< Previous30 Food & Drink International www.fdiforum.net POUCH PACKAGING Quality bag sealing & heat sealing machines from RM Sealers RM Sealers, UK’s leading bag sealing machine and heat sealing machine manufacturer, began its business life in 1969 under the name of RM Tool Company. Having built a formidable reputation as high quality mechanical and design engineers, they were approached by Doboy in the early 1980’s to exclusively design and manufacture their BD range of Rotary Band Sealers for them. The Doboy bag sealing machines were subsequently rebranded under SIG and Bosch, and now are exclusively supplied through RM Sealers. The company is still able to offer a spare parts and maintenance service for all the machines which are still in use today under and branded under either the Doboy, SIG, Bosch, OK International or RM Sealers name, a testament to the longevity of our bag sealing machines. RM Sealers has more recently increased its market share by venturing into International and European countries such as Ireland, Iceland, Holland, Saudi Arabia, Singapore, America and South Africa. To find out more, visit www.rmsealers.co.uk. have also emerged over the last few years to improve the industry’s green credentials. For producers, the benefit of pouch packaging is first and foremost its versatility. As the most flexible and adaptable type of packaging on the market, shape, size and materials can all be adapted to meet specific customer requirements. They also use fewer resources to produce than other common types of packaging such as plastic tubs and tins. They are also incredible durable as they’re often made from laminated polyethylene terephthalate (PET) that can stand up to high pressure and temperatures. This makes it ideal in transit, but also means it’s ideally suited to microwavable cooking, making it a popular choice for ready meal foods such as rice, pasta, cous cous and quinoa. High barrier pouches, meanwhile, employ a protective layer which keeps outside elements from entering the package. It’s also not just in terms of materials where pouches have an advantage over other types of packaging, but they boast reduced retort and serialisation time compared with glass bottles and metal tins. As well as the convenience inherent with flexible pouches, another big draw is the vibrancy of pouch packaging. Designed either to stand upright or hang, pouch packages are easy to pack and display on store shelves. Some might have a clear window allowing consumers to see the product inside, but typically the entire package is the label, offering producers a big canvas to work from. Pouch packaging offers full front image, rotogravure quality printing and improved print quality, but there’s no added cost for extra labelling, as everything is included on-pack. Because of its strong shelf appeal and immediate impact with consumers, these packages also mean that smaller producers and start-ups can compete with major industry players. The consumer demand and industry ubiquity of pouch packaging has led to manufacturers having to increase their production output to keep up. This, in turn, has meant machine makers have had to supply ever more innovative equipment. Some filling machines now boast speeds of 120 pouches per minute and this will only increase. Machine makers have also noted an uptick in orders for bespoke, integrated systems designed to suit their exact needs. © stock.adobe.com/Annartlab 26-31.qxp_Layout 1 22/07/2022 14:50 Page 5Food & Drink International 31 www.fdiforum.net CHILLED PACKAGING SOLUTIONS kitepackaging.co.ukpowered by employee share-ownership 02476 420065 Corrugated Insulated Box Liners Water Ice Packs, Gel Packs & Ice Sheets Temperature Controlled Pouches Recyclable & biodegradable KƉĞƌĂƟŶŐƚĞŵƉĞƌĂƚƵƌĞ ͲϮϬȚƚŽͲϯϬȚ ŽŶƚĂŝŶƐϯϬйƌĞĐLJĐůĞĚĐŽŶƚĞŶƚ &^ĞƌƟĮĞĚ ϭϬϬй Keeps content chilled for ϯϭŚŽƵƌƐ ks, Gel heets ƚƵƌĞ 26-31.qxp_Layout 1 22/07/2022 14:50 Page 632 Food & Drink International www.fdiforum.net MATERIALS HANDLING Handle with care © stock.adobe.com/paulacobleigh Handle with care 32-35.qxp_Layout 1 22/07/2022 14:52 Page 1Food & Drink International 33 www.fdiforum.net MATERIALS HANDLING T he most obvious benefit of a materials handling system is it eliminates the damage and loss caused by human error. Yet, beyond this, a truly well managed system can increase efficiency, reduces handling costs, and facilitates stock management and process flow. Understanding how to increase efficiency with materials handling is useful to know, even if you intend to use a third-party warehousing partner, so as to make an informed investment. Key efficiency