< Previous40 Food & Drink International www.fdiforum.net MEAT, POULTRY AND SEAFOOD Shifts in shopping habits, extreme weather conditions and concerns over sustainability have caused the meat, poultry, and seafood industry to consider the need to diversify operations. As one of the hottest summers on record draws to a close, its impact on meat production has become apparent. Extreme heat has led to diminishing livestock returns. Experts have voiced concerns over the potential for farmers to have to consume their own feed stocks over winter, as crops have become harder to cultivate in extreme temperatures. Sky high fertiliser prices due to the crisis in Ukraine, and a warmer than average spring means that options for farmers are already limited. This is compounded by the fact that the British Meat Processors Association (BMPA) anticipates that, due to this, a high percentage of their offerings will be underdeveloped. This is likely to cause issues with meat processing and will make it difficult to fulfil orders. Climate change is likely to mean that the meat industry will face a challenging autumn. The cost of refrigeration is causing issues for the production and sales of chilled meats. Keeping their products cold in the face of extreme heat has caused supply chain costs to skyrocket, due to the increased need for refrigeration and the current cost of energy. Tom Southall, Cold Chain Federation policy director, recommends increasing inspections and maintenance to reduce heat ingress to keep equipment running as efficiently as possible, thereby reducing running costs. So what can farmers implement to secure their future in increasingly uncertain climates? Vertical farming, a fairly new concept, is an option for farmers concerned about sourcing key ingredients. Crops are grown constantly indoors, within a climate controlled environment, meaning they are not exposed to heatwaves and therefore do not require extra resources to successfully cultivate. Vertical farming Sustainable meats With meat and fish under the microscope when it comes to environmental impact, the industry is having to adapt to a world in constant flux, and heat waves across Europe have done little to help. 42 Á 40-43.qxp_Layout 1 31/08/2022 10:02 Page 1Food & Drink International 41 www.fdiforum.net © stock.adobe.com/ nadianb 40-43.qxp_Layout 1 31/08/2022 10:02 Page 242 Food & Drink International www.fdiforum.net MEAT, POULTRY AND SEAFOOD comprises of small-scale, efficient systems that run indoors, meaning that farmers and food manufacturers can easily integrate them into existing production facilities. A prime example of vertical farming success is Scunthorpe- based Jones Food Company. Hosting 26 tennis courts worth of production availability, the efficiency of the system means that it is able to operate with a staff of six – thus reducing one of the biggest costs for the industry. Another bonus is the significant reduction in carbon required to produce. Water can be reused, therefore saving water and water costs. It is estimated that this could reduce water consumption by up to 95%, compared to traditional farming methods. Integrating vertical farming could be a way for meat and poultry farmers to increase the availability of crops, thereby reducing the potential to have to eat into their own stocks. Furthermore, the ease at which these systems could be integrated, plus the low labour that they require could provide the opportunity for a side business for farms. Regarding cost-cutting, automation within meat and poultry farming is making waves. Efficiency of getting the most amount of meat from a carcass in the least amount of time is key to a solid revenue stream. Deboning robots are fast becoming an industry staple, with the aim of identifying bones and joints, and recognising the areas of high- quality meat before stripping the carcass. These robots match, and sometimes improve upon the pace of human speed, and have a more precise ability to cut around, rather than through, joints. Vision technology has evolved to take a three-dimensional scan of the carcass before cutting, which enables the robot to understand the bone structure, and thus how to cut in order to maximise the meat yield. With their human-like arms, they can adapt cutting techniques to suit bone structure. Whilst some staff should be retained to rectify any errors, this scale of automation could vastly reduce overhead costs and improve efficiency. Having explored meat and poultry, how can the fishing industry secure its future in a changing environment? Much discussion has been had recently regarding sustainable fishing, which aims to guarantee the continuation of populations of ocean and freshwater wildlife in the future. Overfishing is an industry staple, meaning that fish and shellfish populations are rapidly depleting. Around 170 billion pounds of fish are caught each year. Increasingly popular methods are to use purse seining and longlining. Purse seining herds fish using a net, which then draws