< Previouswww.fdiforum.net PACKAGING 11 disposed of is seen as a way to reduce clean- up costs and support sustainability commitments. Not all products or supply chains are suitable for edible formats. High-moisture, high-fat or large-volume goods pose difficulties for structural stability, and long shelf-life items with complex distribution routes are still better served by more traditional recyclable materials. For these reasons, edible packaging is likely to develop as part of a mixed portfolio rather than a single solution. It works best where consumption happens quickly after purchase, in controlled environments such as quick-service restaurants, canteens or catered events. Research partnerships are accelerating progress. Collaborations between food science departments, material technologists and packaging engineers are producing prototypes that go beyond novelty. These partnerships are exploring natural polymers and even 3D printing technologies to create edible packaging with tailored strength and shape. Some companies are looking at hybrid models, where an edible © stock.adobe.com/adha Speak to a member of our team Call on 01442 843387 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. SEALERS © www.rmsealers.co.uk 12 Áwww.fdiforum.net PACKAGING 12 component is combined with a thin, recyclable outer layer for additional protection during long transit. As with other forms of sustainable packaging, the question for businesses is when—not if—this approach will find a place in the mainstream. Brands and their suppliers need to evaluate how edible formats could fit into their broader packaging strategy. Early pilots can help build knowledge, establish supplier relationships and test consumer response. Retailers and foodservice buyers are increasingly open to these innovations, particularly when they align with sustainability reporting targets. The food and drink industry has always had to balance safety, functionality and presentation. Edible packaging adds a fourth dimension: how packaging itself becomes part of the product. It demands new thinking on materials and design, closer collaboration with regulators, and a willingness to invest early in unfamiliar technologies. For businesses prepared to take that step, it offers the opportunity to stand out in a market where packaging is no longer just about containment, but about experience and responsibility. Proud to build your Alpha. André, Product Manager IT’S TIME FOR GENERATION ALPHA. Discover the powerful all-rounder among melters. Reliable adhesive application for your success. Learn more: go.robatech.com/alpha-en © stock.adobe.com/KanStockPngwww.fdiforum.net TEMPERATURE CONTROL 13 I n the food industry, temperature control is not simply a matter of efficiency. It is a cornerstone of safety, quality, and compliance. From the moment raw ingredients enter a facility to the point finished goods are delivered to retailers or restaurants, maintaining precise and consistent temperatures is a non-negotiable element in preserving the integrity of the product. Any deviation can compromise food safety, lead to spoilage, increase waste, and ultimately erode consumer trust. One of the most overlooked yet critical components of temperature control lies in the very architecture of manufacturing facilities. Doors, dock seals, and loading bays play a surprisingly significant role in maintaining internal temperatures. High-speed freezer doors, air curtains, and insulated sectional doors are not luxuries but practical necessities. These systems reduce thermal transfer during the comings and goings of staff or deliveries, preserving the carefully regulated environment inside. Automatic sensors and intelligent door systems that close the moment a person or forklift exits have helped many operations reduce exposure times and energy loss. Loading bays themselves have evolved into precision-controlled zones, often fitted with dock levellers, trailer locks, and advanced sealing systems that mitigate the risk of temperature drift during loading or unloading. Innovations in inflatable dock seals and telescopic lips now allow for closer alignment between the vehicle and the building, reducing the likelihood of warm air infiltration. In high-volume sites, the smallest The tightrope of temperature control 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. 14 Á © stock.adobe.com/Iftikhar alamwww.fdiforum.net 14 inefficiencies in these systems can amount to considerable risk over time. Refrigeration systems, too, have seen major technological advances. Traditional refrigeration relied on a fairly reactive model, where temperature readings would be logged and reviewed periodically. Now, real-time monitoring systems powered by the Internet of Things (IoT) and artificial intelligence are becoming standard. These technologies enable manufacturers to not only monitor but anticipate fluctuations, and trigger alerts or automated responses before a problem escalates. Sensors embedded throughout facilities feed data back into a centralised system, allowing operators to identify patterns, optimise energy use, and flag mechanical issues ahead of failure. Yet even with such digital tools, physical infrastructure still plays a leading role. Floor insulation, wall panelling, and ceiling structures all contribute to a consistent thermal envelope. Materials designed to reduce thermal bridging and