Food & Drink Manufacturing UK - March 2024

March 2024

CASE STUDY:

OVERHAUL OF DIGESTER MIXING SYSTEM DELIVERS BETTER BIOGAS YIELDS

fdm-uk.co.uk

TECHNOLOGY

THE KEY TO SUCCESS IN THE FOOD AND DRINK INDUSTRY

CONTENTS 20

11 Editor Paul Attwood editor@fdm-uk.co.uk Editorial Assistant Anna Startin editorial@fdm-uk.co.uk

30 11

44 48

Appointments to Food and Drink Wales Industry Board

20 Case Study: Overhaul of digester mixing system delivers better biogas yields 30

Opinion Piece: Predictions for the dairy and drinks industry in 2024 and beyond

44

Preview: IFE Manufacturing returns for the food & drink manufacturing community

48

The Key to Success in the Food and Drink Industry

Features Editor Henry Peters editorial@fdm-uk.co.uk Production/Design Laura Whitehead laura@lapthornmedia.co.uk

Editors Note

Sales Manager Holly Jones sales@fdm-uk.co.uk

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

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

In this edition we preview IFE Manufacturing, part of Food Drink & Hospitality Week, at ExCel London between 2527th March. We look forward to seeing the latest products and newest innovations in the manufacturing of food and drink production.

Paul Attwood Editor

We have a piece from Mark Lynch, Partner at Oghma Partners, with some interesting considerations and forecasts for the food and beverage industry in 2024 and also hear from Rasmus Mortensen, CVO of Lyras, with his predictions for dairies and food processing lines in 2024 – including the modernisation of decades-old traditional processes.

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.

03

Industry News

Brakes Cuts Fresh Meat Prices by up to 10% Brakes, the UK’s leading foodservice supplier, has announced that it is cutting prices on around a quarter of its fresh meat lines.

The price cuts will be across a wide range of fresh meats from steaks to mince, across beef, pork and lamb, and will be up to 10% depending on the product range.

Sysco GB Chief Commercial Officer, Michael Andersen, said:

“We are really pleased to be able to support hospitality at a critical time by reducing prices on a wide range of fresh meat.

“As we’re dropping prices on some of our most popular lines, we know that a large number of customers will benefit.”

The reductions reflect changes in the global market where the demand for meat and meat products is falling. With the price of feed also coming down and the

C&D Foods announces €48 million investment in Longford facility The petfood division of ABP Food Group, C&D Foods, has announced an investment of €48 million for flagship facility at Edgeworthstown, Co. Longford. The investment, which includes the creation of one hundred (100) new roles in engineering, operations, supply chain and quality assurance will increase the site’s production capacity by 25%. This is in addition to the employment of approximately one hundred, during the construction phase which is underway.

The investment, which is supported

by Enterprise Ireland, will result in an extension of the building along with the creation of additional state of the art automated multi-packing and pouch filling lines using the most sustainable innovations available.

Commenting on the announcement, Colm Dore, Manging Director, C&D Foods, said: “This is an exciting and significant step forward for our business.

We are seeing a trend across Europe where consumers are favouring pouched pet food for smaller companion animals, and we are in prime position to continue to capitalise on the growing demand for these types of products.

This investment will enable the company to maintain its position at the forefront of the pet food market while also leading to the creation of new high skilled jobs and positive economic development in our local community.”

C&D Foods is the pet foods division of ABP Food Group. C&D Foods is one of the largest own label pet food manufacturers in Europe with production facilities in eleven locations

04

Industry News market adjusting to the challenges of the war in Ukraine, Brakes is passing these savings on to customers. The price reductions will be across around a quarter of Brakes’ fresh meat lines, approximately 70 products.

Stuart Smith, Merchandising Director for Sysco GB, added: “We have been in an inflationary market for some time.

While we have worked very hard to keep costs down as much as we can, there have inevitably been some prices rises.

“It is therefore very satisfying that we can be among the first to reduce our prices now that we can.”

The investment, which includes the creation of one hundred (100) new roles in engineering, operations, supply chain and quality assurance will increase the site’s production capacity by 25%. across the continent. C&D Foods employs 500 staff in Ireland and a further 1,400 across Europe.

In 2021 C&D announced a €60 million contract with Donegal based packaging company ProAmpac in Gweedore.

ProAmpac is now a strategic supplier of pet food pouches for C&D operations across Europe.

Both parties are currently working on the development of more sustainable pet food pouch packaging including recyclable options.

Sysco GB to offer sustainability training to all 8,000 colleagues Sysco GB has embarked on an ambitious plan to offer comprehensive training on sustainability to all colleagues across its British businesses.

The UK’s leading foodservice wholesaler has joined forces with specialist sustainability consultancy, Knowledge Labs from Nutritics, to create and deliver a bespoke training programme that will give Sysco colleagues the knowledge and tools to support customers in becoming more sustainable.

Initially starting with colleagues in commercial roles, the programme, developed following a survey of existing knowledge, is built around eight modules. It covers key sustainability topics including Climate Change; Carbon Footprinting; Operational Sustainability; Healthy and Sustainable Diets; and Food Waste.

This will enable colleagues across the business to better understand the importance of sustainability at Sysco and in its customers’ businesses.

With the topic becoming increasingly important to customers, the training will initially be undertaken by frontline sales colleagues, who will join online training sessions delivered by experienced trainers.

In addition, Sysco GB’s 15 development chefs will receive additional face-to-face training to understand the main challenges for a sustainable food system at every stage of the food chain and how to apply that to the latest thinking on plant-forward and healthy, sustainable dishes.

Stephen Nolan, CEO of Nutritics said: “This partnership provides a fantastic opportunity to work collaboratively with Sysco – sharing our expertise and knowledge to help empower colleagues to make a difference and support customers on their sustainability journey.”

The Knowledge Labs consultancy service from Nutritics launched earlier this year and is steered by Director, Elbha Purcell.

05

Editor’s Choice Innovative Partners: Paving the Way for UK Food and Drinks Companies with Innovation Funding Support In an ever-evolving marketplace, the UK’s Food and Drinks industry stands as a vibrant, competitive sector marked by innovation and the pursuit of excellence. In this dynamic landscape, access to innovation funding has become paramount for businesses looking to maintain their competitive edge and drive growth. Enter Innovative Partners – a name synonymous with expertise in UK innovation funding and Research and Development (R&D) Tax Relief. Let’s delve into how this industry leader has been instrumental in supporting UK Food and Drinks companies throughout the nation in their journey towards innovation and success.

Unlocking the Power of R&D Tax Relief Nationwide Innovation is at the heart of every successful Food and Drinks company. Whether it’s enhancing product formulations, improving manufacturing processes, or revolutionising packaging and sustainability efforts, the potential for innovation is boundless.

However, the path to innovation often comes with its share of financial challenges. This is where Innovative Partners steps in, armed with in-depth knowledge of the UK’s R&D Tax Relief scheme.

The R&D Tax Relief scheme is a powerful tool designed to incentivise innovation across various sectors. It offers companies the opportunity to reduce their corporation tax liability or even receive a cash repayment based on qualifying R&D activities.

While many perceive R&D as exclusive to laboratories and hightech industries, Innovative Partners knows better. They understand that innovation in the Food and Drinks sector takes many forms, from recipe development and quality enhancement to sustainability initiatives and automation improvements.

06

The Innovative Approach to Nationwide Innovation Funding One of the standout features of Innovative Partners is their tailored approach to each client, regardless of their location across the UK. They recognise that the needs and challenges of Food and Drinks companies vary greatly, and their solutions are designed with this in mind. By conducting comprehensive assessments of each client’s innovation efforts, they identify eligible R&D activities that often go unnoticed, ensuring that every possible avenue for tax relief is explored.

Moreover, Innovative Partners goes beyond the paperwork. They collaborate closely with clients across the nation to help them articulate the value and impact of their innovations, making a compelling case for R&D Tax Relief claims. This personal touch not only increases the chances of a successful claim but also empowers companies nationwide to better understand and harness the benefits of innovation funding.

Supporting Sustainability and Growth Nationwide In addition to R&D Tax Relief, Innovative Partners assists Food and Drinks companies across the UK in securing grants and forging strategic partnerships. Sustainability has become a pivotal concern in the industry, and grants play a vital role in funding initiatives aimed at reducing environmental footprints.

By helping companies nationwide access grant funding, Innovative Partners contributes to the industry’s broader sustainability objectives.

Furthermore, they excel in connecting businesses from all corners of the UK with potential investors and partners who share their vision for growth and innovation. These partnerships extend beyond financial support, offering access to valuable expertise

and networks that can propel companies nationwide to new heights.

A UK WIDE Partnership for Innovation Success Innovative Partners has truly established itself as a game-changer in the world of innovation funding for UK Food and Drinks companies across the nation. Their unwavering commitment to maximising innovation incentives, their personalised approach, and their dedication to helping businesses thrive make them an invaluable asset in today’s competitive market.

As the Food and Drinks sector continues to evolve and embrace innovation, Innovative Partners stands as a trusted ally, enabling companies nationwide to turn their innovative visions into reality while achieving financial benefits that support sustainable growth.

In conclusion, the journey of innovation in the UK Food and Drinks industry has found a reliable partner in Innovative Partners, extending their support to companies nationwide. With their extensive knowledge of innovation funding, R&D Tax Relief, and strategic collaboration, they are contributing to the sector’s success, one innovative step at a time, across the entire UK.

To find out how they might be able to support you business with funding, please contact Michael Davie at michael@innovativepartners.co.uk Website: innovativepartners.co.uk

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Labelling

AI predicts what a more eco-conscious future could look like for food and drink manufacturers An AI image generator tool has predicted what the future of food labelling might look like for consumers and manufacturers.

This follows news that the appetite towards a more-carbon-friendly future appears to be turning amongst UK consumers after a recent YouGov survey found more than half of all young adults think they would eat a more

carbon-friendly diet should carbon footprint labelling be introduced in the UK. The research, carried out by food regulatory consultants Ashbury, took 30 popular food items found in the average household and used the BBC’s Climate Change Food Calculator to establish the amount of CO2 per kg emitted for a portion of food.

They then used this information to work out the emissions per standard quantity of food in a typical package size.

Labelling has often had to fight its corner with brands continuing to face challenges in finding a model that works. The traffic light labelling system is just one of those, with the voluntary scheme introduced by the government in 2007. This research follows a soaring demand for consumers to have even clearer information about how their food got to their table and the impact its journey has had on the environment.

Ashbury used these figures to calculate an equivalent figure to enable a real life comparison to be made, such as; the number of miles travelled in a petrol car, the number of days heating an average UK home, litres of water used / number of showers lasting 8 minutes and the equivalent in square metres of land used.

Ashbury used AI image generator Midjourney to then generate what these labels might look like in the future, were this method to be adopted by retailers.

Jade Collins, technical controller at Ashbury, commented on the findings:

Food item: Beef Quantity: 500g Greenhouse gas emissions: 51.53kg Equal to: 131.43 miles driven in a petrol car

08

Labelling

Food item: Coffee Quantity: 300g Greenhouse gas emissions: 15.34kg

The ball is now in the court of the manufacturers and producers to answer consumers’ challenge to provide more information about the impact of their foods.