indicators include time sensitivity, storage temperature, the sealants utilised and accessibility of stock. All of these combine to determine the speed at which the materials can be processed, and the quality of the end product. Given that Unplanned Downtime, Yield, and Inventory Turnover are amongst some of the most common Key Product Indicators measured by food and drink manufacturers, it can be seen how efficiency with materials handling can improve these indicators. If outsourcing your warehousing is the best way to go, it is firstly important to ensure that your warehouse is accredited by the British Retail Consortium (BRC), as this is the gold-standard in ensuring that the warehouse is food grade. This means that safety and manufacturing processes are suitable for consumable products, meaning it is more likely that output will be at the desired pace and of the desired quality. Why is this important regarding materials handling? Their evaluation processes include the evaluation of Management of suppliers of raw materials and packaging and Layout, product flow and segregation, both of which cannot pass these stringent tests without quality materials handling systems. For raw materials and packaging, these could include a receptional unit which funnels into a pre-calibrated furnace to batch cook. This ensures the least possible amount of material waste, and consistency across cooking methods. The output would then feed onto a fully automated conveyor belt system, for transportation to packing robots, and from there a chute conveyor to transport the packaged products towards deposition departments. Alongside these processes would be a quality control system to ensure consistent output. Here, it is recommended that some human interface with the materials handling system occurs, to prevent system failure and outliers. It has been found that when workers are assigned purely for quality control roles, they are greatly efficient, as this is the subject of their undivided attention. The lack of human interference here In a modern world, the supply chain process in food manufacturing cannot survive without efficient and well-planned materials handling. 34 Á 32-35.qxp_Layout 1 22/07/2022 14:52 Page 234 Food & Drink International www.fdiforum.net MATERIALS HANDLING would help to pass the stringent sanitisation tests required for BRC accreditation and ensure a timely and continuous flow across the production process. This is especially required in the food and beverage sector, as it is subject to the ever-changing consumer preferences, and thus a requirement to keep up with change. Automated materials handling systems allow for flexibility within the supply chain, as when a new product is introduced, it is merely a case of recalibrating machinery. If flexible walls were installed in conveyor belts, this would allow for easy manoeuvrability around the warehouse if operations were to be moved, scaled up or scaled down, without significantly increasing downtime. Given the exponential demand for packaged snacks, ready meals, and flavoured drinks, this has necessitated efficiency within materials handling, as the long-lasting nature of these products means that businesses can expand their operations. With increased operations, increases the need for accuracy, food safety stringency, and cost-saving process. For example, frozen pizza is one of the best-selling pre-packaged food products. In fact, more than 350 million tons of frozen pizza is consumed yearly in the US. This requires finely tuned material handling of fresh dough, dairy and other common ingredients. Batch handling systems need to be employed, in a timely manner and without damaging the inventory, such as the automated system above. This is precipitated by a leading trend for convenience stores to provide fast-food services such as frozen food and ready meals. This increases the turnover required at manufacturing level. Once manufactured, the question turns to how to transport the packaged food (such as frozen pizza) around the warehouse. With the rise in mutli- product warehouses, so too has been seen a demand for Automatic Guided Vehicles (AGVs) to transport workers and products across the vast expanse of depot. They remove the requirement for manually operated forklifts, lessening costs for hiring workers who are qualified to operate such machinery. AGV’s can also operate for 24 hours a day. They utilise Artificial Intelligence to drive across pre-determined routes, pick up material, and transport it to another pre-determined destination. This decreases time delays, and the risk of misplaced goods, as a