< Previous• Plain / Printed Labels • Thermal Transfer Ribbons • Lasersheets • Fanfolded Labels • Barcode Labels Self adhesive labels and labelling Tel: 01482 506560 • Email: sales@datamarkuk.com • Website: www.datamarkuk.com 20 Food & Drink International www.fdiforum.net END OF YEAR SUCCESS STORIES should, and then this will propel the food and drink industry to new heights. After years of waiting for that however, it’s more likely businesses will take matters into their own hands. Impressive that they can, but unfortunate that they should have to. The latest and most recent concern that is bound to have an impact on business going forward is what has been discussed at COP26 in Glasgow. The world is finally turning its eye toward sustainability, and while the food and drink industry is leaps and bounds ahead of most others because of consumer demand we have been feeling for years, that still means that Governments will be more likely than ever to start placing targets. Despite the difficult times we have just faced, new laws and requirements for packaging, traceability and food waste are likely on the horizon. Fortunately, businesses in our sector have a head start on that. The race to reduce packaging has been a presence for years now, and food consumers are notoriously picky about where their food comes from, how it was sourced and made, and what the environmental impact of it may be. There is more that is recyclable in food packaging than many other industries, but that doesn’t mean more won’t be done. Even now companies are trialling plant-based packaging, compostable labels and even edible traceability © adobe.stock.com/HollyHarry 16-21.qxp_Layout 1 22/11/2021 12:08 Page 5Food & Drink International 21 www.fdiforum.net END OF YEAR SUCCESS STORIES Packaging Automation launches its most advanced machine ever Last month at the PMA Fresh Summit in New Orleans, Packaging Automation launched their most advanced machine to date – the evolution S. Four years in Research and Development working alongside food producers and manufacturers, Packaging Automation have challenged industry limits to create the latest and most advanced machine ever developed by #TeamPA. Until now engineering principles have limited tray sealing capabilities but, when science meets Industry, anything is possible. The only thing limiting this machine’s output is the upstream process, so the team set about optimising every operation required to seal a tray, accurately, reliably, and efficiently. They employed the latest ground-breaking technology to develop a patented design and to present to you, a world first for this type of application. Capable of sealing up to 250 packs a minute in a single lane format, the evolution S also puts a stop to intermittent stop- start movement, removing the need to decelerate or stop a process to correctly position packs. This achieves continuous controlled movement that streamlines any operation. In addition, the evolution S facilitates transporting packs three times faster whilst maintaining optimum accuracy and accommodating all pack formats without the need for a tool changeover. The machine also removes the needs for transfer arms, which can be notoriously heavy and awkward to move and set up. All this while maintaining high speed feeding of film with accurate and consistent printing. Challenging industry limits Packaging Automation have managed to create a seismic shift with the production of their most technically advanced machine which basically runs itself. To find out more visit www.pal.co.uk, call +44(0) 1565 756555 or email: sales@pal.co.uk logos and stamps. It says a lot about the food and drink industry that we have already taken steps towards what other industries now balk at. While many sectors were rightly criticised and lambasted at COP26, there were blessedly few accusations to be made at food and drink. That’s not to say there aren’t problems – the copious amount of food wasted each year is one such – but those problems are issues more commonly found between retailers and consumers. It’s not hard to see that food manufacturers have taken great strides toward sustainability, aided by innovations in packaging, labelling and process machinery businesses. In conclusion, 2021 has been a troubling year for everything surrounding the food and drink industry. The sector has every reason to feel let down – and yet it has been one of the few industries mature enough to push on through the drama and conflict without being dragged down, and that paints a brighter future. If businesses can succeed through this, they can push through anything. © adobe.stock.com/AntonioDiaz 16-21.qxp_Layout 1 22/11/2021 12:08 Page 622 Food & Drink International www.fdiforum.net PROCESS, CONTROL AND AUTOMATION © stock.adobe.com/ I V iewfinder The future is NOW From introducing collaborative robots to the factory floor, thereby helping to address labour shortages and mitigate challenges posed by social distancing and self-isolation, to reducing emissions during production with ever more innovative solutions, there’s a lot for food and drink manufacturers to consider. 