INTERNATIONAL FoodDrink FoodDrink PACKAGING Finding the right solution PROCESSING Adopting smart processing ENVIRONMENTAL MANAGEMENT A greener supply chain PACKAGING Finding the right solution PROCESSING Adopting smart processing ENVIRONMENTAL MANAGEMENT A greener supply chain INTERNATIONAL 01.qxp_Layout 1 28/06/2019 11:15 Page 1You probably think you know what SMC - the world leader in pneumatics and automation solutions - is all about: actuators, valves and fittings, right? They're the products that SMC has built its success on for over 60 years. But they are just part of how we can help you. Did you know that we can also supply customer specific control systems and engineered specials - whether you need just one, or one hundred. Some of our customers also rely on us for innovative products to help suppress vibration, to eliminate static or to provide precise fluid temperature control. For example, take our new compact and lightweight HRS-R thermo chiller. Developed for use in the Food Industry, this IP54 rated chiller delivers outstanding temperature stability and long life cycle performance. With IP67 internal electronics and stainless steel construction this chiller has been specifically designed to withstand the challenges of working in harsh environments. For more information on our HRS-R chiller contact us on 01908 563888 or check out our web site. Follow us on www.smc.uk SMC - more than just pneumatics 02.qxp_Layout 1 28/06/2019 11:17 Page 1Group Editor: Steve Fisher (s.fisher@blmgroup.co.uk) • Editor: Michael Fisher (m.fisher@blmgroup.co.uk) Editor’s PA: Angela Sharman (a.sharman@blmgroup.co.uk) Journalist: Dominic Cuthbert (d.cuthbert@blmgroup.co.uk), Tess Egginton (t.egginton@blmgroup.co.uk) Sales Director: Teri Cooper (t.cooper@blmgroup.co.uk) • Sales Manager: Sam Trott (s.trott@blmgroup.co.uk) Sales: Vicky Hunt (v.hunt@blmgroup.co.uk) Editorial: Tel: +44 (0) 1472 310305 • Email: fdi@blmgroup.co.uk • Editorial: Tel: +44 (0) 1472 310302 Accounts & Subscriptions: John Downes (j.downes@blmgroup.co.uk) Design & Production: Gary Jorgensen, Mark Casson (studio@blmgroup.co.uk) Part of the Business Link Magazine Group: Armstrong House, Armstrong Street, Grimsby, N E Lincs DN31 2QE England All rights reserved. No part of this publication may be reproduced, transmitted, photocopied, recorded or otherwise without express permission of the copyright holder, for which application should be addressed first to the publisher. While every reasonable care is taken, neither the publisher nor its participating agents accept liability for loss or damage to prints, colour transparencies, negatives or other material of whatever nature submitted to this publication. The views expressed in this publication are not necessarily the views of those held by the publisher. Processing4 As the processing sector faces mounting pressure for improved traceability, faster production of large volumes of high-quality products, and the constant need to heighten efficiency, it is key that food and drink companies embrace new technology. Packaging8 There’s a revolution taking place in the food and beverage packaging sector as manufacturers turn towards more sustainable and environmentally friendly alternatives to plastic. Health, safety and hygiene 14 Matters of hygiene are paramount in the food and drink industry, as is health and safety. Innovations in the sector are less about reinventing the wheel, and more on making those processes more efficient NPD and ingredients 18 The development of new products, particularly confectionery and snack foods, are increasingly favouriting functional ingredients that bring with them some kind of nutritional or health benefit. Prudent in a climate where foods high in salt, saturated fat and sugar have been demonised and consumers turn towards healthier alternatives. Contents Supply chain22 Efficiency in the supply chain is more important than ever, and yet further demands from retailers are placing strain on distributors. Temperature control26 Temperature control remains a powerful facet of the supply chain, but new innovations in transportation might mean things will be heating up in the industry Environmental management30 Understanding the impact of a company’s supply chain requires in-depth carbon monitoring. Through intuitive software solutions and analysis, companies can get a clear picture of what aspects of their operations and supply chain are producing the most emissions and, from there, troubleshoot the steps needed to reduce them 830 22 FoodandDrinkInternational @fdiforumwww.fdiforum.net company/fdiforum Cover photo courtesy of: Shutterstock/asife 03.qxp_Layout 1 28/06/2019 11:14 Page 1www.fdiforum.net PROCESSING 4 T he future of the food and beverage processing sector lies in the smart factory technologies that comprise Industry 4.0. The components of Industry 4.0 – which involves using technology to form a more connected, efficient industry between customer, product and process – include data exchange and automation, alongside advanced robotics, the Internet of Things (IoT), artificial intelligence, cloud, machine learning, and sensors. There are many manufacturing facilities that are decades old working with legacy equipment, but to be able to fulfil the requirements of today’s consumers and to be compliant with new legislation, investing in new elements of smart factory technology is often essential. With the advent of Industry 4.0 technology what can be accomplished in processing plants has changed, and greater control is available over every step. Automation is a major facet of any smart processing plant, and it is key in helping processing facilities reach peak efficiency, streamline processes and minimise costs. It is becoming the prime way to satiate increasing food demand, with the food automation industry predicted to be worth $2.5 billion by 2022. Some firms, however, still rely on human employees for processes that can be automated, with many avoiding the switch because of the perception that automation is not economical. Indeed the more you choose to automate a processing facility in one instance, the higher the upfront install cost will be, but in actuality the automation of a facility can be completed over time and be gradually scaled up. Further, in the long run, the results of investing in this equipment saves money: one can enhance productivity by increasing uptime as automated machines require little rest, and one can prevent all too common and costly human errors and human contamination threats. By implementing automation one can also address the sector’s worker shortage and reduce spend on labour. This does not however Adopting smart processing As the processing sector faces mounting pressure for improved traceability, faster production of large volumes of high-quality products, and the constant need to heighten efficiency, it is key that food and drink companies embrace new technology. 