< Previous20 Food & Drink International www.fdiforum.net PROCESSING SPOTLIGHT The leading UK Manufacturer of Forklift Truck Attachments Call Us On +44 (0) 1686 611 200 | sales@forklift-attachments.co.uk | forklift-attachments.co.uk With over 50 years experience in the food and drink industry, we promise a personal service that offers quality, value & innovation. thin in an environment of inflation for most aspects of production, from energy to materials, and at a time of slowing consumer demand due to rising living costs. Additionally, as a fast-paced sector where food and drink manufacturers typically expect a quick return on investment (ROI) — within 18 months to two years according to the FDF — the business case for longer- term investment is more difficult in comparison to other industries. The lack of skilled labour to identify opportunities and use new tech is also problematic in integrating digital technologies, while a culture of resistance to digital transformation among current employees poses challenging. Strategic investment and close collaboration are recommended as a step to overcome these issues, but in such a volatile environment, the food processing sector requires greater help to support the uptake of technology; it needs investment and the backing of governments to create the conditions that will aid the industry’s evolution. Positively, strides forward are being made, with the Food and Drink Technology Taskforce launched in the UK at the end of 2024 seeking to unite business, technology providers, academics and financial organisations to drive new initiatives to support technology integration, work with government to solve challenges and create the right environment for adoption, and unlock the investment to future-proof food and drink manufacturing. © stock.adobe.com/Thapana_Studio 'GQ WDVXG &(53 7*1,;,0 12,6,& /21+&( 1 <*2/ K3VFLWHPVR&VHJDUHYH% GRR) VL'QRLVQHSVX6VGLOR6JQL[L0JQLGQHO% RFVUH[LPHDZZZ HUR0UHYRFVL' Q,VWQLD3VODFLPHK&ODFLWXHFDPUDK QRLWDVLOLEXOR6QRLWDVLQHJRPR+QRLVUHSV P VQLVH5 VNQ QRLWDFLILVOXP DW6 QL) ( StandD26 www.gilwood.co.uk +44(0)1706360131 YOUR &FOOD FACTORY SOLUTIONS OURRANGE SpecialistFabrications HygienicFoodFactoryProducts &FOOD YOUR PARTNERIN PROCESS PLANT &FOOD +44(0)1706360131 SpecialistFabrications PressureVeVVssels HygienicFoodFactoryProducts MechanicalHandling Conv Findusat: veyorSystems22 Food & Drink International www.fdiforum.net SOFTWARE AND HARDWARE © stock.adobe.com/Quality Stock Arts Smart systems reshape how businesses compete Food & Drink International 23 www.fdiforum.net SOFTWARE AND HARDWARE B ehind every reliable product on the shelf lies a production process that’s growing smarter by the day. In a sector where consistency, speed and traceability are non-negotiable, software and hardware are no longer support tools. They’ve become the backbone of operational excellence and a quiet but decisive factor in winning contracts. Food and drink manufacturers are deploying technology to stitch together every part of their operations. In highly competitive environments, delays or defects aren’t just operational issues. They can cost relationships, contracts and future business. So the logic must be, businesses that can demonstrate tighter oversight and greater consistency are better placed to secure and retain commercial partnerships. One of the most notable shifts in recent years is the integration of factory-floor hardware with cloud-based analytics platforms. Temperature, pressure and humidity sensors once fed into siloed control systems. Now, they sync with central platforms to give real-time performance data. Operations managers can track shifts in product quality as they happen, and respond before small deviations become large-scale recalls. That immediacy protects the product and strengthens a business’s ability to prove compliance across multiple regulatory environments. There’s also increasing interest in machine learning models that flag potential equipment failures before they happen. Predictive maintenance isn’t just about reducing downtime. In food manufacturing, it helps ensure that lines stay hygienic, calibrated and safe, which, in turn, Food and drink manufacturers are turning to smarter software and hardware to boost efficiency, guarantee product integrity and meet growing demands for traceability. In a fast-moving market, the right tech setup is becoming a key factor in securing contracts and staying competitive. 