Food & Drink Manufacturing UK - November 2023

November 2023

FOOD PROCESSING TOP TIPS TO REDUCE FOOD WASTE DURING PROCESSING

fdm-uk.co.uk

FOOD SAFETY

NAVIGATING FOOD SAFETY CONCERNS IN THE PALM OIL INDUSTRY

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CONTENTS 24

12 Editor Paul Attwood editor@fdm-uk.co.uk Editorial Assistant Francesca Amato editorial@fdm-uk.co.uk

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32 34

12

Navigating Food Safety Concerns in the Palm Oil Industry

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Packaging’s place in the plastic crisis: A compostable solution

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International survey from Industrial Physics reveals top packaging innovations

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RICE WITH RE-PURPOSE: Fortress UPGRADES quality control at BULK RICE mill

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Optimising hygiene controls in food processing environments

Features Editor Henry Peters editorial@fdm-uk.co.uk Production/Design Laura Whitehead laura@lapthornmedia.co.uk Sales Manager Holly Jones sales@fdm-uk.co.uk Sales Executive Alex Costa alex@fdm-uk.co.uk Publishing Director Maria Lapthorn maria@lapthornmedia.co.uk Lapthorn Media Ltd 5-7 Ozengell Place, Eurokent Business Park, Ramsgate, Kent, CT12 6PB

01843 808 117 www.fdm-uk.co.uk @fdmanufacturing

Editors Note Welcome to the latest issue of Food & Drink Manufacturing UK Magazine.

In this edition we hear from Todd Gilliam, the Americas industry manager for consumer-packaged goods at Rockwell Automation on how Food Processors Turn to Automation to Solve Their Biggest Challenges. An interesting insight into sensor and control technology helping to improve production.

Paul Attwood Editor

We also hear from Fabian Fischer, Team Leader Application Sales at KEB Automation.

Fabian explains the challenges food and packaging machinery pose for drive and automation solutions and how these can be overcome.

We hope you enjoy this issue and as always, if you have any news that you would like to feature, please email details to editorial@fdm-uk.co.uk

Every effort is made to ensure the accuracy and reliability of material published in Food & Drink Manufacturing UK however, the publishers accept no responsibility for the claims or opinions made by advertisers, manufactures or contributors. No part of this publication may be reproduced or transmitted in any form or by any means, mechanical, electronic (including photocopying) or stored in any information retrieval system without the prior consent of the publisher.

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Industry News

Ball Aerosol Packaging releases new report on innovative Eyeris® printing technology for sustainable aluminum packaging Ball Corporation, the world leader in sustainable aluminum packaging, has released a new report on the transformative power of Eyeris®, its proprietary enhanced printing technology for aluminum cans and impact extruded bottles. Eyeris® offers unparalleled visual appeal in line with the growing consumer demand for sustainable packaging.

monthly across 273+ categories, the competition for shelf placement and consumer attention has intensified.

Notably, at the point of purchase, product packaging plays a pivotal role, with 76% of consumers saying it influences their final purchase decisions, while 66% of consumers try new products solely due to their packaging.

With over 40,000 Fast-Moving Consumer Goods (FMCG) launches

Unlike traditional printing methods, Eyeris® uses advanced printing and imaging processes to deliver highresolution, photo-realistic images directly onto the aluminum packaging surface. This ground-breaking HD imagery spans 360 degrees around the can or bottle, offering not only unparalleled detail and color accuracy to visually showcase ingredients and fragrances within the product, but also offers brands a unique platform to tell their story while creating a strong emotional connection with consumers.

Leveraging Ball’s unique expertise in creative artwork, Eyeris® has the potential to better replicate customer graphics and imagery when developing files for print, ensuring the final

product achieves higher detail and quality. Available in up to nine colors, Eyeris® caters to all dimensions and forms within Ball’s portfolio of aluminum cans and impact extruded bottles for beverages, household items, and personal care products. This versatility unlocks visual possibilities that capture consumers’ attention by combining Eyeris® with aluminum packaging, one of the most sustainable packaging solutions available today.

As a leader in sustainable aluminum packaging innovation, Ball launched the lightweight Aerosol aluminum cans using their proprietary alloy ReAl in 2014 to reduce emissions from transportation. These Aerosol cans are up to 30% lighter than standard ones and contribute to a reduction in transportation-related emissions.

However, widespread adoption of lightweighting has led to standardized can shapes and sizes and less differentiation. Eyeris® is designed to address this issue by ensuring brands and on-pack promotions stand out on the shelf in a crowded market, where creativity may feel squeezed, and captivate consumer attention.

Reconomy launches sustainable food and drink packaging Reconomy, a leading global circular economy specialist providing sustainability technology, data and services to a broad range of industries, is delighted to announce a new sustainable food and drink container service for businesses throughout the UK. In the UK alone, 10.7 billion single-use food and drink take-out containers are discarded each year after just one use, a significant environmental threat that needs urgent attention.

Reconomy is, therefore, helping businesses switch to a reuse solution

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that is practical, commercially viable and environmentally friendly.

The collection includes a diverse range of reusable containers suitable for various applications and will be reusable over 1,000 times helping to cut carbon emissions by up to 96%, create zero litter, landfill and incineration, reduce transportation and storage and be recycled easily at the end of its lifecycle.

As well as increasing circularity, the collection will also deliver significant cost savings estimated to be at

approximately 70-85% over a threeyear period compared to using single use disposables.

Alongside this new service offering, Reconomy has launched its own single-use plastic policy to minimise the use of single-use plastics across its own operations and services and by all colleagues.

The policy will also see Reconomy proactively work with its customers and suppliers to find positive solutions for reducing unnecessary waste plastics.

Industry News

New Campden BRI eBook: Mastering Supply Chain Resilience in the Food and Drink Industry A new Campden BRI eBook is being launched to help food business operators (FBOs) deal with supply chain challenges by being more prepared, agile and resilient.

Eyeris® reflects Ball’s commitment to innovation and sustainability, offering purpose-powered solutions that help brands elevate their packaging while contributing to a more sustainable world. When combined with Eyeris® technology, aluminum packaging not only fulfils but amplifies both sustainability and consumer engagement by allowing high-resolution printing directly on the package, thereby eliminating the need for additional labels.

For more information, and to learn how Eyeris®-highdefinition printing technology can enhance brand visibility, download the report at www. ball.com/packaging/aerosol-cans/ aluminum-aerosol-cans/aerosolspecial-effects/eyeris

Nathan Gray, Head of Sustainability at Reconomy, commented: “This is a completely new service offering for Reconomy and one that will help our customers divert from single use, as well as demonstrating our own commitment to eradicating single-use plastics. Our aim at Reconomy has always been to lead the way in the reuse revolution, bringing our customers on board to deliver significant carbon efficiency increases across a variety of the many sectors we work with. We are excited that this initiative will help more businesses drive forward a positive environmental impact as well as achieving commercial benefits.In tandem with our own single use plastic policy, it is further evidence of our commitment to accelerating the transition to a more circular economy at Reconomy and through our customers and suppliers.”

The new eBook, ‘Supply Chain Resilience: Identifying, planning for and overcoming supply chain challenges’ provides expert guidance for FBOs on how to build resilience within their organisations and be more resistant to supply chain threats such as food fraud.

In recent years, the food industry has experienced a range of high-profile supply chain issues, including recent egg cost and availability challenges in the UK, and the even wider spread disruption to other commodities as a result of the war in Ukraine.

The eBook covers horizon scanning and how to prepare for and even prevent the impact of potential threats to your business. However, even with the right systems in place, factors outside of a business’s control can present challenges that require resilience for businesses to be able to successfully react and recover.

There are several tools and strategies that are discussed in detail in the eBook that form part of supply chain resilience.

The key elements are: • Know your supply chain • Have systems, processes and procedures in place • Ensure the right culture for resilience • Analyse risk and make risk-based decisions • Know your products, packaging and ingredients • Be prepared and look ahead “Building supply chain resilience will enable FBOs to effectively handle incremental changes in their macroeconomic environment and within their organisation, as well as sudden disruptions” says Andrew Collins.

Along with launching the eBook, Campden BRI offers a diverse range of support services dedicated to enhancing organisational and supply chain resilience. This includes helping organisations implement effective food safety management systems, providing expert support for verification activities such as auditing, and offering analytical testing solutions, horizon scanning support and regulatory advice.

Campden BRI offer customised training courses in various areas relevant to supply chain resilience.

They also offer a Culture Excellence Program, developed in partnership with Taylor Shannon International, to promote a positive food safety culture that supports supply chain resilience.

For more information about Campden BRI’s services and how they can support your business in achieving supply chain resilience, please visit www.campdenbri. co.uk/supply-chain-resilience.php To download the free eBook, please visit www.campdenbri. co.uk/supply-chain-resilienceebook.php

05

Industry News

Dairy Digitises Through the Infor Multi-Tenant Cloud Infor®, the industry cloud company, today announced that dairy processor Cremo SA has selected Infor CloudSuite Food & Beverage.

The company is implementing Infor’s cloud native and purposebuilt food and beverage industry solution to optimise its processes and ensure product quality is always up to meeting the highest standards.

powerful IT infrastructure was needed.

The previously used enterprise resource planning (ERP) system could no longer meet the requirements in terms of process optimisation and product quality.

Cremo is the second-largest milk processor in Switzerland, headquartered in Villars-sur-Glâne (Canton Fribourg). The company employs around 750 people across several production sites in Western Switzerland. Cremo is particularly proud of its culture of bilingualism (German and French) as well as its strong connections to milk producers.

Not to forget the products: Based on a tradition of almost 100 years, they are made exclusively in Switzerland and 100 percent from Swiss milk.

Infor CloudSuite Food & Beverage is specifically tailored to the needs of the food and beverage industry and provides unique capabilities for dairies.

Thanks to Infor’s public cloud strategy, Cremo can adopt best practices and capabilities that have proved itself at many food and beverage manufacturers and, more specifically, dairy processors.

The solution meets the industry’s expectations of innovation, traceability, regulatory requirements, margin pressure and transaction speed. The scalability and security of the multitenant industry cloud platform powered by Amazon Web Services (AWS) were further reasons that made Infor the right choice.

To meet customer requirements and guarantee the flow of information within the company, a secure and

To ensure the success of this project, Cremo and Infor identified the relevant value drivers and held workshops

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with the process owners at Cremo to understand their way of working. This made it possible to evaluate the level of coverage of Infor CloudSuite Food & Beverage. The business units have already gained initial insights into how the solution works.

“The Infor team has established itself as a real partner. The methodology of the project had a particularly high added value for us: Through workshops, the employees immersed themselves in the solution very quickly,” said Frédéric Siffert, Cremo’s ERP project manager. “Infor listened to us and provided expert advice throughout the process.”

“With its industry-specific public cloud service, Infor CloudSuite Food & Beverage is tailored to the needs of the dairy industry.

Many specific processes are already integrated in the standard, which minimises the need for customisation,” says Nicolas Rollet, Infor account manager for food & beverage DACH. “Conducting workshops with the project team showed us how many of the processes we can map in the standard. In addition, the team on site already has a good impression of what it’s like to work with the solution.”