tracking system is integrated, which can be reviewed on a cloud-based system. AGVs are expected to reduce workplace accidents significantly, as driving automated paths and the ability to inter communicate with other AGVs reduces likelihood of collisions. It is estimated that 25% of injuries in the workplace are caused by contact with objects and equipment and reducing © stock.adobe.com/Sergey Ryzhov © stock.adobe.com/standret 32-35.qxp_Layout 1 22/07/2022 14:52 Page 3Equipment Design for Storing and Discharging Bulk Materials Advanced Short Course for Industry: Assessment of storage and handling requirements of bulk materials for drawing up specifications and designing hoppers and silos 26 – 27 September University of Greenwich campus, Medway This course is aimed at project engineers involved in the detail specification of bulk handling schemes or design engineers involved in the construction of equipment used for storing bulk materials. wolfson‐enquiries@gre.ac.uk +44 20 8331 8646 www.bulksolids.com Food & Drink International 35 www.fdiforum.net MATERIALS HANDLING the need for manual handling across the production process, underscores the impact of automated vehicles in reducing these incidents. Although the above examples of materials handling may appear futuristic and out of reach, they are more common than ever. America’s leading drinks company, the Dr Pepper Snapple Group, has over 100 warehouses and distribution centres across the States, which is unmanageable without materials handling processes. These systems are increasingly being adopted by smaller businesses wishing to upscale, or simply improve efficiency. Whatever your businesses’ standing, it is undeniable that beginning to introduce materials handling systems will increase the efficiency, safety, and quality across your supply chain. In fact, given their effectiveness, they may become compulsory to install. 32-35.qxp_Layout 1 22/07/2022 14:52 Page 436 Food & Drink International www.fdiforum.net READY MEALS A 2022 study predicted that the global ready meals market will be worth $225 billion by 2030, experiencing a 6.8% annual growth over a decade. The demand is driven by convenience and desire for timesaving, busier lifestyles, and feeling the financial pinch. Yet, ready meals are considered amongst the worst meal choices for health, stuffed with preservatives and other unspecified chemicals. Here, we aim to explore the trends for healthy options across the ready meals market, and other strong and developing trends to get ahead of the curve. A consistent presence within the market, the frozen pizza segment is expected to dominate the market over the next decade. Alongside this, demand for chilled pizza is anticipated to grow. This is due to consumer demand for fresh, yet convenient, offerings for a guilt-free meal. There are efforts to educate consumers on improved nutritional value of frozen pizza, increased variety (such as vegan options), and the ease of cooking. These are expected to pay off and supplement market growth. In fact, frozen and chilled pizza sales accounted for a third of the global ready meal market in 2021. Important to note is the role that stores will continue to play across this period. Research suggests that consumers prefer to shop for food from stores rather than online portals, due to the ability to physically choose based upon individual item appearance. This is important for manufacturers looking to diversify their suppliers – do not overlook stores. Feeding into this is the international outlook of the market. Europe currently leads in demand for ready meals, accounting for approximately one third share in 2021. Key players including Lincolnshire- based Bakkavor Foods Ltd are aiming to increase their share of the European market via launching a specific range of products there. Beyond Europe, the Asia-Pacific is expected to achieve the highest growth by 2030. Of that market, China will occupy more than 50% of that growth. Not to be overlooked, India is also expected to grow by 12.6% in that same period. The increased globality of the ready meals market means one crucial thing – ranges will have to be expanded to accommodate international tastes and cultures. Meals on the go With the cost-of-living crisis hitting many hard, particularly those in rural communities experiencing extortionate fuel bills for simply getting anywhere, sometimes ready meals can be the best option for families under pressure. 