This research gives us an indication as to what this future might look like.

- Jade Collins

Food item: Chocolate (Dark) Quantity: 200g Greenhouse gas emissions: 4.23kg Equal to: Using 71 litres of water and having one shower lasting 8 minutes

“So much is already being done by manufacturers and retailers to keep consumers informed on what is going into their food.

For example, the traffic light system which came in over a decade ago has been able to provide some further clarity to consumers to identify whether a product is considered healthy or not.

But it’s interesting to see consumers

now going that step further and keen to get even more information on how their food was manufactured and produced but crucially the impact that the process has had on the environment.

“The ball is now in the court of the manufacturers and producers to answer consumers’ challenge to provide more information about the impact of their foods.

This research gives us an indication as to what this future might look like.

“It’s easier said than done, as there are some major challenges in collecting and analysing data in this space to create a consistent and transparent approach – which is key to supporting consumer understanding.“ Continued >>>

Food item: Tea Quantity: 200 Tea Bags Greenhouse gas emissions: 8.21kg

09

Labelling

Food item: Chocolate (Milk) Quantity: 200g Greenhouse gas emissions: 2.94kg Equal to: Using 207 litres of water and having three showers lasting 8 minutes

Food item: Rice (uncooked)

In theory, carbon labelling is a great idea with real potential to influence behaviour – it’s something we need to work towards this decade.

Quantity: 1kg

- Daniel Usifoh

Greenhouse gas emissions: 9.9kg Equal to: Heating the average UK home for 1.56 days

Food item: Cheese Quantity: 400g Greenhouse gas emissions: 12.80kg Equal to: Using 47.3m2 of land

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Daniel Usifoh, co-founder at sustainability software provider Axiom also outlines the challenges for manufacturers in providing accurate carbon footprint measurement but also the opportunities it presents when doing it right, explaining: “For food manufacturers, gathering accurate data on Scope 1 and 2 emissions like energy, process steam and fuel use is reasonably straightforward. Scope 3 - supply chain emissions - is where the big challenge lies.

Many manufacturers simply don’t have enough information on where their ingredients come from – let alone how they are grown or produced! Filling these data gaps is the only way to get an accurate carbon footprint measurement – and this starts with effectively mapping the supply chain.

“Once companies have an accurate picture of where all their ingredients come from, they can start engaging with suppliers to gather data. Right now, measuring the true footprint of some commodities is

Food item: Lamb Quantity: 500g Greenhouse gas emissions: 28.87kg Equal to: 73.74 miles driven in a petrol car

virtually impossible – there simply isn’t the traceability in the global supply chain.

“However, companies can use industry averages to provide a reasonable estimate, and start to build up a picture of the total carbon footprint from there and solutions like these designs can help consumers to gain a more tangible picture of how their purchasing decisions have an impact.

“In theory, carbon labelling is a great idea with real potential to influence behaviour – it’s something we need to work towards this decade. However, the labelling needs to be based on accurate data and standardised methodologies if consumers are going to trust the label. If the industry is using multiple different schemes or labels, the whole idea loses its credibility.

“We’re already seeing how keen some companies are to display their environmental credentials – and we expect that to grow over the coming years in the food and drink industry.”

For more information about the research and to view the full gallery of images, please visit: https://ashbury. global/blog/carbon-footprintlabelling-is-this-the-future-ofsupermarket-shelves/

People On The Move

Appointments to Food and Drink Wales Industry Board Six appointments have been made to an industry board which aims to grow, promote and enhance the reputation of the Welsh food and drink sector The six appointments are: Professor David Lloyd (pictured top right), Chair of the Food and Drink Wales Industry Board.

Director of the Food Industry Centre, Cardiff Metropolitan University David began his career in the food industry in the laboratories of a major bakery based in Cardiff. He then worked in various parts of the UK for a variety of major food companies as Technical Director.

In his current role, at the Food Industry Centre, David works closely with both the private sector and Welsh Government. He advises on issues affecting the sector and has also influenced the Welsh Government’s Food Policy.

Welsh food and drink continues to go from strength to strength with exports for the sector reaching £797 million in 2022, a record high.

Mrs Alison Lea-Wilson (pictured below), Deputy Chair of the Food and Drink Wales Industry Board.

Joint owner of The Anglesey Sea Salt Co Ltd In 1997, Alison and her husband David, started the Anglesey Sea Salt Co Ltd. They have built it up and it is now one of the main Welsh food products exported to around 15 countries. The business has attracted at least 30 awards including gaining 3*** Golds in the Great Taste Awards.

Miss Alison Harvey Agri Supply Chain Advisor – Rural Advisor Co. Alison has over 15 years’ experience successfully delivering high level customer service, project management, communications, and knowledge exchange across the UK red meat sector. During that time, she has also developed a range of skills and knowledge within the industry, notably in the areas of supply chain management, export and working with farmers from around the UK and New Zealand.

Mr Andy Richardson Partner – European Food and Farming Partnerships (EFFP)

Andy has over 30 years’ experience in the UK food and drink industry.

He has worked in commercial roles in the animal feed industry for BOCM PAULS and recently worked for Volac where he was Director of Corporate Affairs and Sustainability.

Andy has also co-founded two international collaborations. These are about developing sustainable supply and demand of protein and edible fats.

Mr Graham Black Non-executive Director, Seafish Graham also chairs the Seafish Wales Advisory Committee which has representatives from across the seafood supply chain in Wales.

Prior to his work in Seafish, Graham was Director of Marine Scotland.

Mrs Valerie Creusailor Chief Executive Officer and Cofounder of Goch and Company With a career spanning over two decades, Valerie has played a pivotal role in advancing operational efficiency in both private and public sectors. Her proficiency encompasses skills development, team dynamics, and optimising bottom-line performance across various senior managerial roles.

Rural Affairs Minister Lesley Griffiths said: “Welsh food and drink continues to go from strength to strength with exports for the sector reaching £797 million in 2022, a record high.”

11

Labelling

SATO’s Smart Print Engines Revolutionise Food Labelling Automation for ALTech Building upon a 30-year legacy of trust, collaboration, and innovation, SATO and ALTech continue to push the boundaries of print technology.

Their most recent achievement, the deployment of the S84/86NX smart print engines, paves the way for an even brighter future.

Rory Horton-Smith, Managing Director of ALTech UK, shares his insights on the impact they have already had on ALTech’s labelling processes and the future of the partnership.

SATO, a global leader in auto-ID and labelling solutions, manufacture the innovative S84/86NX smart print engines, designed for automation and on-site usability. Equipped with Application-Enabled Printing (AEP), they offer enhanced customisation and improved performance in harsh industrial environments. The partnership between SATO and ALTech, spanning over three decades, is testament to the benefits of these ground-breaking print engines in food labelling automation.

Rory Horton-Smith, Managing Director of ALTech UK – the UK subsidiary of ALTech, shares his insights on how SATO’s S84/86NX smart print engines have boosted their operational capacity, highlighting the key role of the AEP functionality: “This additional intelligence provides us with the ability to provide solutions that used to be difficult.”

Thanks to AEP, for example, warehouse operators can directly connect to weigh scales, automate weight input and print

The SATO print engines have streamlined ALTech’s customers operations, providing reduced labour costs and enhanced operational efficiency. Automating labelling processes has allowed these companies to focus on boosting productivity and saving costs. from programmable logic controllers (PLCs), halving the reprogramming time required.

The SATO print engines have streamlined ALTech’s customers operations, providing reduced labour costs and enhanced operational efficiency. Automating labelling processes has allowed these companies to focus on boosting productivity and saving costs. The autolabelling abilities of the print engine provide enhanced real-time traceability and extra intelligence that breaks new

ground. Rory highlights the benefits of real-time updates, saying: “From a traceability perspective, the intelligence of the printer potentially allows recording of the label printed (e.g. to a network file) as well as just printing it, for example” The S84/86NX print engines are designed for demanding industrial environments, resistant to solvents and water and ideal for factories and warehouses where extreme temperatures and varying conditions are the norm. Features like the open cover sensors and stronger hinges and nip rollers add durability, extending the product’s lifespan in the 24/7 ecommerce fulfilment era. With SATO’s preventative maintenance service, SOS, users can remotely monitor the status of their print engines on a single dashboard, eliminating downtime and keeping operations running smoothly.

Rory also commends the seamless retrocompatibility of the SATO print engine with existing setups and its emulation. Scope to integrate the new print engines effortlessly makes the transition from older labelling solutions smoother and more efficient.

All of which means the SATO-ALTech partnership continues to flourish, thanks to a shared commitment to innovate and remain ahead of the curve. The SATO S84/86NX smart print engines, with their advanced features and flexibility, have proven invaluable in addressing complex challenges for ALTech and their customers in the food labelling automation industry.

As both companies look to the future, they will continue to provide cuttingedge solutions and set the pace in the market, revolutionising food labelling processes and enhancing efficiency in the sector.

Website: www.satoeurope.com

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Efficient and accurate labelling using thermal transfer technology.

Packaging materials can be integrated into existing lines, and have features like automatic label detection and variable data printing for traceability and safety.

Designed for the most demanding environments, the series is available inboth 4” and 6”, direct thermal/thermal transfer solutions. Ideal for printing text data, barcodes, RFID tags and labels. Its unrivalled versatility in performance is due to its excellent capabilities in emulation, PC-Less printing through Simple Stand Alone Mode or more complex AEP autonomous applications, alongside fast throughput and print speed.

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Editor’s Choice

The importance of door maintenance The fact that Hart Door Systems has built a reputation for quality and longevity of its wide range of industrial doors, the importance of door maintenance should not be understated says Keith Fisher, Hart’s National Operations Manager.

Servicing industrial doors not only improves their reliability and operational functionality but servicing is also a requirement under Health, Safety and Welfare Regulations which protect people who come into contact with the doors. Indeed failure to maintain industrial doors could put the user in breach of Government legislation incurring liability in the case of an incident involving an industrial door which is non-compliant.

As essential support for our clients Hart has comprehensive Service & Maintenance assistance as a specialist department which delivers a range of repair and scheduled maintenance options for its customers to further extend the life of their doors.

Given the very wide variety of industrial classifications we supply doors and shutters to, the emphasis has to be on designing servicing and maintenance packages which are tailored to match the specific needs of our clients’ businesses and the arising usage patterns of the various doors/shutters.

A preventative Servicing and Maintenance Agreement ensures Hart’s servicing is carried out correctly and at the precise frequency thus complying with Regulations. Typically during a Hart servicing visit all mechanical and electrical elements are checked for missing parts, general wear and tear and Compliance issues.

Mechanical checks include inspecting parts such as drive chain tension, alignment and lubrication, bearing wear and tear, motor oil levels and fabric tension and electrical checks include limit settings, cable connections and safety devices.