22-25.qxp_Layout 1 22/11/2021 12:12 Page 1Food & Drink International 23 www.fdiforum.net PROCESS, CONTROL AND AUTOMATION The food and drink sector is in a state of constant flux. Never stalling or stopping, it continually evolves to meet changes in consumer spending and eating habits, new laws and regulations and, more so over the last decade, responding to environmental pressures. COVID aside, the latter is perhaps the single greatest challenge currently facing the sector. Pressure from advocacy and campaign groups, greater regulatory scrutiny, and a public shift towards greener, more sustainable food and packaging has had a dramatic impact on the industry. Companies can now no longer afford to ignore the environmental agenda but should instead meet the challenge head on the same as they do with labour shortages and the widespread move towards smarter, automated production. Greener, cleaner production As well as adopting best practice across the supply chain, companies can make a number of positive changes in- without saying that replacing old and outdated machinery will not only boost a company’s efficiency and output but will also reduce carbon emissions, but too many producers still rely on old machinery rather than investing in new or refurbished replacements. It’s a false economy and counterintuitive besides, yet worryingly commonplace. A McKinsey report found that the average food processing plant is more than two decades old. With the continuing market proliferation of smart technologies (more on that later), companies risk making themselves obsolete. Investing in machinery and equipment that can deliver cost savings will, of course, be a motivation alongside efficiency gains, but part of the criteria also needs to be environmental impact. As well as the specific machinery that’s used, there’s also the way in which they’re used that needs to be considered. A good analogy here is a 24 Á house to reduce carbon emissions. This includes reducing water usage as well as closing the loop and recycling wastewater. Moreover, companies can participate in carbon crediting schemes, switch to energy tariffs that are powered entirely by renewables or take a more proactive approach and invest in solar panels and wind turbines on their facilities, and direct surplus food and wasted yield to anaerobic digestors. Efforts such as these, and plenty more besides, are becoming more common as companies throw their weight behind the net zero agenda, but also committing to science-based targets. Defined by the Science Based Targets initiative, these are targets that “show companies how much and how quickly they need to reduce their greenhouse gas emissions to prevent the worst effects of climate change.” In other words, it provides actionable data for positive change. While these efforts should be lauded, companies also need to think about the production process itself. It should go 22-25.qxp_Layout 1 22/11/2021 12:13 Page 224 Food & Drink International www.fdiforum.net PROCESS, CONTROL AND AUTOMATION car: you’re going to get more miles out of a tank of petrol or charged battery if your car is regularly and thoroughly serviced and maintained, if you drive and consistent speeds and plan ahead for breaking and cornering. The same is true of production and processing where regular inspection and maintenance can sustain efficiency and identify causes for concern before they result in extended disruptions. This will also ensure that machines are running at optimum levels and, thus, at their most environmentally-friendly. Reducing energy consumption during processing can also be accomplished by addressing and altering the cooking techniques themselves. Research carried out by the University of Lincoln, UK in collaboration with industry partner OAL, found that using novel approaches to a process called Steam Infusion can reduce energy consumption by seventeen per cent, cutting close to nine tonnes of greenhouse gas emissions per production line each year. Steam Infusion technology is unique in that it reduces carbon emissions directly at the site of manufacturing, which can support businesses’ plans to incrementally cut emissions throughout their facilities, while the technology enables alignment to UN Sustainable Development Goals. Send in the cobots As well as the ongoing issues that producers and processors have been facing for many years now – including staff shortages and the continuing skills gap – more challenges have arisen over the last twenty-one months. Namely, social distancing measures and self- isolation. The impact COVID has wrought on the food supply chain, at a time when Brexit was seriously impacting seasonal labour, cannot be overstated. Despite a relative return to normal, coronavirus remains a very real concern for food and drink companies with the constant fear that production can be impacted, or halted entirely, due to an on-site outbreak or a high number of staff self- isolating. However, these issues can be mitigated and managed with the use of collaborative robots. These robots – often termed ‘cobots’ – are cost-effective, safe and flexible to deploy, making them an increasing popular option in food processing and materials handling. Added to this is the fact that, as the name suggests, they are collaborative, designed to share a workspace with humans. They can allow even small and mid-sized companies to automate where before it would have been prohibitive. Although cobots have far-reaching applications and capabilities across the entire industrial spectrum, where the food and drink industry is concerned, they are ideally suited to work alongside humans in delicate processes such as pick and place – though a Integrated Controller makes FMCG mass personalisation a reality Drawing on its combined control, motion, vision