< Previous20 Food & Drink International www.fdiforum.net PROCESSING SPOTLIGHT © Shutterstock /Mark Agnor Processing the future Processing the future 20-25.qxp_Layout 1 26/07/2021 08:18 Page 1Food & Drink International 21 www.fdiforum.net PROCESSING SPOTLIGHT There was a time when a dedication to the highest standards would have been considered a USP but retailers and consumers alike now demand these as a matter of course. The challenge for manufacturers is to ensure standards don’t slip at a time when retailers are looking for increased efficiency on the supply chain. Costs need to be kept down at every stage as new products and production methods are introduced. In many cases, this will require the highest degree of operational discipline, excellent interdepartmental communication, far greater awareness of issues and current production status, together with automation, wherever possible, to minimise the risk of operator error. All responsible manufacturers will have carried out in depth risk assessments, and realised how easy it is, within such high pressure environments, to get something wrong. Errors in component handling, out of date ingredients, coding and labelling errors, compromised pack seals and inaccurate weights are just a few things which negatively impact delivery schedules and the bottom line in food manufacturing environments where short batch runs and frequent product changeovers have become the norm. One obvious benefit of the rise of automation in the processing sector is the ability to ensure complete accuracy. That’s absolutely vital with increasingly stringent regulations on labelling - not to mention the huge expense that can be engendered by excessive product giveaway. This has in turn led to an increase in the levels of traceability present within the manufacturing and supply chain - with companies able to find out exactly who the suppliers were of any ingredients used in a given batch of completed products - within a few hours. Accurate traceability enables retailers and manufacturers to find out where faulty produce came from, and where it was delivered to. Due to the damage such scandals can cause A widespread shift to automation, with robotics as standard on production lines, is being hampered. However, there are encouraging signs that the industry, particular here in the UK, is moving with the times. 22 Á 20-25.qxp_Layout 1 26/07/2021 08:18 Page 222 Food & Drink International www.fdiforum.net PROCESSING SPOTLIGHT to the reputations of companies, many retailers now demand stringent traceability methods to be in place. An automated and, perhaps more importantly, monitored line can help in this regard. More troubling news is that 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. The UK is behind countries such as Germany, Sweden and France - but also now falls behind Slovakia, Slovenia and the Czech Republic. 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. This has to change, but there are some who fear it could already mean UK manufacturers cannot compete with their rivals. This is believed to be more of a cultural issue than one of finance, since improving technology has made process and automation equipment more affordable in recent years. Clearly it is something that needs to change to ensure the UK keeps up with international competition and with the greater industrial shift towards automation. When it comes to a process line, however, there is more to talk about than automation as a wholesale term. Individual aspects of a line can be just as important and need to be considered on their own merits and terms, seeing how those can then incorporate into a larger system. In a sense it is comparable to car in that one would not spend all of their budget on the engine and forget to include and suspension. Naturally this can be a daunting task and also different depending on what a company manufactures. Mixers can be a fairly ubiquitous example within the industry and one that sees much in the way of advancement. Integral in specific food products and necessary in many more, mixers can be big sources of downtime within a process line if they are not up to standard. Food deposits can build up producing not only an impediment to efficiency but also a risk to hygiene within future products. This can then spread to pump and fluid systems causing further problems. Naturally this is a known issue and one that manufacturers of mixing systems have been working on minimising and © Shutterstock /asharkyu 20-25.qxp_Layout 1 26/07/2021 08:18 Page 3Food & Drink International 23 www.fdiforum.net PROCESSING SPOTLIGHT HANDLING FOOD WASTE? NOT ROCKET SCIENCE WITH SEEPEX PUMPS. SEEPEX UK Ltd. sales.uk@seepex.com www.seepex.com Hygienic waste removal from high care to low risk areas Elimination of manual handling, cross-contamination and cleaning Reduced waste volume resulting in lower transport costs SEEPEX open hopper BTM progressive cavity pumps with a feed auger and macerating knives chop and pump food waste in a single operation. Products such as whole fruit and vegetables, peelings and fruit stones; poultry (DOA, heads, feet, necks) and even ready meal packaging are hygienically removed through enclosed pipework from high care to low risk areas. CONVEYING CAPACITY Up to 130 m3/h PRESSURE Up to 24 bar Low energy requirements compared to blown or vacuum systems Produces ideal feedstock for biogas and pet food production, and animal feed Handles a variety of challenging food waste yet a food producer would not be able to reap the benefits of such if they do not look at what changes are available and simply stick with an outdated piece of equipment. It