Learn more about Infor CloudSuite Food & Beverage: www.infor.com/ products/cloudsuite-food-andbeverage

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07

Chilled Foods

Unparalleled Temperature-Controlled Solutions Cold Clad: Where Expertise Meets Innovation Welcome to Cold Clad, where we delve deeper into cuttingedge temperature-controlled building solutions.

BELOW: Temperature Controlled Director - Richard Tassinari

For over a decade, Cold Clad has been the industry leader in providing temperature-controlled building solutions that meet the highest standards of excellence, innovation, and customer satisfaction. With over 100 years of collective construction experience and the latest Revit design capabilities, our commitment to delivering superior solutions is unwavering, and we continue to push the boundaries of what’s possible in the field.

Why Choose Cold Clad?

TCS&D Cold Store Contractor of the Year 2023 Expertise: Our team of dedicated professionals brings a wealth of experience to every project. We pride ourselves on our ability to deliver precision and efficiency, ensuring that your temperaturecontrolled environment meets your exact requirements.

Cutting-Edge Design: At Cold Clad, we stay at the forefront of technology and design. With strong relationships with material manufacturers, such as Kingspan, Euroclad & Trimo. We employ continuous R&D and adapt to the latest technologies and designs available. Our commitment to innovation means that your facility will benefit from the most advanced solutions on offer.

Proven Success: With over a decade of satisfied clients, Cold Clad has built a reputation for reliability, diversity, and excellence.

We’ve successfully completed projects, across multiple sectors.

• • • • • • • • •

Government Bodies – DEFRA, NHS Food Importers – Wealmoor, Bidfood, Food Production – Vitacress, West Horsely Dairy, BV Dairy Cold Storage – ACS&T, DP World Major Retailers – Lidl, Tesco, Asda Breweries – Beavertown, Heineken, West Berkshire Breweries Clean Rooms – B Braun, Spaceport Medical Facilities – B Braun, Quanta Aerospace Industries – Spaceport, Rolls Royce, GKN

Your Business, Our Priority At Cold Clad, your business is our priority. We understand that every organization has unique temperature control needs. Therefore, we offer tailored solutions specific to your requirements. Whether you are a food or drinks manufacturer, a temperaturecontrolled storage and distribution solutions provider or in the pharmaceutical sector requiring cleanroom environments, our Temperature Controlled Division has the knowledge, experience and a proven track record in creating bespoke solutions that meet your exact needs.

Discover the Difference Visit us at https://www.coldclad.com/ to explore our portfolio of successful projects and to learn more about how our temperature-controlled solutions can benefit your organization. If you’re ready to discuss your project in detail, don’t hesitate to contact us at 01684 438190 for a consultation.

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Chilled Foods

Maintaining Precise Temperature Control with Enershield Air Barriers Discover How Efficiency and Savings Were Achieved

In the world of cold storage, where precision is paramount, maintaining a set point temperature within freezer and chilled rooms is not just a preference; it’s a necessity.

Temperature control isn’t merely a matter of convenience; it’s the foundation upon which product integrity, energy efficiency, and operational savings stand. In this case study, we provide insight into the journey of our customer, who faced the challenges of fluctuating temperatures within their freezer room, and the compelling reasons why achieving and maintaining a precise temperature set point is of the utmost importance.

The Challenge Ensuring optimal freezer temperatures and improving cost efficiency were critical requirements for our customer.

The transfer of air between the ambient and chilled environments, as well as between the chilled and frozen areas, poses significant challenges, particularly when fast-action doors are frequently

opened. The average freezer room temperature was appx -18 despite the chillers running at full capacity. This environmental transfer compromises precise temperature control and results in heightened energy consumption and increased operating costs.

Key Objectives

If you’re facing similar challenges and want to optimise your operations and reduce costs, trust Enershield Air Barriers.

• Maintain optimal freezer temperature.

• Improve energy costs.

Enhanced Safety and Visibility:

The Solution

Another benefit of installing Enershield Air Barriers was the removal of strip curtains from the doors. This improved visibility within the facility and enhanced site safety.

In order to address temperature control challenges effectively, we conducted a thorough site assessment. This detailed evaluation allowed us to identify the specific issues our customer faced. With this insight, we were able to recommend the installation of two Enershield Durashield Air Barriers on each chilled and freezer room door.

The Results The results were conclusive: with the Enershield Air Barriers in place, the freezer room temperatures decreased by an average of 2.2°C compared to pre-installation levels. This reduction enabled our customer to consistently maintain their desired temperature set point of -20°C, often surpassing it.

This achievement suggests that the chillers, running at their previous capacity, can now operate more efficiently. With reduced energy consumption required to reach the desired temperature, our customer can enjoy substantial energy savings.

Energy Savings Realised: With the Enershield Air Barriers in place, the ingress of ambient air when fast-action doors are opened has been reduced. As a result, the chillers no longer need to work as hard to maintain a constant temperature. This is expected to lead to substantial reductions in energy costs, aligning perfectly with our customer’s commitment to efficiency.

Conclusion Our customer has achieved optimal freezer temperature control, leading to substantial cost savings. By investing in Enershield Air Barriers, our customer now enjoys improved efficiency, reduced energy consumption, enhanced safety, and visibility, while also ensuring that product integrity is maintained.

If you’re facing similar challenges and want to optimise your operations and reduce costs, trust Enershield Air Barriers. Enershield Air Barriers are a precision engineered product that creates a highly effective and robust seal on a doorway, by re-circulating facility air in a laminar (smooth) flow.

This laminar airflow, coupled with the kinetic energy within the moving air, generates up to a 90% seal. This effectively prevents the leakage of air between two areas with different pressures and climates. Enershield Air Barriers are designed and manufactured

by CPA Engineered Solutions, part of the CPA Group. Each Enershield Air Barrier is manufactured to meet your unique requirements.

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09

Automation

Interview: Todd Gilliam We hear from Todd Gilliam, the Americas industry manager for consumer packaged goods at Rockwell Automation on how Food Processors Turn to Automation to Solve Their Biggest Challenges

What is the food and beverage sector currently looking for when it comes to sensor and control technology?

TG: Traditionally, the goal has been to achieve faster, better, more efficient production. But today, while production optimization remains essential, it’s not the only thing on the mind of food and beverage producers when they build, expand or modernize production lines.

Increasingly, producers are also looking to controllers, sensors and other automation technology to help them solve their biggest challenges of the day. For instance, how will a new technology help them address today’s workforce realities, like changing demographics and scarce talent? Or how will it help them meet pressures from both consumers and investors to create more sustainable operations?

For the workforce issue, food and beverage producers are questioning what work should look like in their operations. Given the tight labor market, they want to determine where they can best use the unique skillset and knowledge of humans, and what

One of the most popular uses of AI in food and beverage production today is for yield optimization. activities might be better suited for modern control technology.

Some producers, for example, are using robots like automated guided vehicles — AGVs — to transfer food products, such as from a proofing station to a cooking station. This is made possible by industrial control systems that allow people and robots to work side by side in a safe manner.

Modern control systems that offer enhanced robot integration can also make it easier to integrate, use and maintain robots. For example, engineers can program robots with the same interface they use to program

the rest of a line or machine, without needing to learn specialized robot programming languages.

When it comes to creating more sustainable operations, food and beverage producers are discovering that modern control and automation technologies offer inherent sustainability benefits.

A variable frequency drive, or VFD, for example, can deliver significant energy savings when used in place of an across-the-line starter. Similarly, an on-machine drive can use more energy efficient wiring and reduce wear on motor insulation or windings. This can help the motor operate more efficiently and as a result reduce energy usage.

And while sensor technology continues to improve, providing greater visibility into a process and into the health of the sensor itself, such sensors aren’t always needed for sustainability efforts. Instead, in some cases, a basic temperature sensor can suffice. It goes to show how much food and beverage producers can do to address top challenges like sustainability with minimal investments or even the investments they’ve already made.

How are food processors using connected systems and other Industry 4.0 technologies?

TG: The best way to overcome obstacles to growth, like the ongoing skills shortage, or to achieve net zero emissions is with smarter, more connected operations. Food and beverage producers know this. It’s why they’re embracing digital technologies that make their operations – and their workforce – more resilient and agile.

Digital tools, for example, can significantly ease the jobs of production workers. In one case, a dairy producer used OEE software to free its workers

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Automation from a staggering 2,500 hours of manual data collection. And digital expert-capture tools can be used to retain the critical knowledge of veteran operators or technicians before they retire. Captured information can then be woven into operator instructions, training videos, troubleshooting guides and more.

Greater connectivity and data access is also helping food and beverage companies be more sustainable.

One vegetable oil producer that lacked insights into its energy usage deployed a connected energy management solution that provided visibility into energy usage at the enterprise, site and line levels. The solution also empowered workers with rolebased dashboards and predictive and prescriptive analytics. This helped the company identify 10% energy reduction savings.

It’s also important to know that digitalized operations can have

valuable indirect benefits. For example, as technology like mobile devices, virtual reality devices and robots permeate a production facility, it can smash the perception that jobs in this industry are dull and reliant on decades-old technology. This can help make a career in food and beverage manufacturing more appealing to younger people who use digital technology in almost every aspect of their daily lives.

measurements until it achieves optimal production within the defined quality specifications.

What impact is artificial intelligence AI having on the industry, and how is that likely to change in the future?

Model predictive control has proven especially useful in food and beverage applications that have narrow product specifications and critical quality variables. In powdered dairy production, for instance, it’s used to help optimize the drying process that’s both energy intensive and essential to meeting quality specifications.

In frozen food production, it helps manage the moisture content that can make or break product quality.

TG: One of the most popular uses of AI in food and beverage production today is for yield optimization. This can involve the use of model predictive control software, which continuously monitors a process, compares it against previous batches or runs, and drives the process as needed. With each iteration, the software tightens its control of the process based on variables like line speed, temperature and quality

And AI isn’t only proliferating in food and beverage operations in software. It’s also increasingly built into production systems and devices to create smarter, self-aware assets.

A good example of this is a VFD with predictive maintenance capabilities.

It can alert workers when key components are nearing their end of life, so workers can replace them before they cause unscheduled downtime.

FANUC completes production of 1 millionth robot Factory automation expert FANUC has celebrated a milestone achievement with the production of its one millionth industrial robot. The company, which supplies customers worldwide with a range of CNC systems, robots and production machinery, deployed its first robot back in 1974. Today, thousands of robots build new robots at FANUC’s headquarters in Japan – one of the

most automated factories on the planet.

While industrial robots were traditionally used mainly in the automotive and electronics industries, they have now become prevalent in many other industries, including food and beverage, pharmaceuticals, aerospace and plastics. Increasing labour shortages and improved usability are just some

of the reasons behind the rising popularity of robotics across a range of different sectors.

FANUC offers over 200 robot models that perform various tasks in manufacturing, such as welding, painting, assembly, and packaging.

Collaborative robots (cobots) are also gaining popularity as they can work alongside employees, often without external safety guarding. However, traditional robots still dominate in industrial sectors, and their use, such as in the automotive industry, is accelerating the shift towards electromobility.

