How food chains are being reimagined Smarter hygiene Rewriting the recipe for food production How food chains are being reimagined Smarter hygiene Rewriting the recipe for food production INTERNATIONAL• Also measures humidity and temperature • Auto-report fu nction The new AwEasy complements our range of water activity mea- surement devices perfectly. Measurement probes, penetration probes, laboratory benchtop and handheld devices can be com- bined flexibly according to your requirements. Benefi t from the highest accuracy, effi ciency, and easy calibration to optimize processes and ensure product quality. ProcessSensing.com SCAN ME Rotronic AwEasy – Standalone Bluetooth Water Activity Monitor AwTherm HC2-AW HygroLab AwEasy dQF ancimport ant the i sunderWe u li e ofc d dson.norwww omcn. OUT OF THE aneously me O ltsimul eauge on the mark ONL g s 9 is the etur Series MoisM Coolor oood QuF X!E BO e:asure ant ct thaek on-line YY eintoPr Oil/taF L uality Serie es9On-LineGauge e Engineering i Serie instruments to help you es 9 OnLine Gauge meet global standards. eGroup Editor: Steve Fisher (s.fisher@blmgroup.co.uk) • Editor: Tess Egginton (t.egginton@blmgroup.co.uk) Editor’s PA: Angela Sharman (a.sharman@blmgroup.co.uk) Sales Director: Angela Cooper (a.cooper@blmgroup.co.uk) Editorial: Tel: +44 (0) 1472 310305 • Email: fdi@blmgroup.co.uk • Sales: 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 AI, automation and smart systems are transforming how food and drink are processed, helping the industry adapt to rising demand, stricter standards, and shifting global pressures. Packaging8 From seaweed films to protein-based pods, edible packaging is emerging as a practical way to cut waste and add value. Food and drink businesses are now exploring where it fits into their supply chains. Temperature control 13 From factory floors to final delivery, temperature control is the silent force behind food safety, quality, and trust. In an industry where a few degrees can make or break a product, innovation and vigilance are everything. Health, safety and hygiene16 At a time of increasing stringency, food and drink manufacturers must become more vigilant when it comes to health, safety and hygiene, with a raft of technological advancements ready to help. NPD20 Consumers expect more from their food, demanding health benefits, clean labels, and sustainable sourcing without compromising taste. For product developers, balancing functionality, regulation, and sensory appeal has never been more complex. Supply chain24 Behind every meal lies a supply chain in rapid transformation, driven by innovation and the push for sustainability. Events and shows28 Your chance to keep abreast of forthcoming exhibitions and food fairs from around the world. 16 20 8 FoodandDrinkInternational @fdiforumwww.fdiforum.net company/fdiforum Cover photo courtesy of: stock.adobe.com/darshikawww.fdiforum.net PROCESSING 4 F ood and drink processing, the invisible engine behind every stocked shelf and restaurant plate, is being transformed at pace. Artificial intelligence, automation, and connected systems are changing not only how food is made, but how it is understood, inspected, and delivered. The industry’s long- standing tension between consistency, safety, and efficiency is being rebalanced in real time by machines that learn, sensors that speak, and algorithms that optimise. At the heart of this transformation lies an increasingly urgent challenge: how to meet rising global demand while staying ahead of volatility. Post-pandemic labour shortages, tightening regulations, and pressure to cut waste have created a new urgency for innovation. The response from food manufacturers has been a sharp pivot toward digitalisation. Line by line, process by process, they are rebuilding their operations with the tools of Industry 4.0. It’s a story about control, about making decisions faster, identifying faults sooner, reducing downtime, and adjusting production on the fly. Artificial intelligence is proving particularly adept at tackling tasks once reliant on human instinct. Machine vision systems, for instance, now inspect everything from biscuit colour to bottle fill level in real time, far more accurately and consistently than the human eye. AI- enabled quality control tools can spot subtle inconsistencies that might signal contamination, degradation, or mislabelling, protecting both brand and consumer. In some plants, AI is being used to predict when machines are likely to fail, enabling pre-emptive maintenance and minimising unplanned stoppages that ripple down the supply chain. Across frozen foods, confectionery, beverages and beyond, these models are reshaping factory logic. In tandem, automation is moving from simple mechanical repetition to intelligent execution. Robotic arms and automated guided vehicles Rewriting the recipe for food production AI, automation and smart systems are transforming how food and drink are processed, helping