IF&PT 109

n. 109 - April 2025 ISSN 1590-6515

ITALIAN

Supplemento al n. 03, marzo 2025 di Industrie Alimentari - Sped. in A.P. - D.L. 353/2003 (Conv. in L. 27/02/2004 n° 46) art. 1 comma 1 DCB TO - n. 109 anno 2025 - IP

FOOD & PACKAGING TECHNOLOGY

LMR

ROBOTIC MOULDING LINE OFFICIAL TECNO 3 PATENT

INNOVATIVE FLEXIBLE COMPACT CONSTANT PRECISE

An incredible innovation in the field of automation and robotics, a strategic investment for companies that wish to remain competitive and innovate in a highly challenging sector as the chocolate industry.

LMR has replaced the mechanics and synchronisms with 3 robots highly efficient. This also means ease of cleaning, reduced maintenance, reduced footprint and ease of use.

let’s meet at

Headquarter: Tecno 3 S.r.l. - Corneliano d’Alba - ITALY Tecno 3 Switzerland Tecno 3 USA INC

+39 0173 61.05.64 • www.tecno-3.it

10064 PINEROLO - ITALIA Tel. +039 0121393127 info@chiriottieditori.it

PRODUCT TRENDS

Egg processing market worth $47.2 billion by 2029 According to the latest market analysis published

by MarketsandMarkets agency, the global egg processing market is expected to reach USD 47.2 billion by 2029, with an estimated value of USD 37.5 billion in 2024, representing a compound annual growth rate (CAGR) of 4.7% from 2024 to 2029. This growth surge is primarily attributed to several key factors such as consumers are increasing awareness of the nutritional value of eggs, rich in protein, vitamins, and essential minerals. This drives the demand for both fresh and processed egg products.

The food industry heavily relies on egg products for various applications such as baking, pasta production, sauces, and dressings. The growth of the food industry, particularly in bakery and confectionery segments, directly translates to increased demand for processed eggs. In October 2018, The American Egg Board (AEB) is celebrating World Egg Day by highlighting the egg industry’s commitment to “sustainable nutrition.” This means providing high-quality protein while minimizing environmental impact. Egg farmers are working to reduce their use of land and water, while also making eggs affordable and accessible to people around the world. Studies have shown that eggs can significantly improve health outcomes in children, especially in areas with limited access to nutritious food.

Additionally, the development of functional egg products presents a significant opportunity for low-cholesterol options for health-conscious individuals, high-protein varieties for fitness enthusiasts, and even allergy- friendly solutions. These cater to niche markets while offering unique functionalities including improved emulsification, gelling, or fortification. Advanced technologies such as freeze-drying and enzyme modification further enhance these

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properties. While cost and consumer awareness pose challenges, the growth potential is undeniable. By addressing these concerns and leveraging innovation, the egg processing industry can solidify its position in the evolving food landscape.

MARKET DYNAMICS The expansion of the food and beverage industry catalyzes growth The expansive functionality of egg products, offering attributes such as whipping, thickening, and emulsification, positions them as invaluable components transcending various food sectors. In the realm of bakery and confectionery, eggs serve multifaceted roles, including binding, providing moisture, and act-

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PRODUCT TRENDS

ing as natural leavening, contributing to the structural integrity, texture, and flavors of baked goods.

According to the International Pasta Organization Secretariat General c/o Unione Italiana Food (IPO), global past consumption reaching 16 million tons in 2020 signifies a substantial market for eggs as binding ingredients and natural color enhancers. This statistic underscores the widespread adoption of eggs in pasta manufacturing, contributing to the creation of smooth texture and golden appearance in the final product.

The burgeoning food and beverage industry drives the growth of the egg processing market. As restaurants, bakeries, and manufacturers churn out an ever-increasing variety of products, their demand for processed egg ingredients such as liquid eggs, egg whites, and yolks. This surge is driven by several factors including convenience and efficiency in food preparation, consistent quality and functionality in baked goods, and the versatility of eggs in various recipes. Additionally, the rising popularity of convenience food and ready-to-eat meals further fuels the demand for processed eggs, as they offer a pre-measured and easily incorporated ingredient. Furthermore, the growing health consciousness among consumers is driving the demand for egg- based products perceived as natural and protein-rich. Finally, the expansion of the food service industry, with its extensive use of pre-cooked and pre-processed egg products, contributes significantly to the market’s growth.

Recommendations include increasing the production of raw materials for animal feed, such as maize and soybeans, and ensuring the availability of other essential ingredients like leftover fish, seashells, sunflower cakes, and vitamins.

Cutting-edge technology enhances efficiency and market appeal in egg processing The integration of advanced automation technologies in egg production presents a significant opportunity for the industry’s growth and efficiency. In Canada, where labor shortages and the transition to cage-free systems are driving forces, investments in automated packing, stacking, and palletization technologies are enhancing operational efficiency and egg quality. For instance, the adoption of automated packing and stacking equipment, such as Damtech’s systems, streamlines egg collection and processing, reducing labor- intensive tasks and improving productivity. Additionally, innovations like the Ovoconcept palletizing robot at Rose Valley Colony exemplify how automation can significantly increase efficiency, with the ability to palletize 10,000 eggs in just 30 minutes. These technological advancements not only optimize operations but also improve egg quality and cleanliness, leading to fewer cracked and

Egg price volatility impacts processing costs and consumer confidence The egg industry is susceptible to price fluctuations due to various factors such as disease outbreaks, changes in consumer demand, and production costs. These variations can have a cascading effect on processing costs and profit margins, creating an environment of uncertainty within the industry.

