< Previous30 Food & Drink International www.fdiforum.net MICROBIOLOGY A wide variety of organisms from bacteria to moulds, parasites and yeasts can contaminate food. With supply chains growing in complexity, opening up more opportunities for products to be impacted by these, and recent high profile cases such as the Romain Lettuce E. coli outbreak and pre-made sandwich Listeria outbreak in the UK, the important role of microbiology, microbial testing and microbiological controls in the food industry has only been heightened. At a time when foodborne illnesses are estimated to be responsible for 420,000 deaths a year globally, manufacturers and retailers must prioritise the prevention of microbiological food poisoning to keep the public safe, and avoid microbiological food spoilage, which causes major financial losses. Increasingly stringent regulations in the food and drink industry, as well as pressure from customers, emphasises the requirement for thorough and accurate microbiology testing to assess production lines and products for signs of infection. Microbiology testing is useful for detecting food spoilage organisms and food borne pathogens as well as observing environmental pathogens, is key in forming a solid food quality and safety assurance program and, as it can be used to identify safety hazards in food, is useful in developing HACCP plans. Pathogen testing is applied across production from screening raw materials to verification of sanitation effectiveness. A plethora of technologies are used to pinpoint microbes in food and the production environment, whether it be mass spectrometry or common culture-based methods. When dealing with the microbiological component of food safety, food companies face the decision of using independent contract laboratories, working collaboratively with them by for instance collecting samples, or completing microbiological testing work in house. In-house testing is praised for improving flexibility and saving time and can allow problems to be caught quicker, as sending sample to an external laboratory delays testing, leaving more time for pathogens to contaminate further products. The initial capital investment however is often of concern when setting up on-site testing, with a high price attached to each system needed for a laboratory, alongside costly maintenance and other hidden costs as well as the price of training or hiring staff to complete specialised work. Further, the quick changing nature of testing is seeing new innovations enter the industry that may change how food testing is conducted and an outsourced lab often has dedicated staff following these developments while in-house labs may be left outdated. Outsourcing microbiology testing, then, is often considered more Playing with pathogens The role of microbiology in the food industry has only been emphasised as recalls rise and outbreaks plague the media. 30-33.qxp_Layout 1 19/08/2019 15:46 Page 1Food & Drink International 31 www.fdiforum.net MICROBIOLOGY © Shutterstock / Festa 32 Á cost effective and there is the assurance that experts are conducting the testing. This also allows food firms to spend more time focusing on other aspects of the company. However, with this choice there is chance of miscommunication, increased turnaround times and the time-consuming element of sending samples. Whichever option is chosen, thorough planning is required. Rapid testing, sub-typing and tracking are essential when dealing with contamination events. Methods of next generation sequencing (NGS) are becoming key in these situations and can be used to sequence whole genomes of pathogenic microorganisms in a sample, offering heightened visibility. An NGS technique rising more in conversations surrounding microbiology in the food industry is Whole Genome Sequencing (WGS), which determines the complete DNA make-up of an organism, mapping it to a database. This allows better understanding of variations between species and differentiation between organisms with a higher level of precision than other technologies. It is used at present for foodborne pathogen identification in outbreaks and in ways that could reduce foodborne illness in the long term. The application of WGS in food safety is in identifying pathogens isolated from samples, whether they be food or environmental, which can then be compared to patients’ clinical isolates to see if a link can be found between the two to identify the extent of an outbreak. Faster than culture-based techniques, but still time consuming, its genomic information sequencing is useful in predicting antimicrobial resistance and virulence, monitoring effectiveness of sanitary controls and monitoring emerging pathogens. The adoption of WGS is said to boost safety levels in the 30-33.qxp_Layout 1 19/08/2019 15:46 Page 230 & 31 October 2019 | NEC, Birmingham Visit the UK’s only trade exhibition for the entire laboratory industry REGISTER FOR FREE www.lab-innovations.com Discover • See the newest products and solutions to keep your lab up-to-speed Learn • Learn how to future-proof your laboratory by making sustainable procurement decisions and identifying the right technology to increase lab