< Previous30 Food & Drink International www.fdiforum.net COLD STORAGE The demand for cold storage within the food and drink industry has skyrocketed, driven by changing consumer habits craving fresh food and seafood, expanding supply chains, escalating concern over food waste, and a general increase in the amount of goods that are cold-stored. For much of this year, COVID-19 has placed extra strain on cold storage, with the pandemic pushing consumers to buy frozen goods and take part in more online food shopping and creating backlogs of products due to border/export/port complications. Moreover, with many restaurants across the globe closed, the pandemic has left suppliers scouring for alternative customers and locations to store excess food, while some food processors, running out of storage, are being forced to cut output. The role of cold storage is indispensable in the food and drinks industry with temperatures too far one way or the other leading to product degradation, spoilage and wasted goods – all of which eats into profits. A prudent example of this importance in action is frozen vegetables. In order to preserve the maximum flavour, nutritional content and product integrity, vegetables must be frozen as quick to being picked as possible. Indeed, this has become a selling point for many frozen food producers looking to market their goods as every bit as healthy as their fresh counterparts and less wasteful. However, this means frozen vegetables must move from the freezing process, through to packaging and, finally, be transported into retailers, whilst all the while remaining at a constant temperature. So how exactly can this be accomplished in the supply chain? The first part of this chilled logistics journey typically occurs in-house, such as a production line in an enclosed warehouse or other such facility. Though there are myriad options open to manufacturers when it comes to keeping a consistently cold production line or storage facility, it’s counterproductive to invest in subpar technologies. Even tiny changes in temperature can lead to micro-thawing and the crystallisation of frozen goods. This makes insulation crucial in maintaining a cooler temperature as the cool As the demand for cold storage continues to increase, we explore the importance of the sector, what’s driving the growth, and what the future holds. cool Keeping 30-34.qxp_Layout 1 29/10/2020 07:55 Page 1Food & Drink International 31 www.fdiforum.net COLD STORAGE Chill and take a load off Coolflow DTX is an industry proven high efficiency, non-toxic secondary refrigerant suitable for replacing Propylene Glycol (PG) in food and beverage cooling systems. Customers have reported improved performance and efficiency gains alongside considerable energy/cost/CO2 savings. Arla Foods have seen a significant reduction in energy consumed by the main coolant circulation pumps and process cooling systems after moving to Coolflow DTX. There has also been a noticeable reduction in running time and load on their primary refrigerant compressors which they believe will considerably prolong the life span of their system. The likes of Waitrose, Lidl and ALDI have designed their systems with Coolflow DTX in mind, allowing them to not only make savings in areas such as hardware & capital expenditure but also enjoying continued savings on operational and running costs throughout their nationwide stores. There are also savings to be made by retrofitting existing systems and moving from PG to DTX. For more information, visit www.hydratech.co.uk/coolflow-cooling-fluids. heat outside a facility will be constantly trying to make its way inside. The nature of heat means it can work its way through even the smallest breaches in a manufacturer’s temperature defences, be that a wall, window or door. One of the biggest threats to frozen foods lies in the changeover from one facility to another, such as a manufacturing line to a distribution centre. Manufacturers will likely have temperature controlled loading bays to ensure a constant temperature is carried across and maintained from production and packing. Curtain walls will help to maintain this consistency, creating a barrier to ensure that cold air stays inside its designated area whilst also allowing workers, loaders and forklift trucks to easily pass through. Yet there’s no getting around the fact that loading bays are literal openings into the outside world and so could therefore scupper this carefully controlled chilled environment. To compensate for this, and to maintain the cold integrity, manufacturers and © Shutterstock /hacohob 33 Á 30-34.qxp_Layout 1 29/10/2020 07:55 Page 232 Food & Drink International www.fdiforum.net COLD STORAGE Ice, frost and fog in cold stores can create slippery, dangerous conditions for staff. While many accept that ice is simply part of the cold store, it doesn’t need to be so. Munters IceDry® is a specially designed dehumidifier that targets moisture in manufacturing facilities,cold stores and process freezers to: • Reduce & prevent ice, frost and fog build up on floors, walls and ceilings • Reduce defrosts - case studies available • Lower