the industry adapt to rising demand, stricter standards, and shifting global pressures. www.fdiforum.net PROCESSING 5 (AGVs) are now commonplace in many facilities, but the next generation of automation is more adaptable. Using feedback from sensors embedded in production lines, these systems can adjust processing variables, without the need for operator intervention. The result is tighter tolerances, greater efficiency, and less waste. For fast-changing categories like plant-based meats and ready meals, where formulations and ingredients are continually evolving, such adaptability is no longer optional. The Internet of Things (IoT) is another piece of the puzzle. Sensors now gather and transmit data across every stage of processing, from raw ingredient intake to packaging. This data is not merely archived but analysed in near-real time to optimise yield, track product flow, and improve traceability. In large-scale operations, this can translate into significant savings. For example, IoT-enabled chilling systems can adjust their energy consumption dynamically based on load size and ambient conditions, reducing electricity bills and environmental impact. In meat processing plants, sensors embedded in cutting equipment can track throughput and yield, while ensuring compliance with hygiene protocols. Yet, the path forward is not without its complications. Many producers still face integration issues, with legacy equipment that predates digital networks. The cost of upgrading infrastructure remains a barrier. There’s also the question of interoperability: getting machines and systems from different manufacturers to speak the same digital language. Without industry-wide standards, full end-to-end integration remains an ambition rather than a reality for many businesses. Cybersecurity has become another pressing concern. As processing plants become more connected, they also become more vulnerable. 06 Á © stock.adobe.com/Prostock-studiowww.fdiforum.net PROCESSING 6 Food and beverage companies are increasingly aware of the need to safeguard operational data, recipes, and customer information. In response, some manufacturers are investing in segmented networks and security protocols designed to keep production lines running even if external systems are compromised. Then there is the workforce. Automation and AI may reduce the need for repetitive manual labour, but they create a new need for digital literacy. Engineers, data scientists, and software technicians are becoming as vital to the factory floor as electricians and maintenance crews. Forward-thinking manufacturers are investing not only in new equipment but in upskilling existing staff to manage and interpret the technologies behind it. Some are forming partnerships with universities and technical colleges to build talent pipelines tailored to food processing’s future. This reshaping of roles is not without cultural friction. There is concern in some quarters about technology displacing jobs, particularly in regions where food processing is a major employer. However, many industry leaders argue the opposite: that technology will secure the sector’s future by making it more resilient, more appealing to younger workers, and better able to respond to shifting market dynamics. If production can be scaled or diversified more easily, the argument goes, then the industry will grow in both reach and stability. The pursuit of sustainability is also playing a major role in how innovation is being applied. Food waste, water consumption, and carbon emissions are all under scrutiny, from NGOs and investors alike. Processing plants are responding with smarter systems that monitor and reduce resource use. Heat recovery systems, AI-guided cleaning protocols, and closed-loop water filtration are becoming standard in new builds and retrofits alike. The circular economy is no longer a fringe idea; it is shaping the very design of processing infrastructure. What’s emerging is an industry that’s more agile, data-driven, and prepared to adapt, not only to consumer preferences but to global shocks. During the pandemic, many food processors struggled to pivot from foodservice supply to retail packaging. Today, modular processing lines and predictive analytics offer greater flexibility, allowing manufacturers to switch products or packaging formats quickly and cost-effectively. This kind of operational agility may become the defining feature of the sector in the years ahead. © stock.adobe.com/rdkchowww.fdiforum.net 7 Fluid Transfer Solutions Valves Hose Assemblies Engineered Products Fittings & Accessories cs@dixoneurope.co.uk H Ei Applied Heat in Food Manufacturing Tel: +44 (0)1707 331111 info@welwyntoolgroup.co.uk www.welwyntoolgroup.com Specifically designed to feed process air at inlet temperatures of up to 350°C Quiet operating sound level of 58dB(A) Capable of delivering air flow of 1,640 l/min at 50Hz with a static pressure of 14.6kPa Save energy