efficiency Connect • Schedule meetings with Lab Connect to gain one-to-one insight from industry experts and suppliers Be inspired • Have fun at our keynotes from presenter, physicist and stand up-comedian Helen Arney and synthetic inorganic chemist and presenter Andrea Sella REGISTER NOW MICROBIOLOGY 32 Food & Drink International www.fdiforum.net industry with recent research from Cornell University and the Mars Global Food Safety Centre (GFSC), published in the Frontiers in Microbiology journal, highlighting its usefulness as a consistent detector of salmonella - one of the most common foodborne pathogens which of course has a major impact on public health and can be mild or fatal, depending on the variation. WGS is able to analyse a genome more completely than other sub typing methods, examining the full DNA of an organism at once, and allows a strain of salmonella to be pinpointed more precisely, so that analysts can discover its origin and path quickly in an outbreak. While WGS was previously known as expensive and was only used by a handful of laboratories, the cost is falling and use increasing. WGS also has potential to be automated and is considered more detailed than methods like pulsed field gel electrophoresis (PFGE). Portable WGS devices are also being used and could one day be used anywhere, working off a mobile phone battery. WGS analysis was used by Public Health England (PHE) in the aforementioned Listeria outbreak from sandwiches in the UK and again recently in uncovering a Campylobacter outbreak in Denmark stemming from chicken meat. In the latter case, the type of Campylobacter found in patients was © Shutterstock / Microgen 30-33.qxp_Layout 1 19/08/2019 15:47 Page 3MICROBIOLOGY Food & Drink International 33 www.fdiforum.net Eco-friendly Benchtop autoclaves As many food manufacturing and microbiology laboratories place increasing importance on reducing their carbon footprint and utility costs, Astell Scientific provides one solution in its range of small capacity front loading autoclaves. Astell’s Benchtop range is available in three chamber capacities: 33 litres, 43 litres and 63 litres, and as Classic and ‘Ecofill’ versions. Ecofill Benchtop autoclaves require no plumbing whatsoever - simply plug the unit in to a single phase power supply and fill the integral water reservoir. Once filled, this provides water for up to 15 cycles, and also acts as a collection vessel for condensate and the water that is automatically returned from the chamber at the end of every cycle. Astell Benchtop autoclaves are amongst the lowest power and water consuming sterilisers on the market. For more information, visit www.astell.com/benchtop-range. also discovered in a particular slaughterhouse, to which officials were sent to help track and eradicate the infection source. While WGS has demonstrated its role in outbreak traceability, as it takes several days to receive results, requires high levels of training and despite decreases remains too costly for regular testing, it is not necessarily prime for routine pathogen testing, rather it is to be used as a more investigative tool. Targeted sequencing, which has a turnaround time of less than a day, has instead been recognised as a method of NGS more helpful in this instance for food manufacturers. Its targeted essence means fine tuning is possible for high sensitivity to detect distinct variations no matter if the sample is mixed, pure, liquid or solid. Testing isn't the be all and end all of course, with action needed to be taken on lab results and in-depth prevention methods adopted for a preventative approach to pathogens. Thorough cleaning and hygiene plans are essential, while for pathogen control natural methods to avoid bacteria contamination like bacteriophages are up for consideration as they kill their targeted bacteria without influencing anything else. Nanotech has potential to help in development of antimicrobial ingredients and nano coatings are useful for equipment to stop microbial growth and biodegradable edible films hold potential for killing pathogens on food. Though important in addressing the paramount issue of hygiene and safety it should not be forgotten that microbiology is also key in the production of products from bread to cheese, with fermentation, contributes to production of flavour characteristics and is especially important in the creation of healthy foods like those with probiotic. t.01536 403815 www.sglab.co.uk CONVENIENCE YOU CAN TRUST 4356 QUALITY PRODUCTS FOR MICROBIOLOGY AGARS • BROTHS • REAGENTS • STAINS • BESPOKE MEDIA 30-33.qxp_Layout 1 19/08/2019 15:47 Page 434 Food & Drink International www.fdiforum.net PACKAGING MATERIALS & DESIGN Packaging has long been the determining factor in the success of many brands, and this has changed little in recent years. Consumers may now be more conscious of what they desire, but science still shows that aesthetically pleasing packaging catches the eye. The trick now is in ensuring that once the customer’s attention is caught, they do not put down the product. But with companies beginning to perfect this art, businesses need to compete on different terms. The mysteries of packaging design – if