24 Á © stock.adobe.com/AgusDLaksono24 Food & Drink International www.fdiforum.net SOFTWARE AND HARDWARE protects product integrity. Fewer unexpected stoppages also translate into better scheduling, reduced waste and more confidence in delivery timelines. For customers placing high-volume, high-value orders, that assurance matters. Beyond the factory floor, enterprise resource planning software continues to evolve. But the most effective systems are those that don’t sit in a back office. They’re designed for use by operators, line managers, procurement officers and logistics coordinators. The best-performing businesses are those that have moved away from legacy systems that don’t talk to each other and invested in integrated platforms that provide a single view of everything from batch numbers to customer complaints. Whether they’ve opted for a tailored solution or a modular, off-the-shelf product, the advantage comes from clarity and coordination. The rapid development of digital twins is another notable trend. Manufacturers can now create virtual replicas of their production lines, simulating the effects of process changes, recipe tweaks or equipment upgrades before implementing them in the real world. This allows for safe, low-cost experimentation — particularly useful when seeking to scale up production for a new retail or foodservice client. It also helps teams understand how small changes impact throughput, resource use and waste, without putting a real order at risk. Traceability has become a front-line concern, especially as retail buyers and regulators demand more transparency. Businesses are building traceability frameworks that go beyond the product itself, logging environmental data, transport conditions and even digital records of cleaning and sanitation. This level of data capture isn’t only for recall purposes. It’s increasingly seen as a differentiator in competitive bids. With margin pressures high, buyers are more likely to partner with suppliers who can offer a robust audit trail without added friction. Artificial intelligence, while still under cautious adoption in many food businesses, is starting to show its strengths. Forecasting © stock.adobe.com/KMFood & Drink International 25 www.fdiforum.net SOFTWARE AND HARDWARE tools powered by AI can now factor in far more variables than traditional models. For many businesses, this helps prevent overproduction and underutilisation, both of which have financial and sustainability costs. On the factory line, computer vision tools are now used to spot defects and inconsistencies in shape, size and colour, automating what was once a slow, manual check. That doesn’t eliminate the need for human oversight, but it gives quality control teams more time to focus on systemic improvements. When it comes to logistics and delivery, hardware investments are being paired with smart routing software to ensure cold chain integrity and reduce emissions. Businesses are implementing fleet management tools that account for vehicle location, load temperatures, delivery windows and even driver rest times, all in real-time. For businesses supplying multiple buyers across various retail and foodservice channels, this level of control ensures they remain a low- risk, high-reliability supplier. It also makes it easier to calculate and reduce the carbon cost of each delivery, an increasingly important factor in procurement decisions. A key factor across the board is interoperability. Food and drink businesses work within complex supply chains that include raw ingredient suppliers, co-packers, third-party logistics, retail buyers and regulators. Systems that can’t export data easily or share information across platforms quickly become a bottleneck. That’s why modern infrastructure prioritises open APIs, mobile accessibility, and cross-system synchronisation. It’s not enough for a business to have visibility over its own operation, the value lies in being able to demonstrate that reliability upstream and downstream too. The pressure to digitise isn’t just a technical one. It’s commercial. Retail buyers and distributors are placing increasing value on suppliers who can demonstrate operational control, product traceability, and responsiveness to change. Technology makes a business more credible. That matters in an environment where contracts are hard-won and often short-term.26 Food & Drink International www.fdiforum.net POUCH PACKAGING P ouch packaging has become a familiar sight across supermarket aisles, but its rise goes far beyond surface appeal. For food and drink manufacturers, the shift reflects mounting pressure to optimise operations, reduce environmental impact, and respond to changing consumer habits, all without compromising performance. The benefits begin with logistics. Compared to rigid containers, pouches are lighter, take up less space, and allow more units per pallet. That translates into reduced transport costs and lower emissions, which are critical advantages as distribution networks grow more complex and sustainability targets tighten. With retail margins under pressure, every gain in efficiency counts. The format suits today’s consumption patterns. Resealable and easy to handle, pouches support on-the-go lifestyles, single servings, and food waste reduction. Whether it’s pureed fruit, ready meals, sauces or protein blends, flexible packaging enables better portion control and longer shelf life once opened. For foodservice providers, it simplifies storage, streamlines usage, and cuts spillage. Sustainability, long a sticking point, is beginning to shift in pouches’ favour. Traditional designs relied on multi-material laminates that posed major recycling challenges. Now, producers are developing monomaterial solutions, especially polyethylene-based pouches—that meet barrier requirements while remaining recyclable in standard streams. These changes align with EPR frameworks and help brands stay ahead of upcoming regulations. 