together, enveloping the fish inside. This is typically used to catch schooling fish, such as tuna. Longlining uses a line of up to 62 miles, which is set and dragged behind a boat. The line stretches downwards and is set with baited hooks. Both of these practices are efficient fishing methods. Although they are able to catch hundreds of thousands of fish at once, they are species selective. Furthermore, they are only suitable to be used during certain seasons, which is determined by tides and the moon. This gives the wildlife time to replenish. Experts recommend increasing market research to determine the most popular fish and shellfish at each season, then seasonally catching to enable seasonal repopulation. Furthermore, inspiration could be taken from traditional fishing methods, such as hook and line methods. Although the catch would be significantly reduced, it would also reduce wastage and the potential for overfishing. The meat, poultry and seafood industry remains at the forefront of the public’s choices. However, in dealing in a finite resource, it is important to secure the future for the industry. During a period where the impact of human consumption on the planet is being debated, moving to a more sustainable approach would also help to retain public loyalty. Investing in climate-proof methods will enable the industry to thrive in an increasingly uncertain climate. Climate change has not brought farming to its knees, but reviewing available research and options now will mean businesses can invest ahead of the curve, thus likely making savings as well as securing the future for your operations. 40-43.qxp_Layout 1 31/08/2022 10:02 Page 3Food & Drink International 43 www.fdiforum.net CRYOVAC ® Brand Darfresh ® skin packaging systems extend fresh protein product* shelf-life up to 20 days vs. MAP packaging systems to reduce food waste. You can have all this performance at a price that’s similar to traditional MAP systems. Find out more today *for fresh red meat Skin packaging that enhances sustainability and extends shelf life © stock.adobe.com/ bit24 40-43.qxp_Layout 1 31/08/2022 10:02 Page 444 Food & Drink International www.fdiforum.net VISION AND INSPECTION © stock.adobe.com/Yakobchuk Olena Machine vision Machine vision 44-47.qxp_Layout 1 31/08/2022 10:04 Page 1Food & Drink International 45 www.fdiforum.net VISION AND INSPECTION T he increasing demand for complete product integrity in the food and drink industry means that the production process must now incorporate all- encompassing and effective inspection to ensure potential contaminants are located and removed swiftly. Product consistency – in terms of size, shape and weight – is also essential. However, the industry must do this while retailers and consumers demand the supply chain moves faster than ever. It is no longer reasonable or viable to expect human inspection to be fit for the task. The solution, as ever, lies with technology. This feature examines the ways in which vision systems, ID readers and sensors are being employed to complete these tasks as quickly and effectively as possible. There is only so much that human inspection can achieve in any production environment. Given that food safety is absolutely essential from both a commercial and an ethical standpoint, it is vital that any potential for error is eliminated. The human eye is a powerful organ, but with the advent of Machine Vision Systems we are entering an entirely new – and potentially flawless – world. For the most part, food and drinks manufacturers use Machine Vision Systems to carry out tasks such as counting large numbers of units on the production line, reading product labels to ensure they contain accurate nutritional and allergen information, portion control, and testing for faults in the packaging of a product which could result in contamination or degradation. These systems are also employed during the initial stages of the manufacturing process to measure individual ingredients, so detailed information is available at every step of the supply chain thanks to their integration with ever-more sophisticated hardware. 100% quality control is the bottom line, and virtually every process from harvesting to sorting to packaging is now using these technologies, Quality assurance and health and safety both rely on good inspection, and we are long past the point where the human eye can be of any practical use in a factory setting. As demand for machine vision systems increase however, the complexity of the task rises in tandem. 