one wants to call them that – are slowly being discovered. What works and what does not is becoming increasingly known, which means businesses need to seek USPs in other ways. Many are looking toward increased investment in machine systems to acquire this USP. This can be a daunting task at first glance. How can a process which is not only going to cost money, but also significant investment in machinery – make the product cost less? The answer is simple and complex at the same time; with good planning. Simply installing shrink-wrapping machinery or palletising processes will do little if there isn’t a bigger strategy behind it, as any within the industry might say. There has to be a view on everything that comes after the point, and what tangible benefit the packaging offers. CHALLENGE after challenge Packaging fulfils more needs than any other aspect of the food and drink chain, keeping our food fresh, hygienic, attractive and secure. But with increased need comes increased responsibility. How are companies staying on top of ever-increasing demands? 34-37.qxp_Layout 1 20/08/2019 11:34 Page 1Food & Drink International 35 www.fdiforum.net PACKAGING MATERIALS & DESIGN This has led to major overhauls of the packaging process in many companies – and some find this a challenge. Investment costs for regulation and legislation will always be a difficult factor, especially with varying standards across the EU. These are necessities that cannot be avoided however, and as labelling is one of the fastest-changing sectors when it comes to changes in legislation, it is something that many are forced to quickly adapt to. Some of the most significant developments to the packaging industry aren’t whole machines, but rather sensors. Given the increased demands from the industry, which need to correspond to changes in consumer taste and habits, as well as legislative changes, sensors need to be up to the task. Therefore, the very latest sensors and sensor systems need to be designed for complex, frequently changing tasks while also meeting ever more demanding brand protection, safety and documentation requirements. Working in conjuncture with sensors is the use of offline case marking. Implementing such a strategy greatly reduces the human error which in turn bolsters efficient practices and decreases the risk of damaged goods and loss. The ability to mark-up secondary packaging offline meets a growing need in today’s grocery market, where the emerging retail channels of discount, convenience and online will account for all the growth over the next 10 years as conventional supermarkets decline. For many food operators, this shift is driving a rapid rise in the complexity of their logistics operations as demand grows for mixed cases and little-and-often deliveries to a wider range of locations. With this in mind, having a supply of boxes that are pre-marked with information about their contents and destination helps minimise the chance of human error as products reach the end of the packaging line. As ever, packaging remains a nuanced and challenging industry. Design Innovative technology is improving in-store performance as well through better print capability. High Quality Post Print has transformed corrugated packaging from protective transit packaging into multi-functional, colourful retail ready packs, without compromising product integrity. Liners and coatings are also being developed for corrugated material to provide even greater food freshness and, with the advent of modern corrugated processes, such as new flutings that offer up to 23% storage space saving, it also offers more efficient logistics management through better use of pallets, resulting in fewer vehicles on the road. Digital technology has certainly provided more flexibility for packaging design, especially as legal requirements have required much more information is on packaging that was previously the case. Many companies have introduced 36 Á © Shutterstock / Gts 34-37.qxp_Layout 1 20/08/2019 11:34 Page 236 Food & Drink International www.fdiforum.net PACKAGING MATERIALS & DESIGN QR codes on their products to allow customers to receive promotional material and much else, while it also has value when it comes to traceability. Combined with this, though, the challenge for products more than ever before is to stand out on the shelves – so the importance of a distinctive, high quality package is emphasised. However, this distinctive nature has to go hand in hand with convenience in distribution and display. While creativity is all-important, products that require distributors to obtain new pallets, retailers to invest in new display units and consumers to rearrange their kitchen shelves are unlikely to prove particularly popular at any stage in the supply chain. Design should also be in the spotlight lately due to evidence from the British Brands Group, who cited a report by Which? that identified some 150 food products which marketed themselves by imitating the packaging of better known brands. Out of the 2,244 people surveyed, 20% admitted to buying a copy by mistake instead of the brand they intended to purchase – highlighting the dangers inherent in a whimsical