Hart also has a legal responsibility to ensure doors are left in safe working order after servicing. Again the issues are wide ranging such as measuring the closing forces of automatic doors

A preventative Servicing and Maintenance Agreement ensures Hart’s servicing is carried out correctly and at the precise frequency thus complying with Regulations.

where safe contact is the main strategy to prevent hazards.

The closing force of a door ensures correct force limitation under EN 12978 which prevents injury and crushing.

Testing should always be carried out with an annually calibrated instrument according to DIN 18650, EN 12453 or EN 12445.

On completion of a Hart service visit, a paperless electronic copy of the engineer’s report will be issued which may include additional recommendations necessary to ensure the doors are safe and compliant to relevant legislation due to changing ‘shop floor’ circumstances.

The sophistication of door systems such as Hart’s Speedor range or its Typhoon shutter range has changed significantly over the years to cater for changing needs by its customers across the globe and indeed by changing climate. To ensure hard working doors in busy industrial environments continue to make a significant daily contribution to efficiency and safety, planned maintenance is essential.

Website: www.hartdoors.com

14

Editor’s Choice

Transforming Beverage and Dairy Packaging with Ultrasonic De-Foaming In a world where every sip and every drop of milk matters, the beverage and dairy industry look for innovative solutions to enhance production efficiency, reduce waste, and elevate the quality of every product. Ultrasonic De–Foaming technology is an innovation that is changing the game in beverage and dairy packaging. Additionally, as awareness of environmental issues grows, businesses realise the vital role they play in sustainability.

Ultrasonic De-Foaming technology embodies this ethos, seamlessly integrating efficiency and sustainable practices into your production process.

for beverage, dairy, water, and chemicals.

• Temperature Optimisation: Potential to increase filling temperature by up to +6°C or more above normal in beverages, resulting in energy cost savings and elimination of condensation issues. Similarly, dairy benefits from controlled temperatures that enhance product quality.

• Quality Assurance: Minimise bottle and can rejects due to underfill in beverages and reduce carton and bottle rejects in dairy, saving packaging material and waste treatment costs.

Imagine a world where your packaging line operates at peak efficiency, regardless of the filler type – standard rotary, aseptic, hot-fill lines, linear, or pouch fillers. The Ultrasonic De-Foaming technology does just that, and more.

• Hygienic Excellence: Foam control eliminates contamination on the bottle or package seal reducing the risk of micro contamination issues. Ensuring a cleaner line with potentially reduced cleaning cycles/ CIP, leads to energy, water, and chemical savings.

Key Benefits at a Glance:

• Nitrogen Dosing Efficiency: Improve nitrogen dosing efficiency and nitrogen content in capped bottles or packages, especially in carbonated beverages and dairy products.

• Enhanced Line Speeds: Experience up to 60% higher line speeds in the beverage industry and up to 40% in dairy.

• Optimised Fill Settings: Reduce beverage/syrup losses by 1ml to 6ml per can or bottle through the foam compression effect in beverages, and 1ml to 5ml per carton or bottle in dairy.

• Sustainable Efficiency: Lower beverage and dairy waste means reduced waste treatment costs

By significantly reducing foam during packaging, it creates compressed and denser foam inside the container, delivering unprecedented productivity gains, enhanced filling line efficiency, waste reduction, contamination elimination, and quality improvements.

Imagine a world where your packaging line operates at peak efficiency, regardless of the filler type – standard rotary, aseptic, hot-fill lines, linear, or pouch fillers.

The Ultrasonic De-Foaming technology does just that, and more.

In an industry where innovation matters, our technology stands as the epitome of forward-thinking excellence. Using Ultrasonic DeFoaming technology, you’re elevating your production and setting new standards for sustainability and quality in every bottle, can and carton.

Contact us today and discover how our ultrasonic de-foaming technology can elevate your beverage and dairy packaging. sales@cpa-group.com

15

Events & Awards News

Top plant-based cheeze range wins 15th award One of the UK’s leading plantbased cheezes has kicked off 2024 by winning another award to add to its sizeable haul of trophies.

Multi-award-winning Applewood Vegan has just won its 15th award by scooping the silver gong in the vegan fridge/freezer category of the Veggie Awards 2023 for its Applewood Vegan Bites, the second accolade for the plantbased snacking net.

Applewood Vegan Bites launched in Morrisons last spring shortly followed by a listing in Asda.

Veggie Awards judges described the Applewood Vegan Bites as “little bites of joy that make a great snack or lunchbox addition for kids and adults alike. When it comes to flavour, you’d be hard pushed to tell the cheese apart from its non-vegan counterparts. It has a mouth-watering smoky Applewood smell and taste, along with a soft, pleasingly creamy texture - not too crumbly. Delicious!”

Commenting on the award, Ffion Davies, Brand Manager for Applewood Vegan, said: “What a way to start 2024, collecting our 15th award for Applewood Vegan - and our second for the Bites in less than a year as the Bites also won the Gold Award in the Dairy-Free Cheese Alternative category in the prestigious International Cheese Awards last summer.”

Applewood Vegan Bites are fortified with B12 and calcium, coconut based and free from dairy, lactose, soya, gluten and palm oil.

Applewood Vegan is part of the Norseland portfolio of cheeses - both dairy and vegan - and the company is the established blended and snacking cheese specialist in the UK so has many years of experience making the best snacking cheeses in the UK. The Bites are available to buy at Morrisons and Asda stores across the UK.

Moy Park hits milestone moment, reducing its overall packaging by 10% in 12 months Leading food company Moy Park has reached a significant milestone in its sustainable packaging strategy, reducing its overall packaging by 10% in the past 12 months.

The milestone is a result of the company’s Remove, Reduce, Recycle and Research strategy, which is aimed at reducing its overall packaging by 5% year-on-year, while also increasing the percentage of recyclable packaging by 5%.

Moy Park has collaborated with supply chain partners and innovated across the business to reach the impressive milestone.

This includes initiatives focusing on removing unnecessary plastic components, reducing plastic that remains, developing recyclable options and adopting plastics that are inclusive of recycled content.

Matt Harris, Head of Packaging at Moy Park said, “Our ambition is to make even more progress and we’re working closely across departments, and with external expertise, to extend our current packaging strategy. This will reflect best practice guidance on packaging design, future legislation, and consumer and shopper insights. We already have exciting partner collaborations in the pipeline that will further reduce our reliance on plastic and support consumer and customer goals to recycle more.”

ABOVE: Tom Arkwright, Senior Packaging Technologist at Moy Park and Matt Harris, Head of Packaging at Moy Park are pictured as the company reveals it has reached a significant milestone in its sustainable packaging strategy, reducing its overall packaging by 10% in the past 12 months.

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Events & Awards News Detectamet Clinches Top Honors at 2023 SOFHT Awards with Innovative Metal Detectable Nitrile Gloves Detectamet, a global leader in metal detectable and x-ray food safety solutions, proudly announces its triumph at the 44th SOFHT Annual Lecture, Lunch & Awards 2023.

The company’s Metal Detectable Nitrile Gloves secured the

prestigious title of ‘Best New Product’. The Nitrile Gloves clinched the top spot at the Society of Food Hygiene and Technology Awards in London.

A spokesperson for SOFHT underscored how this showcased the gloves’ profound impact on the food safety landscape: “Detectamet Detectable Products wins Best New Product/Service at the 2023 SOFHT Awards.

“Their innovative Metal Detectable Nitrile glove has taken the industry by storm, becoming their most successful product in twenty years. Well done Detectamet!”

The company’s founder, Sean Smith, described this win as “testament to our company’s commitment to advancing food safety standards”.

Since Detectamet launched its Nitrile Glove range in February 2023, over 2.5 million units have been sold.

Steve Herd, Chief Commercial Officer at Detectamet, poured praise on the ability of his team to continue innovating products in an industry where “precision and hygiene are non-negotiable”.

“It was an absolute privilege to represent my colleagues and collect this prestigious award on their behalf! Wonderful, well-deserved recognition for an amazing team!”

The SOFHT Awards recognises and celebrates the excellence within the food industry and its associated industries. The Awards were judged by a panel of experienced food industry professionals from the Society’s membership.

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17

Facilities Management

Five considerations for the Food & Beverage sector in 2024

By Mark Lynch, Partner at Oghma Partners 1) Consumer demand 2023 has seen many food and drink companies report improved earnings on the back of a very tough comparison in 2022; pricing recovery thereafter and an overall positive volume/price mix.

There has even been some reduction in costs helping the margin picture.

Looking into 2024, we would expect, in the UK at least, the pressure to mount on consumers as the full impact of increased mortgage costs and record rent rises influence demand. This has already been seen in the de-stocking of premium items (like spirits) and reduced volume of consumption across a range of products as well as switching from brand to own-label and away from less cost focused retailers to more value focused offerings and product ranges.

2) Wage/cost growth Wage growth is expected to be a further challenge in 2024. The minimum wage increases in April by 9.8% - this will put upward pressure across the food sector where a lot of wage costs move in tandem with the minimum wage figure. Currently raw material costs are forecast to be broadly stable or declining with one or two exceptions. Overall, however, we expect a relatively neutral commodity input costs environment in 2024.

Management attention is therefore likely to be focused on wage costs and combined with issues around labour availability, we may see a renewed focus on capital investment to reduce labour usage across the manufacturing estate which may, in turn, drive productivity gains across the sector.

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Looking into 2024, we would expect, in the UK at least, the pressure to mount on consumers as the full impact of increased mortgage costs and record rent rises influence demand.

3) Funding costs remaining high Whilst bond markets are beginning to think that the battle against inflation has been won, central bankers appear to be taking a more cautious view.

While we might see some signs of easing of interest costs in 2024, these cuts may be relatively modest and back end weighted - therefore unlikely to materially impact the cost of funding in the year. High rates feed through to equity market ratings for quoted food companies and exit prices for businesses being sold. We do not therefore expect any significant increase in the multiples paid for businesses being exited in 2024 compared to 2023 or 2022.

4) Continued and increasingly fractious trading with the EU Export friction with the EU is likely to continue in the year however the government has finally committed to introducing reciprocal checks covering health certification and sanitary and phytosanitary (SPS) checks on

all agri-food products from the EU. These checks will be introduced on a phased basis. This introduction has the potential to increase cost and disrupt supply chains. Ultimately, we think a new Labour government will seek to resolve the issue by rejoining the EU Phytosanitary regime which would be a relief to the UK and EU food industry and highly unlikely to affect any proBrexit voters.

5) Plant based foods go bust!

2023 has seen significant upheaval in the plant-based food market with reduced ranges, falling consumption and businesses going bust in the sector. 2024 will likely see the fall-out continue which will allow the category and sector leaders to re-position themselves for growth going forward.

A more streamlined offer and a focus on marketing, consumer messaging, pricing and product quality should help re-align the sector with consumer expectations and demands.

People On The Move

FPA appoints new executive chair The Foodservice Packaging Association (FPA) is pleased to announce the appointment of Mark Byrne as its new executive chair, effective from 01 February 2024.

“I am honoured to have the opportunity to work even more closely with the FPA’s members, partners and stakeholders – ensuring the interests of the entire membership are represented and their issues and concerns heard”, says Mark.