“Demand for our robots is currently at an all-time high,” says Marco Ghirardello, the President and CEO of FANUC Europe.

“Applications for robots are expanding, and the demand is expected to continue to grow significantly in the future. In order to support our customers’ automation needs, FANUC will strive to further improve quality, performance, and supply capabilities.”

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Food Safety

Navigating Food Safety Concerns in the Palm Oil Industry: Quality Assurance as a Path Forward

By Fransisca Tedjo, Head of National Food Safety and Quality, Golden Agri-Resources

Fransisca Tedjo, Head of National Food Safety and Quality, Golden Agri-Resources

Ongoing advances in palm oil processing are helping to ensure that this widely used product can continue to meet increasingly stringent demands for food safety from customers, regulators, and ultimately, consumers.

The focus on palm oil has historically been on the challenge of deforestation linked to its production – a challenge that producing countries such as Indonesia are successfully addressing.

Data from Trase Insights shows that deforestation linked to palm oil production in Indonesia, the world’s largest palm oil producer, is at its lowest level for a decade, while palm oil production has continued to increase.

About Fransisca Tedjo Fransisca Tedjo heads Golden Agri-Resources (GAR’s) National Quality Food Safety department.

Based in Jakarta, she oversees all aspects of food safety and quality, including improvement projects to enhance quality processes, and ensures all our products meet industry food safety standards.

With over 20 years of experience in the quality assurance & food safety field, she is currently focused on transforming GAR’s palm oil refinery operations by establishing a fully integrated, digitalised system that will position the company at the forefront of Industry 4.0 innovation.

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Food Safety Data from Trase Insights shows that deforestation linked to palm oil production in Indonesia, the world’s largest palm oil producer, is at its lowest level for a decade, while palm oil production has continued to increase.

Through enhancing uptake of standards across palm oil production, close collaboration with customers, and harnessing technologies to tackle emerging food safety issues, palm oil producers can stay ahead of regulatory requirements to offer ingredients that match functionality with food safety.

Embedding Standards to Combat Contaminants

- Fransisca Tedjo

The presence of mineral oil hydrocarbons (MOH) in food products was identified as early as the 1990s, but has come under increasing scrutiny since 2012 when a study by the European Food Safety Authority (EFSA) outlined its potential impacts on human health.

What’s less widely known is the progress the palm sector has made in addressing food safety and quality concerns. Palm oil is found in 50 per cent of the products found on supermarket shelves, and the food and beverage sector is the largest consumer of palm oil products.

MOH comprise a number of chemical compounds derived mainly from petroleum distillation and refining, grouped into two main categories: mineral oil saturated hydrocarbons (MOSH), which can accumulate in human tissue and may harm the liver, and mineral oil aromatic hydrocarbons (MOAH) which are potentially carcinogenic.

In my role as Head of National Food Safety and Quality at palm oil producer Golden Agri-Resources (GAR), I’m in regular contact with international food producers to understand and address their food safety concerns and to understand how we can continue to learn from others in the industry to improve our practices.

Vegetable oils, including palm oil, were identified as having high levels of MOH, raising concerns for young people, especially infants fed with formula containing elevated MOSH levels – and leading to calls for bans in 2016. The challenge for addressing MOSH and MOAH contamination is that these substances can enter

INSET: MOSH and MOAH can enter food at a number of points from raw material to finished product [via FoodDrinkEurope.eu]

food at any point during processing and storage – presenting a complex problem for food and ingredient manufacturers. MOH are not present in palm fresh fruit bunches (FFBs), the raw materials used to produce palm oil and derivative products, but can be introduced at points from raw materials to storage and transportation, and particularly from packaging materials – most commonly recycled packaging.

In 2019 GAR launched a study to investigate MOSH and MOAH issues engaging a third-party laboratory in Germany, testing samples from our refineries to investigate mitigation options. Crucially, this study covered the entire supply chain – from refineries to owned mills and third-party mills – to identify points where contaminants could be introduced.

As a result, GAR has taken steps to address sources of MOAH or MOSH, putting in place monitoring to ensure that levels meet the safety standards set out by our customers and regulators.

Mitigation steps are in place in six GAR refineries, with pilots in place at one mill and one kernel crushing plant to address possible contamination at the earliest stages of the production process.

Investment in quality assurance and quality control facilities and equipment, as well as implementing recognised standards, are another step towards addressing these risks.

Continued >>>

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Food Safety All of GAR’s refineries have implemented Quality and Food Safety Management System (ISO 22000/FSSC 22000) which takes MOSH/MOAH risks into consideration. At GAR’s R&D Centre in Marunda, near Jakarta in Indonesia, we have established ISO 17025-accredited R&D and Quality Control facilities to provide additional assurances on the steps taken to combat food safety risks.

Partnership Approach Key to Tackle Food Safety Risk Beyond MOH, palm oil producers are also taking action to address other potentially harmful compounds such as 3-MCPD (3-Monochloropropane-1,2-diol) and Glycidyl Esters (GE) which can be formed during processing and refining of edible oils, particularly at high temperatures.

In 2021, the European Union put in place regulations to cap the presence of 3-MCPD in vegetable oils and fats to 2.5 parts per million (ppm). GE is limited to 1 ppm.

Ongoing collaboration between palm oil producers and customers has helped to drive down the presence of these potentially harmful byproducts by adopting internationallyapproved identification methods to test for these substances.

Simultaneously, we are actively exploring and testing new mitigation technologies to address the EFSA’s risk assessment and other global regulations. GAR’s refineries have established a CPO washing process that is critical in removing the precursors of 3-MCPD to minimise risk later on in processing.

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For customers with the most stringent limits on 3-MCPD and GE levels beyond the levels required by the EU, GAR can reduce the presence of these compounds through low temperature deodorisation and alternative refining processes.

Harnessing Technology to Address Emerging Concerns Embedding technologies including automation and AI into food safety operations is another area where palm oil can find significant opportunities to enhance safety standards while improving efficiency.

At GAR’s Lubuk Gaung palm oil refinery in Riau, Indonesia, a pilot project is using automation to reduce the risk of food fraud – one of the top three emerging food safety issues identified by regulatory intelligence network SGS Digicomply.

Each batch of CPO is tested for compliance with GAR’s quality standards when it arrives at our refineries. The automated Crude Palm Oil (CPO) sampling system is designed to minimise human intervention and reduce the risk of manipulation and contamination when receiving CPO – the unprocessed oil extracted from palm FFBs – from suppliers.

Rather than collecting samples manually from individual trucks, a process that can involve operators climbing on top of the truck to access the right spot to take their sample, the automated CPO sampling system uses probes to take a sample at multiple points, reducing sampling errors and removing risk for the operator in taking manual samples. The sampling process generates a unique identifier for each delivery, rather than relying on truck plate numbers, further reducing the potential for error and fraud.

The palm oil industry is actively engaged in addressing food safety concerns head on. By embedding rigorous standards, fostering partnerships, and embracing technological advancements, the industry can ensure the safety and quality of palm products while working with food and drink manufacturers to uphold the highest standards and meet the evolving demands of consumers worldwide.

LEFT: Automated CPO sampling helps to combat food fraud while enhancing efficiency compared to manual processes.

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Industry News PP Control & Automation aims to be top of the crops with £3m AgriTech ‘outsourcing’ opportunity One of the UK’s leading strategic outsourcing manufacturing specialists has launched a five-point mandate to explore a potential £multi-million opportunity in the AgriTech sector.

PP Control & Automation (PP C&A), which supports 20 of the world’s leading machinery builders, believes its ability to deliver cost savings, ‘scale-up potential’ and

speed to market will be essential for companies looking to deliver new innovations that will drive global food security.

It is already in the final stages of negotiations with one critical supplier to the sector and is now targeting over £3m of work in this arena in the next eighteen months.

Part of the Manufacturing Assembly Network (MAN), PP C&A has also signed-up as the latest member of the Agri-EPI Centre Network.

The latter, which was established as part of the UK Government’s AgriTech Strategy to develop, fund and commercialise new precision agricultural technologies, is doing amazing work to bridge the gap PP Control & Automation will be pushing its 5-point outsourcing

mandate when targeting customers involved in AgriTech.

It starts with the company’s expertise and in-depth manufacturing knowledge that can cater for the intricacies of this industry and flows through cost efficiencies gained from resource allocation, supply chain optimisation and scale-up capacity.

By outsourcing non-core functions, machine builders and innovators can focus on the R&D activity that makes them different, whilst flexibility to grow in keeping with market fluctuation can be achieved easily.

Finally, PP C&A can deliver complete quality assurance that aligns with specific AgriTech regulations, with UL508a accreditation already in place for dealing with the North American market.

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To discover how we can improve your production environment visit www.filtermist.co.uk or speak to one of our sales team +44 (0)1952 290500 sales@filtermist.com

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Industry News

New zero carbon solution to commercial food waste from Swancote Energy Campden BRI issues new eBook on managing food allergens With food allergies affecting up to 10% of adults and 8% of children globally, food manufacturers are obligated to ensure food labelling and allergen information is accurate, clear and easy to understand.

“Biomethane is an important part of UK strategy to combat climate change and achieve long-term, sustainable growth from a low-carbon economy. It can be used as a direct alternative to fossil gas, but does not include CO2, which we will capture at the point of production”, said Swancote Operations Manager James Wood.

The result of getting it wrong can lead to food recalls, loss of consumer trust, legal action and expensive fines.

To help food manufacturers mitigate these risks, Campden BRI has launched a new e-book: ‘Managing Food Allergens’, to help ensure producers understand the issue and the requirement to have robust food safety management systems in place.

“This is a complex and ever-developing area which food businesses need to ensure they are addressing effectively and thoroughly,” said Helen Arrowsmith, Regulatory Affairs Manager and Allergen Specialist of Campden BRI. Many individuals have food hypersensitivity, where they experience an adverse reaction to specific foods, ranging from mild irritation to potentially lifethreatening anaphylaxis. A study released in February 2023 revealed that more than half of food recalls in the UK over a 5-year period were due to allergens. Of the 1,036 recalls in the UK from 2016 to 2021, published by the Food Standards Agency (FSA) and Food Standards Scotland (FSS), 597 were related to allergens.

This has serious consequences with real-world effects. Statistics show that there were more than 7,700 hospital admissions with a primary diagnosis of allergic food reactions in the UK in 2019-20, and 10 food allergy-related deaths occur annually.

Swancote Energy is investing in new facilities to generate renewable biomethane gas from commercial food waste. The facilities also enable carbon capture and will be built alongside the company’s existing food waste and packaging recycling plant in the centre of the UK.

“These cases can be the result of crosscontact in the production process,” said Christopher James, Safety and Quality Specialist - Allergens.

“A recent poll by Campden BRI revealed that 70% of food and drink industry professionals considered it to be the biggest challenge when dealing with food allergens. Cross-contact or lack of information can occur at any stage of food production. Our new e-book: ‘Managing Food Allergens’ is a guide to understanding food hypersensitivity and how allergen cross-contact can occur. It also includes information on labelling and testing to aid the production of safe food.”

