< Previous20 Food & Drink International www.fdiforum.net PACKAGING SPOTLIGHT microwavable ready meals and pouches to protective packaging on meat and dairy, flexible packaging is commonplace across the food and drink retail landscape. Not only do they provide protection, freshness and functionality – such as withstanding heat in the case of ready meals – but they are also designed to appeal to consumers with strong visual profile and eye-grabbing aesthetics. Any replacement must offer the same functionality, not to mention cost the same (or less) to produce. One of the most promising solutions to replace traditional plastic in film and barrier packaging is cellulose. Not only is © Shutterstock /Ink Drop 22 Á Tray sealing, pot filling & factory efficient intelligent weighing systems www.pal.co.uk +44 (0) 1565 755000 Contain it in our recyclable jars Measom Freer manufacture and stock jars in sizes ranging from 10ml to 150ml. The 10ml jar is available in thick walled fully recyclable SAN with colours to order and the 25, 50, 100 & 150ml are available in thick / thin-walled clear food grade fully recyclable polystyrene with SAN and colours to order, matching jar caps are also stocked. These quality jars have a glass-like appearance with the advantage of being light in weight and shatter resistant. Ideal for confectionary, supplements, dried snacks and condiments, please ask for samples to test your products with. Small to large orders welcome, all our products are manufactured in the UK with a minimum of 30% recycled content (PCR). For more information visit www.measomfreer.co.uk 16-24.qxp_Layout 1 26/10/2021 12:40 Page 5Go nature. Go carton. Today only 13.5% of global waste is recycled 1. What if food packaging were always recycled and never became litter? Tetra Pak ® carton packages are already recyclable 2. But we won’t stop there. As part of our ambition to deliver the world’s most sustainable food package 3, we’re always exploring new ways to expand the value and use of recycled materials from cartons, helping them find new life as park benches, roof tiles, paper towels and many other valuable products. That’s how we keep the materials in use for as long as possible. Learn more at gonature.tetrapak.com 1. The World Bank, What a Waste 2.0. 2. Carton packages are collected and recycled worldwide, where waste management and recycling infrastructure is in place 3. Made solely from responsibly sourced renewable or recycled materials, fully recyclable and carbon neutral. What if all used food packaging were turned into useful products? 191879_TetraPak_GNGC_Ad_Recycle_Food&Drink_International_210x297_Global.indd 113/09/2021 16.58 16-24.qxp_Layout 1 26/10/2021 12:40 Page 622 Food & Drink International www.fdiforum.net PACKAGING SPOTLIGHT cellulose manufactured from wood or cotton, making it bio-compostable, but it can also preserve the aroma of food products such as tea, coffee and spices, giving it a sensory as well as an environmental advantage over plastic. Although seaweed has been a culinary staple in countries like Japan for centuries, it is only within the last ten to fifteen years that it has caught on as a healthy superfood in the west. Yet there’s more to seaweed than simply its nutritional profile. Indeed, seaweed and kelp have the potential to be used as an alternative to wood in packaging. Given the abundance of seaweed, the ease with which it can be grown and harvested, and the swiftness that it biodegrades, it presents an exciting opportunity to create more eco- friendly packaging that doesn’t compromise on functionality. Packaging company DS Smith is currently exploring this very possibility in a move which could see the company use seaweed across its packaging networking. Following initial testing, the company is also exploring the potential of seaweed to play a significant role in the purge of plastics by acting as a barrier coating to replace petroleum-based packaging. At present, the company is talking to a number of biotechnology companies to explore the use of seaweed fibres in a range of packaging products such as cartons, paper wraps and cardboard trays. Over the last decade, there have been numerous fascinating trials and initiatives involving bio-based plastic packaging as food companies and packaging experts double down on R&D efforts. Some have utilised mushroom-based packaging as an alternative to Styrofoam while others have used waste streams of organic matter like tomato stalks to replace wood as the raw fibre material. Not to mention the more common bioplastics made from sugar cane, wheat and even potatoes. Despite these encouraging advances, and the market proliferation of eco-friendly packaging, there’s still many hurdles to overcome before the industry can significantly Martini perfects the packaging of pasta with OMRON technology Based in Italy, Martini