< Previous30 Food & Drink International www.fdiforum.net END OF LINE PACKAGING BAG SEALING MACHINES RM Sealers remain a leading British manufacturer and supplier of high quality Bag Sealing Machines, also known as Rotary Band Sealers and Impulse Sealers. Call 01442 843387 to speak to a member of our team SEALERS © www.rmsealers.co.uk There’s a myriad of machinery that fall under the wider end of line packaging umbrella – from case formers to palletisers, the list goes on and on. Although each plays an important role, many will change depending on the product that requires packing. Yet every product needs to be packed for transport, distribution and delivery and, therefore, everything needs to be clearly labelled. Of all these many machines two of the most ubiquitous are case sealers and label applicators. Case sealers Commonly known as case sealers, carton sealing machines fold and seal the top lids of packed cartons, offering a reliable and efficient way of sealing cases after the initial packaging process. As one might expect, these are incredibly flexible solutions, with the best being fully adjustable with quick format changes – a must for companies packing different products on the same line or the same products into a variety of different cases for different markets or sales channels. A smarter way to package, they are available in semi- and fully-automatic options; while some companies might have one time bemoaned the initial cost of investment or derided their complexity, case forming has never been simpler or more low cost. By eliminating the need for human workers armed with messy and often unreliable handheld tape or staple guns, companies can pack faster, with lower labour costs and reduced downtime. Packing with automating sealing machines is more efficient and productive, not to mention smarter with features such as tape detection and distance measurement. It doesn’t only make financial sense moving towards From case sealers and label applicators to pick and place machines, Food and Drink International explores the impact of automation on end of line packaging. automation automation The argument 30-35.qxp_Layout 1 22/11/2021 12:21 Page 1Food & Drink International 31 www.fdiforum.net END OF LINE PACKAGING BENCHTOP BAG SEALING MACHINE IMPULSE BAG SEALING MACHINE HORIZONTAL BAG SEALING MACHINE VERTICAL BAG SEALING MACHINE automated case sealers but is environmentally savvy by reducing the volume of packaging materials, unnecessary voices in each parcel, and the use of trucks for shipping and distribution. Label applicators Label application is an area where efficiency and accuracy can be seriously encumbered if relying on human hands and eyes. Often, a desktop label printer and applying by hand is ideal for small batch and artisanal producers who might only produce a hundred jars, cans or bottles at a time, but for larger operations faced with ever increasing consumer demand, automatic options are the only way to go. As with any other machinery on the production line, there is a dizzying amount of labelling applicators to consider – blow on, wraparound, seal labelling, pallet labelling et al. A more popular option in recent years is © stock.adobe.com/Itsanan 32 Á 30-35.qxp_Layout 1 22/11/2021 12:21 Page 2END OF LINE PACKAGING 32 Food & Drink International www.fdiforum.net resealable labels and seal and tear labels as consumers place greater emphasis on snacking, sharing and portion control. The core tenant of any automation argument is that it improves accuracy and efficiency whilst reducing labour costs. The same is absolutely true when it comes to label applicators. Accuracy is particularly prudent when it comes to food and drink as labelling requirements in this industry are greater than most others – with labelling needing to convey a lot of critical information pertaining to production, nutrition and safety by law. Yet labels themselves will also need to adhere to safety laws and be made from food safe materials for product contact. Automation increases efficiency, but even with automated machines in place, downtime can still accrue with counterintuitive design. So, machine surfaces need to be made of hygienic materials that are easy to clean, while format parts should be easy to be change without tools. All that said, it shouldn’t be a challenge to find a label applicator that does it all, with a plethora of excellent machinery makers and suppliers to choose from. And, when in doubt, you can go bespoke to ensure a solution that’s entirely suited to your needs. Pick and place While pick and place machines have become more commonplace right across the production line, they are particularly prevalent in end of line packing. Offering speed and flexibility for manufacturers, pick and place machines take infeed of sealed trays and packs them into cases or crates. Another boon for manufacturers is that they are often incredibly adaptable, changing to single, twin or dual lane infeeds from a tray sealer or thermoformer. Pick and place machines have become emblematic of © stock.adobe.com/Sergey Ryzhov 30-35.qxp_Layout 1 22/11/2021 12:21 Page 3END OF LINE PACKAGING Food & Drink International 33 www.fdiforum.net y raweaakw ts ne’agingacke PKit agingo packOn the g our to all of yect partner te is the perfangr g business with our complete tseaty trast Kit out your b at y takeaway pack p kaging range powered by employee share-ownership 02476 420 065 kitepackaging.co.uk automation on the production line, replacing what was historically undertaken by human workers. Not only can these machines move at incredible speeds – with the fastest reported as up to 200,000 components per hour – but, by replacing a manual workforce, they’re actually keeping human workers safe. Injuries such as carpal tunnel syndrome, repetitive strain disorder and even arthritis can arise from repetitive movements. But pick and place robots not only boast speed but high accuracy with worker errors of placing packs in the wrong place or in the wrong way reduced to almost zero. The grippers and vacuum powered suckers used are much more dextrous and sensitive than human hands, ensuring that delicate foods, ingredients and packs are not damaged or compromised when they’re lifted and set back down. Despite this sensitivity, they are incredibly strong, able to lift a much greater 34 Á © stock.adobe.com/I V iewfinder 30-35.qxp_Layout 1 22/11/2021 12:22 Page 434 Food & Drink