04-07.qxp_Layout 1 28/06/2019 11:16 Page 1www.fdiforum.net PROCESSING 5 mean that masses of employees have to be let go, rather it presents a chance to retrain employees into new positions such as running machinery. In addition, by automating roles from weighing to cutting to sorting with robots, a facility can reach higher levels of accuracy and consistency that humans are not capable of, which can also ensure higher throughput. Taking a closer look at the optimisation of the process of sorting in processing facilities, by automating this task one can be rid of the less accurate, limited, process of using the human eye, and potentially reduce waste. Without human input, automated sensor-based optical sorters, for example, can determine food quality by colour and work to remove unwanted raw materials and food products such as those with rot, contaminants, damage or defects to offer a safer and higher quality product that meets standards. Advances in automated sorting have even seen technology hit the market that can re-route materials that may not be suitable for one product but can be used for another. Robots are also capable of fulfilling other highly useful roles that boost the safety and quality of goods such as detecting microscopic bacteria and foreign materials that don’t appear in metal detectors or x-rays, and label verifying, where they can accurately check two hundred labels a minute, a significant time saving in comparison to humans completing this task. While the premise of automation is not new to the food and drink industry, when implemented with the wider technology available in Industry 4.0 one can push past what traditional automation of individual tasks achieves, to benefit from a fully connected system where machines with the right communication protocols and sensors are now capable of sharing information across process lines and providing a continuous flow of data that can be used to adapt operations to create 6 Á 04-07.qxp_Layout 1 28/06/2019 11:16 Page 2www.fdiforum.net PROCESSING 6 © Shutterstock / SeventyFour a more efficient system and to adjust a system as needs be, for instance slowing down sections when necessary. With wireless sensors one can monitor a variety of processes and equipment. For instance, one can install IoT-enabled sensors on equipment, from pumps to motors, which then send real-time data on its performance to software that can be used to analyse it. With this information one can gain deep insights on the quality of equipment, its performance, availability, and one can predict when a piece of equipment will break down and thus when it needs to be repaired. Facilities can then ensure replacement parts are on site and maintenance can be scheduled in a way that minimises downtime and can be completed before the failure of a machine halts production and causes the waste of perishable products and the resulting loss of revenue from missed shipments. This is known as a predictive maintenance system. Sensors are also useful for tracking products and keeping an eye on conditions to make sure they are maintained as goods are being processed - from cooking temperature to carbon dioxide levels. This is particularly useful as food processors are being asked to keep ever more detailed records of the products they supply. In a time where the number of food and drink product recalls in Europe have quadrupled since 2008, retailers, consumers and regulators are demanding better traceability. Food manufacturers must now make sure they can track not only where their raw materials come from, but every step and hand a product passes through as it is processed. With sensor data and digital records, end-to-end traceability is enabled, and processing facilities can react quicker in an emergency or recall situation and find precisely where a problem may have occurred. This end-to-end traceability also gives managers greater oversight to see where the processing line can be improved and allows them to remove any bottlenecks. 04-07.qxp_Layout 1 28/06/2019 11:16 Page 3www.fdiforum.net 7 tel: 01792 586800 www.hydratech.co.uk Specialist Fluid Solutions A range of non-toxic high performance heat transfer fluids, with antifreeze function, for use in food and beverage cooling systems. Corrosion, scale and biological inhibitors to protect cooling and heating systems. Cleansing and sterilising chemicals for cooling systems and production vessels. To maximise thermal efficiency, minimise downtime and extend component life. Sureflow Purachem Fluid Management Services Process Cooling Solutions for Food & Beverage Systems • Vacuum Tube Lifters • Hygienic Materials Handling Solutions • Powder Processing Machines For The Food & Drinks Industries 04-07.qxp_Layout 1 28/06/2019 11:16 Page 4www.fdiforum.net PACKAGING 8 I n 2017 global plastic production reached almost 350 million tonnes, a significant increase on the previous year. Packaging is, unsurprisingly, the market sector with the single biggest demand for plastic, dwarfing the second largest user – building & construction – by some twenty per cent. Of course, this refers to plastic packaging en masse, but food and drink takes the lion’s share with arguably the biggest offender being the food- to-go sector. Driven by convenience, competitive prices and consumer choice, the sector has continued to expand over the years with research and training charity IGD predicting it will be worth as much as £23.5 billion by 2022. It’s an issue that packaging manufacturers are having to contend with, taking things back to the drawing board and designing new solutions that are fit for purpose but aligned with the environmental agenda. It’s not a case of reinventing the wheel so to speak, but rather adopting more sustainable alternatives to traditional plastics. The biggest viable alternative at present is paper and paperboard, a segment which will continue to dominate Finding the right solution There’s a revolution taking place in the food and beverage packaging sector as manufacturers turn towards more sustainable and environmentally friendly alternatives to plastic. 11 Á 08-13.qxp_Layout 1 28/06/2019 12:20 Page 108-13.qxp_Layout 1 28/06/2019 12:21 Page 2Next >