Mark takes over from former executive chair Mark Pawsey MP, and brings with him a wealth of experience following a 33-year career in the foodservice packaging industry.

For the past 14 years, Mark has worked in senior sales roles within global organisations such as Anchor Packaging, Sharpak, RPC, and latterly at Sabert.

“By continuing to extend our reach and influence, and adding our voice to the challenges impacting FPA members, I hope to be able to contribute to the ongoing success of both the FPA and the foodservice packaging sector in general”.

Having been involved with the FPA for over 22 years, half of that time as vice-chair, Mark has an unrivalled understanding of the association and the needs of its members.

Mark Pawsey, outgoing chair of the FPA says: “It has been a privilege to serve as the FPA’s chair for the past four years and I am proud of what the team has accomplished together during that time. Mark is already well known throughout the industry and our membership, so it was no surprise to see his nomination so well supported. I know he is looking forward to taking the FPA to new heights and I wish him all the best for the future”.

Eurostar Commodities appoints managing director Leading Yorkshire based ingredients experts, Eurostar Commodities has appointed Jason Bull to Managing Director.

Jason has worked in the business for over 23 years and has been instrumental in tripling the size of the business to a £15 million turnover business operating worldwide across the globe and with the UK’s most trusted and well-known food brands.

range have more than doubled on the same period as last year (2022 – 2023). He has also shaped global infrastructure enabling Eurostar’s global network of food producers to supply Britain’s leading brands.

He has spearheaded the companies’ role as an Export Trade Champion for the Government’s Department of Business and Trade, and launched the UK’s first Clean Label production facility.

Founder, and Father to Jason, Phillip Bull, who established the company in 1994 will become Chairman.

The business has also made senior appointments to international logistics, purchasing, marketing and sales bolstering the team to 23 people in the UK, with a large network of global partners.

The business recently launched a new advertising campaign to support its award-winning range of Gluten Free Chapati flours. The campaign is running across Sky TV channels and on Sunrise Radio with additional digital advertising.

Jason has pioneered the company’s technical development creating new products, brands and creating the award-winning Gluten Free Chapati flour range. Sales of the

Jason’s initial plans for 2024 include expansion into a triple-sized factory facility; increased capacity in purchasing and logistics; several new food brands; increased gluten free product development; creation of

new consumer brands in emerging farming sectors for sustainability; and an increased presence in UK, Northern European and Middle Eastern retail and foodservice as well as physical expansion into Europe.

Eurostar Commodities Gluten Free Chapati Flour has been developed

by Eurostar’s technical development team to provide specialist flours for all kinds of baking and cooking. The products are already widely available across the UK in independent and ethnic supermarkets and wholesalers. The gluten free chapati flour can be used in a variety of recipes has been developed with enhanced texture and flexibility to produce outstanding results.

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Pumps - Case Study

Overhaul of digester mixing system delivers better biogas yields Following an extensive upgrade of its reception tank and digester mixing system, Eco Verde Energy (EVE) has put a once troublesome Anaerobic Digestion (AD)+ plant firmly back on track with encouraging new biogas yields.

At Holton in Suffolk, England, which receives around 65% of its feedstock from the adjacent Bernard Matthews poultry facility, the AD plant, under a series of different operators, had seen biogas production drop significantly, and eventually to a complete halt for a much-needed overhaul.

Initially, the primary digester (2700m3) was drained down, discovering, as expected, faults with the mixers, but also a broken stanchion. Later, further inspections revealed that there was damage to the roof of the digester, so the decision was taken to postpone operations for a complete maintenance revamp.

“The mixers that were sold in as part of the biogas package were never going to last in the long-term,” said Eco Verde’s Site Manager at Holton, Kris Martin.

“It is hard to understand a design that doesn’t allow equipment to be looked after! The mixers couldn’t be lifted out of the tank for

The more Landia and I worked together, the more we had a focal point.

for our needs, or did not seem to have a deep understanding of the industry. Either way, the essential assistance we required was not readily available. We couldn’t for example, get anyone to look at the feed-in module (which is a jacketed tank to provide heat) we have between the reception tank and the digesters. The previous chopping pump had failed because of the high temperatures, so again, it wasn’t specified properly. There can be a huge difference in supplying equipment in 304 stainless steel compared to 316. For a biogas process with food waste, compromising is only going to lead to problems. This has been the classic case of a package plant being sold on price rather than quality.”

even the most basic of service tasks such as an oil change and cleaning the propellers.

Matters took a significant turn for the better though when Kris made contact with Landia, about whom he’d heard good reports.

“At one point, the site was being run remotely, but it has now benefitted from a complete review of operations. When we shut down for the maintenance overhaul, trying to get shipshape became more challenging, due to some suppliers not being able to assist; either unable to provide equipment quick enough

‘Clearly wanted to try and understand how a solution could be found’ He continued: “They’re a pump and mixer company, and there are plenty of those,” he said, “but unlike some others, they actually listened and clearly wanted to try and understand how a solution could be found. As soon as they first came to the site, there was a good vibe. Linking up the mixing operation from the reception tank, through the feeding module, and then on to the digesters, and finally through to the pasteurisers, wasn’t going to be easy, but rather than just try and sell us equipment, Landia were keen to find a way to help make the Holton plant perform as it should.”

New submersible mixers (5.5kW) from Landia have been installed for the reception tank, which unlike the previous units, can be easily lifted up on a crimped rail system for inspection to remove any plastics and perform LEFT: Eco Verde Energy’s Kris Martin (left) with Paul Davies from Landia.

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Pumps - Case Study

ABOVE LEFT: The Landia Chopper Pumps and venturi nozzles constantly recirculate the mixture of liquid and gas.

ABOVE MIDDLE: In addition to the digester mixing system Landia also supplied and installed all the pipework.

ABOVE RIGHT: The Landia pasteurisers are supplied as complete processing units (tank chopper pump and controls). standard maintenance such as oil changes.

For the feeding module, which is batch-fed from the reception tank, a Landia Chopper Pump (invented by the company in 1950) has replaced the failed unit. The unique external knife system (combined with the addition of a new shredder propeller) ensures that particles are continuously reduced in size, and that solids cannot enter the pump’s casing.

level, the feedstock is automatically transferred to the secondary digester.

The simple, but highly effective combination of submersible mixers, chopper pumps, and the venturi nozzles work to constantly recirculate the mixture of liquid and gas, even though it only typically has to run in 10-minute intervals, rather than mixers at many plants that run flat-out 24/7.

At the end of the process, in order to meet the legal requirements of a feedstock that contains animal biproducts, there are now two (25m³) Landia pasteuisers, which heat the final effluent to the required temperature of 70 degrees centigrade. The pasteurisers are supplied as complete processing units (tank, chopper pump, and controls), to break down the food waste effluent and any remaining solids.

Each tank from Landia is made with a double stainless-steel tank wall that acts as a heating jacket. From here, heat is transferred by circulating hot water, meaning that a heat exchanger is not always required. Post-pasteurisation, with the maximum possible amount of gas extracted, the final digestate from Holton makes a first-class, nutrient-rich fertiliser.

The primary digester was first upgraded to replace the failed units with Landia mixers. By utilising a preexisting hatch system that provides easy access, these new 18.5kW mixers were installed with minimal disruption to the biogas process, and can likewise be easily serviced without causing downtime.

‘Nothing on this site is now off-the-shelf ’

The secondary digester is now served with a system that comprises the proven Landia chopper pump, fitted with venturi nozzles to provide truly comprehensive mixing. When the primary digester meets the right

Kris Martin added: “The more Landia and I worked together, the more we had a focal point. Although they do provide some guide rails and pipework, it’s not their main business, but when looking at how we could transfer everything from the start of the

process, right through to the pasteurisers, it made sense for Landia to include it as part of their service, rather than me having to bring in another supplier. They did a top-quality job in putting all the extensive pipework together. It’s very impressive and we’re all proud of it. Nothing on this site is now off-theshelf. Paul Broadhurst ( from Landia) and I have put this all together step-by-step. It’s not been easy, but we’ve worked through it with a very healthy rapport and that all-important common goal of wanting something to work and work well for the long-term. It’s a world away from the daily hassles that we had previously. Paul’s attitude to whatever we ask is ‘we’ll sort it out’, and I know he and Landia will, because they value us as a customer and care about the plant’s success.”

In addition to its primary feed (which is first treated by a DAF -Dissolved Air Flotation) piped in from the Bernard Matthews poultry facility’s treatment plant, EVE’s Holton site also receives effluent from the local Adnams brewery and distillery, plus various fats and oils from nearby food processing plants.

This variety of intake then takes very careful managing to maintain a steady feed for the now, much loved biogas plant.

Kris Martin continued: “With the Landia submersible mixers at the front end, we’ve gradually developed a constant, homogenous feed, which provides excellent stability for the remainder of the process and our drive to maximise biogas yields. The consistency we have means happy bugs, because otherwise, too much of one intake at one time can cause foaming. That’s not an issue at this site any more.”

Continued>>>

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Pumps - Case Study At 1.1MW, the new-look Holton biogas plant (which now has two CHP engines and additional gas storage), can provide most of Bernard Matthews’ 1.4MW energy needs, with a grid connection in place for times if/when the poultry facility is on shutdown.

‘Low energy consumption and maximum biogas yields’ Kris commented: “The investment here safeguards the future, with plans for a lagoon to be built and to have PAS 110. With Landia’s help, it means that we’ll be in good shape with low maintenance costs, low energy consumption and maximum biogas yields, which of course means profit – not to mention the fact that we do something great by making renewable energy from waste.

“Having to shutdown and clean out a couple of digesters creates downtime of almost three weeks; costing in the region of £150,000. We’re pleased of course to have now sorted out all the problems; turning everything around so that instead of having put out fires, we can finally be proactive and concentrate on making gas, rather than having to react to all the problems on site.

The initial issues were made all the worse by having equipment that you couldn’t work on without having to shut the plant down! A design that effectively traps mixers inside the tank without access is ridiculous.

22

“We now have a proper maintenance schedule in place, and unlike in the past, no problems or delays in the availability and delivery of parts. If we order before lunchtime, Landia deliver the next day.

During installation, there were also never any problems with the paperwork and permits from Landia; progress emails, and all the necessary RAMS (risk assessment and method statement) and proof of qualification were in place so that the work was seamless, with no delays. This differs significantly from others who simply aim to provide a product, without considering how it integrates into our process.

“Site managers can overcome all sorts of challenges, but aren’t necessarily engineers.

You need calculations. You need experts to answer your questions to complete the jigsaw puzzle. No two plants are the same. It is reasonable to expect seamless support from the companies that provide equipment, but often, you find yourself navigating through various departments – from quotations to RIGHT: The feeding module (which is a jacketed tank to provide heat) at Holton which now benefits from a Landia Chopper Pump.

BOTTOM LEFT: The Holton plant is now performing very well but fine-tuning helps maximise biogas yields.

