctuations to be addressed efficiently. They can also help ensure that products are stored by their expiration date, utilising a first-in, first-out method to identify which items need to be used first to combat waste, amongst providing other tools, such as for picking and packing processes, resource utilisation, and analytics. When WMS are integrated with other tech - from AI to robotics - their capabilities grow even further. The star of the moment in innovation, integrating artificial intelligence (AI) into warehousing operations enables huge swathes of data to be analysed, including order volumes, stock information, staff levels, available space, and historic sales information and seasonal trends, facilitating efficient resource allocation, allowing potential disruptions to be managed, and even helping proactively adjust stock levels based on predictions for consumer demand by tapping Warehouses are becoming the subject of optimisation and innovation as demand swells in the fast-paced food industry. 38 Á38 Food & Drink International www.fdiforum.net WAREHOUSING AND DISTRIBUTION into internal brand data and external data like weather forecasts. AI can also analyse warehouse layouts to provide dynamic routing, allowing the routes of stock pickers to be adjusted to the most efficient option, preventing wasted time walking between locations, and speeding up order processing. Similarly, when products leave the warehouse and hit the road, AI can assist fleet managers, assessing the best delivery route to a retailer, restaurant, or other destination by analysing real-time and historic data on traffic, weather conditions, and vehicle capacity, to reduce travel time, delays, cut fuel consumption, and optimise delivery schedules. Employing automation and robotics can further bolster warehouse efficiency and assist in a time of labour shortages. Robotic arms, cobots (collaborative robots), and automated guided vehicles (AGVs), for instance, can make picking and transport a much more rapid process with minimised human error, navigating through narrow aisles with ease and precision. Concurrently automated storage and retrieval systems (AS/RS), incorporating tightly configured totes, bins, dividers, drawers and holders, enable quicker retrieval and restocking of goods and facilitate full use of facilities, increasing storage capacity by being able to work in more densely stocked warehouses, removing wasted aisle space, and using the full height of a facility, that would otherwise be less reachable by human workers. Automation systems are also highly useful in environments hazardous to or challenging for humans, like those with extreme temperatures dealing with frozen goods. Making use of the Internet of Things (a network of interconnected devices embedded with sensors, software, and communication tools), meanwhile, enhances real-time Food & Drink International 39 www.fdiforum.net WAREHOUSING AND DISTRIBUTION monitoring and control, with Internet of Things (IoT) sensors positioned throughout a warehouse, on stock, and within equipment able to collect data in real time for smarter decision making. Continuously collecting data, such as on a facility’s environment, conditions can be monitored remotely and deviations alerted to, like changes in temperature or humidity, to be rectified promptly and minimise the chance of a spoilage incident as well as maintain the integrity of products. When used to monitor equipment, meanwhile, predictive maintenance is unlocked, with IoT sensors able to alert managers of potential failures in advance, reducing downtime. These sensors can be extended into delivery vehicles and on packages for real-time monitoring, to track goods and ensure the perfect conditions are maintained while products are transported to their next destination, preserving the quality of goods and also offering transparency as products are moved. Moreover, delivery vehicles can be equipped with IoT technologies to monitor fuel consumption, engine performance, and maintenance requirements, creating safer and more efficient fleets. This forms a dynamic and responsive ecosystem throughout warehousing and distribution. Integrating modern technology into food warehouses is key to keep up with the growing pressure being placed on the industry, requiring quick, efficient, and accurate storage and distribution. From WMS to AI, automation, robots, and the IoT, the options available are wide ranging, but for each individual operation, the technology employed should be tailored to its precise needs to guarantee the best return on investment and the most appropriate systems are installed for the products being stored. © stock.adobe.com/panuwatNext >