A comprehensive assessment of the causes of price volatility in the egg commodity value chain provides valuable insights. One primary factor contributing to this volatility is the imbalance between egg production and demand. To address this, efforts should focus on enhancing egg production through initiatives like improving chicken breeds, implementing efficient chicken feed strategies, and introducing insurance schemes to mitigate risks. Furthermore, the high cost of egg production inputs, particularly chicken feeds, plays a role in price fluctuations.

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PRODUCT TRENDS

The edible oils market

According to the latest report published by MarketsandMarkets agency, the edible oils market is estimated at USD 250.78 billion in 2024 and is projected to reach USD 306.92 billion by 2029, at a CAGR of 4.1% from 2024 to 2029. Some of the key factors fueling rapid growth in the global edible oils market are increasing consumer awareness of healthier cooking alternatives and higher disposable incomes. A rise in plant-based diets and sustainable food choices has resulted in increased demand for health-benefiting oils such as olive, sunflower, and coconut. These oils improve digestion but also offer the possibility of adding essential fatty acids and improving heart health. Edible oils have a wide variety of uses frying, baking, dressings, marinades, etc.

The global edible oils market is witnessing high growth, led by increasing population, ever-increasing disposable incomes, and changing dietary patterns in the world. Food processing, industrial applications, and various forms of baking and cooking account for widespread applications in the market. Key players that are engaged in this market include Wilmar International (Singapore), Cargill Incorporated (US), and Bunge (US). These companies cater to the expanding demand for oils like soybean, palm, sunflower, and olive oils, enhancing their footprints across developed and emerging countries.

This market growth is in line with the upward trend in world median incomes, according to the World Bank report in October 2023. The average daily median income

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PRODUCT TRENDS

Meat products in the world The meat products market, valued at USD 44.3 billion in 2023, is on track to grow at a 9.2% CAGR, reaching USD 68.9 billion by 2028 according to the latest report published by MarketsandMarkets agency. This dynamic sector within the global food industry encompasses a wide range of products, including beef, poultry, pork, lamb, and processed meats. The demand for meat products has been steadily increasing in recent years, driven by several key factors, and this upward trend is expected to continue.

One of the primary drivers of this growth is the expanding global population, particularly in emerging markets. As populations grow and disposable incomes rise, meat consumption increases, reinforcing its role as a staple protein source. Additionally, urbanization is reshaping dietary habits, with more people moving to cities and seeking convenient, processed meat products that align with fast-paced lifestyles.

Global meat products market ecosystem analysis

ing, and fermentation processes cater to the evolving culinary tastes of a more adventurous and discerning consumer base.

The globalization of food culture has also played a pivotal role, exposing consumers to a broader array of culinary traditions and fostering a demand for unique and exotic flavors. As disposable incomes rise globally, consumers are more inclined to opt for convenience foods, with processed meats fitting the bill as a ready-to-eat or easy-to-prepare option. Despite health considerations, the indulgent and savory qualities of processed meats continue to attract consumers, prompting manufacturers to adapt by introducing healthier formulations.

In essence, the burgeoning demand for processed meatproducts reflects a dynamic interplay of convenience, culinary diversity, economic trends, and evolving consumer preferences in the contemporary food landscape.

Processed is one of the types that Accounted for the Highest Market Share in 2022. The surging demand for processed meat products, encompassing cured, dried, roasted, smoked, and fermented varieties, can be attributed to a confluence of factors reshaping consumer behavior.

In today’s fast-paced lifestyles, characterized by time constraints and hectic schedules, the convenience offered by processed meats has become increasingly appealing. These products require minimal preparation, aligning seamlessly with the preferences of busy individuals and professionals seeking quick and easy meal solutions. Moreover, the diverse flavors and textures achieved through curing, smok-

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PRODUCT TRENDS

for alternative proteins in these regions is growing from its current low level, but with high growth rates.

According to the British market research institute Euromonitor International, global volume sales of meat products will increase by 8% and sales of plantbased alternatives by 25% until 2028.

Demographic developments, nutritional trends, changing consumer habits and ever shorter product life cycles are shaping the markets. In addition, the high demands placed on food safety, quality and variety as well as sustainable production and high price and competitive pressure are ensuring continued investment in technology.

services remotely. Data and its use generate added value in terms of increased efficiency, product safety and transparency throughout the entire manufacturing and packaging process.

Artificial intelligence (AI) is playing an increasingly important role.

AI facilitates the analysis of real-time data from the production process, detects anomalies and helps to reduce unplanned downtimes. In cleaning processes, artificial intelligence (AI) enables the detection of contamination levels and self-adapting cleaning processes.

The simulation of production processes with the help of AI and digital twins is becoming increasingly important. In particular, it helps with complex investment decisions and creates investment security.

These and other topics will play a central role at IFFA 2025. “We are very much looking forward to the international supplier industry presenting a wide range of innovations and to discussing requirements and trends with the international visitors in a personal exchange,” concludes Klaus Schröter, Chairman of the VDMA Process Technology Division for Meat and Protein Processing. www.vdma.org

Digitalization and AI for sustainable production Customers focus on sustainable solutions for the production process: energy efficiency, avoiding product losses, reducing water and media consumption, holistic energy concepts for waste heat and optimized, easily recyclable packaging are the most important topics.