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.uk Packaged to perform Packaged to perform Why are food and drink manufacturers turning to pouches to meet the demands of modern consumers and complex supply chains? 28 ÁFood & Drink International 27 www.fdiforum.net POUCH PACKAGING © stock.adobe.com/Sergey Ryzhov BENCHTOP BAG SEALING MACHINE IMPULSE BAG SEALING MACHINE HORIZONTAL BAG SEALING MACHINE VERTICAL BAG SEALING MACHINE28 Food & Drink International www.fdiforum.net POUCH PACKAGING Some manufacturers are trialling refill models using flexible pouches, appealing to consumers who prioritise minimal packaging. Though still niche, refill formats are gaining traction in D2C channels, where packaging is less about shelf impact and more about function, weight, and waste reduction. Automation has played a significant role in accelerating uptake. Filling and sealing machines compatible with pouches are now more affordable and adaptable, opening doors for smaller businesses and co-packers. That’s reshaping production lines and allowing quicker responses to market demand without costly infrastructure overhauls. There’s also been a marked improvement in how pouches look and feel. The latest designs use soft-touch finishes, gusseted bases, and high- resolution graphics to present a premium image. Clear panels highlight freshness. Textured films reinforce brand identity. These small details help reposition pouches from budget-friendly to high- quality. In the drinks category, innovation is moving quickly. Pouches are appearing in areas like cold brew, cocktails, and energy blends. They’re not yet a replacement for cans or bottles in carbonated drinks, but they are filling gaps in functional and wellness beverages. Convenience, durability, and controlled dosing make them attractive for active consumers and parents alike. © stock.adobe.com/Synthesia Studiopackaging as an afterthought. It’s now integral to how a product moves through the system, from factory floor to consumer kitchen. Pouches meet multiple demands across that journey, efficient to produce, economical to ship, convenient to use, and increasingly, easier to recycle. The rise of pouch packaging reflects a shift in mindset. It’s not just about shelf presence or cutting costs, but about designing packaging systems that work across the full lifecycle. As technical challenges get solved and recycling infrastructure improves, flexible packaging is fast becoming a default, not a compromise. For manufacturers balancing performance with pressure, the pouch delivers. Material reduction continues to be a strong argument in favour of the pouch. Rigid alternatives often use far more plastic and create more waste, even when recyclable. With growing scrutiny from both regulators and retailers, manufacturers are prioritising packaging that achieves more with less. The pouch hits that brief. Online shopping is adding further momentum. Products that travel better survive longer. Pouches are tough to crack, easier to pack, and less prone to damage than glass or rigid containers. For D2C brands focused on subscription models or cost-effective fulfilment, flexible packaging provides a clear commercial edge. Food manufacturers no longer treat Food & Drink International 29 www.fdiforum.net POUCH PACKAGING Cold chains bring their own challenges. Pouches are more vulnerable to puncture and leakage, especially when frozen or jostled during transit. But manufacturers are mitigating risks with stronger laminates and better seals. Products that once required bulky packaging can now be pouch-packed and safely stored with minimal footprint. The perception barrier still exists in some categories. Certain demographics associate pouches with disposability or low value. That’s beginning to change as high-end brands embrace flexible packaging as part of a minimalist, performance-driven product identity. Smart packaging cues—understated branding, clean lines, and practical features, are helping to shift the narrative. ationmarking innov winning coding &d-arwA ✓ ✓ ✓ O nt CLowest T ug & PrinPl y dear no-maintenance by5-esign © stock.adobe.com/New AfricaNext >