condensation risk are increasingly being used, particularly in ambient-to-chilled transition zones. Proper air circulation also prevents hot or cold spots within storage rooms or production floors, ensuring an even climate for the product and minimising the chance of localised spoilage. Transport introduces a fresh set of challenges. Refrigerated lorries, vans, and containers must adhere to the same strict standards as processing facilities. However, once the product is on the move, external variables like traffic delays, weather conditions, or loading times become harder to control. The solution lies in a combination of improved vehicle design and smarter technology. Multi- compartment lorries now allow for different temperature zones within a single vehicle, enabling mixed loads without compromise. Real-time GPS tracking combined with temperature monitoring ensures not only that temperatures remain within threshold, but that any deviations can be quickly addressed. Some firms are investing in solar-powered refrigeration units or hybrid technologies to maintain cooling even when vehicles are parked or during power outages. Meanwhile, advances in phase change materials (PCMs) are enabling better temperature maintenance during last-mile delivery. These PCMs absorb or release thermal energy to maintain a © stock.adobe.com/Thirawatwww.fdiforum.net TEMPERATURE CONTROL 15 constant temperature, reducing the reliance on active cooling over short distances. In urban settings where delivery schedules are tight and idling is discouraged, these passive technologies are becoming an increasingly attractive option. The rise in e-commerce and direct-to- consumer delivery services has added complexity to the cold chain. Consumers now expect chilled or frozen products to arrive at their doorsteps in perfect condition, placing further pressure on logistics and packaging solutions. Insulated boxes with integrated sensors and temperature indicators are becoming more common, helping customers verify the safety of their order on arrival. Compliance frameworks are also growing more rigorous. In the UK, the Food Standards Agency mandates strict adherence to cold chain principles, with documentation required at every handover point. The implementation of HACCP (Hazard Analysis and Critical Control Points) plans often includes multiple temperature monitoring steps, and failure to demonstrate control can result in costly recalls or penalties. Globally, regulations differ slightly, but the overarching expectation is clear: food businesses must demonstrate that temperature control is maintained, monitored, and documented from start to finish. Sustainability goals are also shaping the conversation. Refrigeration is energy-intensive, and as the food sector works to lower its carbon footprint, innovations that reduce energy consumption while improving control are in high demand. Variable speed compressors, natural refrigerants, and integrated heat recovery systems are just some of the technologies being deployed. By reducing dependency on traditional refrigerants and maximising energy efficiency, manufacturers can address both operational and environmental priorities. There is, however, no silver bullet. Temperature control in food manufacturing requires a combination of technology, infrastructure, process, and human oversight. Training staff to understand the importance of cold chain integrity remains critical. The best systems in the world can still fail due to human error. Culture, then, becomes part of the equation. When every employee understands the stakes, from warehouse worker to transport driver, the entire chain becomes stronger. © stock.adobe.com/Grispbwww.fdiforum.net HEALTH, SAFETY AND HYGIENE 16 S tringent health, safety and hygiene practices are critical in the food and drink industry, to protect products, consumers and workers, ensuring food is hazard and risk free. They enable compliance with regulations such as the US Food and Drug Administration’s Food Safety Modernization Act and adherence to Good Manufacturing Practices (GMPs), prevent damage to brand reputation by minimising the chance of recalls, and in turn legal penalties and financial losses, and build trust amongst customers and consumers. They are essential to securing contracts, with manufacturers required by retailers and foodservice operators to illustrate their commitment to quality and a formal health and safety policy, with detailed information on potential flashpoints and measures in place to deal with them. From raw material handling to packaging finished products, food firms must prevent contamination throughout the production process, making sure goods are free from pathogens, facilities are designed for optimal hygiene, that cleanliness is maintained, and that staff are well trained to facilitate this. With increasing awareness and stricter regulations, strong hygiene practices have never been more crucial, with one misstep leading to foodborne illnesses or an allergic reaction, a major recall, and lost customers and contracts. As businesses in the industry become more vigilant, they are enhancing sanitisation, documentation and verification protocols, implementing clear, comprehensive procedures, policies and schedules, enhancing facility Smarter hygiene Smarter hygiene 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. www.fdiforum.net 17 design to