Digitalization is a central component of sustainable production, as process data evaluation can optimize the use of resources, reduce production downtime and provide

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FOOD PROCESSING

Four macro trends impacting food manufacturing today In today’s volatile economic and geopolitical landscape, staying ahead of market trends is essential for food manufacturers.

As we step into 2025, the start of the year shaped by geopolitical crises, cost-of-living pressures, supply chain disruptions, and political shifts, several trends are poised to define the future of food production.

As a complete technology solutions partner to food manufacturers – spanning every aspect of the production line, including project management and aftermarket support – TNA Solutions is committed to helping customers navigate these trends, enhance resilience and drive growth in an increasingly competitive market.

Here is a closer look into what food manufacturers can expect over the next year and how technological innovations could help them thrive.

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Persistent supply chain disruptions Global supply chains remain fragile due to geopolitical tensions and climate change. The Russian invasion of Ukraine disrupted global supplies of key commodities, with Ukraine previously accounting for 46% of sunflower oil exports and 9% of the global wheat market, according to the USDA’s Foreign Agricultural Service. Conflicts in the Middle East, including attacks on shipping vessels, have affected trade routes. Simultaneously, extreme weather events like droughts and floods, exacerbated by El Niño, have strained agricultural productivity, leading to increased raw material costs.

According to Food Engineering’s 45th State of Food Manufacturing report, producers are focusing on efficiency to combat rising costs, which have increased

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FOOD PROCESSING

low-sugar, and plant-based snacks, as well as confectionery with added nutritional benefits like high-fibre and high-protein ingredients. Consumers are increasingly prioritising organic and natural options, encouraging manufacturers to innovate while balancing costs. For instance, the rise of veganism is expected to increase manufacturing costs, leading to higher pricing for authentic plant-based items.

TNA is dedicated to helping food manufacturers navigate these challenges with innovative technology and complete solutions designed to enhance production efficiency. One way food producers can adapt to economic pressures is by rethinking the use of materials, typically considered waste. For instance, rejects from a french fries line – perfectly suitable in quality but not in shape – are often discarded. TNA works closely with its partners to explore transforming these rejects, as well as slivers and nubbins, into value-added products like hash browns, formed potato items or potato flakes. This approach not only reduces waste but also creates opportunities for new revenue streams, aligning with a commitment to responsible practices.

Additionally, reducing material consumption remains a key focus for TNA. As such, single-serration jaws on VFFS systems help minimise the use of biaxially oriented polypropylene (BOPP), a recyclable but non-biodegradable material. By enabling a 5-millimetre material saving per seal, a system producing 150 bags per minute can save 2.26 million bags monthly. In a facility operating 10 packaging lines for 12 hours a day, this equates to near-

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ly 390 kilometres of film saved per month. By reducing waste and material use, manufacturers can navigate economic challenges more effectively and continue delivering value to consumers.

Labour shortages The food manufacturing sector faces a significant labour shortage. A report by Deloitte and the Manufacturing Institutesuggests that US manufacturers will need 3.8 million new workers by 2033, with nearly half of those roles potentially remaining unfilled if current labour gaps persist.

Similarly, Deloitte reports that 62% of European manufacturers struggle with recruitment and retention, with this shortage expected to continue well into 2030.

This issue is compounded by an ageing workforce. According to a study by the Food and Drink Federation, nearly a third of the UK workforce is projected to reach retirement age by 2033–2035, leading to the loss of valuable skills and knowledge from the industry.

To address these challenges, the industry has accelerated its adoption of automation and prioritised user-friendly technologies. TNA recently introduced the tna ropac® 5 – the world’s fastest case packing system. Case packing often represents a bottleneck in many manufacturing sites, and some manufacturers are just beginning to automate this function. Australian snack

manufacturer Majans achieved a 140% increase in throughput within 12 months after implementing the tna ropac® 5.

Andrew McManus, Manufacturing Manager at Majans, highlighted its impact: “Just five years ago, we regularly had between 28 and 35 people on a single shift, bagging, mixing and case packing. Today, with the help of TNA Solutions, that same factory operates with just 10-11 people per shift at outputs up to 6.9 times greater than before the automation process began. Casual jobs have been transformed into stable, full-time employment contracts, and technicians and maintenance crews have also been upskilled to effectively service and support these systems at a higher technology level.”

TNA engineered the tna ropac® 5 to operate at up to 95% efficiency, even at elevated speeds.

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FOOD PROCESSING

Users can thus carry out complex sorting and quality controls for irregularly formed items, which is difficult, if at all possible, to carry out using rulebased vision systems. In contrast to humans, AI systems are able to scan hundreds of products a minute continually and find tiny flaws or contaminations, which could impair the quality of the food. AI especially demonstrates its advantages in highly-automated packaging lines where the priority lies on speed, flexibility and efficiency. This ensures that only goods that meet the strict quality demands reach the consumers.

An eye on everything during the snack check In addition to the established R(ed) - G(reen) - B(lue) camera technology and the laser scan, more and more systems that work in the ultraviolet or infrared wavelength range have recently been implemented to inspect food. The reason for this are tasks that can no longer be solely solved using sensors that work in the visible wavelength range. Here, the hyperspectral image processing of the Austrian company, Insort, reaches down to molecule level. It allows the chemical composition of the products to be assessed spa-

tially-resolved inline and in real-time. And even if test objects with a higher variance have to be inspected and sorted, like dried fruits and nuts, AI is no longer a future vision. With the aid of Deep Learning, modern vision systems like the Sherlock Hypernova by Insort decide themselves whether an object belongs in a snack mix or whether it is a foreign body. All foreign bodies, whether plastic, stones, metal or fragments of glass are removed in just one step. It is also possible to determine the bitterness of almonds and have them discharged safely, where necessary.