srl produces high-precision weighing and packaging machines for the food sector. Its new MCRS-VD packaging system enables the packaging of up to 180 packs of pasta per minute. At the heart of the solution is an OMRON NX701 1600 machine controller. This manages the movements of the MCRS-VD. OMRON’s NX-TC Perfect Sealing technology enables the end user to improve the stability of the thermoregulation involved and reduces the costs associated with the use of packaging films. The MCRS-VD automates all the stages of packaging - including folding, sealing and labelling. The system was created by Martini to meet the growing need for greater speed, efficiency and flexibility from pasta producers all over the world. A key aspect of the structure of the new machine is two continuous, vertical box-motion packaging machines. These are mounted on a segmented belt with intermittent feed and are fed by a double weighing system that uses Infinity - a digital, multi-head model. Martini’s Infinity weighing system enables users to dose the pasta quickly and very precisely, with the doses conveyed to the two packaging machines. A digital filter, equipped with the control electronics of each head of the weigher, ensures the accuracy of each dosage. The creation of the new system was largely supported by OMRON’s automation technology and technical advice. The final performance of the packaging system is managed by the OMRON NX701 1600 machine controller. The Martini MCRS-VD can pack up to 180 packs of pasta per minute per pillow and 160 double-square packs. Associated with the packaging system, there is also a double volumetric weighing system, or a mixed dosage version consisting of a multi-head weigher and a volumetric doser for packaging various types of products. To find out more, visit www.industrial.omron.co.uk. Harkstead Hall Barn, Harkstead, Ipswich, Suffolk IP9 1DB Tel: +44 (0)1473 893990 Fax: +44 (0)1473 893995 email@penn-packaging.co.uk www.penn-packaging.co.uk • Case/tray Packing machines • Shrink Wrapping systems • Stretch-Film Wrappers • Depalletisers • Palletisers • Bag Closing Machines • Pillow pouch systems • Pre-made pouch • Stand-Up / Doypack • Slider/Zipper • Wet glue / PSL / hotmelt and combination rotary labellers 24 Á 16-24.qxp_Layout 1 26/10/2021 12:40 Page 7Food & Drink International 23 www.fdiforum.net PACKAGING SPOTLIGHT The Responsible Pack rBDF™ film creates premium-looking packs with superior shrink, gloss and clarity. The film can be used to pack food with any trays or without trays to reduce your plastic footprint. The food-grade recycled content has been certified by the International Sustainability and Carbon Certification (ISCC). Contact your local Sealed Air respresentative to learn more or visit: www.sealedair.co.uk/en-gb/cryovac-bdf CRYOVAC® Brand rBDF™ The world’s first ultra-thin, barrier film with 30% recycled content 3 times thinner than thermoformable materials Skin-tight shrink, leak-proof seal 30% food-grade recycled content © Shutterstock /Sergey Ryzhov 16-24.qxp_Layout 1 26/10/2021 12:41 Page 824 Food & Drink International www.fdiforum.net PACKAGING SPOTLIGHT move away from plastic. One of the biggest concerns the production line itself. Not every manufacturer can move to using more environmentally-friendly packaging materials on their production lines – be that for financial reasons or due to a limited available space on the production floor where new machinery simply cannot be made to fit. Bioplastics often require different treatment during manufacturing than traditional plastics, so in many cases, companies will need to invest in order to transition to producing more eco-friendly packages. Last year, a report from PMMI Business Intelligence found that one in four consumer packaged goods (CPGs) companies were making machine purchases or modifications specifically to address packaging sustainability goals. According to the report, there are five functional machine improvements that would have the greatest impact on CPG operations for manufacturing a more sustainable package: reliability, flexibility, automated changeover, cleanability and sensor feedback. Utilising these criteria, companies can not only introduce greener, more sustainable packaging into their production lines, but can help to future proof their operations. Although no one can truly predict future market trends, it’s safe to assume – given the pressing environmental crisis – that sustainable packaging is here to stay and will rapidly become industry standard. Companies can therefore align themselves with the change and position themselves at the forefront, rather than risk being left behind. As with many issues in the food and drink sector, the issue is less to do with the existence of packaging, and more about transitioning towards using materials that come from renewable and/or