Save money Integrate the LHS 210/410 series air heaters with Leister’s new CHINOOK blower. HIGH PRESSURE HOT AIR RECIRCULATION Tennant RUBBER 70 YEARS Tennant Rubber Ltd is a family run business with 70 years of experience in the Rubber Industry. • GASKETS • STRIP • FABRICATIONS • MOULDING & EXTRUSION • HOSE • HOSE ASSEMBLIES • TUBING • DUCTING • FITTINGS & FASTENERS • SHEET & MATTING • ENGINEERING MATERIAL • ROLLER COVERING T 0115 985 2300 E sales@tennantrubber.co.uk W www.tennantrubber.co.uk From gaskets to fasteners, we offer a large selection of rubber and polymer products to suit almost any requirement. With both off-the-shelf and custom solutions, our products are specially designed for use in a wide range of applications, from powder processing to filling hoses and seals. Our experienced team supplies rubber and many other polymer products into a range of markets in the UK including food, brewing and beverage, pharmaceuticals, locomotive, bulk processing, engineering, utilities, construction, chemical and many more.www.fdiforum.net 8 E dible packaging is moving from concept to commercial reality, and the food and drink sector is now watching closely to see how it can be scaled. While the idea of packaging that can be eaten alongside the product has been around for years, the urgency of cutting single-use plastics has brought new investment and research. This is no longer a laboratory exercise; trials are running in production environments, and the interest from retailers and foodservice is significant. The principle is simple: if packaging can be eaten, it does not become waste. That appeals to regulators, brands, and consumers alike. The challenge has always been performance. Edible materials need to protect products as effectively as conventional packaging, withstand transport, and meet hygiene standards, all while being palatable. The latest advances are overcoming these hurdles through formulations based on plant proteins, seaweed extracts, milk casein and starch composites. These materials are being designed to behave like a thin film or coating, sealing a product from moisture and oxygen, Edible packaging moves closer to the mainstream Edible packaging moves closer to the mainstream From seaweed films to protein-based pods, edible packaging is emerging as a practical way to cut waste and add value. Food and drink businesses are now exploring where it fits into their supply chains. www.fdiforum.net PACKAGING 9 yet safe to consume. One area seeing the fastest progress is in portioned, ready-to-eat items. Small sachets containing ingredients or condiments that can be dropped directly into a dish without removing a wrapper are now in pilot use. Similarly, drink pods encased in edible membranes, designed for single servings of water or soft drinks, are being trialled at events. These applications reduce secondary packaging waste and remove the need for disposal on site, making them attractive to foodservice and catering operators. For food manufacturers, edible coatings on products such as fresh produce or confectionery can extend shelf life and reduce the need for separate wrapping. Applied as a thin layer, these coatings slow moisture loss and delay spoilage while adding negligible bulk. Some coatings can even be tailored to deliver additional nutrients, colour, or flavour. They also allow packaging to remain transparent, a feature that consumers associate with freshness and minimal processing. The regulatory environment for edible packaging remains complex. Products must meet food safety standards in every market in which they are sold, and manufacturers must be able to demonstrate that the material remains stable throughout distribution and storage. Labelling is another consideration: even though the packaging is edible, consumers must be informed clearly about its contents and composition. These requirements mean that edible packaging cannot be treated as a simple swap. It demands a rigorous approach to testing, certification and supply chain communication. Cost is a barrier for now. The processes involved in producing edible films and pods are more expensive than traditional plastic or paper formats, particularly when equipment needs to be adapted or built specifically for these products. However, there are signs that scaling up production will bring costs down, just as it has in other areas of sustainable packaging. Food and drink companies looking to position themselves as early adopters are working with specialist suppliers to test lines, understand performance limits and identify where the value can outweigh the additional spend. There is also a commercial benefit in brand differentiation. Edible packaging has strong appeal in premium markets and can help create a distinctive consumer experience. For businesses supplying foodservice operators, hospitality or travel, the convenience of packaging that can be consumed rather than 11 Á © stock.adobe.com/HelgaQNext >