approach to packaging design. In the study, the key factor which led to the customer’s mistake was seen to be colour, so brands that rely on a distinctive colour scheme could be most at risk. Naturally, older customers also had a higher risk of buying a copy by mistake. While this approach to business may be seen as shameless to some, it is an evolutionary approach used by animals in the wild to avoid predators, often by mimicking the distinctive colours and markings of more dangerous (or poisonous) creatures. Here, the intent is different, but the methodology the same. To know that some of the largest brands in the food and drink industry write off 20% of their market share in such a way is jarring, but there is much that could be done to protect from this, and all of it related to the design of packaging. Although many brands will have a well-known and core identity, it’s never too late to change packaging or update it. The more complicated the design, the harder it is to imitate, and it is important to keep in mind that copycat brands will usually have less funds available than the original. Distinctive shapes are an option for drinks and some packaged goods, especially if it’s a dramatic change that could either be copyrighted, or one that would be too expensive to mimic. For bottled goods, an unusual shape can be one such defence against mimicry. © Shutterstock / MOLPIX dŚĞh<ΖƐůĞĂĚŝŶŐƉĂĐŬĂŐŝŶŐƐƵƉƉůŝĞƌƚŽƚŚĞ ĨŽŽĚĂŶĚĚƌŝŶŬŝŶĚƵƐƚƌLJ͕ŽīĞƌŝŶŐĂǁŝĚĞ ƌĂŶŐĞŽĨƉĂĐŬĂŐŝŶŐƉƌŽĚƵĐƚƐŝŶĐůƵĚŝŶŐ͗ ŝƌ^ŚŽĐŬďŽƩůĞƉĂĐŬƐ WĂůůĞƚǁƌĂƉΘƐLJƐƚĞŵƐ ŽdžĞƐĨŽƌďŽƩůĞƐ >ĂďĞůƐ an employee-owned business 34-37.qxp_Layout 1 20/08/2019 11:34 Page 3Food & Drink International 37 www.fdiforum.net PACKAGING MATERIALS & DESIGN Innovia’s new Strata Film awarded ‘Made for recycling’ quality seal Innovia Films has worked with Interseroh, an independent German recycling and consulting company, to have its newly launched high barrier BOPP Propafilm™ Strata SL film evaluated. The film has been awarded a ‘very good’ rating and has been awarded the ‘Made for recycling’ logo. Interseroh analyse and evaluate packaging based on sound criteria along with the entire after-life processes. The result is a scale which determines whether the packaging is non-recyclable through to very good. Alasdair McEwen, Global Product Manager Packaging at Innovia Films, explains: “This certification proves the recyclability of our new Strata BOPP film. As it is a mono structure, the film performs much better in recycling than composite films and can be added to the PP closed loop and reused.” Propafilm™ Strata SL provides an effective barrier to aroma, mineral oils and oxygen even at high relative humidity levels ensuring increased shelf life and reduced food waste. For more information, email packaging@innoviafilms.com. Recyclable food packaging solutions Looking for a UK- based manufacturer and stockist of fully recyclable food packaging, then look no further as Measom Freer & Co Ltd have been doing just that for over 80 years. The company manufactures a huge variety of recyclable food grade plastic packaging, including bottles and caps in all shapes and sizes ideal for sauces, marinades, oils, food colouring, and dressings. Its bottles range in size from 2.5ml to 1 litre with a huge range of closures to fit including screw, tall, ball, flip, nozzle caps and spray pumps. Jars from 10 – 150ml and small clear boxes are ideal for confectionery, nuts, honey, dried snacks, spices and condiments. Measuring scoops from 0.5 – 150ml and hand scoops in small to large sizes are suitable for grains, coffee, herbs, dried goods and powders. Measom Freer also stock rigid tubes in 5-25ml suitable for seeds, cake decorations, confetti and spices. For more information, visit www.measomfreer.co.uk. Plastic free – plastic reduction from National Flexible National Flexible invite you to consider the future of flexible packaging. The Academy is the perfect forum for packaging professionals to source the latest information of sustainable film and plastic packaging reduction. Some of the currently enrolled participants include Premier Foods, Hovis, Jordans and Greencore. “Keep up the good work. Keep pushing this, it’s important for everyone to understand!” said Steve Fletcher from Premier Foods. To find out more, visit www.nationalflexible.co.uk. Why not join us as a customer and become part of our culture? Many years ago, packaging supplier, National Flexible, asked everyone in its company to think of one word which best described how it works with its customers, suppliers and each other. The most common responses were: ‘Caring’, ‘Sharing’ and ‘Being Different’. “National Flexible are brilliant problem solvers. Their technical and logistical help is invaluable to us. They are a welcome extension to our team,” said Paul Wilson from TAG (Kinder). A company is only as good as its customers and 100% of National Flexible customers would recommend them as a supplier – as can be seen in a 2018 Customer Survey. For more information, visit www.nationalflexible.co.uk. 34-37.qxp_Layout 1 20/08/2019 11:34 Page 438 Food & Drink International www.fdiforum.net LOADING BAYS AND DOORS Loading bays and doors are rightly considered