Generative AI ensures smart processes in the everyday routine Thanks to AI, food producers not only have the opportunity to solve complicated quality control tasks. Generative AI models that are trained using large data sets, can also help develop optimised recipes or suggest alternative raw materials. They enable combinations of ingredients and production methods to be discovered that meet the requirements of the consumers more readily and which are at the same time more cost-efficient. www.prosweets.com

+ NEWS + INFORMATION www.foodexecutive.com FOODEXECUTIVE 1-4.indd 4

31/03/21 16:32

FOOD PROCESSING

Suitability for ovens, freezers, cooling tunnels, and primary packaging areas When to Choose It If the production line requires frequent washdowns – for example, in clean rooms or at the exit of processing machines – the modular chain spiral conveyor is preferable to traditional models.

The design allows for more effi-

cient cleaning, reducing the risk of contamination.

Which spiral conveyor should you choose?

The choice depends on the specific needs of each facility.

If the product is packaged and the priority is maximum efficiency in limited space, AmbaFlex offers the most efficient solution.

If the production environment requires high sanitization standards or handles unpackaged products, Intralox modular chain spiral conveyors are a safer and more hygienic alternative.

(M.H. Material Handling - Via G. Di Vittorio, 3 - 20826 Misinto MB - Italy - Tel: +39 0296720176 email: info@mhmaterialhandling. com - www.mhmaterialhandling. com)

Radiofrequency inactivation of Salmonella in black pepper and dried basil leaves Radiofrequency (RF) heating has been extensively studied for pasteurizing low-moisture foods.

Currently, bulk foods are treated with radiofrequency; potential cross-contamination may occur during packaging of pasteurized products. As an alternative, in-package RF processing was

evaluated by US Researchers for Salmonella inactivation on black peppercorns and dried basil leaves and prevention of cross-contamination during storage postprocessing.

In-package steaming refers to the process in which the samples were heated in a steam vent

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package to generate and retain steam during the treatment.

This treatment achieved good heating uniformity which could be because of the circulation of steam within the package.

One-way steam vent allowed the release of excess steam once a threshold pressure was achieved and later returned to its original position to seal the package, when the RF energy was removed. In-package RF steaming of black peppercorns and dried basil leaves for 135 s and 40 s, respectively, resulted in more than 5 log reduction of Salmonella. The steam vent remained stable posttreatment and properly sealed the package to protect the product from any external contamination.

These results, published in Journal of Food Protection, indicate that the use of steam vent could effectively pasteurize black peppercorns and dried basil leaves could be beneficial in preventing the potential cross-contamination postprocessing.

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PACKAGING TRENDS

Food and beverage metal cans market worths $70.72 billion by 2029 According to the latest marketing report published by Markets and Markets agency, the food and beverage metal cans market is estimated at USD 50.42 billion in 2024 and is projected to reach USD 70.72 billion by 2029, at a CAGR of 7.0% from 2024 to 2029. Metal cans are widely used for packaging various food and beverage products because they maintain quality in terms of appearance, texture, flavor, and nutritional value while also ensuring food safety.

These aspects drive ongoing innovations in the metal can market, where manufacturers prioritize food safety. However, growth is constrained by strict regulations on materials like aluminum and steel, as well as inadequate infrastructure in emerging countries.

As consumer preferences shift toward healthier and more natural products, there is a noticeable trend toward packaging innovations that align with these desires. The rising demand for ready- to-drink beverages, plant-based foods, and premium food products is contributing to the increased adoption of metal can packaging. This trend is attributed to the superior ability of metal cans to preserve flavor, nutrients, and freshness. Additionally, metal cans provide a barrier against light and air, which helps maintain the quality and integrity of health- focused products throughout their shelf life. Consequently, metal cans are becoming a preferred choice for brands striving to meet evolving consumer demands and ensure product excellence.

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PACKAGING TRENDS

High barrier films for food packaging growth advances While food packaging is largely recognised as a long-term and resilient industry during economic downturns, its enduring growth is surpassed by demand for high barrier films in food packaging.

In the latest market report from AMI, titled “High Barrier Films for Food Packaging - The Global Market 2024”, the expert consultants have combined first-

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hand industry insight across all polymer substrates with data analysis to give a comprehensive picture of this increasingly important sector. The research, which was released in November 2024, gives investors and industry participants a thorough grasp of the competitive challenges, market dynamics, and industry development.

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PACKAGING TRENDS

The report divides the global market into eight separate regions, differentiating between the four distinct markets of Asia, which show differing speed of growth, direction of growth and use of substrates and barrier materials with the Indian Sub-Continent enjoying the highest rate of growth contrasted with North East Asia, where demand for high barrier films is stagnant.

Growth drivers are varied and complex. Sustainability is a key factor in the rise in demand for high barrier films as these films serve to prevent food waste, reduce packaging and replace mixed material alufoil laminates. However, in developed regions, poor consumer perception of plastics could hinder growth, as brand-owners and converters seek alternatives through the use of paper, with many development projects and trials underway. Across Asia, more cost-effective mixed material laminates are expected to remain prevalent. The report provides insights into the different reasons behind these distinct drivers for growth and offers analysis of future outcomes.