maintenance costs • Improve safety for staff & forklifts • Increase productivity • Improve evaporator efficiency 01480 432243 info@munters.co.uk munters.com/icedryseries Improve Safety & Climate Conditions in Cold Stores Free CPD Seminars Proven global installations “The cold store is the best it’s ever been for excessive ice & snow” - Kitchen Range Foods FREE site surveys Labfacility offer thermocouple temperature alarm / on-off controller The Labfacility L300-TC (Thermocouple) temperature alarm / on-off controller can be used in conjunction with a PC to provide accurate monitoring and alarm or on-off control of up to 8- zones simultaneously. It can also be used as a stand-alone instrument without the need for a PC. The in-built, self-calibration facility for the thermocouple version is a rapid and convenient method for on-site calibration and does not require any additional equipment other than a special, external link. The L300TC has 8 thermocouple (type J, K, T, E, N, R, S & B) inputs and a resolution of 0.1°C on display, 0.01°C in software. This unit is RoHS compliant and CE marked. To find out more, visit www.labfacility.com. 30-34.qxp_Layout 1 29/10/2020 07:55 Page 3Food & Drink International 33 www.fdiforum.net COLD STORAGE For the food & drink industry THERMADATA® WIFI LOGGER thermometer.co.uk Cooking • Reheating • Refrigeration • Oven • Grill Helping your business be HACCP compliant Designed & built in the UK, we offer a wide range Bluetooth® logistics operators rely on hoods around the bay door opening. In practice, this means a truck or lorry can back into a bay and open its doors, thereby creating a seal and ensuring that the cold air isn’t diffused and compromised by the warm. Frozen and chilled foods can then be loaded without fear of their thawing or warming up. Though many of the precautious observed in the cold chain might seem obvious, there are other subtler dangers that must be considered. Now that we’re in the thick of summer, it’s important that manufacturers understand how the performance of their temperature controlled systems can be affected by the heat and what they can do to counteract those negative effects. Electrical equipment of all kinds generate heat, and these temperatures have been attributed to electronic components tripping or failing outright altogether. Moreover, temperatures can get so high inside a panel that fire risks become a clear and present danger. While cold storage has been slow to embrace innovation, change has arrived in the sector. A plethora of technologies have been implemented to improve cold chain and storage management. Automation and, though not fully integrated like in traditional warehouses, robotics are on the rise, replacing manual workers and processes to speed up the movement of food to efficiently fulfil orders. This is prompting taller, high density and smaller footprint builds capable of 24/7 operation. Building upwards rather than out is fitting as facilities are further established in urban areas, with robotic stacker cranes accessing high shelves, and with less square footage and less land needed, savings can be made in property costs for what are already expensive facilities to create. In addition, with a smaller footprint comes a smaller roof area, allowing real gains in energy conservation, with heat from roofing reduced, making a building easier to keep cool. Automation is also being employed to decrease labour costs and make up for a staff shortage, with just a small talent pool willing to work in the extreme conditions associated with cold storage. Some facilities are keeping this to a smaller scale with semi-automated systems like automated truck loading systems, while others are implementing fuller automation with receiving, picking and retrieving systems (like AS/RS), minimising human contact with goods as far as possible. AGVs such as automated lift trucks are also © Shutterstock /Sorn340 Studio Images 34 Á 30-34.qxp_Layout 1 29/10/2020 07:55 Page 434 Food & Drink International www.fdiforum.net COLD STORAGE being utilised, though it should be noted that problems with condensation on sensors used to navigate has limited their use. A significant trend in cold storage is the use of Internet of Things (IoT) systems and cloud computing, which offer improved visibility and accountability for cold storage and shipping. IoT sensors in warehouses and refrigerated trucks facilitate real- time remote temperature monitoring, often when tracking other parameters too, transmitting data to cloud software platforms for use, and can provide automatic alerts if temperatures reach an unsafe level. With these real-time notifications when goods are no longer in ideal temperatures, one can uncover cooling system malfunctions, quickly work to correct problems to avoid product damage, and prevent the spoilage of a shipment. One could even reroute a shipment to preserve products. With automated 24/7 temperature monitoring and recording manual documentation is eliminated and on demand reporting can be accessed, as well as historical cold storage data, which is particularly useful for food safety compliance. In part this