Helen Arrowsmith added: “Since food allergens cannot be removed from products once they are present, and generally cannot be destroyed by treatments typically used for killing microorganisms, effective food allergen management and accurate labelling and provision of information are essential for ensuring the safety of food for consumers with food hypersensitivity.

Our new guide is essential reading for food and drink professionals.”

Swancote Energy was established in 2011 and produces renewable energy from a combination of commercial food waste and purpose grown energy crops, via a natural process known as Anaerobic Digestion. “Anaerobic Digestion breaks down food waste to create gas and solid material called digestate which we use to make nitrogen-rich fertiliser. Until now we have used the gas to generate electricity, but this new investment also enables us to capture carbon dioxide and supply gas to the national gas grid network” said James.

The need for renewable energy generation is driven by government legislation and guidance at both a local and national level in the UK. The British Energy Security Strategy was published in April 2022 and seeks secure, clean and affordable British energy for the long term. “Biomethane cuts emissions in the hard to de-carbonise sectors of heat and transport,” explained James, “and of course we’re putting commercial food waste to good use.”

“Our goal as a business is to reclaim all the carbon from food waste, both from the food itself and its packaging,” said James. “We are already the only UK biogas plant able to recycle all types of food packaging, including rigid plastics, removing the need to send material for incineration. With this new investment we will be able to offer customers a complete carbon capture solution for their food waste.”

Click here to download the Managing Food Allergens e-book.

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Industry News

Frozen food volume growth picks up speed in Q2 2023 The volume of frozen food sales continued to grow in the second quarter of 2023, according to new Kantar data from the British Frozen Food Federation (BFFF).

The 12-week figures to 11 June show that volume sales of frozen food grew by 7,559,000 tonnes, compared to the same period last year. At 1.6%, the rate of growth is increasing compared to the 0.5% in the 12 weeks to 19 March.

Frozen vegetables, meat & poultry, potato products, pizza and savoury foods are all driving volume growth in the 12 weeks to 11 June. More indulgent, premium products such as ice cream, confectionery and fish have seen a drop in sales volume, as shoppers became more budgetconscious during the cost-of-living crisis. The frozen ready meals sector,

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which saw volume growth in Q1, has seen demand drop.

The value of retail frozen food sales also continued to increase in the same period, up +20% (£326,501,000). This growth in value is largely a reflection of the inflation affecting the entire food industry.

The fresh and chilled market continued to see volume sales decline (-3.3%), as price conscious consumers switched to frozen food to help stretch their budgets.

Rupert Ashby, chief executive of the British Frozen Food Federation commented: “The cost-of-living crisis continues to have a significant effect on consumer spending habits, with more shoppers buying frozen food to help make their budget go further. With more AB

shoppers now visiting the frozen aisle, it’s clear that consumers are recognising frozen food as a tasty, nutritious and affordable choice that can help them deal with the current economic climate.”

Mr Ashby added: “Whilst the growth in sales is good news, our members continue to face significant challenges throughout the entire frozen supply chain, with the effects of the coronavirus pandemic, the war in Ukraine, Brexit and inflation still putting members under huge pressure.

However, volume growth shows that consumers are continuing to choose frozen food for its high quality, value for money credentials.

Industry News

House of Lords Horticultural Sector Committee visits Kent-based vertical farm, GrowUp Farms Members of the Lords Horticultural Sector Committee visited pioneering Kent-based vertical farm, GrowUp Farms, in Sandwich last week to find out about how vertical farming will play a key role in the future of farming.

Lord Carter, Lord Colgrain, Lord Coles, Baroness Fookes, Lord Redesdale and Baroness Walmsley visited the farm - called Pepperness - which is leading the charge in vertical farms in the UK as it was the first to sell its salad ranges through UK supermarkets.

The House of Lords Horticultural Sector Committee was created in April this year to produce a report on the horticultural industry. A 12-strong committee from all parties including crossbenchers is considering the challenges faced by the sector, which is worth billions to the UK economy and is a significant contributor to UK food security.

GrowUp Farms is the UK’s leading vertical farm, and launched its Unbeleafable salad range in Tesco stores in July this year.

from overseas. It tastes fresher and crisper and lasts longer than other salads, which means there’s less waste produced too.

“We’re very proud of what we are achieving here at Pepperness, and the part we’re playing in the future of food security for the UK” said Kate Hofman, founder and Chief Brand Officer of GrowUp Farms. “Currently the UK imports around 67% of its salad from warmer climates, and this rises to 90% in the winter*, so vertical farms can help the UK to be more self-sufficient in producing food.

We were delighted to welcome the House of Lords Horticultural Sector Committee to Pepperness, and we very much support the inquiry into the considerable challenges facing this sector, not least the effects of climate change.

“We grow, harvest, and pack our salads for supermarkets across the UK, all at Pepperness in Kent. The farm’s highly controlled environment simulates a beautiful Mediterranean spring day, every day, providing the perfect growing conditions for salad.”

Lord Redesdale, Chair of the Committee, said: “Horticulture is worth billions to the UK economy. From healthy fruit and vegetables to the multitude of crop and plant varieties that can be grown in the UK, it is a fundamental component of a secure food supply, supports the wellbeing of millions of people, and could provide innovative solutions to the challenges presented by climate change. Despite this, horticulture has been continually overlooked and undervalued. As part of our inquiry, we were delighted to visit Pepperness and see how GrowUp Farms is putting real innovation into practice to build resilience into the UK horticulture sector.”

A vertical farm is an innovative agricultural system, designed to grow crops in vertically stacked layers in a controlled indoor environment. The growing process means that salad can be grown year-round in the UK and uses up to 94% less water than traditional growing.

Pepperness grows the salad without the need to use pesticides of any kind, nor does it need chlorine-washing, in fact the salad doesn’t need to be washed at all before eating - all processes which degrade the quality of the leaves. The supply chain is significantly reduced, so the salad only travels from Kent to UK supermarkets, rather than

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Packaging

Introducing the Aero Carbon Fiber Pallet Wrap Dispenser: Precision Meets Performance In the fast-paced world of manufacturing, where time and efficiency are critical, the Aero Carbon Fibre Pallet Wrap Dispenser emerges as the peak of innovation.

Inspired by Formula One technology and designed for factory and warehouse floors, the Aero transforms pallet wrapping with its exceptional features.

Ergonomic Design: Crafted with meticulous attention to ergonomics, the Aero dispenser ensures that workers can wrap pallets comfortably and efficiently. Its intuitive design minimises strain, allowing operators to maintain peak productivity without compromising on well-being.

Versatile Adaptability: The Aero is engineered to effortlessly accommodate various sizes of pallet wrap, making it a versatile addition to any factory.

Say goodbye to the hassle of switching between dispensers for different jobs. This adaptability streamlines your processes and optimises your workspace.

Feather-Light Efficiency: Constructed from cutting-edge carbon fibre, the Aero is astonishingly lightweight.

Manoeuvring it through your workspace is a breeze, and operators

Constructed from cuttingedge carbon fibre, the Aero is astonishingly lightweight.

Manoeuvring it through your workspace is a breeze, and operators can effortlessly reach and wrap the bottom of pallets. Less physical effort translates to saved time and reduced fatigue. can effortlessly reach and wrap the bottom of pallets. Less physical effort translates to saved time and reduced fatigue.

Low-Profile: With its sleek, lowprofile design, the Aero excels in accessing those hard-to-reach areas beneath pallets. Every inch of your load can now be securely wrapped with ease, eliminating the need for timeconsuming adjustments.

The Aero Carbon Fibre Pallet Wrap Dispenser is specifically designed for use with Armour Wrap pallet wrap, offering unparalleled compatibility and performance synergy. Improve your pallet wrapping game to Formula One standards with the Aero.

Visit Springpack.co.uk/aero for more information and to buy online.

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Packaging

Cutting, dosing and packing with safety drives Fabian Fischer, Team Leader Application Sales at KEB Automation, explains the challenges food and packaging machinery pose for drive and automation solutions and how these can be overcome. Functional safety concepts, for example, are of particular importance.

Food and packaging applications are characterised by harsh environmental conditions. In many cases, the machines are cleaned with aggressive washing substances and high pressure. Motors, frequency inverters and controllers must therefore be robust and hardwearing. The circuit boards in the current series of drive controllers from KEB Automation are equipped with a protective lacquer specially developed for these environments.

HMI control panels from KEB are made from stainless steel and are protected to IP69K. High pressure cleaning and even temperatures up to 50°C do not affect the devices.

Performance is also important: food and packaging machines must ensure precise cutting, dosing, mixing and filling in the shortest of cycle times. For this purpose, KEB offers compact, energy-saving, dynamic drives with high overloads and precise control.

Functional safety from drives Up to now, safety technology was often set up decentrally with external safety modules. These were expensive, complex to wire and required space

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Performance is also important: food and packaging machines must ensure precise cutting, dosing, mixing and filling in the shortest of cycle times.

- Fabian Fischer

in the control cabinet. KEB builds functional safety concepts in a smart way. Functions such as “Safe Torque Off” (STO) or “Safely-Limited Speed” (SLS) are integrated in the COMBIVERT range of drive controllers and can be selected on a modular basis. Wiring is not required if a safety controller with, for example, Safety over EtherCAT or PROFIsafe is used. With many speedbased safety functions, the safe encoder can even be eliminated. With KEB’s integrated safety function “Safe DoorLock Control” (SDLC) door switches on food processing machines with knife

drives, for example, are only released when the knife has come to a standstill.

An external module for monitoring is not necessary.

Complete system solutions From HMIs, controls and drives, to motors, brakes and clutches, KEB implements drive solutions from a single source. Individual components are optimally matched to each other, resulting in maximum machine efficiency. As, for example, the motor and drive controller harmonise perfectly, KEB also complies with the new IE2 energy efficiency label according to the EN 61800-9-2 standard. Another advantage for the machine builder is that there is only one contact person required for all matters concerning the drive. The flexibility of interfaces to components from third-party suppliers is retained in all this, in order to integrate components effortlessly into existing systems.

For more information, please visit www.keb.co.uk

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Packaging

Packaging’s place in the plastic crisis: A compostable solution Daphna Nissenbaum, CEO and Co-Founder of TIPA

With over 60% of flexible plastic packaging consumed by the food industry and an estimated 180 billion polybags used every year for fashion, apparel, and accessories, the packaging industry is undoubtably contributing to the plastic crisis.

There is, however, growing consumer demand for sustainable packaging. The 2023 Buying Green report found 63% of consumers are now less likely to buy

products wrapped in packaging that is deemed harmful to the environment.

Whilst individual governments are legislating on plastic packaging, with New Zealand recently banning thin plastic bags often used by customers to collect fruit and vegetables, packaging is still a necessary part of our everyday lives. Packaging is essential for several reasons, from ensuring food maintains hygiene standards to providing a protective shield to food whilst in transportation. This means in order to end our reliance on plastic we must seek out better plastic packaging alternatives.

One such alternative, one that mimics the look and durability of plastic, is compostable packaging. This type of packaging, when left in a compost bin, will integrate and biodegrade into beneficial compost in only a few months. The compost biomass will include molecules which contain useful elements such as carbon and nitrogen, both are important for plant growth and mineralisation.