the first obstacle a company faces on the food and drink supply chain. Whether finished products are coming straight from the manufacturers to the warehouse, or from suppliers to the manufacturing plant itself. This is the first point at which savings in terms of time and efficiency, can realistically be made. It is perhaps unsurprising then, that despite the relative lack of excitement in loading bays and doors, that the industry is considered so important. The requirements of a company will likely always depend upon the size of the operation at hand. With larger companies often creating dedicated loading bays for trucks and lorries, while smaller-medium sized distribution centres favour the versatility of container ramps. Despite that, however, there are always a number of aspects which will remain integral to all companies in the food and drink industry. One such example is tools to prevent the ingress of weather. No matter what you’re transporting, and how safely packaged it is the last thing you want in a factory or warehouse is snow, rain or other weather conditions forcing their way inside. The obvious concern here will be damaged goods and potentially ruined perishable food products. But wet or icy conditions can also prove a danger for the staff working at the site. With heavy duty vehicles, heavy stock and materials handling equipment scattered around, a loading bay is perhaps one of the worst places for an employee to have a nasty trip or fall – so having as sealed an environment as possible is necessary. Traditionally companies might use dock seals and extendable shelters to cut out the inclement weather, but more advanced bays might have modular functions that mean the trailer actually comes further into the warehouse, leaving only the front half of the vehicle to become wet. Dock seals and shelters can also help protect ambient temperature loss, not only protecting cold storage facilities, but also reducing energy bills in terms of lost heat, or refrigeration. Another area which seems to prove prevalent across all business sizes is the need for some kind of buffer or protection for the building itself. Reversing vehicles can do an untold amount of damage if they manage to connect with the building itself. And no matter how skilled the driver, accidents can and will happen. Dock bumpers are a common method of mitigating this, allowing for some level of error to be made – but some companies are now looking more to alignment curbs to achieve a better result. Clearly these do not do much to prevent the vehicle from continuing to reverse into the building, but they do subtly correct and adjust the angle of the approach. The first obstacle As the first step in the supply chain, it’s important to get the loading process down, as efficiently and safely as possible. 38-40.qxp_Layout 1 19/08/2019 16:12 Page 1Food & Drink International 39 www.fdiforum.net LOADING BAYS AND DOORS Ensuring that not only does the vehicle hit the bumpers, but also can reverse quicker into the bay, saving the unloading teams more time. It’s not just arrival that presents problems for the workforce however, there have been numerous cases of vehicle drivers departing too soon, perhaps misinterpreting a signal. Or perhaps a signal to leave was given at a wrong time. In either case, the threat to the workforce as well as the products themselves can be high, particularly given that all loading bays are a few feet off the floor at least. Given the heavy machinery and materials handling equipment that is used to remove goods from the back of a lorry, the injuries staff might receive if all of it suddenly shifts can be fatal. There are a few preventative measures which can be included here, from simple wheel locks, to more complicated vehicle restraints – which can only be removed by the warehouse team, once the all-clear is given. Ultimately though, it is better communication that prevents more accidents in this manner. As always human interaction is the biggest factor for mistakes, and it is easy for a person’s words to be misheard in a busy environment. Visible signals, including lights or signs is often more effective. And these should only be activated once the entire team is clear of the vehicle and bay. When it comes to doors itself, focus should be placed on efficiency wherever possible, and it is surprising to many in the industry, in terms of just how many options are available. The key here is to look at the requirements of the company in question and choose a solution which suits. In terms of pure efficiency, the speed at which a door opens will likely be one of the bigger concerns. Enabling staff to access the docked vehicle as soon as possible, while also ending the process sooner so that the vehicle can depart. Roller shutters remain a popular choice here, and with recent technological advancements, the speed at which these can open and close is becoming ever increasing, with some models now opening at over 30cm a second. An added benefit of a door which opens and shuts faster is also that it reduces energy lost in terms of temperature 40 Á © Shutterstock / Pavel L Photo and 38-40.qxp_Layout 1 19/08/2019 16:13 Page 2Next >