has come as a response to customers desiring temperature confirmation and regulation, for instance the FDA’s Food Safety Modernisation Act which pinpoints requirements for maintaining temperature. Shipments must be traceable and have verifiable temperature records. The importance of temperature control in the food and drinks industry cannot be overstated. The tiniest changes in the carefully controlled environment can render product integrity null and void. As well as ensuring that food remains at its best, manufacturers also need to mind their equipment, especially in these summer months where the heat inside machines can be a very real danger. © Shutterstock /Mehmet Cetin Klimate High Speed Doors: durable, reliable & high-quality With the pandemic impacting all aspects of business operations, companies within the temperature controlled storage and distribution industry need to monitor their running costs especially carefully, particularly energy usage. With a constant flow of traffic entering and leaving a climate-controlled warehouse, clients need a door that has rapid opening and closing to maintain a constant working temperature and to keep energy loss to a minimum. The product had to be durable, reliable and of high quality. The fast-acting Klimate range of doors provides valuable energy savings by minimising heat loss in high usage areas. Klimate High Speed Doors is a division of BID Group Limited and boasts a product range suitable for all ambient storage facilities. Klimate products are manufactured at BID Groups HQ based in Bolton. All Klimate doors are characterised by their low maintenance technology and low repair costs. To find out more, visit www.bidgroup.co.uk. 30-34.qxp_Layout 1 29/10/2020 07:55 Page 5www.fdiforum.net Plan your campaign with Food & Drink International… ...your competitors are! As marketing is the vital ingredient for the success and growth of any business, we can offer advice and packages to suit all budgets. Speak to one of our experienced account executives. CAN YOU AFFORD NOT TO? • Print • Online • E-Newsletters • Regular News • Topical Features The perfect medium to give your brand the best chance of being seen! Contact us below for our 2020 editorial schedule Call today on +44 [0] 1472 310310 or email: s.trott@blmgroup.co.uk INTERNATIONAL Food &Drink Food &Drink 2019 AUGUST I N T E R N Food Food &&& Food Food & £3.50 .fdiforum.net www N A T I O N &&Drin Drin Drin &&Drin 0 STERLING A L nk nk nkk thi Fre i ki h ND EXPORT NEWS IMPORT AND E G SPOTLIGHT PROCESSING S SEPTEMBER 2019 I N T E R N Food Food &&& Food Food & £3.50 .fdiforum.net www N A T I O N &&Drin Drink Drin &&Drink 0 STERLING A L nk nk nkk tota The t l GY TOTAL SHOW pac cka PPMA TOTAL MICROBIOLOGY MHX 2019 IMHX 2019 ge 54) V N preview on pag otal Sh OBER 2019 OCT I N T E R N Food Food &&& Food Food & £3.50 .fdiforum.net www N A T I O N &&Drin Drin Drin &&Drin 0 STERLING A L nk nk nkk cho The i t t l mental c ws Environmen Spotlight Spotlight auBeBrra evvial ale NOVEMBER 2019 I N T E R N Food Food &&& Food Food & £3.50 .fdiforum.net www N A T I O N &&Drink Drink Drin &&Drink 0 STERLING A L nk nk nkk Packaging ging Packaging spotlight for s Ingredie Fi Europe ent rs and epositors llers MINIMUM COST…MAXIMUM IMPACT! www.fdiforum.net 35.qxp_Layout 1 29/10/2020 07:57 Page 136 Food & Drink International www.fdiforum.net FOODSERVICE © Shutterstock /ShutterOK 36-39.qxp_Layout 1 29/10/2020 07:59 Page 1Food & Drink International 37 www.fdiforum.net FOODSERVICE With the COVID-19 pandemic, closures, re- openings, constantly changing restrictions, and curfews, it is no surprise that 2020 has been a year of struggle for the foodservice industry. Restaurants, fast food establishments, canteens, catering operations, and their supply chains have been dealing with complete resets. The sector is undergoing significant change, not only in response to coronavirus, but as new tech is embraced, and consumer preferences evolve. Heightened safety and sanitation practices have become essential in winning and retaining customers concerned about the health and safety of food prepared out of the home in the “new world.” Though these aspects have always been important focus areas, the pandemic has pushed them into the spotlight. Considering restaurants, sanitation is no longer something kept back of house, with consumers assuming it is taking place. Consumers want transparency on the measures being taken, with overt cues. They also expect to see masks, reconfigured spaces to accommodate social distancing rules, and frequent cleaning, while restaurants are taking it upon themselves to improve ventilation and install antibacterial door handles and separators with, for example, plexiglass to make customers feel safe. Enhanced employee screening is also being utilised with electronic health surveys sent out prior to shifts, and kiosks conducting temperature scans and recognising the faces of staff even with masks on, with the resulting information trackable for human resources and outbreaks. As these changes are made, those in the foodservice sector must also ensure to maintain employee training, perhaps via