sustainable sources and which can themselves be recycled by end users. One need only look at how far the industry has come over the last ten years to appreciate how rapidly the industry is changing. One can only imagine how our store shelves will look in another tend years. Naked’s BIG EAT has reduced plastic by 50% Since 2015, Symington’s Naked brand has taken consumer’s taste buds on an adventure in an instant, with authentic Asian flavours. The brand team identified the opportunity to review their packaging formats during an annual brand planning last year. From market research, they learned that consumers were massively favourable towards any format that reduced its plastic. Working closely with Greiner Packaging, Naked carried out a full review of the packaging options. For the BIG EAT, they reduced the diameter from 116mm to 95mm, to match their core range. This resulted in an immediate plastic saving of over 50%. Coupled with the advantage of the K3® cardboard-plastic packaging being perfectly recyclable. Symington’s Marketing Director, Kevin Butterworth, explains; “Throughout the project, the Greiner Packaging team worked closely with us, identifying the most suitable packaging solutions, and pushed the boundaries to create the new pack size which was outside what its existing machinery could produce at that time.” For further information, please visit: www.greiner-gpi.com Recyclable pouches join the family of McCoos How can a recyclable pouch possible do justice to the Steven Brown Art’s - the McCoos? When Deans of Huntly wanted to launch their range of Cookies in a recyclable pouch they approached National Flexible for ideas. They had the designs which are incredible, incorporating Steven Brown Art’s McCoos but were worried that a recyclable laminated pouch wouldn’t do the designs justice as some recyclable materials can have a ‘dull’ finish like polyethylene. National Flexible had already had extensive experience of recyclable films and pouches and were able to help. The pouches needed to have intensity of colour not only in the main design but also in the photographs of the small packs on the front. “We needn’t have worried. National Flexible understood exactly what we wanted to achieve. We are extremely happy with the pouches they look amazing!” Michael, Deans of Huntly. For further information, please visit: www.nationalflexible.co.uk Leading the way in top seal packaging – the evolution S by Packaging Automation Four years in development working with food producers, the evolution S challenges industry limits, it is the most advanced top seal machine to hit the market. This machine does the thinking for you and has been designed for ease of use during operation. When it comes to cleaning and maintenance, the intuitive design makes these routine tasks as pain- free and simple as possible. * Synchro technologies optimize every stage of the packaging process. * Features the latest robotic technology to avoid any costly errors. * Packs 3 times faster than other top seal technology while operating in a continuous motion to have the highest output rate and in single lane format! * Enables high-speed feeding of the film for accurate and consistent printing. * Eliminates intermittent stopping removing the need to stop to reposition the packs. For more information visit www.pal.co.uk 16-24.qxp_Layout 1 26/10/2021 12:41 Page 9Food & Drink International 25 www.fdiforum.net FACILITIES MANAGEMENT When it comes to facilities management, efficiency and continuity are key. Gone are the days where managers might seek to drive their staff into exhaustion in efforts to increase productivity – as we now know that a workforce which is able to maintain an efficient pace continuously, is more valuable than one that is burned out too soon. Beyond that, with rising energy costs, fuel costs and the impact of COVID-19 – there is a real push towards offsetting costs through overheads, rather than hoping for that lucky break on a new contract. For many in the food and drink industry, when facilities management is mentioned, this refers to some form of manufacturing plant – or processing line. Often with tens of thousands of units travelling through the system on a daily basis. The smallest hiccups with efficiency on such a line can have drastic effects through the entire system and considering that large retailers are some of the least forgiving in terms of operational managers Tough times for Facilities management is more than just ensuring the continual running of a processing line – it is ensuring the continual running of the workforce, and that has never been harder than in today’s tumultuous world. 