BOTTOM RIGHT: Part of the Eco Verde Energy plant at Holton.

finance, engineers, and a loosely termed ‘support team.’ Having to repeatedly explain your requirements can be very frustrating and time-consuming. It is always easier to work with those who have been to a biogas plant, and who aren’t worried about getting their hands dirty. It’s been a long journey to get where we are, but we now have peace of mind with a plant that is performing very well and with fine-tuning, will get even better. It shows exactly what can be achieved with the right people, the right equipment, and a belief in our industry.”

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Measurement & Control News Data can be displayed locally, integrated with an existing telematics system, or streamed directly to the Tan Delta online portal. full-spectrum holistic (FSH™) oil quality analysis, which continuously monitors the ratio of two key measurements, capacitance and conductance, to provide real-time insight.

Tan Delta Systems launches new real-time oil monitoring system to reduce operating costs and optimise output in food manufacturing sector

The SENSE-2 Display Kit is easily installed on existing food manufacturing equipment and will continuously monitor the real-time quality of the oil with the molecular analysis taking place every few seconds. Data can be displayed locally, integrated with an existing telematics system, or streamed directly to the Tan Delta online portal.

Tan Delta Systems, a manufacturer of real-time oil quality monitoring sensors and systems, is leading the way within the food manufacturing industry with the launch of SENSE-2. The new oil condition monitoring kit provides real-time data about machine oil quality to optimise maintenance and reduce operating costs.

The OQSx-G2 oil quality sensor within the SENSE-2 kit is also available as a Mobile Oil Tester (MOT) Kit, created with workshops and mobile maintenance teams in mind. Any oil from any equipment can be sampled and tested simply and easily on-site in seconds. The sensor is used in conjunction with the MOT software, which operates on any Windows-based laptop, tablet, or PC. Users simply install the MOT app, connect it to the sensor, collect the sample in one of the bottles provided, and follow the steps in the software to test the sample.

The SENSE-2 is plug-and-play and accurately identifies when oil reaches the end of its life, superseding traditional time-based maintenance schedules, which can result in oil being discarded prematurely with the potential of wasting up to 50 per cent of its useful life.

With the uncompromising hygiene standards throughout the food manufacturing industry, its equipment must be able to withstand water washdowns, high temperatures and areas highly susceptible to oil contamination by product ingress. The demand to meet production requirements means the costs associated with equipment failures can often be overlooked,

24

but if a processing machine has a catastrophic failure, its repair or replacement is one cost but can also lead to the potential loss of production and product.

Research has shown that by switching to a condition-based monitoring approach, manufacturers in the food and drink industry could reduce their predictive maintenance tasks by up to 30 percent.

The real-time aspect of the system is what sets it apart, utilising unique active molecular-level analysis to detect all changes in oil condition and any contamination. The Tan Delta sensor works by providing a

Website: tandeltasystems.com.

With the VEGAPULS 42 radar sensor, VEGA expands its IO-Link portfolio for factory automation and thus offers an optimal performance spectrum for all level, switching and pressure applications. The all-inclusive range of instrumentation from a single source makes everything easier – including the setup and operation of the most varied and complex processes.

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Measurement & Control News

Stainless steel elastomer coupling for offshore applications ENEMAC elastomer couplings (claw couplings) are plug-in equalising couplings for backlash-free, angularly accurate transmission of torques in direct drives.

The elastomer core made of polyurethane, available in different Shore hardnesses, has a vibrationdamping and electrically insulating effect.

With the EWJ type, the drive specialist from Kleinwallstadt is now launching

a stainless steel version on the market.

This can be installed in a temperature range from -30°C to 120°C and is suitable for many outdoor applications such as offshore wind farms, mining and pump construction or agriculture thanks to its stainless hubs.

With its 11 sizes, this stainless steel elastomer coupling covers a nominal torque range from 6 Nm to 650 Nm and can be used at speeds of up to 29,000 min-1.

Complex sandwich processing aided by ‘smart’ sensors ‘Smart’ sensors have become an essential component in many manufacturing systems as the demand for ever more sophisticated automation continues apace across a huge range of processing applications.

In many automated processes specific information is essential to ensure the smooth running of systems, typically provided by optical, inductive, ultrasonic sensors, or cameras. However, a more versatile, lesser known alternative are smart 2D profile sensors, such as the OXM 2D sensor, developed by sensing and instrumentation specialists BAUMER. A good example of where these smart sensors have proven to be very effective is on a fully automated sandwich and filled rolls production line at a German

company Weber Maschinenbau. The company specialises in developing slicing systems for food industry applications and their latest production line accommodates over 70 sandwiches rolling off the line every hour, perfectly topped with sausage or cheese.

For this application, precise edge control, margins and positioning data is essential to smooth operation, for example; what is the exact position of the sandwich or filled roll on the belt? We need to know its height and is the edge even? For example, the robot in the roll section needs to know roll height and centre (lengthwise and crosswise) and whether the roll may not be properly aligned on the belt. Basically, can one sensor provide the entire measured value calculation, and also deliver the calculated coordinates correctly in the units (millimetres) required?

The OXM sensor delivers all this information thanks to integrated measurement and evaluation functions. In other words, the entire measured value calculation is provided by the sensor including the calculated coordinates in millimetres - as specifically required. The sensor also measures the bread height and every edge to calculate the centre of the roll which enables suction pads

to gently lift off the finished product without causing damage.

On the sandwich line, the sensor also determines the lateral position and height of the sausage and cheese slices on the belt allowing the gripper to position the slices accurately on the bottom half of the sandwich. Weber Maschinenbau exploits this functionality not only on its sandwich lines but also on the slicers that cut and portion cold cut optimally prepared for packaging.

Here, the sensors deliver the position data required for precisely aligned slices of salami, ham or cheese, which is essential for allowing the finished product to always be placed in the same position in the packaging process.

The latest versions of these smart 2D profile sensors are compact and lightweight with simple connectivity using a single cable via IO-Link, Ethernet and more. They provide measurement ranges of up to 500mm with a field view of up to 300mm and operate with a precision of up to 5µm. These features make the sensors ideally suited to height checks of assembly parts, control and positioning tasks in robotics, such as position checks of feeder parts for pick-and-place applications, or gap checks in automotive manufacturing.

More at: https://www.baumer. com/gb/en/always-keeping-aneye-on-web-edges-and-margins/n/ smart-profile-sensors

27

Measurement & Control

Ready Meals Manufacturer Saves Millions with MWS Weighing Station Upgrade A large ready-made meal manufacturer faced a looming crisis: over 300 of their weighing stations were becoming obsolete, requiring a potential seven figure replacement expense. Their incumbent supplier offered only new equipment, along with slow response times for breakdowns.

Micro Weighing Solutions (MWS Ltd), known for its innovative weighing solutions, rose to the challenge.

Leveraging expertise from design, fabrication, service, and systems departments, MWS proposed a creative solution: upgrading the existing scales. This not only addressed the obsolescence issue but also brought about substantial CAPEX savings, a key consideration for an unplanned project.

The Solution The process involved transporting the weighing stations to the MWS factory, where new steel components were fabricated and integrated into the existing structures. The highlight was the upgrade to the MWS Micro 6000 model, equipped with a bespoke takeaway weighing app and Wi-Fi connectivity to alternative management software. Crucially, the hygienic design of the new model prevented water accumulation,

ensuring a longer lifespan for the equipment.

Acknowledging the client’s dynamic and fast paced production environment, MWS strategically removed and returned the weighing stations in small batches, minimising downtime.

The Results The result was the refurbishment of over 300 scales, achieving an impressive 50% reduction in CAPEX compared to the initial supplier’s quote.

Beyond cost savings, MWS significantly improved response times to breakdowns, a critical concern raised during discussions. The dedicated service team’s proximity to

the client’s factories contributed to a 50% reduction in call-out wait times.

The partnership with MWS not only optimised the financial aspect but also demonstrated environmental responsibility by repurposing existing stainless steel stands, limiting waste and energy consumption associated with new station construction.

• • • •

300+ Scales Refurbished 50% CAPEX Savings 50% Faster Response Reduced Waste and Energy

By choosing MWS, the FMCG group not only secured substantial CAPEX savings but also benefited from lower ongoing repair costs and enhanced breakdown response times. This case exemplifies MWS’s commitment to providing efficient, cost-effective, and sustainable weighing solutions for clients in the fast-paced FMCG industry.

Website: www.mws.ltd.uk

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Opinion Piece

Predictions for the dairy and drinks industry in 2024 and beyond Rasmus Mortensen, CVO of Lyras, believes over the next 12 months, there will be a big change from the old traditional process to more advanced models while also seeing an uptick in sustainability initiatives and more emphasis on automation.

2023 has seen many challenges for the dairy and drinks industry.

With rising cost of living issues and mounting energy costs due to conflicts abroad, the squeeze on the UK market has been damaging for many businesses throughout last year. As we move into 2024 and beyond, it’s important for dairies and food processing lines to recognise shifts in the industry and be prepared to make changes to their operations to keep up with competition.

For food and beverage producers, pasteurisation has been a staple of processing lines for over a hundred years.

But what key shifts will 2024 bring?

Rasmus Mortensen, CVO of sustainable dairy technology manufacturer Lyras, outlines his top dairy and drinks industry predictions to expect in the new year, and where businesses should expect to make dramatic changes to operations to keep up with their competitors.

Prediction #1 – Continued adoption of sustainability strategies 2023 saw a rise in general sustainability strategies becoming more adopted across many industries. With distance from the pandemic, more business leaders are scrutinising their current operations to increase their operation efficiency without sacrificing quality, but with the rising energy squeeze across Europe, sustainability initiatives and energy-efficient technologies have been at the forefront of new proposals across many industries.

The dairy and drinks sectors are no different from this. Sustainable

practices continue to be a top priority for producers across both industries.

Individually, companies have their own sustainability goals, thus the choice to partner with more sustainable tech manufacturers have become less of a risk and more of a necessity. Common sustainable practices that can be expected to be renewable and rolled out industry-wide include reducing food waste and energy usage, which are clear focuses for many sustainable technology providers that processing companies choose to partner with.

Prediction #2 – Wider demand for automation and quality control With the implementation of modern technologies into industry operations, the dairy and drinks sectors can also expect to see an increased demand for automation across all production lines.

Businesses have already seen marked improvements from implementing higher technology strategies across single test lines, so deploying these across the rest of their operations is the natural next step.

Increased automation has proven results in improved quality control, increased food safety, and enhance traceability across supply chains. But equally important is how automation

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Opinion Piece years. The process has not just been used for milk and dairy, but also when it comes to treating juices, sodas, beers and whey production. Yet despite this process being streamlined over the years with the influx of more efficient technologies, there is still a resistance to adoption, with the more conservative processors not interested in “fixing” something that isn’t broken. can help address growing labour shortages across operations. As production costs have skyrocketed, even leading to the outright closure of dairies and food processors. By employing the automation of up-todate technologies with quality control, it gives processors a better standing against competitors as their operations can become even more efficient and cost-effective.