The report covers all transparent and non-transparent barrier materials which are typically used to replace alufoil. It explores the significant future potential of emerging barrier and substrate materials, some of which accelerated in uptake during raw materials shortages.

Chilled products such as meat/fish and dairy account for the majority of high barrier films applications in 2023, and whilst snack foods will be the fastest growing application, meat/fish will provide the largest volume growth as retailers seek to further protect this high value segment.

New technologies Advances in technologies such as MDO-PE and BOPE as well as improved coating solutions will enable further growth in the use of high barrier films for stand-up pouches and retort pouches, which are increasingly popular for their convenience features,

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while allowing for increased regulation for sustainability and recycling purposes.

The report will enable anyone using, converting or considering adopting high barrier films to improve their knowledge of the different barrier methods available, and which end-use applications have the best growth potential for each barrier material.

Readers will obtain consumption data for each barri-

er type in each world region and get an independent assessment of the implications for future material sourcing.

The third edition of AMI’s highly regarded High Barrier Films for Food Packaging – the Global Market report is the result of an extensive research programme, providing a detailed independent assessment of this industry. AMI Consulting has been monitoring the trends in high barrier films since its first high barrier films report was published in 2015 and, building on the previous editions, this study has evolved into the most detailed analysis of high barrier films for food packaging currently available on the market. It represents an essential guide for industry players as they optimise business activities and plan future investments. www.amiplastics.com

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PACKAGING EQUIPMENT

Efficient automation: planning your packaging right from the start Manufacturers of consumer goods such as food, beverages or cosmetics who wish to automate their packaging processes may quickly come up against mechanical limitations.

This is because not every product packaging can be used immediately and efficiently in a packaging machine. So what can be done? No matter what packaging, what product and what automation is involved, it always makes sense to get not only the packaging manufacturer but also the machine manufacturer on board – right at the outset of the project.

Although small and medium-sized companies still do a lot of their packaging manually, the use of automated, robot-assisted packaging processes continues to increase worldwide. And it’s no wonder. Many decisive advantages can only be achieved with automation: Higher productivity, less waste, compensating for labour shortages and transparent production are just some of them. The machine solutions range from small, cost-effective entry-level variants through to all-inclusive lines. Despite all the enthusiasm, it is important to take a close look at the viability and cost-effectiveness of the entire automation process. It is essential that the packaging and the machine work so well together that maximum machine output can be achieved. Only then will the small increases in efficiency

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per carton or flowpack add up and guarantee long-term cost reductions.

Many factors influence automation’s overall performance Equally relevant to the cost calculation is how often formats are changed and, as a result, how often the packaging process has to be reorganised in production – as this reduces the overall output. The duration of each individual format change also has an impact on results. A quick and easy changeover to a different format is essential to maintain the availability and efficiency of the automation solution. This can only be achieved with an appropriately designed packaging machine.

everal factors come into play to achieve this: The format parts and robot tools should be easy to change via plug & play. The more lightweight and manageable the components are, the greater the chance that only one person will be needed to change them. 3D printing now plays a major role here, as the freely designable plastic parts often replace several metal parts in a tool in one go and are significantly more lightweight. Another key factor is the line’s start-up time after a format change. If the format parts first have to be adjusted, the packaging machine cannot usually start immediately with optimum quality – and product losses are virtually inevitable. If, on the other hand, the change parts are designed in such a way that enables the product to be packed immediately in the expected quality, these losses can be reduced to a minimum.

The interaction between packaging, machine and formats is essential The issue of format changeovers not only plays an important role when deciding on a machine, but also when selecting the pack-

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PACKAGING EQUIPMENT

With any automation, it is key that the packaging and the machine work so well together that maximum machine output can be achieved.

A quick and easy changeover to a different format is essential to maintain the availability and efficiency of the automation solution.

es is gluing and erecting a carton blank, filling the erected cartons and closing them with an attached or separately erected lid.

This requires even greater technical precision than with flowpacks, as there are significantly more robots with their various tools involved.

The challenge here is that every carton packaging or carton blank has certain tolerances that always react differently during production. These include the bending stiffness of the material, the curvature of the blank, and the humidity and temperature of the environment during machine processing. The smaller these tolerances are, the higher the performance of the packaging system. Packaging that was previously erected manually does not always meet the values required for optimum machine performance when existing formats are automated.

Valentin Köhler, cardboard packaging developer at Gerhard Schubert for the past 14 years,

here is the modular design of the top-loading machines – using tried & tested system components – as this enables technologies to be retrofitted without the need for major conversions or exorbitant costs. For example, a closed surface can be sucked in during capping, thereby increasing the contact pressure during gluing.

Occasionally, the restoring forces of the cardboard also cause difficulties when folding.

This creates unsightly bulges on the sides of the carton, which can disrupt the subsequent processes. “There are several measures that can be taken to counteract this,” explains Valentin Köhler.

“On the one hand, optimisation of the die-cutting lines leads to a reduction in the restoring forces on the packaging material. And on the other, pre-folding processes can be integrated at various points in the machine. Which of these measures is most suitable is always closely coordinated with the customer.”

explains what is possible in this case: “If the packaging should be retained even after automation, we discuss with our customers how we can achieve an efficient, economical solution. There are always advantages to be gained with our flexible technology: We can optimise the individual robot movements and the functions of the tools to make the process more tolerant of material fluctuations.” The background

Valentin Köhler has been developing cardboard packaging at Gerhard Schubert for the past 14 years.