and robotics expertise, OMRON has developed the Robotic Integrated Controller (RIC) - a unique control platform with the ‘brainpower’ to coordinate personalised FMCG production. What could previously only be done manually and on a very limited scale, can now be executed via a fully automated workflow. This opens up unprecedented opportunities for the FMCG industry to add value, differentiate and enhance the consumer experience. The personalisation potential promised by this innovation is unrivalled by anything that exists on the automation marketplace today, as Dan Rossek, Marketing Manager for OMRON UK, explained: “The RIC redefines ‘flexibility’ in a production context. There are companies who are supplying flexible manufacturing systems, but their definition of flexibility is making changeovers quick and easy to allow small batch production. What we are talking about here is flexibility at a unit level, the ability to make every single product unique.” Unit-level manufacturing flexibility requires seamless synchronisation of all the automation elements within the line, from conveyors, motors and drives, to vision systems and robots. As the only automation specialist to have a portfolio that includes robotics, vision, control and motion capabilities, OMRON is uniquely placed to take on this challenge. By taking a total integration approach, OMRON’s engineers have conceived an omni-control unit for these automation elements. Motion, logic, sensing, inspection, and robotics are integrated on a common network and programmed via common software. Rather than having a separate PLC, motion controller and robot controller, the RIC controls everything. From an end user point of view, the entire line can be easily managed from one interface, which makes for highly simplified operation. From a machine builder perspective, development time is massively reduced as the integration of the various automation elements negates the need for protocol development or complex programming. For more information visit www.industrial.omron.co.uk 22-25.qxp_Layout 1 22/11/2021 12:13 Page 3Food & Drink International 25 www.fdiforum.net PROCESS, CONTROL AND AUTOMATION © stock.adobe.com/ ctrl+s photo risk assessment will need to be undertaken first. With all that in mind, many have touted cobots as the future of food factories. Looking at the data, it’s hard to disagree. Research from Interact Analysis found that in 2018, global revenues from cobot production exceeded $550 million – an almost sixty per cent increase over 2017. The market researcher forecasts that revenues for cobots will reach $5.6 billion in 2027, accounting for almost one-third of the total robotics market. There’s no single solution to meeting the ongoing challenges facing the food and drink industry. However, automation and smart technologies can not only boost efficiency and output but can also help to reduce carbon emissions. Now, more than ever, automating is affordable and within reach for smaller firms. The future is indeed now. Reliable pressure emulsion line pressure prevents pump failure When taste buds explode with delight, it’s not just the aroma, but consistency of products that counts. Kievit, of the Friesland-Campina Group, is a specialist in such taste experiences. Technologies like emulsification, spray drying, microencapsulation and agglomeration are used to convert liquids into powders or give products certain desirable properties. One application has been under observation for many years: where the emulsification process is monitored and controlled. “In the past, pressure gauges from another manufacturer were used, but they had a short lifespan and caused problems,” explains Ger van den Berg, responsible for production and project engineering at Kievit’s Meppel site. The VEGABAR 38 was thus installed - a universal pressure transmitter with a ceramic measuring cell, operational up to 130°C. This compact sensor for efficient automation solutions has no compromises in safety or accuracy. The hygienic adapters make installation easy: process fittings can be selected as required and adapted. Sensors also feature a display with LED 360° status colour ring. The instruments have a standardised communication platform including IO-Link, and the new VEGABAR measuring instrument series can be read and configured with a smartphone or tablet. For further information: info.uk@vega.com 22-25.qxp_Layout 1 22/11/2021 12:13 Page 426 Food & Drink International www.fdiforum.net TRACEABILITY Keeping tack of the importance of traceability Traceability is considered to be an only legal and management requirement for any business and industry, but its importance, especially in the food and drink industry, has now reached the attention of consumers. 