Compostable packaging has a minimal impact on the environment and most importantly, and unlike conventional forms of plastic packaging, due to the natural polymers, no harmful toxins or chemicals are released.

Whilst compostable packaging is seen as a ‘new’ solution, it has been around for over 20 years. However, with limited performance capabilities compostables had been restricted to service basic products such as bags and disposable tableware. With advancements in technologies, businesses can now call upon leading compostable packaging manufacturers to fulfil their sustainable packaging requirements.

At TIPA, the team continues to make technological developments in innovating with compostable packaging. These developments have

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Compostable packaging has a minimal impact on the environment and most importantly, and unlike conventional forms of plastic packaging, due to the natural polymers, no harmful toxins or chemicals are released.

- Daphna Nissenbaum

even allowed for the advances of compostable metalized laminates that have extremely high barrier, and are perfect for crips and bars.

As the world’s governments, businesses and consumers are looking to end their reliance on plastic packaging, the tried and tested environmentally friendly alternatives are already being utilized across the world. With proven successful partnerships within the food and fashion industry, globally leading compostable packaging manufacturers such as TIPA continue to advance the field of compostable packaging, ensuring that there is an end to the suffocating impact of plastic packaging pollution on the environment.

Packaging

Celebration Packaging survey shows consumers confused over which materials best for environment when compared to plastic We concluded that takeaways are still going to have a requirement for singleuse cutlery of some kind, despite the bans.

- Nick Burton

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A recent survey by Sapio Research, conducted on behalf of Celebration Packaging, looked at consumer understanding of the bans on single-use plastic packaging, the alternative materials available and expectations around reusables.

“In our previous report on the findings of the survey, we looked at how over 50% of consumers expect a food-to-go outlet to provide cutlery, while 51% of consumers never, or rarely use reusable cutlery for eating on the go,” says Celebration Managing Director Nick Burton.

“We concluded that takeaways are still

going to have a requirement for single-use cutlery of some kind, despite the bans.

Here, we look at consumer understanding of alternative materials, sustainability and end of life options.”

Material choices When compared to plastic, the survey showed that 42% of consumers in the UK agree that wood is their most preferred type of cutlery, because it is sturdy (43%) and it is recyclable or compostable (42%).

Only 17% of respondents in the survey were aware of moulded fibre

Packaging

cutlery, otherwise sometimes called bagasse, as a viable alternative. While they described it as ‘environmentally friendly’ as it uses natural fibres, and found it to be sturdy, various comments were made about its characteristics. “I don’t like the feel of it and food sticks to it,” was one observation, while others were: “It is not as strong as plastic,” and “The texture is not smooth like plastic or metal.”

Thinking about the environment

“In the survey, the preference expectations around bamboo and metal as reusable cutlery lead us to believe that consumers are yet to discover the benefits of bagasse cutlery alternatives,” says Nick Burton.

“It is important for consumers to understand the varying environmental impacts of different materials, but they also need to know if these materials are sustainably sourced,” says Nick Burton. “We always say: ‘look for the FSC® logo‘ to see if wood, paper or bamboo products are Forestry Stewardship Council certified.”

“When we established our EnviroWare® brand over 16 years ago, we set out to seek better and more sustainable packaging solutions, made from different materials which can be reused or recycled.”

We always say: ‘look for the FSC® logo‘ to see if wood, paper or bamboo products are Forestry Stewardship Council certified.

When asked to comment on the environmental impact of different materials, three in four (75%) felt that plastic cutlery is worst for the environment, while there is less consensus on which is the best. Around a quarter believe that metal (27%), wood (25%), or paper (23%) is best.

End of life Understanding of how to dispose of different cutlery types differed widely.

The survey shows that over a quarter (27%) of consumers in the UK don’t know how to dispose of moulded fibre cutlery, while nearly two thirds (63%) know that plastic cutlery should be recycled.

“It is interesting that the understanding around whether materials are recyclable or compostable varies so much depending on the age group,” says Nick Burton.

“Surprisingly, older people are more likely to prefer a material for being recyclable – 25% in the 18 to 24 group versus 58% in the over 65s. 43% in the 55-64 age group

In the survey, the preference expectations around bamboo and metal as reusable cutlery lead us to believe that consumers are yet to discover the benefits of bagasse cutlery alternatives.

- Nick Burton

preferred materials for being ‘good for the environment’, but this fell to 20% for 18–24-year-olds.

“Celebration Packaging offers a wide range of options including EnviroWare® packaging made from compostable and recyclable materials.

“As a consultative business with many years’ experience in the sector, we can help outlets choose the most appropriate solutions which best match their business.”

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Packaging

International survey from Industrial Physics reveals top packaging innovations for the food sector Industrial Physics’ latest research reveals that professionals in the food packaging industry are addressing demands for greater sustainability and consumer preference with innovative approaches to material choice and the processes involved in production.

The leading packaging, product, and material test and inspection provider conducted a worldwide survey of packaging professionals operating across industries including food and beverage. It was uncovered that the biggest drivers of packaging innovation for those in the food and beverage industries were: 1. Ensuring quality of the packaging produced (69%) 2. Ensuring quality/safety of the product contained within the package (63%) 3. Ease of consumer use (56%) 4. Supporting sustainability initiatives (50%) Toby Lane, Product and Applications Manager at Industrial Physics, commented: “Sustainability continues to drive material developments including

For food can makers, light weighting not only facilitates a reduction in the cost of production and the materials wasted, but also allows the transport of a higher volume of cans with the same fuel usage. plastic eradication from brands across the world. However, we must look at the broader picture in terms of material transportation weight, production energy, testing capability, food safety approval, and other related challenges.”

Packaging professionals operating in the food and beverage sectors shared

that although the cost of materials is proving a challenge for well over half of respondents (60%), investment in new material development is still proving popular. Reducing the use of plastic remains high on the agenda (43%) for investment, with biodegradable material (58%) and organic material (51%) cited as those with the most potential when it comes to exploring new packaging mediums.

Lane continues: “Material use debates often end with the question, ‘can the material ensure the quality and safety required?’ For example, plastic is currently used for food storage because it is highly effective at sealing food while offering a tough, lightweight barrier with various sealing options.

“Therefore, if manufacturers select a less effective material to support sustainability or cost objectives, they risk triggering negative impacts such as increased food waste. This would be in direct contrast to the wider objectives uncovered in the research around waste reduction.”

The research also uncovered that packaging professionals in the food and beverage sectors are investing in recyclability (60%) and reducing waste (59%).

The report explores how over a third (37%) of food and beverage packaging professionals are exploring manufacturing processes such as lightweighting to support waste reduction throughout the supply chain. Lightweighting reduces the overall amount of material that is used to create metal packaging, while still maintaining the level of durability and performance required to protect the can’s contents. Today, cans can be produced with a wall thickness of 0.097 mm – as thin as a human hair, and by using less material in the manufacturing process, professionals can benefit from a reduction in the cost of production and ensure a more efficient use of the raw materials required.

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Packaging

Item Products’ carry handle solution creates cost savings for Britvic Soft Drinks Item Products, Europe’s largest designer and producer of recycled plastic components for the packaging and pointof-sale industry, has recently supplied Britvic Soft Drinks with a carry handle solution for their Robinsons 1.75L twin bottle pack assigned to the wholesaler, Costco.

Made from 100% recycled material, the handle is able to carry the twin bottle pack securely by the collar.

Once at home with the consumer, the plastic handle can be simply added to the domestic waste recycling system.

Adam Horvath, packaging development manager at Britvic plc, said: “Working closely with the packaging

development and procurement teams here at Britvic, Item Products set out timetables for the design, models, tooling, testing and approval of samples through to full UK manufacturing.

“The end result ticked all Britvic’s ‘must have’ needs and was delivered on schedule and to specification first time.”

“We are delighted to provide a solution for Britvic,” said Item Products’ managing director, Julian Cook.

“Being able to facilitate their requirement for a UK manufactured carry handle solution has helped to significantly cut their lead times and reduce transport costs.

The added benefit of producing the handle in a universal black colour enables Britvic to remove the need for specific masterbatch, allowing the device to be used across multiple brands.”

Item Products designs and produces a unique range of components for the packaging industry, including carry handles for cartons, connecting clips for corrugated board, hooks, studs and rivets for merchandising units, wheels and stabilisers for big or heavy packs, garment rails for wardrobe boxes and stackable trays.

Visit here to find out more.

“For food can makers, light weighting not only facilitates a reduction in the cost of production and the materials wasted, but also allows the transport of a higher volume of cans with the same fuel usage. However, professionals must consider factors including retention of the can’s durability and ensuring that material reduction doesn’t compromise quality.

“Throughout the lightweighting process, cans must still adhere to stringent regulations, including food-grade coatings, seam closures and tamper-evident features,” adds Lane.

On experiences of testing, although overall packaging decision-makers are significantly in favour (96%) of new developments, professionals in the food and beverage sector are already raising challenges from material and process development. The research revealed that manufacturers are struggling to test new types of packaging, due to: • The high cost of expertise required (63%) • Limited testing facilities (50%) • A lack of in-house expertise (44%) Lane concluded: “Despite perceptions, the testing equipment and methods are still

as applicable today. There are instances, for example in the case of recycled polymers where materials will behave differently and a new bank of data will need to be built, however, industry collaboration can prove valuable

to gather a wider sample more quickly. Also, the equipment available today is often so automated that professionals do not need to have a highly specialized knowledge base to conduct the testing required.”

To learn more about how packaging innovation goals are impacting the packaging landscape, download Industrial Physics’ free report here.

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The Corrugated Packaging Manufacturer

r D i n & k d o o F r Fo

By buying our packaging you help take care of the world’s forests FSC® C147497 • www.fsc.org

Product Focus

NSK bearings deliver major savings at snack food plant When a major snack food producer began experiencing repeat failures of the bearings on its cutter lines, a switch to NSK Life-Lube® housed bearing units delivered savings in excess of €130,000, primarily thanks to the elimination of lost production.

Production uptime is vital in process industries such as food and beverage. Many companies in this sector operate a business model based on high-volume throughput and narrow profit margins in order to remain competitive in a fierce marketplace. Any line stoppages can therefore have a highly detrimental effect on bottom-line profitability.

A case in point is a producer of snack foods that began experiencing frequent bearing failures on its processcritical cutter lines. To resolve the situation as quickly as possible, the plant turned to the expertise of NSK. As part of NSK’s Added Value Programme, AIP, a process map survey was conducted on site encompassing an investigation of the failed bearings

by NSK’s experienced engineering team. This activity identified grease expulsion as the problem due to line wash-down procedures. The issue was prompting bearing replacement every six weeks during routine planned maintenance to help prevent unplanned stoppages. However, failures sometimes occurred before scheduled maintenance, resulting in the loss of valuable production time, the cost of which ran into six figures a year.