International www.fdiforum.net END OF LINE PACKAGING load than their human counterparts. As was the case with case sealers having an environmental benefit, so too do pick and place machines. Their inherent efficiency gains and the speed of throughput helps to cut down on the time a product is hanging around in the factory, therefore giving it a longer life on shelves and for consumers. This reduces the chance that it will be wasted and helps to curtail the food waste epidemic – given that figures from the Waste and Resources Action Programme show that the UK produced around 9.5 million tonnes of food waste in 2018, it’s an issue that the industry is still grappling with. Combined with other areas along the production line where automation has yielded efficiency gains, this can offer a profound time saving, boosting throughput for manufacturers, but extending shelf life for retailers and consumers. Everyone’s a winner. Time and money can also be saved by the smart nature of pick and place machines. They can reliably and effectively reject any defective product before it is packed. Not only does this make things easier for quality control and assessment purposes, but significantly reduces the chance of faulty or compromised product making it to consumers (thereby reducing the possibility of complaints and the cost of product recalls). For manufacturers looking to keep up with the times and automate, end of line packaging is the ideal starting point. Automated packing equipment can perform the necessary tasks quicker and more efficiently than a human workforce and to a highly accurate standard without requiring the critical eye of a team member as in other areas of the production line. Doubtless once the benefits have been realised here, manufacturers will look to automate other areas of their factory floor. © stock.adobe.com/industrieblick 30-35.qxp_Layout 1 22/11/2021 12:22 Page 5Food & Drink International 35 www.fdiforum.net END OF LINE PACKAGING We are witnessing a plant-based food revolution. Between 2016 – 2020, the number of vegans in Europe doubled from 1.3 million to an estimated 2.6 million. Meanwhile the flexitarian demographic has experienced the fastest growth of all, now making up 22.9% of all Europeans, according to the Veganz Nutrition Study. This monumental and disruptive shift in consumer behaviours has been driven by a conscious desire to reduce meat consumption and replace with plant- based proteins and meat alternatives as part of more ethically driven and sustainable lifestyle choices. However, producers that are offering consumers more eco-compliant, meat- free food products risk negating their efforts if their supply chain processes aren’t aligned to support reducing carbon emissions or if they involve animal derivatives. This is crucial when it comes to packaging. The Lancet’s Food in the Anthropocene Journal reported that current dietary trends, combined with projected population growth to around 10 billion by 2050, will exacerbate risks to people and the planet as a result of food production’s effects on greenhouse-gas emissions, pollution, biodiversity loss, and water and land use. This highlights a need to reduce global meat consumption and encourage more meat alternatives, which can be produced using alternative agricultural methods with lower environmental impact. In fact, analysts at Barclays estimate the global market for meat alternatives could reach $140 billion by 2029. Alongside this, there’s growing demand for transparency from food producers, processors and retailers about the sustainability and ethical credentials of their products and their supply chains. With more plant-based and meat alternative product choice on the market, consumer purchasing decisions will increasingly be influenced by their understanding of a brand’s ethical values and the commitments it has made to protecting the planet’s resources. Packaging features as a key part of the consumer experience. By its very function of protecting and preserving food, packaging is in the direct eyesight of shoppers when they’re viewing food on a retailer’s shelves and in chillers and freezers. For these reasons, outer packets provide a canvas for brands to engage the customer, which heightens the consumer interest in how their food is packaged. Furthermore, people increasingly interact with packaging when they are opening, preparing, and cooking foods. This is leading to consumers increasingly scrutinising the materials used to wrap and pack food. Brands must therefore carefully consider the importance of transparency to the consumer, and whether their products and processes are truly ethically viable in the journey to market. At Sealed Air, we are continuously exploring new methods for the circular reuse and recovery of packaging, to create innovative new materials that protect both products and the environment. Our food packaging materials do not contain animal derivatives such as tallow (animal fat used as a lubricant or slip agent during plastic production). We’ve identified alternative options including non-animal fats and hydrocarbon waxes, that offer the same high performance, low friction and polymer compatibility, yet are not derived from animal sources. As a business we are continuously accelerating innovation and development of end-to-end solutions, engaging in new technology and leading collaborations with our partners worldwide to increase reuse and recycling and reduce waste across the value chain. While consumer demand for plant-based and meat alternative products shows no signs of abating, companies bringing new products to market can be sure that Sealed Air’s products are both eco-compliant and effective. Is your packaging fit for plant-based produce? By Matt Baldock, Business Development Leader Food Packaging at Sealed Air For further information, visit www.sealedair.com or contact us at foodcare.europe@sealedair.com 30-35.qxp_Layout 1 22/11/2021 12:22 Page 636 Food & Drink International www.fdiforum.net WAREHOUSING OPTIMISATION Removing the human element wherever possible may improve efficiency. But how viable is it to extend this philosophy to the entire warehouse? machines Running with 36-40.qxp_Layout 1 22/11/2021 12:28 Page 1Food & Drink International 37 www.fdiforum.net WAREHOUSING OPTIMISATION When it comes to operating a warehouse or distribution centre, optimisation is always going to be the most important factor. With the