26-29.qxp_Layout 1 22/11/2021 12:16 Page 1Food & Drink International 27 www.fdiforum.net TRACEABILITY The main goals of traceability are still to better manage products, their processing and access in the market, and ensure food quality and safety. Additionally, a good track and trace system is a legal requirement for companies and suppliers if they want to avoid any liabilities in case of recalls, withdrawals, counterfeits, adulterations, or damages. However, the purpose of traceability today is not limited to matters of management and public health anymore, but it has extended to meet customers’ growing demand for a more sustainable and transparent market. Between the environmental crisis and COVID-19, more and more people are now focusing not only on the quality and provenience of the food they eat, but also on the impact the food will have on the environment. Food production processes contribute to over 37% of global greenhouse gas emissions, including both animal-based food productions and plant-based food productions, that is causing the deforestation and destruction of many habitats. These factors have become powerful elements able to motivate people to shift their shopping habits and behaviours towards more sustainable choices. Through traceability food business operators and companies can provide customers with all the information they are looking for in order to shop responsibly, from provenience, ingredients, nutritional values, and allergies, to how to discard of any waste. The more transparent and reliable a company is, the more authentic it will appear in the eye of a consumer, which in the long run will be a way to gain people’s trust. In a matter of product management, 28 Á © stock.adobe.com/Monet © stock.adobe.com/auremar 26-29.qxp_Layout 1 22/11/2021 12:16 Page 228 Food & Drink International www.fdiforum.net TRACEABILITY traceability is fundamental in the event of the recall or withdrawal of an unsafe product. Good record keeping is a preventative measure that allows food business operators to quickly and easily identify and locate the faulty products at any stage of the supply chain and find a solution rapidly and efficiently, whether the issue presented itself still during the processing stages or once the product was already on the market. However, the importance of traceability in the event of recalls is not remarkable only from a management and legal point of view, but also from a sustainability and marketing aspect. The swift intervention on unsafe products allows companies, suppliers, and producers to manage costs, but also to prevent any damage to the brand, and, in fact, it can help promoting a better image. Being able to recall only a limited and controlled number or batches of products means that there will be a limited and controlled amount of waste and companies will be able to reduce not only their costs, but also their carbon footprint. From a food safety point of view, traceability allows all food business operators, from producers to distributors, and consumers, to track and trace all ingredients and processes involved in the production and transport of any food and drink item. This will help determine the source of any issue and promote a prompt response and mitigation actions. But following the sustainability trend, traceability can become a very powerful tool in battling other elements of the supply chain that can have a big impact on the environment, like waste and carbon footprint. Traceability allows companies to manage their inventory that leads to the prevention of spoilage and waste. The need to be fully traceable and transparent with the public, however, does not always go along with the global interest in reducing waste and single use plastic. Successfully tracking and tracing products requires the presence of tags and barcodes, and therefore of wrapping, stickers, and packages. Many governments are trying to phase out the use of single use plastic and limit the amount of plastic companies use on their products, and even consumers are increasingly demanding companies to reduce their use of unnecessary packaging Therefore, the need to gain more and more information on a product and the need to limit the amount of plastic and wrapping oppose each other. A University of Sunderland start up, Label Says Ltd, has created an edible printed bar code that, according to them, will “transform food industry packaging.” The bar codes can be printed on any kind of food or drink item and can easily be scanned by customers, providing them with information they need without requiring any additional plastic. Similarly, in New Zealand, the apple growing company Bostock has introduced the use of compostable stickers on their apples. These stickers are made from 100% compostable Ecolabel material and their use allows Bostock to provide customers with all the information they need about their products while reducing their use of plastic. The role of traceability, therefore, is not limited to managing products, inventories, and liable safety incidents, but it has the potential to have a big impact on the environment and the management of waste by creating a circular economy that keeps track of its waste, maximises its value and saves energy. In a world where consumers are increasingly aware of the impact of what they eat and drink, this could have big impacts on a brand’s bottom line. Traceability allows companies to manage their inventory that leads to the prevention of spoilage and waste. 26-29.qxp_Layout 1 22/11/2021 12:17 Page 3Food & Drink International 29 www.fdiforum.net TRACEABILITY Food Safety Consultancy, Support and Training Food Care Solutions aims to help our clients achieve their aims. We have helped food businesses throughout the UK since 2003 with our services, including: • Food Safety and Food Quality • BRC and FSSC 22000 certification • Supplier Auditing • Training • Hygiene Inspections & Internal Audits • Complaints & Incident Tel: 01933 276 400 • Mob: 07811 192545 • Email: fcs@food-care.co.uk • Web: www.food-care.co.uk FOOD CARE SOLUTIONS FOOD CARE SOLUTIONS © stock.adobe.com/Monet 26-29.qxp_Layout 1 22/11/2021 12:17 Page 4Next >