36-39.qxp_Layout 1 22/07/2022 14:54 Page 1Food & Drink International 37 www.fdiforum.net READY MEALS Young consumers typically dominate the ready meal market, which has increased demand for canned and dried product ranges. From 2020 – 2027, canned meals are expected to expand the fastest. This is due to the convenience and longevity of the product, whilst having the ability to retain healthy protein, carbohydrates, and fat that other ready meal types do not have. A traditional favourite of students, instant pasta and noodles are the biggest offering from the dried foods segment. The U.S., China, India, and the UK provide the largest demand for these products. In the UK and US, a rise in demand for Korean and Chinese dried products such as ramen has been seen amongst teens and young adults. Important to this trend is the notion of authenticity, so those looking to expand their ranges must source and manufacture these products similarly to the country of origin in order to truly take advantage. Precooked offerings tick the convenience requirement for families, and they help save time and effort required for meal preparation. This has led to an increased demand for healthier ready meals, especially among the working population and students across the globe. Ready meals are a cost-effective alternative as they are precooked, but noticeably unhealthy. This has resulted in an upsurge in the 38 Á © stock.adobe.com/Prostock-studio 36-39.qxp_Layout 1 22/07/2022 14:54 Page 238 Food & Drink International www.fdiforum.net READY MEALS We specialise in Halal Certification of Food Ingredients, Beverages Dairy, Confectionery, Flavourings, Colourings, Pharmaceuticals, Toiletries, Cosmetics and other non-food items. We also certify Meat, Poultry, Slaughtering, Cutting, Portioning, Processed and Ready Meals for national and international markets. www.halalfoodauthority.com | info@halalfoodauthority.com | 0044 (0) 20 8446 7127 LONDON - IRELAND - BELGIUM GLOBALLY RECOGNISED SINCE 1994 Halal Food Authority SYMBOL OF TRUST & AUTHENTICITY number of delivery services available such as Hello Fresh, as they deliver all the ingredients for your meal for the exact number of people you need (as specified by you at the point of ordering). This has increased exponentially in popularity as it is convenient, and environmentally friendly in packaging (it comes in a brown paper bag without cellophane wrapping on the ingredients). Yet, it is fairly expensive, with packages priced at around £30, so many people choose to do this once or twice a week, rather than nightly. Given this trend, a noticeable gap is between convenient and cheap food delivery services (such as Deliveroo) and the desire for healthy, yet quick food. Food Ingredients First, a food development publisher, has founded a guideline on how to increase healthy offerings in ready meals. This includes the continuous utilisation of alternative grains such as quinoa and spelt to manufacture commonplace products such as pasta. These can also be used as “star ingredients” for side dishes, such as polenta chips. Other suggestions include using clean label fat replacers, increasing fibre within products, and using saltwell as a salt alternative (a low-sodium rock salt that looks and tastes identical). Finally, involving consumers within the recipe refinement process will help understanding of how to marry up flavour and convenience demands with healthier ingredients. The ready meals sector is also expanding beyond the home cooking market. Many schools rely heavily on pre-cooked meals to cut costs and the time for cooking a meal from scratch. For instance, in September 2020, FiveStar Gourmet Foods ltd launched the Simply Fresh2GO ready meals © stock.adobe.com/nblxer 36-39.qxp_Layout 1 22/07/2022 14:54 Page 3Food & Drink International 39 www.fdiforum.net READY MEALS စထထ ႅဈဈ#င%စဉထဓဇဒဇထဒဒ *+ product line to deliver both in retail and school food services channels. The meals are designed to meet strict national school lunch dietary standards. It maintains that each item in the line has a balanced complete meal including protein, grains, fresh vegetables, and fruits. The ready meals market, already booming, is set to grow exponentially within the next decade. Key trends are healthy foods, environmentally friendly packaging, and international dishes. Beyond this, sensitivity will have to be considered regarding religious and cultural requirements from new ranges. With the market set to grow even further, businesses are looking into as yet unexplored areas to market the ready meal products. The combination of demand for healthy food, and the increasing demands in places such as schools and offices provide ample opportunity for expansion. © stock.adobe.com/Glen 36-39.qxp_Layout 1 22/07/2022 14:54 Page 4Next >