NSK proposed replacing the incumbent bearings with the company’s Life-Lube® housed bearing units. The Life-Lube® series combines the corrosion-resistant properties of NSK’s Silver-Lube® thermoplastic (paint-free) housings with the excellent sealing and lubricating properties of the company’s Molded-Oil inserts, which feature solid lubricant. This proprietary material consists of lubricant and a polyolefin resin with an affinity for oil. Grease releases steadily and continuously over a long period, keeping the operating environment clean as there is no need for replenishment and no lubricant can escape.

performing well with no failures, eliminating production downtime entirely. Alongside far lower costs for parts and maintenance labour, the plant is seeing impressive annual savings of €134,478. Thanks to this success, NSK Life-Lube® housed bearing units now populate the snack food plant’s other two cutter lines.

Life-Lube® units are specifically for use in applications where contact with water and process fluids is unavoidable, and where long lubricant life is necessary. NSK therefore identified Life-Lube® as the optimal solution for the snack food plant and its detergent-based wash-down procedures.

NSK proposed a trial of Life-Lube® housed bearing units on one of three cutter lines at the snack food plant, the monitoring of which would determine suitability. After one year, the bearings were still

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Industry News itself by reconditioning and mounting 13 existing metal detector heads onto new incline conveyor frames robustly designed to transport heavier bags of rice, introducing an innovative bidirectional sweep reject.

From soil to steam

RICE WITH RE-PURPOSE: Fortress UPGRADES quality control at BULK RICE mill One of the largest rice cooperatives in North America has more than 50 Fortress Technology metal contaminant inspection units installed in its processing plants, including 13 ground-breaking incline conveyor metal detectors.

Being able to upgrade to the latest, greatest inspection features is why this bulk rice processor has remained loyal to Fortress for close to two decades.

The ‘Holy Grail’ of any food machinery investment is to maximise Total Cost of Ownership in a sustainable way, without compromising performance and consumer safety. Continuing to benefit from Fortress Technology’s contaminant detection ‘Never Obsolete’ pledge, this dry rice manufacturing and packing facility now has in excess of 50 gravity, bulk, lab unit and incline conveyor metal detectors.

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Processing and packaging more than 100 long and medium-grain rice brands - supplying retailers, restaurants, food service companies and exporting globally - Fortress has supported the farmer-owned rice cooperative by issuing a number of technology and machine upgrades.

Analogue metal detectors more than 10 years old have been converted to digital to improve contaminant detection and add data logging and reporting capabilities. Making them comparable to new Fortress metal detectors. However, in the latest and largest project, Fortress surpassed

Harvesting, milling, grading and packing over 60-million rice bushels annually, the US producer is reliant on robust best-in-class metal detection.

Upstream, prior to packing, are a number of Fortress Gravity metal detectors located between product shoots and hoppers. Each rapidly inspects between 40,000 and 75,000 cubic feet of free-falling dried longgrain rice hourly, automatically rejecting metal contaminants from the product flow and keeping rice waste to a minimum.

Compact offline lab units are then deployed to quickly examine any rejected product and separate the metal contaminants from the rice. This enables the rice producer to filter out and rework all good product, again helping to minimise waste and identify contaminants for further investigation.

For bulk bags of rice weighing up to 50kg, large bag metal detectors are, for weight and safety reasons, located at floor level. Featuring a large aperture, a special coil structure, and Vector heavy duty conveyor, this market-leading bulk inspection metal detector can guarantee detection of ferrous and nonferrous metals as small as 1.5mm, and 2.0mm non-magnetic 316 stainless steel contaminants in the aperture centre.

To inspect smaller rice packs weighing up to 9kg, Fortress engineered a special

Industry News incline conveyor frame to overcome the plants’ limited floor space. Measuring 4.25 metres in length, packs move up a special flighted conveyor belt at a 45° angle.

Designed to handle a fast product rate, a Stealth metal detector with a customised head and aperture ensures performance and detection sensitivity is not forfeited. Having ground level remote access enables staff to safely select the inspection parameters and access data from the metal detector heads if the HMI control panel is beyond reach.

Sustainable and waste reducing Many Fortress engineers contributed to the design. Yet, as testament to the level of detail and collaboration that goes into each and every Fortress commission, company founder and President Steve Gidman couldn’t restrain himself from getting involved.

Steve reflects: “Because the conveyor was inclined and as the product had to be rejected perpendicular to the flow, rubber grips were not advisable as they would inhibit reject performance, damage bags and make a mess.

Knowing that this would create unnecessary Green Advert Half Page_FINAL.pdf

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waste, to address this we instead opted for belting with flighted sections.

“This solution allowed the rice bags to be conveyed uphill at a steep angle, without impacting the lateral rejection.”

Due to the high product rate – on average 150ppm - and the flighted belt, deploying a reject device with a return stroke was ruled out. To avoid collisions with the belt features and trailing rice bags, Fortress instead created a bi-directional paddle sweep reject. Rejecting contaminated packs on either side of the conveyor, chutes funnel rejected product safely to ground level, securing it behind lock and key for authorised quality control personnel to remove.

For this customer, like many, the sensitivity of each metal detector combined with the compatibility of components, provides added assurance that investments can be spread out.

Knowing that the technology will never be obsolete is especially valued by this customer. Parent company Fortress Inc is currently in the process of upgrading more than 10 Phantom metal detectors to Stealth, on machines purchased by this rice producer over 10 years ago.

Very often, metal detection hardware remains fit for purpose long after the software has evolved.

“Very often, metal detection hardware remains fit for purpose long after the software has evolved. Many fast-growth companies approach us to discuss adding extra features, including sophisticated data logging capabilities,” explains Fortress Europe’s Managing Director Phil Brown.

Because Fortress always sticks to its universal modular design, upgrading to a Stealth Metal Detector is very straightforward. Not only does this save customers a lot of money disposing of and replacing assets that remain perfectly functional, it also prevents industrial assets adding to the environmental costs. Being able to offer this upgrade service and additional field support is a huge tick for responsible waste stewardship, reports Phil.

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Food Processing

Optimising hygiene controls in food processing environments

By Jodie Curry, Commercial Manager, Fortress Technology

Recent events, particularly the Coronavirus pandemic, has heightened awareness on hygiene compliance and the need for people throughout the food supply chain to accept personal responsibility for maintaining equipment cleaning routines and sanitation protocols.

Metal and X-Ray contaminant detection and checkweighing specialist Fortress Technology outlines some simple ways to build compliance custodians that will embrace food safety from start-to-end on food processing lines, and the role that hygiene habits, equipment innovation and leadership support play.

Without effective cleaning and hygiene systems in place, inspection equipment could actually become a source of contamination. Chemicals used for cleaning can also contaminate food if not effectively flushed through.

Adhering to best hygiene practices is the single thing that food manufacturers cannot cut corners on. Across Europe, standards are already very high. However, the pressure since the global pandemic has changed the landscape for a number

of food processors, with localised labour challenges and supply chain disruptions further complicating mandatory audits.

The pandemic reinforced the importance of food processors conveying confidence and having robust and proactive HACCP, GFSI/ SQF, BRC and hygiene protocols in place. The challenge now is making sure that these remain aligned to evolving colleague and consumer health, safety and wellbeing expectations.

Although price remains king when it comes to food purchasing drivers, safety has now emerged as an equally critical consideration. A report

by Deloitte – The Future of Fresh – summarises this well, citing food safety as having multiple dimensions.

Among the factors listed in this report is safety for self, others, and the workers who produce food, as well as safety in terms of packaging, to prevent contamination.

BELOW: In pipeline inspection systems, special attention should be paid to the speed that reject units can be removed, cleaned and reassembled

Adhering to best hygiene practices is the single thing that food manufacturers cannot cut corners on.

- Jodie Curry

Calming allergen fears Today, more than 150 million Europeans suffer from chronic allergic diseases, with predictions that by 2025, half of the entire EU population will be affected. Many more also report hypersensitivity to specific ingredients.

For example; one in 100 Europeans are affected by coeliac disease, although only a third have an official clinical diagnosis for the condition.

For food safety reasons, all food and beverage manufacturers have a responsibility to identify allergens that are contained in their products.

This responsibility extends to isolating them from other non-allergen products processed in the same facility. However, problems may still occur on the supplier side, especially when sourcing from multiple or multi-function sites.

As one example, dairy-free products are still often produced at sites that make dairy products. Some might not have dedicated dairy-free machinery and zones. Although thorough clean downs are used to flush away residual dairy products, this method cannot be relied upon as being totally fool-proof.

Planning production schedules to isolate products containing allergens is a common tactic in manufacturing facilities where a dedicated line cannot be allocated. The storage of ingredients should also be separated.

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Food Processing Gluten in particular has become a major source of concern, with many sites introducing segregated glutenfree stations and changes of work clothes for operatives.

Following a number of high profile incidents, allergen labelling has inevitably got stricter. New UK legislation came into force on 1 October 2021. Known as ‘Natasha’s Law’, businesses are now required to label all food that is pre-packed for direct sale (known as PPDS) with a full list of ingredients and the 14 allergens emphasised in bold.

Customers that invest in a Fortress or Sparc Systems x-ray and metal detector conveyor, checkweighing or combination inspection machine may benefit from integrating an advanced label verification system. As well as actively inspecting for allergen ID codes, these label systems also check product descriptions, bar codes, lot numbers and date codes. Checking for errors on the top, bottom, lid or pot of packaging, mis-labelled products are automatically pushed into a rejection bin, safeguarding against potentially business critical events and product recalls.

Making processes habit forming It’s human nature. People like things to be streamlined, efficient, faster and better. Yet, taking hasty shortcuts, particularly with hygiene and consumer food safety is a risky strategy. Being careless with compliance can become a catalyst for more shortcuts. It’s not a cycle any food business would or should encourage. Especially given that many a shortcut results in a bigger problem that takes longer to correct.

ABOVE: Look for smooth, crevice-free contact surfaces to reduce the risk of cleaning agents not being fully rinsed away BELOW: Adhering to best hygiene practices is the single thing that food manufacturers cannot cut corners on

Despite high levels of automation, food processing plants continue to have numerous manual touchpoints.

Cleaning manufacturing and inspection processing machinery being one.

Continued >>>

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Food Processing Ultimately, good housekeeping is common sense.

Most food processors are strong custodians of hygiene and safety practices.

- Jodie Curry

For this reason, Fortress has concentrated its efforts on developing smarter designs to enhance hygiene and safety measures.

This includes eliminating the use of tools on the company’s newest range of food inspection systems. The conveyor quickly and easily lifts off the frame and can be disassembled just as quickly to facilitate deeper and faster cleaning by trained operatives. Improving line efficiencies, the belt tension and alignment are instantly restored when reassembled after maintenance and cleaning.

Routine risk assessments and audits help to control the introduction of foreign material into products. External eyes provide a different perspective.

Many internationally recognised audits follow set standards and provide a complete 360-degree review. A number of these information gathering audits remain hybrid, blending in-person and virtual observations. Digital evidence of all actions, from maintenance and testing of machinery to documenting hygiene checks is integral to the success of these hybrid certification models.

It requires a shift in culture, where everyone up and down the hierarchy is encouraged to be hygiene-conscious food safety champions.