Prediction #3 – Upgrading decades-old traditional processes For food and beverage producers, pasteurisation has been a staple of processing lines for over a hundred

As we move into the new year, adopting modern technologies is becoming more of a necessity industry-wide for processors looking to survive in an increasingly competitive landscape.

Modern processes offer levels of quality control that their previous generation counterparts simply did not have access to in the past.

Prediction #4 – Saving more whilst tasting better Retaining customers during challenging times is a problem for both retailers and producers alike. With the squeeze of inflation, implementing solutions that can save on waste costs

Treatment and processing operations that cut waste costs without sacrificing quality is key. can be appealing, but if the quality is sacrificed it can lead to a food product buyers will just end up avoiding anyway. Treatment and processing operations that cut waste costs without sacrificing quality is key.

Taste is key for this, and choosing a processing manufacturer whose technology doesn’t damage the taste of the product should be a priority for all looking to upgrade next year. A good tasting product is going to be the swing factor when it comes to where consumers will spend their money, so keeping high quality across all stages of processing is key to ensure that at the end of the day a cost-efficient product doesn’t go unwanted.

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31

Packaging News

Compostable film first at Empack event The latest in sustainable packaging materials – compostable shrink film – will be on show at this year’s Empack event! Yorkshire Packaging Systems (YPS) will be demonstrating the film on their stand – D50 – showing the excellent finish achievable, as sample products are wrapped live.

The compostable film will be teamed up with an l-sealer for a high-gloss finish and strong seal, ideal for display packaging. It’s the first time event

visitors have had the chance to see both this film and this machine from YPS. The European-made compostable film is available from 12 - 38 microns, with excellent tensile strength and a bright, highly transparent finish.

This sustainable innovation joins a wealth of green film options from YPS, whose materials range is the widest in the market. All films the company offer are recyclable, many are available with recycled content of 30% or more and their range even includes both bio-based material and foodcontact approved recycled-content specifications.

Demonstrating how the compostable film is handled, it will be running on an exclusive l-sealer machine. This equipment is fully automatic and can achieve professional display-standard wrapping at speed. Designed for the operator’s ease, it features an enlarged LEFT: The widest auto-bagging machine on the market will also be on show at YPS’ stand, D50.

ABOVE: YPS will be demonstrating the use of compostable film on its shrink wrapping line on stand D50. infeed belt for loading, front and rear opening for improved access and simple, graphics-based controls.

And there’s more…

The YPS stand will also feature not one, but two, other examples of leading packaging equipment from the company’s comprehensive portfolio of equipment.

Upfield introduces plastic-free paper tub for plant-based foods Global plant-based food company Upfield has launched what it claims to be the world’s first plastic-free, recyclable tub for plant-based foods such as butter and spreads.

The new paper tubs are developed in partnership with Footprint, MCC, and Pagès Group.

Using Footprint’s material sciences technology, Upfield’s research and development (R&D) team developed the packaging solution from compressed wet paper fibres, ensuring they are waterproof, oil-proof, and fully recyclable in local paper waste streams.

This innovation is said to be a significant step in Upfield’s commitment to reducing its plastic content by 80% by 2030.

It is also in line with the company’s goal to replace up to two billion plastic tubs by 2030, which is expected to eliminate more than 25,000 tons of plastic waste annually.

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Packaging News To complement the l-sealer wrapping line, YPS will also show a twin-lane side-feed sleeve wrapper, designed for transit packaging applications.

Flexibility is key for this machine, creating multiple collations, including trayed and trayless, with fast changeover routines.

Last but not least, the shrink wrapping equipment will be joined by a market-leading bagging machine, representing YPS’ e-commerce and mailing fulfilment machinery offering.

This machine takes the crown as the widest autobagger on the market. It’s also the only hybrid bagging machine available, able to use both paper and plastic materials.

The YPS Team are looking forward to talking through the materials and equipment on show, plus answering any questions about the ideal packaging combination for visitors’ operations. With over 45 years’ experience in the industry, YPS are ideally placed to discuss how to achieve packaging goals across a myriad of industries and products.

Upfield began rolling out its Flora Plant brand in late 2023 in Austria, with plans to introduce it to additional European markets and brands this year.

The new packaging has secured the Conventional Plastic Free Certification and the company is also working towards obtaining home compostability certification for the tubs by 2025.

Upfield Packaging head Karina Cerdeira said: “We are proud to have created, with Footprint, an innovative paper-based tub that is durable, oil-resistant and appealing and which many thought would be impossible with paper.

“But after years of dedicated focus from joint Upfield and Footprint R&D teams and dozens of prototypes, we made the impossible, possible.

“This new paper tub marks a true milestone for sustainable packaging that significantly minimises reliance on plastic.”

UK announces proposal to change egg labelling rules The UK government has announced a new proposal to change its existing egg labelling regulations to better support farmers during avian influenza (bird flu) outbreaks in the country.

Current legislation requires a change in labelling from ‘free-range’ to ‘barn eggs’ after 16 weeks of mandatory housing, a period known as ‘derogation’.

The new proposals aim to eliminate this requirement, allowing eggs to retain their free-range status throughout mandatory housing measures.

An eight-week consultation has been launched on amending the Egg Marketing Standards Regulations as part of this.

The consultation, which began yesterday (9 January 2024), seeks input on the proposed regulatory amendments and will remain open until 5 March.

The changes are set to apply to England and Scotland within the UK.

British Egg Industry Council CEO Gary Ford said: “With the vast majority of eggs produced in the UK meeting free-range standards, the sector is very important to both British consumers and farmers. The changes are essential to ensure a long-term future for British free-range eggs, which we know consumers want, and we strongly support the consultation.”

The latest move is further intended to reduce red tape and labelling costs for British egg producers, strengthen supply chains, and support the government’s goal to maintain at least 60% self-sufficiency in food production.

According to the government, the threat of highly pathogenic avian influenza H5N1 has escalated globally, with more than 360 cases confirmed in the UK since late October 2021.

The past two years have seen the 16-week derogation period exceeded, leading to significant costs for the industry due to mandatory packaging changes.

UK Farming Minister Mark Spencer said: “We understand the pressures bird flu outbreaks place on our poultry and egg producers, which is why we continue to prioritise ways to support the industry during outbreaks of this disease.

“I encourage all those with an interest to take part in this consultation to ensure that our free-range industry continues to thrive in years to come.”

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Packaging

FIELD TO CAN IN DAYS: How food cans are a vital force against food waste

By Jason Galley, director and chief executive, Metal Packaging Manufacturers Association (MPMA)

The world’s population is expected to increase by nearly two billion people in the next thirty years, from the current eight billion, to 9.7 billion in 2050, and could peak at nearly 10.4 billion in the mid-2080s.

So says the United Nations, which also claims that the way humans produce, process, transport and consume food accounts for eighty per cent of deforestation, 29 per cent of greenhouse gas emissions and the leading share of biodiversity loss.

The organisation also states that around a third of the food produced around the world, is wasted.

It’s certainly a bleak picture and a huge challenge to everyone, but food manufacturers can help make a difference: by simply using the right food packaging, they can help reduce food waste, limit carbon emissions, and protect biodiversity.

And metal packaging – food cans – can do all this better than most.

A report by the University of Delaware and Crown Packaging exploring the effects of metal packaging on energy

Once canned, most canned food has a shelf life of up to five years. and food waste, predicts that if the USA’s entire fruit and vegetable supply were canned, then the estimated saving would be 7M metric tonnes of food.

This has an equivalent saving of 22 million metric tonnes of CO2.

ABOVE: Jason Galley, director and chief executive , MPMA

So how is it that the food can is such a vital force in reducing food waste?

With canned food the field to can process can be hours rather than days or weeks, with crops picked and cooked locally in the can at peak condition: flavour and nutrients are retained and waste through deterioration is minimised from the outset.

Canning also eliminates the frantic race to get freshly picked crops in store which can often only be done using refrigerated transport and instore storage which is high in energy use and cost. Any extended time between harvesting and consumption impacts negatively on nutrient values and taste which means there is inevitably a high degree of food waste through natural deterioration creating a comparably short shelf life for food on open display.

Canned food is typically cooked in sealed cans under steam pressure and rarely requires preservatives. Once canned, most canned food has a shelf life of up to five years. In some cases, food quality is actually enhanced by canning and many well-known cooks and chefs now openly advocate the use of canned food, recognising that the quality and nutritional value can be as good as freshly picked.

LEFT: Theo Michaels, celebrity chef and cannedfood.co.uk CANbassador

And once used, the can keeps on Click here giving because to learn more across Europe, about Field metal packaging to can has among the highest recycling rate of any packaging format.

Metal can be recycled over and over with no loss of quality and is easily extracted from the waste stream. It’s estimated that around eighty per cent of all metal ever produced is still available for use today.

Canned food can reduce energy costs and emissions; it retains nutrients, flavour and has a second to none shelf life so reducing food waste. It’s recycling rate help reduce carbon emissions in metal production and while the food can is not the full answer to the world’s food waste problems, it can certainly be a major contributor.

Website: www.mpma.org.uk

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Processing

PhoenixTM solution to HACCP Cook & Chill CCP Validation As part of any Food processors HACCP program, validation of cook and chill processes is a critical and significant task, taking time, effort, and resources.

PhoenixTM have developed a thru-process temperature monitoring technology specifically for this task, designed to meet the challenges of the food processing market. Ideal for the validation process for any new cook regime, new product, or annual process certification. Whether performing an oven survey “oven mapping to identify cold spots” or validating the cook under production conditions, the thruprocess profiling solution gives you the accuracy, efficiency, and reliability you need to satisfy your HACCP demands.

As its name suggests, thru-process profiling is the method by which product and or process temperature is monitored throughout the complete cook / chill process. The data logger

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making the physical temperature measurement, with multiple thermocouples, travels safely with the product through the process. Protection from process conditions such as heat, steam, water, and oil is provided by a suitably designed thermal barrier.

The thermal barrier provides robust protection to the data logger to prevent damage but also ensure that it maintains a safe operating temperature to give accurate temperature readings.

Monitoring of continuous conveyorised linear and spiral ovens and semicontinuous or rotational batch cooks is feasible where the use of external recorders with trailing thermocouples is tedious, completely impractical, and possibly unsafe.

Employing the thru-process principal, process monitoring can be performed under true production conditions without compromising line productivity .

At the heart of the thru-process monitoring system is the PhoenixTM data logger. The PhoenixTM NT data logger range has been designed specifically for the challenges of monitoring food processing applications with an IP67 case design protecting from moisture. Type K or Type T data logger options allow accurate measurement of both cook and chill processes (Type T measurement range -200 °C to 400 °C).

Data logger and thermocouple correction factors can be applied to the recorded data logger data to maximise measurement accuracy. PhoenixTM offer a range of thermal barriers to suit the process type, duration, and temperatures. Even if a standard thermal barrier cannot meet the process requirements, PhoenixTM can often custom design a unique solution to suit.

Monitoring core temperatures of food products can be a challenge and getting

values for the process against target micro-organisms.

it right or wrong can have a significant influence on the data collected and therefore any decisions or conclusions made.