balance between minimising costs and maximising throughput, isolating and identifying factors that cause delays or problems becomes increasingly important. In many cases however, it is the human element that impedes total efficiency. Employees become fatigued, both physically and mentally, and must take regular breaks for food or to visit the bathroom. They also make mistakes, either accidentally, or through negligence. And when an employee is involved in an accident, it is obviously far more worrying than a piece of machinery. So is it possible to completely remove the human element from the warehousing industry? And would it really be a good idea? The arguments for moving towards fully automated warehouses are many and varied. One of the largest elements is obviously the goal of reducing costs. Currently in the EU wages are falling across most countries, but this trend is certainly not going to be a permanent one. Being able to remove employees from the picture could save a company millions in terms of wages, while also cutting out other related costs involved, such as payroll, HR, and legal matters. It’s worth noting that automated warehouses don’t truly attempt to live in a world where humans don’t exist. There is likely to be a team monitoring an automated warehouse from another location, ensuring that everything runs efficiently and running the warehouse. But even then, the costs of having a few centralised control teams would be far less than having teams at every single distribution centre. Also by cutting out manpower there is less risk for accidents or mistakes. While `to err may be human` is all well and good, it’s not something that will placate major customers who haven’t received their shipment on time, or who now have lost or damaged stock. Automated systems reduce the chance of human error. Of course they do not completely remove the potential for accidents, such as a wooden pallet splintering – a fully automated system also cannot be injured by the resultant mess. Space is another benefit to an © stock.adbobe.com/ industrieblick 38 Á 36-40.qxp_Layout 1 22/11/2021 12:28 Page 238 Food & Drink International www.fdiforum.net WAREHOUSING OPTIMISATION automated system. Walkways and mezzanine floors can be unnecessary if a distribution centre is set out properly. Aisles could theoretically be removed entirely if a warehouse was to use roof- mounted shuttles or cranes to move goods about. But even if a company preferred to use remote-operated forklifts, there would be less requirements in terms of the width of aisle – a remote forklift unit of course not needing to be as wide as a normal one, due to its lack of a driver cabin. Conveyor belts and systems are commonplace in automated warehouse systems like these, particularly for bringing goods to loading bays to be delivered to any logistics crews arriving for stock. Conveyor belts again can help make efficient use of space, as there are no requirements on where they must be placed. If a company truly wished to do so, then the conveyor system could be near the ceiling, allowing for the ground level of the warehouse to be used for storage. Temperature controlled warehouses can benefit doubly from this, as the lack of workers travelling to and fro reduces the opening of doors and access points, causing loss of temperature. An automated conveyor system might more commonly involve an automated shutter that only allows the product through, before closing behind it – preventing escape of chilled air. However the most obvious reason for looking towards automation in the warehouse will always be productivity. Workers will always be ruled by the physical limitations of the human body, while machines do not suffer the same fatigue. An automated system can continue running for 24 hours a day, without the need for changing teams, shifts and breaks. For food and drink retailers who operate online stores and delivery, this enables companies to have more flexible cut-off times for deliveries, improving customer relations and perhaps even making them a more attractive choice for consumers. So, what is holding companies back? Costs remain an important factor, with a fully automated warehouse system requiring not only specialist machinery 36-40.qxp_Layout 1 22/11/2021 12:28 Page 3Food & Drink International 39 www.fdiforum.net WAREHOUSING OPTIMISATION and software, but also a lot of planning and preparation. For existing warehouses it might mean alteration, or removal of all existing systems, which would lead to a lot of wastage. While for new builds, there is already such high investment being utilised for distribution centres that adding another facet to the mix in what is already a tough economic climate, simply isn’t desirable. Return on investment tends to be a little slower with fully automated systems, despite high labour costs. On top of that there are also concerns about the flexibility of automated systems vs their more standard counterparts. When creating a new warehouse there is always the possibility that sales fall, or the space is not fully utilised in some way. In the event that a warehouse suddenly finds itself only operating at 50% capacity for instance, it is a relatively simple affair to move the racking around, designate the space to a different sector, rent out the space – or even just cut down on the size of the workforce to save costs. With a fully automated system this just isn’t quite so simple. Excess equipment could be sold for some quick capital, but that just leaves the warehouse unable to pick back up if sales increase, while leaving half of the warehouse inoperable will only result in marginal savings in terms of energy costs. Automated systems that are locked in place are not as easy to move around as workers, and even if a company was able to rent the space out to another – software systems and operating procedures would need to be adapted to the new products, causing further confusion. Ultimately, many companies are forced to adapt some kind of balance, reaping the benefits of automated systems where they can, while also keeping a certain degree of manual labour in place to work around it. While there is no telling if in the future the industry can adapt more effective means of fully automating warehouses, for now the decision is a difficult and demanding one for logistics and distribution managers. © stock.adbobe.com/sveta 36-40.qxp_Layout 1 22/11/2021 12:29 Page 4Next >