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PACKAGING EQUIPMENT

Packaging automation from the production line to shipping Tecno Pack Group is now capable of handling, through its own companies, any food product – from the moment it arrives from the production line to shipping – by automating all packaging stages up to logistics.

All companies can find solutions tailored to their needs, allowing small, medium, and large industries to choose from a wide range of packaging machines the best one for their food products.

As a reference point for companies seeking customized solutions from a reliable long-term partner, Tecno Pack consistently meets expectations thanks to its ability to listen to clients and develop tailored solutions for baked goods (both sweet and savory), cheeses, snacks and bars, fish and meat, beverages, as well as medical devices and cosmetic products.

The company’s international expansion strategy has long been a necessity for Tecno Pack, both for market growth and for the opportunities in production relocation. “Privately owned but with an international organizational structure and cutting-edge technology, Tecno Pack Group is a company capable of provid-

ing the best packaging solutions for any industrial sector,” confirms Andrea Motta, Sales Manager. “We always guarantee tailor-made projects. We are reliable and competent, offering global support with response times that allow us to serve both the world’s largest groups (such as Kraft, Nestlé, PepsiCo, and Barilla) and small industrial bakeries with full satisfaction. Additionally, we prioritize sustainability, with our 5.0 plants enabling customers to benefit from the tax advantages provided by the new transition plan.”

In its path of improvement and growth, Tecno Pack has undergone significant expansion over the years, driven by strengthening its corporate structure through major acquisitions. The goals of this expansion are to optimize the use of company resources and gain increasing strength against other players in the food market.

In synergy with Tecno Pack (which specializes in horizontal flowpack and vertical pillow pack machines, car-

Horizontal packaging FP 100E series (Tecno Pack).

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A120 CE cartoning machine (Tecno Pack).

toners, wrap-around cartoners, automatic feeders, and complete systems for primary, secondary, and tertiary packaging), its subsidiaries also contribute to the Group’s success: - Skilled Group-Euroimpianti (tran­ sport systems and automatic palletizers) - IFP Packaging (machines and systems for shrink film, shrink tunnels, and bundlers) - GSP (horizontal flowpack packaging machines and medium-output systems).

Horizontal packaging The FP 100E series is Tecno Pack’s latest technological innovation, designed to serve the most demanding food industries. This high-speed horizontal packaging machine is the result of decades of technological evolution and experience with the world’s leading market players. It is the most advanced version of the company’s horizontal flowpack packaging machine, fully electronic, with a cantilever structure that ensures complete sanitization.

The film unwinding system is motorized, as is the longitudinal sealing unit (featuring two independent motors). The transverse sealing units available on the FP

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RESEARCH

Accelerated aging of beef The purpose of a U.S. study published in Meat Science was to determine the impact of accelerated aging (AA) on shelf stability, product loss, sensory and biochemical characteristics of 2 lower quality beef cuts.

Triceps brachii (TB) and semimembranosus (SM) were collected and fabricated from 10 USDA Choice beef carcasses and assigned to 1 of 6 treatments: 3 d cooler aged (control), 21 d cooler aged, AA 49°C for 2 h, AA 49°C for 3 h, AA 54°C for 2 h, and AA 54°C for 3 h. The results showed that AA can decrease APC counts on steak surface and in purge and redness, but increase lightness and product loss of the steaks

(P < 0.01). Lower shear force was also found for AA steaks compared to those from the control (P < 0.01), with the AA 54 °C treatments being comparable to 21 d cooler aging. However, the trained sensory panel determined AA steaks were less juicy and flavorful than those from the control and 21 d cooler aged samples (P < 0.05). There was no off-flavor detected in AA steaks though lipid oxidation was higher in AA samples than those in the control steaks (P < 0.01). The AA treatments stimulated cathepsin activity (P < 0.05), which may have enhanced the solubilization of stromal proteins and led to a different troponin-T degradation

pattern compared to those from the 21 d aged samples (P < 0.01).

Although AA is an economical and time-efficient method to increase tenderness of lower-quality beef cuts, further research is needed to determine strategies to mitigate the decrease in juiciness from AA treatments.

Agaist the formation of acrylamide in coffee Acrylamide is an amide that is formed during the Maillard reaction, with asparagine being the primary precursor of the amino

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acid. The intake of large amounts of acrylamide induced genotoxic and carcinogenic effects in hormone-sensitive animal tissues.

The enzyme asparaginase is one of the most effective methods for reducing the formation

of acrylamide in foods such as potatoes. However, the sensory results reported for coffee so far have been unsatisfactory.

A Brazilian study published in Food Research International aimed to produce coffees with reduced levels of acrylamide by treating them with asparaginase while retaining their original sensory and bioactive profiles.

Three raw samples of Coffea arabica, including two specialty coffees, and one of Coffea canephora were treated with 1000, 2000, and 3000 ASNU of the enzyme.