PhoenixTM offer a range of different designs of thermocouple to suit different product types and sizes. The needle thermocouples ensure you can measure the true core/cold spot of the product accurately and repeatably.

Fitted with standard miniature thermocouple sockets, the data logger is also compatible with other generic commercially available thermocouple designs.

Employing the thru-process temperature monitoring principle provides the food technologist with a complete temperature profile of the cook process from start to finish. This information is like the Cook DNA giving full details of the product and or process temperature which is invaluable to allowing validation of the Cook CCP. From a temperature profile it is possible to accurately quantify product safety (pasteurisation) knowing both the temperature, and time at temperature, of the product.

From the profile graph you can see instantaneously the variation in

Employing the thruprocess temperature monitoring principle provides the food technologist with a complete temperature profile of the cook process from start to finish.

For a typical chicken cook process the lethality parameters for Listeria Monocytogenes (Tref 70 °C, Dt 16.2 s and Z value 7.5 °C) can be input to automatically and accurately calculate for each monitoring point the number of decimal reductions of the pathogen achieved during cook to meet CCP limits.

The information gathered, further to process validation, can be used to allow informed process problem solving and optimisation to maximise product quality, yield, process productivity and efficiency.

Contact PhoenixTM to help Find, Fix and Forget your Food Cook Problems!

product temperature at any point in the process either at different locations on the product (whole chicken) or different product positions within the cooker, cooking rack or across a mesh belt.

The PhoenixTM Thermal View Food Software provides a comprehensive suite of analysis tools to convert the raw profile temperature data into useful process information. The analysis tools include the ability to calculate Fo/Pu

Further Information www.phoenixtm.com

37

Processing

Heat regeneration should be key consideration

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

Many industrial processes require energy, but only a portion of that energy input is used for each operation such as pasteurisation or evaporation. Unused energy is wasted, often passing to the environment as hot gas or liquid.

However, by using heat exchangers, it is possible to recapture most of this untapped energy through waste heat regeneration.

Heat regeneration (or heat recovery) is the process whereby heat from a process which would otherwise be lost or wasted is recaptured and used for useful heating purposes. Heat regeneration should not be confused with ‘regenerative heat exchangers,’ which are a specific type of heat exchanger in which the product and service fluids flow alternately and the heat is stored in the structure of the heat exchanger.

At HRS when we talk about heat regeneration, we mean the recovery of as much surplus heat (or cooling capacity) as possible after the primary function of the heat exchanger has been performed. This can then be reused to either improve the efficiency of heat exchange process or used elsewhere.

‘Recovery and re-use of industrial waste heat is an attractive concept that could LEFT: Matt Hale, International Sales & Marketing Director, HRS Heat Exchangers BELOW: Heat regen can reduce overall energy requirements by up to 40% in some systems

simultaneously reduce energy costs and CO2 emissions.’

Given the importance of energy efficiency in reducing the use of fossil fuels and greenhouse gas (GHG) emissions, it can be argued that it is imperative to employ heat regeneration and recovery at every opportunity.

As at least one paper has pointed out, ‘The use of excess heat could also be important to improve the economic and climate footprint feasibility of new processes… by avoiding the addition of new heat production capacity.’

Benefits of heat regeneration Heat recovery improves the energy efficiency of heat exchange processes, so the greatest benefit of heat regeneration (recovery) is that less energy is required for a particular heating or cooling operation. This obviously provides financial benefits but is also better for the environment compared to systems without heat recovery.

Repurposing recovered heat can also reduce the amount of heat required for certain processes. For example, if a material is pre-heated with recovered heat, then it may be possible to complete the necessary heating (for example for pasteurisation) using hot water from another source or part of the factory, instead of requiring a dedicated boiler to provide the necessary temperature rise.

By increasing the energy efficiency of the heat transfer process, heat recovery can also make it possible to reduce the size of the heat exchange equipment required or reduce the necessary processing time.

Heat recovery in action One example can be found in food pasteurisation processes, where

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Processing LEFT: A Digestate Concentration System (DCS) from HRS Heat Exchangers in use at a UK wastewater treatment AD plant

products such as cream need to be heated to the necessary temperature to achieve pasteurisation, then rapidly cooled to maintain shelf life and quality. Such systems involve the use of two heat exchangers: one uses hot water to raise the temperature, while the second uses chilled water to cool the cream down again. The cooling process produces warm water which can be discarded, cooled for re-use, or cooled with some of the heat contained being used to pre-heat the cream before the pasteurisation process. This last option utilises heat recovery or heat regeneration, reducing the amount of new energy required for the subsequent first heating phases.

As another example, many biogas plants use heat exchangers to pasteurise the digestate produced during the anaerobic digestion (AD) process. The ‘surplus’ heat which is generated after the system has been running can also be used to pre-heat the digestate, reducing total heat load and improving overall efficiency.

Perhaps the most common use of heat regeneration is demonstrated in multi-effect evaporation systems, where a number of heat exchangers are combined, for example in the HRS DCS Digestate Concentration System.

The first evaporation stage heats liquid digestate and uses a cyclone separator; the steam produced from this first cycle (usually available at 70˚C) is then used as the heating media for the second effect, whereby the process is repeated. The subsequent steam (usually available at 60˚C) is then used as the heating media for the third cycle.

The number of effects is determined by the level of dry solids required and the amount of surplus heat available, up to a maximum of four cycles. After the final stage, the steam is condensed back to water and this heat is used to pre-heat the incoming product before the first stage of evaporation. In all, the heat is regenerated up to four times in the process.

Many biogas plants use heat exchangers to pasteurise the digestate produced during the anaerobic digestion (AD) process. can be retrofitted to many processes, but their design is often a compromise and retrofitted solutions may involve excessive pipework and other connections.

Other considerations

To maximise the benefits of heat regeneration it is important that waste heat is transferred to the storage media (e.g., water or thermal transfer fluid such as glycol) as soon as possible after its source. This is particularly true where the waste heat is in the form of a gas, as this has a much greater energy constant than liquid, meaning that the heat is lost much faster.

To determine the potential value of waste heat, and therefore determine what it can be used for, it is necessary to know a number a parameters about the process temperature, the product and heating (or cooling) medium being used, and the performance of the heat exchange process in terms of heat transfer area and flow rate, for example.

It is therefore important to consider energy regeneration or recovery as early as possible. Heat recovery systems

By considering all of these factors, it will be possible to calculate both the additional capital costs associated with specifying heat regeneration in a project, together with the savings in running costs and energy, and from this determine the return on investment for the project. Although capital costs may be higher, the longer term financial and environmental benefits will make the use of heat regen in heat exchanger projects highly attractive.

Heat recovery can also be used in gaseous applications. Whether it is using the heat from the flue gas of a biogas combined heat and power (CHP) engine to pre-heat digestate, or a large gas-to-gas heat exchanger to capture waste heat from chemical processing, there is no reason to waste the heat present in gaseous products or waste streams.

RIGHT: Water which has been heated by cooling food products can be used to pre-heat the same product ahead of pasteurisation, reducing the overall energy requirement

39

Processing

Why Continue to Give Away Your Profits?

Strategies to Address Underfilling & Overfilling, Remain Legal & Reduce Wastage

Billions of packages are being filled in factories around the world – coffee beans into box bottom pouches, whisky into bottles, tablets into medical packs, and many more. Two common challenges that factories often struggle to overcome are underfilling and overfilling.

Both issues can lead to significant consequences for businesses, including product defects, recalls, wasted raw materials and packaging, customer dissatisfaction and brand damage.

Systematically Underfilling to Save Cost When we conducted our research, we found that some factories in other countries deliberately underfill to save on the cost of raw materials.

Customers end up paying more than they receive. While most people may overlook this, some choose to take action against such practices.

Two customers in the US filed a lawsuit against a potato chips company for consistently underfilling their chip bags. Although nitrogen gas may contribute to keeping the chips fresh and damage-free during delivery, the net weight of the chips was 58% to 75% lower than the information labelled

on the packages. The lawsuit gained widespread coverage on news and social media platforms, leading to even more customer complaints and causing serious damage to the brand.

Unintentional Underfilling Bringing it closer to the UK manufacturing industry, there were still some underfilling incidents happening, even though Average Quantity has been the law for most pre-packaged consumer goods, produced and sold in the UK since

1979. A leading dairy plant pleaded guilty due to T2 failures within the Weights and Measures Act. This was attributed to inadequate testing procedures that had been in place for over 15 years. Though the underfilling was unintentional, it caused huge damage to the brand and the manufacturer was fined.

We can’t just assume that what was ‘good’ yesterday will be good enough tomorrow. Manufacturers need to revisit every aspect of the manufacturing processes and ask: Why? What? Where? When? Who? and How? And most accept answers like ‘We have always done it this way.’

Overfilling to Ensure Compliance & Protection from Risk Knowing the consequences of underfilling, many factories decided to take action to be compliant. With the introduction of Average Quantity Law, there was no longer a Minimum Quantity Law for most pre-packaged goods. However, some companies continued to pack to what they called ‘Minimum Quantity.’ This simply meant that they were giving more product away in overfill, whilst gaining no greater legal protection.

Let’s have a look at some numbers.

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Processing

Imagine you are a medium-sized whisky bottler producing, say, 10 million cases per annum. The industry standard for a case is 9 litres (based on 12 x 750ml bottles).

10 million cases at 9 litres per case equals 90 million litres. With just 1ml of overfill on average, this amounts to giving away 90,000 litres per year. As whisky must be matured in oak casks for at least 3 years before it can truly be called whisky, it has to be worth at least £1 per litre at the time of bottling (3 years later). Thus, this must represent a giveaway cost of around £90,000 per annum on such a volume, per average of 1 ml in overfill.

A Few £Millions Spare?

What’s even worse, HMRC could raise an estimate as they are entitled to the excise duty on overfill, which could be traced back through the previous 6 years. Out of interest, the excise duty charged on 40% strength spirit is £11.50 per litre. The extent of risk is realised by doing the maths - 90,000 x £11.50 x 6 = £? Don’t forget this is only based upon overfill of only 1ml per litre.

Several years ago, when an HMRC Inspector was asked for advice of “How much overfill is acceptable?”, the

Being stuck between rising input prices, and little or no opportunity to pass on these rising costs to retailers, manufacturers need to do everything to protect consumers, their financial health and brand reputation. response (knowing nothing of process variation and capability) was “Zero – just get it right gentlemen!”

Strategies to Tackle Underfilling and Overfilling Being stuck between rising input prices, and little or no opportunity to pass on these rising costs to retailers, manufacturers need to do everything to protect consumers, their financial health and brand reputation.

Optimising filling process should not be an option – why give it away?

Preventing underfilling, measuring and controlling overfilling, can significantly reduce production costs.

Many manufacturers are unaware that technologies are available to help ensure optimal control of the filling

level, with real-time data collection and analysis, feeding back to the management team. Managers can, therefore, take immediate action to ensure legal compliance and reduce the wastage of overfills.

To better control your filling processes, we suggest three key strategies you could implement for your factory: 1. Choose a reliable and trusted technology partner with a proven track record to work with to help you remain compliant and reduce giveaway.