Optimising cleaning efficacy To ensure this happens, sanitation protocols should be formalised and included in staff training. Every cleaning process needs to be verified and documented. As part of a validation process, regular tests, including swabs of Critical Control Points, should be scheduled to ensure these CCP areas are hygienic and allergen-free.

For in-process contaminant inspection equipment, look for smooth, crevicefree contact surfaces on conveyor, pipeline and gravity systems. This is partly to ensure that no traces of product, allergens or bacteria are left, but also to reduce the risk of cleaning agents not being fully rinsed away.

When selecting an inspection system, care should be taken to identify equipment with an ingress protection (IP) rating appropriate to the washdown regime and water pressure being applied.

Product residues, including allergens, can be especially troublesome in metal detection and x-ray pipeline systems processing liquids, semi-liquids and slurries. Special attention should be paid to the speed that reject units can be removed, cleaned and reassembled.

Ideally, this will be easy to roll out, dismantle and clean working parts before securely reattaching to pumps.

It’s why the Fortress Pump Pipeline Metal Detector now features ultra-

hygienic, food-safe Delrin removable plastic tubes. Intentionally constructed with no metal ends helps to ensure a pipe is completely clear of bacteriaharbouring crevices. Another thing to look out for are Clean in Place modes on equipment.

Rather than using unhygienic stickers and labels, all safety symbols, industry-approved markings and the machine nameplate are laser-etched directly onto every Fortress X-Ray, metal detector and checkweigher steel cabinet.

Food processors might also consider the advantage of being able to manoeuvre machines around the plant. If a machine isn’t fixed to ceilings or frame it is inherently easier and quicker to deep clean. From a flexibility perspective, it also enables easy reconfiguration on upstream processing lines. With all moveable machinery, do check to see if they are balanced systems, as this mitigates the risk of the machine tipping over when being relocated. For facilities with sloped floors, adjustable casters enable easy correction of pipe angles, for example.

Ergonomic features can also enhance workforce safety. For example, an extension pipe on the reject output helps to prevent injury during sanitation and maintenance, and electric-powered height adjustment controls can mitigate back injuries.

Changing the food safety narrative Listening to different perspectives and mapping out hygiene protocols collaboratively rather than reverting to hierarchies is the best way forward to create the safest food processing ecosystem.

Ultimately, good housekeeping is common sense. Most food processors are strong custodians of hygiene and safety practices. However, given the numerous critical control points in a manufacturing facility, Fortress would always advise routinely and systematically revisiting potential hygiene hazards as part of a regular risk assessment and food safety program.

LEFT: UK law now mandates that businesses label all food pre-packed for direct sale (PPDS) with a full list of ingredients and the 14 allergens emphasised in bold

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Food Processing Al Amir Food Industries invests AED 35 million on its food processing unit in Ras Al Khaimah Al Khaimah Economic Zone (RAKEZ) continues to support big players in the agri-tech sector with the setting up of Al Amir Food Industries’ (AAFI) 13,500 m2 processing unit for healthy pulses and spices. With an investment of AED 35 million on its new factory at Al Ghail Industrial Zone, the Indian company will be importing products from Canada, Australia and Russia and exporting to GCC, MENA and East African markets, while wholesaling locally in the UAE. Furthermore, AAFI aims to create 50 new jobs in Ras Al Khaimah over the next three years.

Ramy Jallad, Group CEO of RAKEZ and Yasin Abdul Majid Ranani,

Managing Director of AAFI marked the beginning of the latter’s journey in the economic zone during a signing ceremony held between the two parties at RAKEZ Compass Coworking Centre.

“We are excited to trade in a range of high-quality, sustainably grown, healthy pulses and spices into the UAE and foreign markets with speed and precision. Our aim is to enhance the culinary experiences of consumers by introducing an array of flavours, aromas and exotic variations that stimulate taste buds and delight the senses,” said Ranani.

Apart from importing and exporting, the company will also provide white labelling solutions, wherein AAFI’s end products can be customised as

We are excited to trade in a range of highquality, sustainably grown, healthy pulses and spices into the UAE and foreign markets with speed and precision. per customers’ brands. The solution will be targeted at retailers, highend supermarket chains and ethnic stores.

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Food Processing

Top tips to reduce food waste during processing

By Matt Hale, International Sales & Marketing Director, HRS Heat Exchangers

According to some estimates, over a third of all the food produced globally is wasted. The UK generates around 9.5 million tonnes of food waste a year, of which some 1.5 million tonnes (16%) comes from manufacturing1. While not all of this material is edible, in terms of efficiency and reducing greenhouse gas (GHG) emissions, prevention of this waste is preferable to other methods such as food redistribution or use as animal feed, or recycling, energy generation or disposal via anaerobic digestion, composting, incineration or landfill.

Waste food also has significant financial costs for businesses. Not only does the raw material have a cost, but additional costs are associated with the redistribution or disposal of waste food products. Some key areas to consider include: 1. Improve packaging Good quality packaging improves the shelf life of food and therefore reduces waste in the distribution chain and in households.

However, there is increasingly a balance between reducing the use of plastics and nonrecyclable materials, while increasing product shelf life (wrapping cucumbers in plastic is a classic example). Choosing the right packaging during the manufacturing process can improve shelf life and reduce handling, improving efficiencies and reducing waste.

2. Improve forecasting Inaccurate forecasting can mean you waste raw materials and ingredients. Don’t assume that you need to produce a certain number of products unless you have clear evidence for such demand (such as agreed orders or demand modelling). Ordering enough ingredients to produce a certain volume of product but actually producing less, is one of the biggest sources of waste in food businesses, particularly when using fresh or perishable ingredients. Better and more accurate forecasting models allow you to guess less and maximise the use of ingredients.

As with other areas, staff awareness, education and involvement play a huge role in minimising waste.

- Matt Hale

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Food Processing a. Redistribution to people b. Use for animal feed c. Anaerobic digestion d. Composting e. Incineration with energy recovery f. Incineration, landfill or disposal via sewerage systems

ABOVE: The HRS R Series can be run in reverse, effectively emptying the heat exchanger tube(s) of product 3. Measure and plan Without measuring waste, you can’t tell if you are reducing it, or adequately calculate what it is costing you. Feeding this data into company-wide systems so that it can be analysed centrally helps to identify areas of inefficiency and waste, allowing manufacturers to streamline processes and reduce waste.

4. Review quality control systems Quality control is vital to maintain standards and food safety, but there is a need to avoid overzealous standards which may result in ingredients which are perfectly usable being discarded.

Likewise, under- or overcooking-food, or having unnecessary trimmings or off-cuts results in unnecessary waste.

As well as making sure that the quality standards and specifications being applied are appropriate for the product, it is also important to make sure that the processes used for quality assurance are operating correctly, whether that is calibrating equipment or training staff.

5. Involve staff

It may also be possible to utilise certain products in novel ways, for example vegetable oils and animal by-products (ABPs) can be converted into biodiesel where facilities allow.

7. Use technology to reduce waste during production New technology or equipment may help increase utilisation, for example by recovering more usable protein from meat carcases. Another option is to optimise existing production processes, particularly when it comes to production changes or cleaning-inplace (CIP).

New technology or equipment may help increase utilisation, for example by recovering more usable protein from meat carcases.

- Matt Hale

For example, the HRS R Series of heat exchangers uses a scraper bar within the inner tube to enhance product flow, prevent fouling and minimise pressure drop. It has the unique feature is that when configured correctly, the unit can be run in reverse, effectively emptying the heat exchanger tube(s) of product without damaging it or changing its characteristics, so it can be recovered and utilised.

Due to the amount of product saved, and the fact that it is often unnecessary to install additional product recovery systems, the R Series heat exchanger can quickly pay for itself, and in the long term can be a more economic option than alternative systems which have lower capital costs.

LEFT: Matt Hale, International Sales & Marketing Director, HRS Heat Exchangers BELOW: Consider how you dispose of unavoidable waste. For example, anaerobic digestion is preferable to landfill

As with other areas, staff awareness, education and involvement play a huge role in minimising waste. Employees should be invested and committed to reducing waste and building it into company culture. As well as educating staff about the impacts of waste, they should be encouraged to take part in a full dialogue as employees often have useful insights.

6. Improve ‘disposal’ of unavoidable waste Even with the best will in the world, some ‘waste’ is likely to be generated.

This should be dealt with in a way which maximises its usefulness or value. According to the food waste hierarchy, in order of preference these disposal options are:

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Thermal Processing

The environmental benefits of aseptic filling

By Matt Hale, International Sales & Marketing Director, HRS Heat Exchangers

The thermal processing of food and drink products, and the production of the relevant packaging have significant environmental impacts.

- Matt Hale

The use of heat exchangers for pasteurization and cooling as part of aseptic filling provides significant energy savings

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Over the last decade or so, the benefits of aseptic filling technology compared to traditional hot filling techniques have become well known in the food and drink sector.

The benefits in terms of product quality have been well documented and discussed. However, the environmental benefits, both in terms of energy consumption and typical life cycle analysis of this packaging method are less understood.

A number of Life Cycle Analysis (LCA) studies have shown that aseptic filling techniques using ultra heat treatment (UHT) systems of pasteurisation or sterilisation, which are based on heat

exchangers, generally have lower environmental impacts. This is down to two main factors: the packaging used in the two different processes and the energy footprint of the process itself.

The thermal processing of food and drink products, and the production of the relevant packaging have significant environmental impacts. However, despite this there have been few studies looking at the energy footprint and other environmental impacts of these processes.

Aseptic filling provides robust product quality, minimal thermal impact on the beverage, and greater bottle design flexibility with the ability to use lighter

Thermal Processing weight PET bottles or cartons. In contrast, hot filling requires a higher energy requirement, has a thermal impact on the beverage itself, and has less flexibility of bottle design than aseptic filling.

Aseptic filling has a lower GHG footprint than hot filling

Key difference between systems In an aseptic (cold fill) system, the product is pasteurised or sterilised using UHT systems and then cooled immediately. It is then placed in the packaging which has either been presterilised (or is sometimes sterilised at filling). Heat exchangers are generally used for both the heating and cooling processes, enabling very efficient heat transfer and the use of heat regeneration to minimise the overall energy requirement. In these situations, ‘considerable energy is saved by using the hot product’s heat to pre-heat the cold one, and vice versa.

In a hot filling system, the product is pasteurised or sterilised (using heat exchangers or other thermal technologies). The packaging is then filled at a high temperature (typically between 80 and 92 °C) which has the result of sterilising the packaging. The packaging is then tilted or agitated to ensure complete contact with the hot product and the temperature is maintained for a specified period, such as two minutes. After this the packing and the product are cooled. How this is done, and how soon after filling the process is carried out, depend on the product and the packaging. Typical methods include blast tunnels, falling water coolers or even cold storage.

While the initial capital investment in an aseptic system is often higher than for a comparable hot fill system, aseptic systems have lower daily operational costs (e.g., less energy usage) and allow for the use of lighter weight PET bottles. As a result, the Total Cost of Ownership (TOC) of an aseptic system is lower than for a hot fill system.

Typical methods include blast tunnels, falling water coolers or even cold storage.