Asparagine and bioactive compounds (chlorogenic acids-CGA, caffeine, and trigonelline) were quantified in raw and roasted beans by HPLC and LC-MS, while

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Recycling of almond skin through the production of novel brioche The global sustainability policy emphasizes the reuse of agrifood waste and by-products to improve the bioactive properties of food. In a study conducted at the Department of Agricultural, Food and Forestry Sciences of the University of Palermo, Italy, brioches were processed incorporating almond skin powder (ASP): control (CTR), without ASP addition; 5-ASP, with 5% (w/w) ASP; and 10-ASP, with 10% (w/w) ASP. Seven different brioches shapes were obtained for each recipe. Flavonoids were mainly detected in Tuono almond skin

by Ultra-High Performance Liquid Chromatography coupled to High-

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Resolution Mass Spectrometry (UHPLC-HRMSMS), in particular, flavan-3-ol monomers. The ethanolic extract of Tuono almond skins contained polar lipids (oxylipins and phospholipids). Gas Chromatography–Mass Spectrometry (GC-MS) identified six major fatty acids, mainly oleic acid (48.01%). Photothermal degradation impact on bioactive compounds was evaluated using a first-order kinetic model.

Antioxidant activity was studied using 2,2′-azino-bis(3-ethylbenzothiazoline-6-sulfonic acid), 2,2-diphenyl-1-picrylhydrazyl and β-carotene bleaching test. α-amylase, α-glucosidase, and lipase

Inhibitory effect were also tested.

The acidification of the doughs was consistent across all trials.

Lactic acid bacteria and yeast levels increased. Importantly, the final products were free from undesirable microorganisms.

As reported in the Journal of Agriculture and Food Research, addition of ASP led to reduced weight loss and specific volume for all seven brioche types.

Furthermore, the firmness, crumb structure, and sensory profile of the final products were noticeably influenced. Tasters clearly favoured the Treccina brioches. The production of sweet leavened baked goods was carried out in triplicate in two independent experiments. The statistical model applied to the data considered the effects of brioche shape and the addition of ASP. Kinetic data revealed that the half-life extension for both total phenol and flavonoid content was observed in the 10-ASP sample (18.00382).

10-ASP sample exhibited promising ABTS radical scavenging activity, with inhibitory concentration 50% (IC50) values of 18.64 mg/mL after 9 days of photothermal degradation. Moreover, when testing 10-ASP Treccina against α-amylase and α-glucosidase, the IC50values were 198.16 and 190.23 μg/mL, respectively, even after 9 days.

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Taste perception and composition of dark chocolate The chemical composition of dark chocolate has a significant impact on its complex flavor profile, so a French study published in Molecules investigated the relationship between the chemical composition of the volatile fraction and the perceived flavor of 54 dark chocolate samples made from Trinitarian cocoa beans from the Dominican Republic.

The samples were evaluated by a trained panel and analyzed using gas chromatography-mass spectrometry (GC-MS) to identify and quantify volatile compounds.

Predictive models based on a partial least squares (PLS) regression enabled the identifica-

tion of key compounds to predict individual sensory attributes.

The models were more successful in classifying samples based on the intensity of bitterness and astringency, even though these attributes are primarily related to non-volatile compounds.

Acetaldehyde, dimethyl sulfide, and 2,3-butanediol were found to be key predictors for various sensory attributes, while propylene glycol diacetate was identified as a possible marker for red fruit aroma.

The study highlights the potential use of volatile compounds to accurately predict the flavor of chocolate.

Pistachio spread with no added sugar The production of multi-component foods requires a correct ratio of ingredients in order to achieve specific quality parameters. In recent times, there has been an increasing trend towards healthy products, low in sugar and saturated fat, and with a higher protein intake. Nut spreads require a high percentage of sugars and fats to ensure their spreadability and good palatability.

A work conducted at the Department of Industrial Engineering of the University of Salerno (Italy) and published in the journal LWT – Food Science and Technology was therefore aimed at designing a pistachio cream with no added sugar, low

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in saturated fats, spreadable and able to induce positive sensory attributes to the consumer.

An optimal formulation of a no added sugars and high pro-

tein pistachio spread was obtained by using olive oil based oleogel as unsaturated fat replacer and increasing the amount of milk originated powders (skimmed milk powder and whey protein concentrate) as structural modifier. The optimization, done by mixture design, considered technological and sensorial aspects together. The experimental design consisted of twelve different formulations in which oleogel, wheyproteins and skimmed milk were set as the ingredients while spreadability, oil binding capacity, and sensory attributes like meltability, mouth adhesiveness and undesirable flavours were used as responses. Polynomial regression models were used to fit the experimental data for each type of investigated response of pistachio spreads. The optimized formulation in terms of the selected quality responses was identified in a spread characterized by 20% of olive oil based-oleogel, 13.16% of whey proteins and 26.84% of skimmed milk, achieving an overall desirability score of 0.56. The optimized spread formulation showed a spreadability of 11.71 N mm, OBC of 95.88% and sensory scores of 5.61, 9.31 and 5.42 for meltability, adhesiveness to mouth and other flavours respectively.

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Biscuits rich in polyphenols and dietary fibre Wine lees, a by-product of the winemaking process, still contain bioactive molecules (especially fibers and polyphenols) with potential functional properties.

Considering the high frequency of consumption and high versatility of biscuits, the aim of a work published by researchers from the University of Bari in the

nificantly higher values of fibres, proteins, phenolic compounds, antioxidant activity, and higher oxidative stability than the control (F0). Different flavonoids and anthocyanins were detected in F10 and F20, such as ellagic acid and malvidin-3-acetil glucoside with a concentration greater than 200 mg/kg. The in-

creased fibres and polyphenols in the F20 led to a significant lowering in glycaemic index (pGI) and starch hydrolysis (HI).