can be difficult to extrapolate results, particularly in an automated line, from a single piece of equipment - which can be both a real issue and a simple excuse for many. In most cases it is better to ask if a trail can take place within a factory, often using your own products as test material. This way the results can be monitored first hand and then estimated across the entire system. Methods of transition between individual pieces of equipment must be considered as well. These are just as important, and perhaps even more so, © Shutterstock /Sergey Ryzhov 24 Á 20-25.qxp_Layout 1 26/07/2021 08:18 Page 424 Food & Drink International www.fdiforum.net PROCESSING SPOTLIGHT than any other piece of machinery. Whether a company makes use of pumping systems in fluid and viscous food material or conveyors and separators for more solid foods, these can be potential flashpoints for problems within a process line as they mark the movement of material from one system to another. Ensuring that your transition equipment is up to date and well-maintained is integral and should be of the highest priority. There is a tendency when something goes wrong to check the larger machinery, but as it is the pumps themselves which see the greatest amount of use, and these should always be a focus point. High quality pumps certainly assist companies in dealing with delicate ingredients in large quantities - but how can they be assured that product build-up isn’t happening to too great an extent? Many manufacturers are now turning to vision detection and inspection for the answer to this, with a view to using x-ray or other inspection technologies to remotely monitor pipes. With capital expenditure budgets remaining tight, increasing numbers of processors are seeking operational improvements that deliver cost savings, increased production levels, enhanced product quality and reduced plant downtime without the financial implications of new equipment. As well as the requirement to speed up processes, the new techniques that are now used can also ensure complete traceability at every part of the lengthy supply chain, allowing inefficiencies to be pinpointed. Computerisation of procedures, together with automation wherever cost justifiable, minimises the risk of operator errors, either because changes to the production line are done automatically, or because in the sampling procedures, operational personnel have no alternative but to follow pre-determined procedures prescribed by management. While software may allow companies to identify flashpoints however, there is still a requirement of addressing these issues to ensure machinery runs smoother and is more energy efficient can prove to have the most noticeable effect on the bottom line. © Shutterstock /Gumpanat 20-25.qxp_Layout 1 26/07/2021 08:18 Page 5Waste is an unavoidable part of the production process at fruit, vegetable and poultry processing facilities. However, some waste products are notoriously difficult to handle. As a result, some operators still rely on traditional methods to remove them from the production area. It is not uncommon to find conveyor belts, compressed air systems, vacuums, water flumes, and manual handling via waste containers such as tote bins being used even at large food production factories. These methods can be inefficient, unsanitary and expensive. Automated, all-in-one alternative Fortunately, there are sophisticated, hygienic and cost-effective alternatives on the market. Seepex BTM pump range is one such option. The patented chopping and pumping solution, featuring an enclosed pipework system, is already being used in waste handling applications at many fruit, vegetable and poultry processing factories throughout the UK and Europe. Thanks to an integrated cutting unit that reduces particle size, the BTM effectively chops and pumps in a single operation, reducing the solids volume by up to 60%. This creates a pumpable consistency, without requiring the addition of water, enabling whole vegetables and even entire birds such as DOA or off- specification chickens to be hygienically and efficiently removed off-site. Hygienic waste removal The benefits to food manufacturers of switching from conventional waste removal methods to an enclosed, automated solution like the BTM are three-fold. Firstly, it is more hygienic. Transferring waste products through a closed pipe system eliminates, for example, the need for dedicated cleaning of tote bins prior to re- entering high-care areas which prevents potential cross contamination. Improved health & safety Secondly, it is safer. Manual handling or conveying systems often result in waste product falling or being dropped onto the floor, presenting an immediate health and safety risk to operatives, who are in danger of slipping on it. Furthermore, this fully automated solution requires only one staff member to load product into the hopper. This leads to improved health and safety on the factory floor due to a reduction in traffic and hazards in high-risk areas – fewer forklift trucks, fewer operatives and fewer tote bins. Cost-saving solution Finally, the BTM pump range is more efficient, generating significant cost savings. By chopping, pumping and transferring all-in-one as the BTM is able to create a pumpable consistency without requiring any additional water, resulting in savings from water usage. This has the additional benefit of reducing the volume of waste by up to sixty per cent, making it easier to transport and thereby cutting transport costs. The operating and energy costs of the BTM are considerably lower than vacuum or compressed air systems, generating savings there. And