mitigate contamination and bolster control, and establishing strong food safety cultures where all employees understand their accountability. From colour coded cleaning equipment indicating where it can be used and foot activated faucets on hand washing stations, to installing mixers without hard corners that curb build-up, and implementing robust temperature control measures, vast improvements can be made to food facilities to boost health, safety and hygiene. Continuous refinement is key, by conducting regular reviews and updates to policies, and undertaking assessments and audits (both internal and external), utilising the likes of Hazard Analysis and Critical Control Points (HACCP) management systems to pinpoint risks throughout production. Reinforcing workforce training is also vital to educate and provide employees with the knowledge needed to execute procedures effectively, and update them on the latest regulatory requirements. Strengthening health, safety and hygiene are a raft of technological advancements, improving cleaning, hazard detection, prevention and monitoring, quality control, and document management. Artificial Intelligence (AI), for example, can be used to analyse large 18 Á © stock.adobe.com/Seventyfourwww.fdiforum.net HEALTH, SAFETY AND HYGIENE 18 pools of data to uncover potential hazards before they become a problem, using machine learning to predict contamination points and identify risks. Advanced sensors and cameras, meanwhile, can constantly monitor temperature, humidity, and cleanliness levels to verify food safety, detect hazards and immediately alert staff to take corrective measures where conditions deviate from safety standards. Integrated into the Internet of Things (IoT), data from sensors can be aggregated and sent to the cloud for analysis, enabling businesses to monitor food safety in real time across locations. Moreover, cloud-based process management platforms streamline record keeping and allow for remote monitoring of food safety data, which regulators can check for compliance. Modern software solutions are facilitating the centralisation and digitisation of food safety compliance, making it easier to control documentation, conduct quality control and assurance procedures, prepare for audits, and implement HACCP plans. From one device, firms can ensure food safety compliance, quality management, and enhance productivity and efficiency. Automation is also evolving hygiene in food facilities. In general, increased automation reduces contamination risks by minimising the number of times food has to be handled by human workers, but automating the cleaning process itself has additionally become more popular. Automated cleaning systems, including cobots, can sanitise equipment and surfaces at regular intervals, and provide data on cleaning performance to address any issues promptly. At a time of staff shortages this decreases the need for human intervention and roles that are labour-intensive and repetitive, with these systems able to work tirelessly and consistently, curtailing human error. Clean-in-Place (CIP) systems have been a key choice for automating cleaning and sanitisation of interior surfaces of production equipment, ensuring thorough, consistent cleaning without disassembly, reducing downtime and contamination risks. Though not new, CIP systems are being enhanced, with © stock.adobe.com/Mihail© stock.adobe.com/Stephen Davieswww.fdiforum.net HEALTH, SAFETY AND HYGIENE 19 automated data collection allowing for precise monitoring of parameters such as time, temperature, flow rate, and concentration, to guarantee reliable cleaning results. Features are also being incorporated to optimise water consumption and waste. Other advances have seen ultraviolet (UV) light robots take on cleaning in the food industry, having entered the spotlight during the COVID-19 pandemic, using UV light to destroy the DNA structure of microorganisms as the robots navigate complex layouts and disinfect surfaces to eliminate pathogens precisely. As businesses become more vigilant, exploring these technologies presents an opportunity to augment health, safety and hygiene standards against a backdrop of increasing stringency. Helping to ensure consistent execution of hygiene protocols, heightened monitoring, rapid identification of issues, and improved record keeping, greater food safety can be unlocked, protecting products, consumers, and the success of food manufacturers. ˖˚ˡ˜ˡ˜˔˥˧ˬ˥˧˦˨˗ˡ˜ ˢˢ˙ ˜ ˡ˜ˡˡ˜˪˗˥˔˪ʴ˚ ˦˘˦˥˨ˢ˖ ˗ˢ CONTACT OUR EXPERTS With extensive expertise and over 40 years of service, we specialise in microbiology, chemistry, nutritional, allergen and species testing for food manufacturers. Your Partner in UKAS Accredited Safety sales@micro-search.co.uk 01422 4056780 Microbiological Analyses: Pathogen detection, challenge testing, rapid pathogen screening ▶ Our Offer Chemical & Nutritional Analyses: Hydroxy- proline, meat content, mycotoxins ▶ Allergen and Species Tests: All 14 UK allergens, meat and fish speciation, GMO ▶ Your Added Value bespoke IT systems ▶ expert technical support ▶ 365 laboratory operations ▶ DZYNXRFD ˇˆʼʿʴʼʶʸ˃ˆ˯ʺˁˁʼˇʷˈʴ˯ˌˇʸʹʴˆʷ˂˂ʹ˯˃ʶʶʴʻ JQLQLDUW JQLQLD HF QRV U GQDGK VHVU GQD\U K HOEDOLDYDRVOD WHNRSVHEGQDHVXRKQΖ UWHWRPHUURPRRUVVDO& VVHHWWDDUUVVVVDDSSPPDD[[HHKKJJLL+ FQHLUHS[H\UWVXGQLGRRI + KKKWKLZVUHQLLDUWWQHLOOOHF[O( UXRFOHYHOWQHPHJDQDP RVLYUHSXVQLVWVLODLFHS6 ( Next >