26 Á © Shutterstock /chinahbzyg facilities.qxp_Layout 1 26/10/2021 14:05 Page 126 Food & Drink International www.fdiforum.net FACILITIES MANAGEMENT deadlines – and that there are many competitors in this industry, then it becomes obvious that companies cannot afford to take any risks in this regard. Automating the system wherever possible is the preferred method of increasing efficiency, as this takes out the ever-unreliable human element which could slow things down. On a managerial level, software can be used to ease the burden on an Operations Manager, by organising and arranging shift hours based on delivery times of raw materials to the processing plant. This removes another task for the manager to try and deal with, while also instantaneously checking the shifts of workers within the factory – and assigning those that are free to the task. This automation also has the added benefit of reducing any paper-trails within the facility, or at the very least – centralising them all in a single location, which can be accessed at the push of a button. Another benefit to higher levels of automation is of course the protection it can offer to other members of the team. Most health and safety accidents occur as a result of over-working, or poor allocation of resources, leaving a single worker to try and lift more than they realistically can. An automated system does not make the same © Shutterstock /ASA studio facilities.qxp_Layout 1 26/10/2021 14:05 Page 2Food & Drink International 27 www.fdiforum.net FACILITIES MANAGEMENT © Shutterstock /Apostolos Mastoris mistakes, and as such reduces the risk in that regard. And of course, health and safety does play a large role in facilities management. It is not uncommon for sections of a plant to be closed down when an accident occurs, and then there is of course the injured party to try and treat – reduced productivity from those who are trying to help them. Not to mention the lost man-hours as the person recovers, and the potential for legal action as well. As such, investing in a good health and safety scheme is paramount to the successful running of a food and drink facility. A benefit our industry has in this regard however, is that many health and safety products also work towards improving hygiene – allowing a company to effectively kill two birds with one stone. Non-slip and hygienic flooring is one such example, that can both reduce the risk of accidents within the facility – while also adding a clear hygienic defence against contaminants. Ultimately, the goals of good facilities management must always be the protection and efficient operation of all aspects of a factory. And while some may suggest seeing the workforce as nothing more than a tool to be politically incorrect – investing in their protection is as important as any maintenance one might perform on a key piece of machinery. facilities.qxp_Layout 1 26/10/2021 14:06 Page 328 Food & Drink International www.fdiforum.net DEPOSITORS AND FILLERS flow From flow to the viscosity of throughput, there’s a lot to consider when it comes to depositing and filling. Maintaining 28-31.qxp_Layout 1 26/10/2021 12:46 Page 1Food & Drink International 29 www.fdiforum.net DEPOSITORS AND FILLERS © Shutterstock /PhotoMavenStock It’s almost inconceivable to imagine a food and drink production line without depositing and filling machinery, making it an area ripe for innovation. Yet despite this ubiquity, many companies are still relying on manual fillers, where they could save time and, in the long run, money by moving to a semi- or fully-automatic system. Now, it needs to be said that manual filling isn’t without numerous advantages over pouring or portioning product by hand – such as increased accuracy and reduction in spillages etc – and, for some companies, manual fillers and depositors are the only workable option. Of course, they favour smaller production facilities, but they are also ideally suited in locations where electric supply or compressed air are not available for pumping the product. In those examples when a company has the space to expand – or is planning to move into a larger production facility – and has ample access to electric and compressed air, they still might be relying on manually operated hand pumps. Yet investing and upgrading to even a semi-automatic solution can save time and increase efficiency and throughput. Semi-automatic filling machines are typically operated by pumps driven by compressed air. Not only can filling be set to repeat, but precise portions can be filled through accurate measuring and dosing equipment incorporated in the weighing or volumetric controls. Needless to say, these machines offer a greater degree of speed and accuracy over manual. Automatic filling machines, on the other hand, boast controls and incline equipment which manages the filling process from material handling, loading, dosing and packaging. For larger companies and those looking to expand product © Shutterstock /Parilov 30 Á 28-31.qxp_Layout 1 26/10/2021 12:47 Page 2Next >