Based on simulated colonic fermentation, F20 also exhibited a slight prebioticeffect supported by the significant increase in lactic acid bacteria cell density compared to F0.

Dietary fiber and low-fat ice cream

journal LWT – Food Science and Technology (198, 115943, 2024) was to replace wheat flour with 10% (F10) and 20% (F20) of wine less flour (WLF) to produce biscuits with an improved nutritional profile.

This study assessed the impact of substituting 10 and 20% of WLF on the physico-chemical, nutritional, textural, sensory, and volatile aroma compound characteristics. These results were compared with those of a control biscuit exclusively made with wheat flour (F0). The statistical comparison allowed for demonstrating how the fortified biscuits (F10 and F20) had sig-

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A study conducted at the Faculty of Agricultural, Environmental and Food Sciences of the University of Bolzano, Italy, investigated the effect of incorporating dietary fibers, inulin, acacia, oat, and apple, in a low-fat vanilla ice cream. A significant increase in the ice cream mixture viscosity was observed with the addition of dietary fibers. Significant differences (p < 0.05) were observed in the crystallization temperature when apple and oat fibers were used.

Additionally, low-fat dietary fiber ice creams displayed statistically lower (p < 0.05) glass transition and melting temperatures than full-fat ones, with the most pronounced reductions observed for samples enriched with acacia and apple fibers. Dietary fibers affected (p < 0.05) the sensory profile of low-fat ice cream. However, inulin and acacia fibers samples showed a sensory profile comparable to the full-fat ice cream for nearly all attributes.

These findings, published in the journal LWT - Food Science and Technology, suggest that utilizing inulin and acacia fibers in low-fat ice cream yields characteristics of full-fat, underscoring the potential for crafting high-quality, reduced-fat ice cream products.

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a crumb appearance and an airy structure similar to the control.

Croissants formulated with the other blends were more compact and had higher hardness values.

Therefore, formulation containing SL blend was selected for

further analysis. Control and SLbased doughs followed the same pattern when large deformations were applied: shear stiffening and shear thinning behaviour.

Regarding sensory analysis in final croissants, no differences

in appearance, texture, flavour and overall liking were obtained; there was also no difference in purchase intention, so that the formulation with SL oleogels was optimal for the healthier croissants proposed.

Cell-based fish production case study for developing a food safety plan Given the expanding global population and finite resources, it is imperative to explore alternative technologies for food production. These technologies play a crucial role in ensuring the provision of safe, nutritious, and sustainable food options to meet the growing demand. Cellular agriculture plays an important in developing an alternative method for developing food products. While, cellular agriculture is emerging rapidly, food safety aspects and regulatory frameworks stayed behind. Despite developing several regulatory framework papers on cellular agriculture, there is no systematic approach for developing a comprehensive food safety plan (FSP), particularly for cultivated seafood.

Thus, the overall goal of this work published in Heliyon journal is to develop a FSP for cultivated seafood. The main differences between the food safety plan for cultivated seafood and the conventional seafood industries were the number of allergens in cultivated seafood products, including soy, wheat, and fish cells, compared to only fish for the conventional seafood industry. In addition, there are several hazards associated with myco-

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plasma in cultivated seafood, which should be considered. This guidance intends to help regulatory agencies, food safety experts, startup companies, and the cultivated seafood industry

as a comprehensive food safety plan, it could be easily adapted for other cultivated seafood products.

This guidance applied systematic approaches to developing

by providing a valuable platform to develop regulations, guidance, and food safety plans applicable to most cultivated seafood companies. This article will also help the industry to identify the hazards in their processing line and develop preventive controls, and

food safety plans using cell culture, pharmaceuticals, fermentation, seafood, meat, and aquaponics safety plans, collaborating with experts with different backgrounds, and working closely with the conventional and cultivated meat and seafood industries.

italian food & packaging technology - cix (2025) - april

NEWS

Tovard to a sustainable future for the food and beverage industry DNV, the independent assurance and risk management provider, published a new report highlighting the urgent need for the food and beverage sector to transform its supply chains to meet sustainability demands amid global challenges like climate change, regulatory shifts, and evolving consumer expectations.

The report ‘The Future of Sustainable Food Supply Chains: Spotlight on Europe’s Food and Beverage Industry’ reveals that

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sustainability has become the number one supply chain priority for food and beverage companies, with 75% ranking it among their top three goals, ahead of cost efficiency (63%) and regulatory compliance (49%).

To succeed, companies must adopt a holistic approach that integrates visibility, digital transformation, and compliance with emerging regulations.

With food systems accounting for a third of global carbon emissions, the report identifies critical

areas where the industry must focus to balance environmental responsibility, cost-efficiency, and compliance with increasingly stringent regulations.

The report’s key findings on critical challenges facing food and beverage supply chains include: • Digital transformation as a catalyst: The adoption of digital tools such as supply chain traceability, connected product passport as well as supply chain risk management platforms is gaining momentum, but the sector lags behind others in integrating key technologies. A focus on verifiable and trusted data, as well as ease of use across all supply chain actors is essential to enable transparency and cost-effective compliance.

• Evolving regulatory landscape: New EU directives, including the Corporate Sustainability Due Diligence Directive and the Packaging Waste Directive, are driving companies to address sustainability comprehensively, from carbon footprints to human rights concerns.

• Consumer and retailer influence: Today’s informed consumers demand sustainable

italian food & packaging technology - cix (2025) - april