46 Á 44-47.qxp_Layout 1 31/08/2022 10:04 Page 246 Food & Drink International www.fdiforum.net VISION AND INSPECTION significantly cutting down costs while reducing the risk of contamination at every stage. The options in this area are certainly becoming more advanced, however – meaning contamination and mistakes can be spotted almost immediately without the requirement of lengthy downtime or the need to destroy a large number of products. Of course, product recalls are also something to be avoided, especially since they can fatally damage relations with both customer and consumers It is of course welcome news for those using machine vision technologies, that they are becoming much more cost effective: multispectral cameras – a relatively inexpensive technology that is already used frequently in other industries – are used to inspect large quantities of perishable harvested products such as fresh vegetables, which they sort according to colour systems, while laser triangulation systems are employed to ensure that the volume of each unit is consistent. The data is then processed using the integrated hardware and any undesirable products are rejected. The increasing availability of these systems means that companies can ensure maximum productivity whilst being sure of the quality of their products; swift production can now take place without cutting corners. We are now looking at a situation where the machinery can inspect over 3,000 small products per minute. If you’ve ever wondered how food manufacturers make the products you see on supermarket shelves so consistent in size, shape, colour, and weight, and why there are now relatively few cases of food poisoning caused by pre-packaged, massproduced products, Machine Vision Systems provide the answer. Supermarket retailers demand absolute consistency of portion size, and laser technology is by far the most accurate way to achieve this. And there’s more: this technology can also be used to ensure that the best, most visually appealing examples of a particular product appear at the top of a multipack or crate. Some vision systems can even be used to aid the assembly of multi-part products such as pizzas and cakes if the machinery is pre-programmed with the correct information and integrated with the © stock.adobe.com/xiaoliangge 44-47.qxp_Layout 1 31/08/2022 10:04 Page 3Food & Drink International 47 www.fdiforum.net VISION AND INSPECTION METAL DETECTOR & CHECKWEIGHER RAPTOR COMBI AWARDWINNINGDIGITAL INSPECTION SYSTEMS www.fortresstechnology.co.uk FULLY INTEGRATED X-RAY SYSTEM RAPTOR X-RAY required robotics on the production line. Product safety – an absolute must in a quality-driven environment – can also be guaranteed through the use of Machine Vision Systems. For example, laser triangulation devices similar to those used to measure size, weight and consistency can be employed to ensure the overall integrity of a product’s packaging. To guarantee maximum freshness and prevent potential contamination, it is vital that any seals, lids, bags and bottle-tops are checked for flaws or signs of tampering. Triangulation devices will do a much better job than older 2-D imaging systems because they are able to capture a far greater level of detail, identifying even the smallest imperfections. The other advantage of using a 3D system, of course, is that it will pick up flaws on every side of a unit of packaging or raw product and not just on its immediately visible surfaces. Manufacturers are also focused on reducing the impact of their systems on the manufacturing process. While hygiene and safety are important, the efficiency and profitability of a site still needs to be a major concern – as even the slightest interruption can prove costly. Machine Vision Systems will shape the future of the food and drinks industry in a variety of ways. Automated systems can help save time and money at every stage of the production process. They can also be used to ensure product safety, which, in a quality-driven world where reputations are constantly on the line, is all but necessary. © stock.adobe.com/funfunphoto 44-47.qxp_Layout 1 31/08/2022 10:04 Page 4TENDRING PACIFIC Q&A Can you tell us a bit more about the company? Tendring Pacific is the UK Distributor and Audited Service Centre for Ametek Mocon’s range of Dansensor MAP products. We are a privately owned business, 25 years old and our office and national service centre is in Cambridge. Customer Service is front and centre of what we do – we have an enviable reputation for both our expertise in gas flushed packaging and the support we give to our customers - which is why we get a significant proportion of our new customers referred to us by existing contacts. Support should start before a purchase is made, so we provide Site MAP Audits, Equipment Demonstration and Trials, to ensure we are offering the most appropriate equipment and solutions. We install equipment and train users and subsequently have a FOC Helpdesk for ongoing support. There is an ongoing labour and skills shortage in the Food Manufacturing Industry, you say you can help alleviate that issue – how it that possible? The industry has largely relied on taking sample packs from the production stream and manually testing them, invariably by destructive means and then manually recording the results on paper. The vast majority of production is therefore dispatched unchecked, on the assumption that it conforms to the sample taken. As well as being statistically