by removing a manual element from the process and automating it, food producers are saving on labour costs, too, freeing employees for more lucrative, primary production roles. Bespoke options for most challenging waste streams Where more challenging by-products need to be transported, customised solutions are available. ‘Bridging’ can be an issue with certain wastes, so the BTM pump range includes augers with a large pitch that enables the product to be conveyed into the cutting elements to ensure continuous pumping. Hard-to-handle fruit, veg & poultry waste proves easy pickings for SEEPEX BTM pumps www.seepex.com +44 (0) 1935 472376 A sophisticated chopping, pumping and waste removal solution from progressive cavity (PC) pump specialist, SEEPEX UK, is making light work of previously challenging by-products from whole chickens, potatoes and cabbages to peelings and fruit stones. SEEPEX BTM pumps chop and pump in a single operation SEEPEX bespoke waste pumping solutions Food & Drink International 25 www.fdiforum.net PROCESSING SPOTLIGHT 20-25.qxp_Layout 1 26/07/2021 08:18 Page 626 Food & Drink International www.fdiforum.net SOFTWARE AND HARDWARE Boosting output & efficiency With aims of bolstering efficiency, safety and product integrity, firms within the food industry turn to software and connected hardware for insight and control over all aspects of food production and distribution, from forecasting to planning, inventory management, quality control, tracking, logistics, processing and more. © Shutterstock /DedMityay 26-28.qxp_Layout 1 26/07/2021 08:21 Page 1Food & Drink International 27 www.fdiforum.net SOFTWARE AND HARDWARE view of how a firm is performing, ERP’s made for the food industry are vital in streamlining processes. ERP systems created with the food industry in mind are being designed with efficiency, safety, and accountability a priority. The tool can help with regulation compliance, traceability, and quality assurance, while presenting forecasting, planning, inventory, production, and logistics management. The growth of ERPs comes as firms look to ditch the use of various independent platforms, to overcome issues of data integration and disharmony between processes. By consolidating data (production to financial, compliance and inventory data) into one system an aerial view is provided, enabling control of all processes from a centralised point and as a result improved analysis. Features to look out for when selecting a food industry-specific ERP solution should include the ability to integrate with different systems used in different areas of a company, like CRM, and automated regulatory compliance to identify problems when recalls or audit inspections occur and boost traceability by recording ingredients used and the processes they have been through from start to end. It should also provide features like financial management to correctly record costs and expenses, quality management - handling allergen and testing management - automated shelf life alerts, sales and stock management to prevent shortages and spoilage, and recipe control to handle formula, costing and quantity information. One should additionally assess the support and maintenance offered with a solution if problems arise or updates are needed and the intuitiveness of the software. Moreover whether to adopt a cloud-based solution or on-premises option should be considered. In general cloud software solutions have gained momentum alongside the move to SaaS. The focus on offering cloud-based software over on-premises solutions comes as they require a simple web browser for access. Cloud software presents easy access from multiple locations and usually does not require a specific operating system for use such as Windows. In addition, with cloud software, one can bypass the need for servers and support for hardware repair or replacement. Developments in the space continue to see firms move away from standalone software in its complete form to that that evolves with new developments along with the offer of long-term support, and easy updates, i.e. SaaS. SaaS solution applications for the supply chain vary from supplier management to transport and warehouse management, demand planning and more. Seen benefits of SaaS and cloud solutions include software responsiveness, lower total cost of ownership, data security, flexibility, scalability, and connectivity. Innovative software and hardware solutions are being utilised throughout the supply chain. With the rise of the Internet of Things, growing use of its associated sensors and connected devices, and the recognition of its benefits, smart factory software is ready to enhance productivity and visibility in food manufacturing. One way in which this is achieved is through automated real time data collection, bidding adieu to manual, error susceptible collection. Smart factory software solutions allow the collection, analysis and reporting of data in real time to boost accuracy, assure quality and permit data-driven decision making. Reports can be created to save resources and energy, reduce waste, save operator time, improve inventory management, and enable preventative maintenance. Looking closer at preventative maintenance, smart sensors and artificial intelligence (AI) analysis are able to identify equipment anomalies, prevent downtime and increase the lifespan of machinery. In these programmes, engineers can be sent alerts upon the discovery of something out of the ordinary and manufacturers given time to order replacement parts prior to breakdowns. The use of AI here offers a further step into prescriptive maintenance, not only anticipating