learning management software, so staff are prepared to handle food safely and clean to now higher expectations, and must establish a food safety culture from the top down. Meanwhile, behind the scenes, innovation is bolstering food safety management. Where in the past paper records of fridge temperatures and cleaning schedules were kept, these The foodservice sector has had to implement numerous changes in 2020 to meet not just new expectations in light of COVID-19 but shifting consumer desires. Significant 38 Á change 36-39.qxp_Layout 1 29/10/2020 07:59 Page 238 Food & Drink International www.fdiforum.net FOODSERVICE © Shutterstock /weedezign processes are becoming much easier and more efficient with the variety of software and mobile apps available for food safety records. Readings can be input into one place, and information kept in the cloud, allowing it to be accessed wherever required. Furthermore, refrigeration monitoring systems can ensure products are kept at the proper temperature and send notifications if this falls outside of an ideal range. Internet of Things (IoT) devices, like sensors and smart fridges, are also being utilised to automatically log temperatures of prep areas, freezers, and other equipment, and are actively monitoring inventory, alerting managers when stock is low or reordering supplies automatically. This reduces chance of running out of ingredients, ordering error, and only orders ingredients as needed, avoiding stockpiling, and meaning less food is likely to expire and be wasted. Moreover, to match current consumer needs and desires, and survive the pandemic, foodservice firms are diversifying, with restaurants becoming grocery stores, those never offering off- premise options now serving take-out, while delivery only restaurants, or ghost kitchens, are booming, presenting the possibility of delivering to consumers without physical restaurant costs. The growth of delivery has seen restaurants need to reassess their delivery model, based on speed, delivery economics, customer location and menu type. Click and collect and pre-ordering are on the rise too, enabling convenient queue skipping, and all of these mean that those in foodservice must reconsider their products, to create items that travel well, and utilise packaging that can preserve quality, heat and freshness. As more packaging - from containers to bags, cutlery and napkins - may be on the cards with increased off-premise orders and growing use of and demand for individually wrapped products from caterers, the shift to green packaging and utensils is vital in the foodservice sector. Packaging needs to be reusable, recyclable, or compostable if it is to meet modern customer expectations. Governments and conscious consumers are continuing to push those operating in the foodservice industry to develop and use new, environmentally friendly 36-39.qxp_Layout 1 29/10/2020 07:59 Page 3Food & Drink International 39 www.fdiforum.net FOODSERVICE packaging. For instance, Canada recently became the latest country to reveal it would ban certain single use plastics. By the end of 2021 foodservice items such as plastic straws and cutlery, and some takeout containers, face the ban. With going green now a requirement, options like bamboo, paper and compostable packaging are being considered. Opportunities for greener delivery extend past packaging, however, and businesses will need to address their carbon footprint with low- carbon and zero carbon delivery, via electric motorcycles and mopeds, and bicycles. Further changing foodservice is consumer desire for convenience, with use of digital channels, online delivery, click and collect, contactless ordering, and cashless payments. As mobile apps are more integrated in people’s day-to- day lives, it is unsurprising an increasing number of restaurants are creating apps that offer table booking, menus, and in app ordering and payment. This level of convenience is attracting new customers and helping restaurants retain them. Restaurants and caterers are also responding to changing consumer dietary preferences. A focus on wellness, healthier choices, and the explosion in demand for plant based options, from vegans, vegetarians, and flexitarians who want to not only be animal friendly but are taking into account the environmental impact of livestock, should be noted when planning menus and meals. Foodservice operators are creating nutritious and ethical menus to meet consumer desires, taking advantage of more natural, healthy ingredients, and offering “low in” and “free from” options that do not sacrifice taste. Concurrently, consumers are seeking more transparency about how their food has been processed, to know what is in their meals, and software is being employed to allow consumers to identify meals that are suitable for them based on their dietary choice, or allergies. Adding further transparency and enhancing food/ingredient traceability, as demanded by consumers and governments, bar coding and blockchain are helping create digital records of a product’s journey from farm to fork. © Shutterstock /Pixel-Shot 36-39.qxp_Layout 1 29/10/2020 08:00 Page 4Next >