invalid, it is very labour intensive, creates waste for landfill and produces non-digital records. If a test result is found to be out of tolerance, the common practise in the industry is to halt the dispatch of those packs produced since the last known ‘good’ check. Those packs are then stripped out, creating more plastic waste for landfill and using valuable labour on a non-invoiceable task. The solution is online gas analysis and flow control, which will monitor the pack headspace gas and stop the line if the test results are out of specification. The test results are then automatically exported to a Paperless QA system, to form a permanent record that can be easily retrieved or used at Audits. The most recent price increase in CO2 has cause a significant spike in packing costs, how can you help users to reduce their CO2 consumption while conforming to headspace gas specifications and ensuring the designated shelf life of the product? Historically and typically now, the permitted tolerance on the mix proportions of a mixed flushing gas has been wide; - + or – 5% appears to be Q&A Tendring Pacific The food industry is facing a raft of issues, from a shortage of skilled employees to demands for more environmental and sustainable operation. We speak to Tendring Pacific, specialists in end of line inspection, to see how these problems can be addressed with quality detection and inspection. 48 Food & Drink International www.fdiforum.net 48-49.qxp_Layout 1 31/08/2022 10:05 Page 1TENDRING PACIFIC Q&A quite usual. For example, on a target 70% N2 /30% CO2 mix – 25% to 35% is deemed to be acceptable for the 30% gas and satisfactory to ensure the product reaches the end of its stated shelf life. This has probably come about because of the operational limits on old technology gas mixers. However, the new technology gas mixers, such as the Dansensor MAP Mix Provectus have an accuracy of +/- 2%. So if 25% CO2 was/is acceptable for achieve the required shelf life, then by setting the Dansensor MAP Mix Provectus to 73% / 27%, the user will save 10% of CO2. The Dansensor MAP Mix Provectus is universal and can be used for both buffer and flow applications. Users of flow wrap and bagging lines have a further opportunity to optimise the consumption of CO2, by installing a Dansensor MAP Check3 online headspace gas analyser and flow controller. The typical gas saving is 40%! The Dansensor MAPCheck3 controls the rate of flow of flushing gas automatically, according to the %O2 in the headspace gas analysis. With a plastic tax now in force and a combined demand from Retailers and Consumers alike to reduce plastic waste, how can food manufacturers introduce more environmentally acceptable substrates while maintaining production speeds and efficiencies? The down weighting of packaging films is no longer a realistic way to reduce plastic waste. We know of many food producers who have and are devoting significant resources to finding and introducing new substrates to reduce their plastic waste and carbon footprint. The sealing parameters (temperature, pressure and dwell time) of new substrates are invariably different to those previously used. “Experimenting” and “Trial and Error” on a packaging line is very expensive and it is frequently difficult to know if a change has improved the resultant seal or not. We have supplied the Dansensor Lippke 5000 Seal Strength Tester to a number of plants to help in the optimisation of the sealing parameters for new packaging materials. Packing is a dynamic process, so the Dansensor Lippke 5000 can subsequently be used to maintain optimum sealing conditions, based upon the testing of the packs being produced. What trends to you see in MAP – Gas Flushed Packaging? The immediate issues faced by food manufacturers are containing spiralling costs, reducing their environmental impact and dealing with the labour and skills shortage. All of which can be alleviated by “getting it right first time” through online monitoring, automated control, digital data collection and analysis and continually optimising the process. The final goal is the Smart Factory. We see the most progressive of food manufacturers installing the building blocks to achieve this end point and enroute their OEE improves hugely. The proven technology already exists for: * Tightened tolerances on gas mixing – Dansensor MAP Mix Provectus * Online headspace gas analysis and flow optimisation – Dansensor MAP Check 3 * Paperless QA and Data Storage – Plantstats QCPro * Optimising the sealing parameters of environmentally friendly packaging materials - Dansensor Lippke 5000 * End of line final inspection of individual packs – Trivision VisioPointer * Central control of the entire production and packaging process. For more information or to get in touch with Tendring Pacific directly visit www.tendringpacific.com call +(44) 01223 492 080 or email sales@tendringpacific.com Food & Drink International 49 www.fdiforum.net 48-49.qxp_Layout 1 31/08/2022 10:05 Page 2Next >