- Matt Hale

Difference in packaging LCA In practice there are many different types of packaging used in both systems, although in general terms board-based cartons and light-weight PET bottles are used with aseptic systems, while hot fill machines are associated with heavier PET bottles, glass or cans.

In an effort to accurately compare the environmental impact of both systems, some researchers compared aseptic and hot fill systems based on the production of 500 ml PET bottles of orange juice. Because a thicker gauge of plastic bottle is required to withstand the higher temperatures in hot filling

systems, more plastic is used (in this example 24 g for hot filling versus 16 g for aseptic filling). As a result, the greenhouse gas (GHG) emissions associated with the packaging are 80.4 g CO2e per bottle for the hot fill process, compared to 61.8 g CO2e per bottle for aseptic filling – a saving of 23.1%.

Difference in energy consumption The difference in energy consumption between the two systems is due to different heat treatment, filling and cooling methods has often been ignored by researchers.

Continued >

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Thermal Processing As energy prices around the globe rise rapidly, and the need to take action on climate change intensifies, more and more food and drink manufacturers are looking to reduce the energy costs of their production processes.

- Matt Hale

Orange juice produced via aseptic filling has a lower greenhouse gas (GHG) footprint than that produced with hot filling techniques

One typical (and totally inaccurate) observation is, ‘the energetic matrix was assumed to be the same for all systems.’ This is patently untrue, as other studies have shown that ‘There are several advantages to aseptic processing and packaging over traditional pasteurisation. Advantages include extended shelf life [and] lower energy costs.’

Where the energy footprint of aseptic filling has been compared to hot filling techniques, it has shown that, ‘the product treatment in hot filling appears to have higher impacts die to the higher energy requirement that occurs during the warming and the chilling phases’ and, ‘in hot filling systems the heat of the treated product cannot be recovered.’

Some of the benefits are less clear cut than may be supposed and vary according to the heating medium source (such as steam), as well as the electrical and compressed air consumption of different system components. However, using heat exchangers with energy recovery provides significant energy savings.

Despite these complications, using the same 500 ml PET bottles of orange juice example above, GHG emissions associated with energy consumption by the process were 31.6 g CO2e per bottle for the hot fill process, compared to 24.4 g CO2e per bottle for aseptic filling – a saving of 5.32%. While this may seem small, when applied up to a theoretical production of 250 million bottles per year, this represents a saving of more than 1,500 tonnes of CO2e each year.

Based on our experience of thermal processing systems around the world, at HRS we believe that the GHG impacts of hot filling technology are in fact higher than this. There are a number of different techniques used to cool product and packaging after hot filling, and not all of these are as energy efficient as the chilled-water drench described in the above study. For example, where cold rooms are used, their overall cooling efficiency is low and the electrical energy requirements are significant.

The combined effects As energy prices around the globe rise rapidly, and the need to take action on climate change intensifies, more and more food and drink manufacturers are looking to reduce the energy costs of their production processes. Switching from hot fill to aseptic production lines is increasingly attractive, and for new lines, the arguments for adopting aseptic techniques are clear.

As the scientific studies above show, overall GHG savings of 24.9 g CO2e per bottle are possible, something that is far from significant. To discuss how the HRS range of heat exchangers, pasteurisation and sterilisation technologies, and complete aseptic treatment and filling systems, can help your business to realise these monetary and environmental savings, please contact us.

For more information: www.hrs-heatexchangers.com

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Dairy Sustainability

Addressing dairy sustainability with energy-efficient technology Food & Drink Manufacturing Magazine hear from Rasmus Mortenson, CEO at Lyras, talking about how pasteurisation production lines currently contribute to unnecessary waste and energy costs.

There is no doubt that the dairy market is a global giant. Milk production and the demand for dairy continue to increase at a rapid rate worldwide, in large part due to population growth, rising incomes and urbanisation. This increased demand puts growing pressure on natural resources, which includes freshwater and soil, alongside energy resources needed for manufacturing raw materials into high-quality and great-tasting products.

Millions of farmers worldwide tend approximately 270 million

dairy cows for milk production.

Because of this staggering statistic, its production impacts the surrounding environment in various ways, the scale of which depends on the practices of dairy farmers and feed growers.

From a consumer perspective, dairy enthusiasts have the right to not feel guilty about how their products are farmed, but in terms of dairy businesses, creating more sustainable methods of production should always be a priority to reduce waste, cut energy costs, and continue to make changes that best help the overall push towards net zero being adopted across all industry sectors.

Sustainable production practices in the dairy industry may currently be harder to come by, but to truly address dairy sustainability and create a more energyefficient, greener future, sustainable technologies need to be adopted across production lines on a global scale.

The problems of milk pasteurisation Cow’s milk does take a heavy toll on the planet. For every litre produced globally, approximately 3kg of greenhouse gases is released into the atmosphere. With total global emissions currently around 50 billion tonnes of

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carbon dioxide, dairy emissions equate to about 3.4% – almost double the impact of aviation. By far, the biggest source of those emissions is methane, although CO2 emissions play a part due to massive energy costs and production waste.

Over 80% of total energy use on a dairy farm is accounted for by milk cooling, water heating and vacuum pumping. This figure can be attributed to traditional pasteurisation techniques, which are carried out by using heat. During the process, significant energy is needed to heat liquids to relatively high temperatures to kill bacteria, and then similarly just as much is needed to rapidly cool them to ensure no lasting damage is done to the nutritional makeup of the product.

Due to this, regular pasteurisation techniques can cause a massive amount of wasted energy. These energy costs quickly add up, alongside the process producing more water waste and carbon dioxide emissions that directly combat the demand for sustainability in dairy systems, adding to the overall global environmental footprint of the industry.

Shining light on a low-energy solution UV light utilisation holds the answer to providing a new alternative pasteurisation solution. Its benefits allow the removal of pathogens from liquid products – not just water, but also when applied to milk production as well. In comparison to heated solutions, a UV-light-powered process can reduce energy consumption, whilst maintaining – if not heightening – end-product quality.

With more sustainable pasteurisation technology that utilises UV instead

Dairy Sustainability of heat, dairies can save between 60 and 90 per cent of the energy and 60 to 80 per cent of the water that traditional pasteurisation methods would otherwise require. This paves the way for major energy and carbon dioxide savings in dairy production lines worldwide – especially important given the continually rising energy prices we’ve seen over recent years.

In switching to this sustainable solution, greenhouse gas emissions per company can decrease rapidly – a significant impact if adopted industrywide.

A greener future for the dairy industry High-technology dairy production alternatives can lead to not only relatively short returns on investment, but also significantly lower operation costs through reduced energy and water consumption, increased operational hours, and overall, less cleaning and maintenance needed. An improved, higher quality end-product

UV light utilisation holds the answer to providing a new alternative pasteurisation solution.

Its benefits allow the removal of pathogens from liquid products – not just water, but also when applied to milk production as well.

also provides benefits both on a business demand end, and also directly for consumers.

Yet ultimately it comes down to the dairy farm as to whether the impact can be as great in helping the environment. Larger dairy production lines will have significantly greater potential to reduce their energy consumption by switching to these solutions than smaller dairy farms with lower energy consumption. Like it is across many industries, we look to the massive production giants to adopt sustainable solutions in order to cause wider change, and because the incentive of a higher-quality, lowercost product is there, it only makes sustainability that much more enticing for a business incentive perspective.

- Rasmus Mortenson

Over 80% of total energy use on a dairy farm is accounted for by milk cooling, water heating and vacuum pumping. Maximising quality can therefore become part of moulding a greener future for the dairy industry,

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Sustainability

Sustainability in Food Manufacturing:

How Tork Bio-based Paper Towels Clean Up on Impact Tork, from leading hygiene and health company, Essity, offers expert advice on achieving efficient cleaning in Food and Drink Manufacturing.

Food and drink manufacturing today faces a particular challenge – how to balance the demand to continuously improve productivity with the need to meet sustainability goals. Sitting alongside Tork’s targets to provide better hygiene across a range of sectors, is the mission to make hygiene in manufacturing as sustainable as it can be. Sustainable innovation and collaboration are key to accelerating progress on the UN Sustainable Development Goals. Tork products help to improve more from less and create circularity by helping factory owners and manufacturers to close the loop. From the start of a product’s life at its raw materials such as wood fibres, to how to product is used and disposed of at the end. Reducing packaging, reducing CO2, building upon sustainable practices and improving wellbeing can all contribute to establishing this circular component of hygiene in collaboration with Tork products.

Beginning at the start of the production line, Tork paper towels are sourced using three key sustainable resources: recycled fibres, alternative fibres, and fresh wood fibres. All wood-based fibres used in Tork products are FSC or PEFC certified. The Tork HeavyDuty Cleaning Cloth, 99% biobased, is made from 99% plant-based fibres and sustainably sourced – independently certified by TÜV Austria as OK Biobased. It helps companies reduce their environmental impact while

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benefiting from improved performance for absorption, durability, linting and solvent consumption. In addition, Tork Cleaning Cloths are interfolded for easier, faster access and one-at-a-time dispensing. This means customers only touch what they take, reducing waste and cross-contamination. The cloths also save 32% on cleaning time compared to rags, with a reduction in effort of 25%.

“Sustainability has become a significant factor in customer choices,” said Anna Königson Koopmans from Essity. “We are creating products that strive to maximise efficiency and deliver greater sustainability while maintaining rigorous performance standards.”

Today, 90% of Tork packaging is made from renewable resources such as recyclable paper or cardboard. Not only is sustainable packaging fundamental to protecting products, but it’s also about seeing the whole picture, such as responsibly using plastic where necessary to make products easier to handle. Looking forward to the future, by 2025, all plastic packaging used will contain 30% recycled content.

Also, 100% of plastic packaging will be recyclable, although many products under Tork’s offering already meet these requirements. Today in Europe, only three out of ten plastic products are recycled, making these kinds of measures even more important.

Creating circularity in sustainability also extends through production processes. Tork has taken steps in using innovative design techniques to reduce plastic waste and CO2. With no wrap plug or core, Tork Coreless toilet paper reduces packaging and carbon footprint. Tork PaperCircle is the world’s first paper hand towel recycling service. Waste towels are collected from factories and facilities, returned to the Essity warehouse, and recycled into new paper hand towels, closing the loop for something that before, would have been sent to waste.

Tork Cleaning Cloths are interfolded for easier, faster access and oneat-a-time dispensing.

By recycling Tork paper hand towels with Tork PaperCircle, we can reduce the carbon footprint together by 40%.

Essity is also continuing to take steps to work towards reducing and reusing water in factories, with the target that all production waste will be subject to material and energy recovery by 2030.

Creating sustainable circularity has also shown the benefits of wellbeing in the workplace. In a survey from Essity, two in three people that look for a new job select a company based on its sustainable reputation and actions, and 1 in 7 has considered leaving a job due to the lack of green practices in the workplace. Sustainable choices made within a business make a direct impact on employees’ thoughts about their place of work, highlighting the importance of eco-friendly practices.

Tork products and services support green workspaces, through ecolabelcertified hygiene products and datadriven educational tools and advice to help businesses optimise sustainable practices and create circularity.

Website: www.tork.co.uk

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Recycling of faulty/ contaminated goods

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