failures but recommending actions. For instance while with predictive maintenance it can be indicated when, say, a motor is likely to fail based on As a fast-paced industry, food and drink firms are often exploring new solutions to ensure processes run smoothly and to offer the highest quality levels. It is key that firms of all sizes keep a finger on the pulse, making note of the latest software and hardware that will facilitate improvement aims and assist in the winning of major contracts, as well as help retain them. Perhaps the most important, commonplace, system for food and drink firms is an ERP solution, especially as firms look to become more digitised and better react to shifting consumer trends and a growing need for heightened food safety. Standing out as a management tool making use of integrated apps and offering a comprehensive, real time 28 ÁÁ 26-28.qxp_Layout 1 26/07/2021 08:21 Page 228 Food & Drink International www.fdiforum.net SOFTWARE AND HARDWARE vibration and temperature profile, with prescriptive maintenance the impact of motor temperature and speed can be highlighted with suggestions to reduce speed to extend how long machinery can work before a stop. The use of AI-based software solutions, particularly with the AI technique machine learning (ML), has further extended purposes in the food industry, handling the vast amounts of data that can be collected by food firms, for example facilitating more accurate demand forecasts. AI and ML make probabilistic forecasting easier, assessing large amounts of data from internal and external sources: news, events, and weather as well as sales data, inventory amongst other sources to predict demand more confidently and produce what if models for different scenarios. Those dealing with warehouse management can also use these predictions in automated processes that arrange stock for picking based on demand. With more accurate forecasting one can also mitigate the costs of overstocks and being out of stock. The debate of off-the-shelf or bespoke solutions continues to come into play when selecting software and hardware. There are pros and cons to both. Off-the-shelf software offers a ready-made, immediately available product, created for a wider market. It is cheaper, quick to implement, often includes updates and is owned by another party who take on upgrade costs. In addition, reviews of the software usually exist and can be accessed. However, the solution can be inflexible, require compromise, and purchasers have less control. Furthermore, over time support may drop off, and the software may come with more or less features and functions than you require. On the other hand bespoke software, built new to a business’s requirements, comes with advantages such as tightened control of development, increased flexibility, the potential to gain a competitive advantage with a unique solution, a better ROI, a chance to wipe out compatibility issues, and the ability to build in heightened security as a priority. However, bespoke software comes with a higher initial cost due to the time and expertise required for its design and could take months or years to develop. Ultimately cost, time and features will need to be considered to make a purchasing decision. With little budget and time, off-the-shelf will generally be the software of choice. Alternatively if a company needs certain features not covered by off-the- shelf software, developing a bespoke solution will be chosen. Wider software development trends are seeing a rise in vertically aligned industry specific software - aka software not just for the food industry as a whole. A key shift is employing a micro-verticalized food ERP software - a specialised software targeting micro- verticals. More specific solutions hold importance as vastly different companies which fall under the “food and beverage industry business” umbrella - from beer to poultry producers - face distinct problems, demands and regulation. Holding complex supply chains, the technology required by varying businesses in the industry can be significantly different. Food and drink firms should consider partnering with software providers able to meet their particular challenges. © Shutterstock /TRMK 26-28.qxp_Layout 1 26/07/2021 08:21 Page 3Food & Drink International 29 www.fdiforum.net MICROBIOLOGY AND TESTING © Shutterstock /Sergey Mironov Although food safety is possibly the most principal role of microbiology, it is not the only one – a factor which some forget. With the consumer market shifting ever more towards healthy foods, and especially those with probiotic or beneficial microbes and bacteria. It was innovation in this sector which helped lead the push towards functional foods, and the race to identify and corner yet more markets is a continuous one. Microbiology, and the research labs associated to it, are at the forefront of that, while also testing for food safety, contamination and other microbial hazards. One such food hazard that has come to the fore recently is that of contamination due to a shortage of food-grade carbon dioxide, which many food safety regulators fear will lead to increased contamination from non-food-grade carbon dioxide. 2020’s carbon dioxide shortage significantly impacted many businesses in the drinks and meat industry across the EU. It’s anticipated that the use of non- food-grade carbon dioxide will have a relatively low risk to human safety, but the fact that some companies have Under the With stringent requirements and increased focus on foods with microbial benefits, microbiology is more important than ever. microscope 30 Á 29-31.qxp_Layout 1 26/07/2021 08:22 Page 1Next >