PACKAGING Closing the loop NPD AND INGREDIENTS Changing tastes SUPPLY CHAIN Driving efficiency PACKAGING Closing the loop NPD AND INGREDIENTS Changing tastes SUPPLY CHAIN Driving efficiency INTERNATIONAL Food&Drink Food &Drink YOUR ESSENTIAL SUPPLIERS GUIDE INTERNATIONAL YOUR ESSENTIAL SUPPLIERS GUIDE 01.qxp_Layout 1 29/07/2020 08:50 Page 1MASTER OF LAWS (LLM) IN FOOD LAW GAIN A QUALIFICATION IN FOOD LAW WITH THIS FLEXIBLE DISTANCE LEARNING COURSE Improve your career prospects by gaining a Masters in Food Law while remaining in full-time employment Tailor the course and choose the modules that are right for you dmu@informa.com +44 (0)20 7017 4483 www.informadl.com/food 02.qxp_Layout 1 30/07/2020 11:59 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 The future of the food and beverage processing sector lies in smart factory technologies that comprise Industry 4.0, as automation continues to increase throughput, uptime and efficiency for producers. Packaging8 Packaging is the market sector with the single biggest demand for plastic. Although this figure refers to plastic packaging across the industrial spectrum, the food and drink sector is responsible for the lion’s share with the ever- expanding food-to-go market bearing much of the blame. Fortunately, manufacturers are constantly redesigning their packaging and turning towards ever more eco-friendly options. Health, safety and hygiene 14 The fallout from a health, safety or hygiene scare can be difficult for any company to manage. It’s therefore critical for food and beverage companies to minimise risks along the supply chain. NPD and ingredients 18 Driven by changes in legislation and consumer demand, the food and drink industry is developing healthier products. Contents 14 18 8 FoodandDrinkInternational @fdiforumwww.fdiforum.net company/fdiforum Cover photo courtesy of: Shutterstock/stockcreations Supply chain22 An upsurge in consumer demand is placing unprecedented strain on supply chains, with logistics operators forced to step up. However, there are a number of solutions to usher in greater levels of efficiency. Temperature control26 Temperature controlled storage and distribution remains one of the most powerful industries across the supply chain, with the cold chain accounting for roughly nine per cent of the £187 billion of sales in the food and drink sector. As such, there are several operational challenges to mitigate. Environmental management30 There are several ways in which food and beverage companies can achieve greater environmental management of their operations and, by extension, their supply chains. We explore some of the most important areas where companies must focus their environmental management efforts in order achieve the most significant gains. 03.qxp_Layout 1 29/07/2020 08:53 Page 1www.fdiforum.net PROCESSING 4 Industry 4.0 uses technology to form a more connected, efficient industry between customers, product and process. Components include data exchange and automation, alongside advanced robotics, the Internet of Things (IoT), artificial intelligence, cloud computing, machine learning, and sensors. There are myriad 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, ever more stringent legislation, investing in new elements of smart factory technology is often essential. With the advent of this advanced 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 many processes that can and, often, should be automated. Many The future of the food and beverage processing sector lies in smart factory technologies that comprise Industry 4.0, as automation continues to increase throughput, uptime and efficiency for producers. Perfecting processing 04-07.qxp_Layout 1 29/07/2020 08:54 Page 1www.fdiforum.net PROCESSING 5 avoid the switch because of the perception that automation is not economical. Indeed, the more one chooses to automate a processing facility in one instance, the higher the upfront install cost will be, but, in actuality, the automatisation of a facility can be gradually scaled up. Moreover, 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 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 mean, however, that masses of employees have to be let go, rather it presents an opportunity to retrain employees into new 6 Á © Shutterstock / MOLPIX 04-07.qxp_Layout 1 29/07/2020 08:54 Page 2www.fdiforum.net PROCESSING 6 www.adelphi.uk.com +44 (0)1444 472300 info@adelphi.uk.com From benchtop to fully automatic solutions ISO certified, award-winning UK manufacturer Food & Beverage filling machinery 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 simply not capable of, which can also ensure a higher throughput. Taking a closer look at the optimisation of sorting in processing facilities, by automating this task, one can be rid of the less accurate and limited process of relying on the human eye and, also, 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, contaminates, 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 © Shutterstock / Ser gey R yzhov 04-07.qxp_Layout 1 29/07/2020 08:54 Page 3Hose FittingsValves Engineered Products dixoneurope.co.uk FiFiFittttttt iininingsgss HHoHoHoHoHosesesese Enngiigineneneererereed Fittttininggs EnEn iiigigineneeerrededed i iVVVaVaVaVallvlvesessVaalvlveses +44 (0)1772 323 529 www.fdiforum.net PROCESSING 7 capable of filling other highly useful roles that boost the safety and quality of goods such as detecting microscopic bacteria and foreign materials that don’t appeal in metal detectors or X-rays, and label verifying, where they can accurately check two hundred labels a minute! While 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 in individual tasks achieve, 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 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 can 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, performance and availability on a piece of equipment, and predict when it will break down and, thus, when it will need 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 process 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 when 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 29/07/2020 08:54 Page 4www.fdiforum.net PACKAGING 8 Packaging is the market sector with the single biggest demand for plastic. Although this figure refers to plastic packaging across the industrial spectrum, the food and drink sector is responsible for the lion’s share with the ever-expanding food-to-go market bearing much of the blame. Fortunately, manufacturers are constantly redesigning their packaging and turning towards ever more eco-friendly options. Closing the loop 08-13.qxp_Layout 1 29/07/2020 08:56 Page 1www.fdiforum.net PACKAGING 9 © Shutterstock / Interpass Driven by convenience, competitive prices and consumer choice, the food-to-go market 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 a pressing 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 are 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, ensuring products are both recyclable and comprised of recycled materials themselves. 10 Á 08-13.qxp_Layout 1 29/07/2020 08:56 Page 2Next >