2. In your choice of partner, make sure that they fully understand and can effectively communicate the benefits of process control and legal compliance.

3. Ask your chosen partner to come to your site and prove the claims of 1. and 2.

Why Choose Harford?

In 1979, following the introduction of Average Quantity Law, we introduced our ground breaking weight control software which not only met the demanding legal requirements for Average Quantity, but also combined process capability analysis, so that actions prompted to users were based upon true process/machine capability, rather than simply guesswork. This unique solution has never been improved upon and the well-tested algorithm continues to be the mainstay of our Average Quantity/Process Control system.

Let’s make 2024 your best year yet!

Choose Harford Control for your process control improvement journey.

Share your interest by calling +44 (0) 1225 764461 or sending an email to info@harfordcontrol.com.

Visit our website: www.harfordcontrol.com

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Processing

Why More Needs to be Done to Change Salt Consumption Habits Comment from Caroline Klinge, LoSalt

Following the Government’s decision at the end of last year to delay the latest HFSS restrictions around volume and price until 2025, there is so much more that needs to be done to change salt habits and support the nation’s health. Current NHS and government guidance is having no impact on consumer salt intake, with figures showing discretionary salt use has not changed in over a decade.

Given the negative implications of high salt consumption on the nation’s health, we feel there is a very urgent need to tackle salt intake in the UK. At LoSalt, the UK’s leading reduced sodium brand, we are calling for a renewed focus on salt reduction from retailers, manufacturers and the government. salted snacks like crisps and nuts.

But much of the salt we eat comes from less obvious sources – canned soups and stews; gravies; soy sauce; ketchups, relishes and pickles; pizzas; ready-made meals and even bread. It’s therefore important to choose foods lower in salt to reduce the risk of high blood pressure and strokes.

Why is salt bad for health? What health issues can it cause?

The amount of salt in your diet is important, because too much salt intake increases your risk of high blood pressure. High blood pressure and raised cholesterol are two of the biggest risk factors for stroke and heart attack. Almost two million deaths can be prevented each year if global sodium consumption is reduced to WHO recommended levels .

It’s actually the sodium in salt that causes health issues. Too much salt disrupts the natural balance of sodium in your body and makes your body retain more water, which in turn puts more pressure inside your blood system. The excess fluid presses on the walls of your arteries, which carry blood from your heart round your body, leading to high blood pressure.

High blood pressure can then lead to blockage of arteries which supply blood to your brain – in other words, to a stroke.

On average, we eat about 8.4 grams of salt a day in the UK – when in fact

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What should the UK Government do to combat high salt consumption?

we shouldn’t be having more than 6 grams. The Department of Health has estimated that if we all cut just one gram of salt from our diets, we could prevent over 4,000 premature deaths a year in England alone. In fact, Public Health England has called it one of the most important risk factors we can do something about.

Processed and smoked foods like salami, smoked fish, deli meats and sausages are very high in salt. So are

Current NHS and government guidance is having no impact on consumer salt intake, with figures showing discretionary salt use has not changed in over a decade, as shown in these figures: • Volume sales of salt in 2013/14 were 22,868 MT, compared to 22,824 MT today • The majority of people (62%) add salt to their meals habitually, without tasting it first • 27% of people add salt to meals when eating out in a restaurant, compared to 20% in 2020

Processing We work with a variety of food manufacturers, including well-known brands such as Greggs, who use LoSalt across a range of its products to help achieve its salt reduction targets without compromising on great taste.

It is very disappointing that the Government has delayed the latest HFSS restrictions until 2025. With this in mind, we are calling for a renewed focus on salt reduction from retailers, manufacturers, and the Government.

The Government needs to play its part to educate consumers and the food industry on salt intake and the positive impact cutting intake will have on the nation’s health.

Brands and retailers can play their part by educating consumers on the benefits of reduced sodium salt and ensuring they are visible on shelf. But for lasting change we also need efforts from the Government to introduce a mandatory and enforced salt reduction programme covering food manufacturers, brands and retailers.

Reduced sodium salts are a simple and effective way to reduce consumer salt intake and support the nation’s health.

This is supported by both the World Health Organisation and Resolve to Save Lives: • Both the World Health Organisation and Resolve to Save Lives cite reduced sodium salts as one of the best strategies for improving global cardiovascular health, the world’s leading cause of death.

• As Bruce Neal, Executive Director at The George Institute for Global Health Australia Resolve to Save Lives states - “Salt substitutes are one of the most exciting opportunities in salt reduction – if salt substitutes were adopted worldwide, several million premature deaths could be prevented each year”.

What do you feel retailers and manufacturers can do to reduce salt consumption?

with another option (branded or own label), sales in the category decrease, meaning consumers switch back to regular salt.

Manufacturers need to play their part to reformulate and reduce the levels of salt in their foods – this is often the salt that goes unnoticed by consumers. We work with a variety of food manufacturers, including wellknown brands such as Greggs, who use LoSalt across a range of its products to help achieve its salt reduction targets without compromising on great taste.

We would welcome the opportunity to work with more food manufacturers and retailers to help them reduce the salt levels in their food and ultimately support the health of their customers.

What is LoSalt? How does its reduced sodium salt retain the taste of normal table salt?

Reformulating food products to reduce their salt levels, particularly in foods such as ready meals and snacks, is key in helping consumers to reduce their salt intake. Many people just don’t realise how much salt is in these foods. A simple way to reduce salt in manufactured products would be to use a low in sodium option, such as LoSalt.

This would mean no change in the taste of the food but a huge difference in the amount of salt consumed from eating it.

Often in salt alternatives, the bitter notes of potassium chloride can be detected, but in the case of LoSalt, the taste results remain overwhelmingly positive. This is because we expertly blend two natural mineral salts (potassium chloride and sodium chloride) ensuring that no flavour maskers are required. It can be used as a like for like replacement to regular table, sea and rock salts allowing for 66% sodium reduction without compromising on taste.

Retailers could promote processed foods with lower sodium content and make reduced sodium salts more visible to consumers. The salt market is divided into several sub-categories, the leading players being (by volume): table salt (76%), sea salt (15%), rock salt (4%) – all of these are 100% sodium chloride, albeit some may have more trace minerals than others. The only healthier alternative is reduced sodium salts which make up just 2% of all volume sales.

Taste is ultimately a key factor in manufacturers, foodservice providers and consumers choosing to switch from regular salt to a potassiumenriched salt and there are many poor substitutes available on the market.

The product must look, taste and feel like ‘the real thing’ to ensure repeat purchase or continued use.

We’d like to see manufacturers and retailers address the benefits that swapping from traditional salt to a reduced sodium salt in their foods would bring to the nation’s health.

Retailers and the hospitality sector also have the perfect opportunity to drive the message around seasoning with sense to their customers via their marketing and promotions.

Retail buyers can help shift this split by making reduced sodium salts more available and having greater visibility on shelf – do we really need 15 different types of rock and sea salts and a plethora of flavour salts?

Once a consumer switches into a reduced sodium salt, the key is to offer a product that looks, tastes and feels the same – LoSalt delivers just that with 3 out of 4 people who try it liking it and there being a 94% likelihood of repeat purchase according to data from loyalty card holders. LoSalt is stocked across most major supermarkets in the UK, and across 30 countries globally. Recent buyer insights show that when LoSalt is removed from shelf and replaced

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Show Preview

IFE Manufacturing returns for the food & drink manufacturing community IFE Manufacturing, part of Food, Drink & Hospitality Week, returns to ExCeL London on 25-27 March to showcase the very latest products and innovations in the world of food & drink.

IFE Manufacturing is a mustattend event for brand owners and manufacturers to source new packaging, ingredients, technology, and manufacturing solutions, with opportunities to discover a wide range of products and meet directly with brand owners.

Visitors to the show will have the opportunity to connect with brands including ingredients leaders Belazu, Biospringer by Lesaffre and Lallemand Bio-Ingredients, packaging innovators Elopak UK, Magnum Packaging (N.E) Ltd and MM Packaging, and organisations such as Make UK, QAD Redzone and Ashbury.

Plus, the Trends & Innovations Platform will play host to a wide range

of presentations, discussions and debates on the most important topics in the food & drink manufacturing sector including sessions covering precision fermentation, allergens, the potential impact of AI on the industry, consumer insights and some of the disruptive forces impacting on the world of food & drink in 2024.

The Trends & Innovation Platform will see the launch of the IFE Manufacturing Ingredients Awards, in partnership with the Institute of Food Science & Technology. These new awards were created to highlight innovation in early-stage food development and celebrate trailblazers at the forefront of food science and technology.

IFST CEO Tim McLachlan says: “IFST is pleased to celebrate 60 years of advances in food science and technology in collaboration with IFE Manufacturing and looks forward to future innovations that will drive the creation of a sustainable food system that provides safe, healthy nutritious, affordable and delicious food for all.

“Our collaboration with IFE Manufacturing provides an excellent opportunity to showcase ingredient innovations that will deliver these attributes and provides an opportunity for our members and the wider food science

community to recognise and honour past and future leaders in the sector.”

Each year IFE Manufacturing also works with a number of key partners in the manufacturing sector including the British Contract Manufacturers and Packers Association (BCMPA).

CEO Emma Verkaik comments: “The BCMPA is delighted to be exhibiting again at IFE Manufacturing 2024 on behalf of our 200 plus membership and to be able to have the opportunity to talk face to face with visitors about their production and outsourcing needs.

“Outsourcing has become a valuable resource for brands and retailers and the ability to talk directly around the solutions that are available to customers when looking to take a product to market are invaluable. There is nothing like collaboration to understand the challenges and new innovation within the food and drink sector and IFE Manufacturing allows this conversation to develop – we are very much looking forward to the show in March.”

IFE Manufacturing takes place alongside IFE, The Pub Show, HRC and International Salon Culinaire as part of Food, Drink & Hospitality Week on 25-27 March at ExCeL London. Don’t miss out on your chance to be part of the UK’s biggest celebration of industry innovation, register for your complimentary trade ticket at ifemanufacturing.co.uk.

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Discover the future of food and drink manufacturing Key partners include:

IFE Manufacturing is co-located with:

Scan the QR code to secure your free trade pass or visit:

ifemanufacturing.co.uk

Latest News

Comment from FMCG consultancy Acumen’s co-founder, Nick Ryan Comment from FMCG consultancy Acumen’s cofounder, Nick Ryan below on what this rise inflation means for consumers and manufacturers and how brands can help tackle the issue and ease the burden for shoppers still struggling with the cost-of-living crisis.

Nick Ryan, co-founder and CCO, Acumen “With today’s figures from the ONS finding inflation rose unexpectedly in December, largely due to the increasing costs of alcohol, there continues to be ongoing challenges for FMCG brands – especially in the alcohol, food and drink industry. This rise in prices puts pressure on manufacturers to raise prices, further squeezing consumer budgets. Avoiding additional price hikes will be important for brands to maintain loyalty.

Managing input and transportation cost pressures will continue to be difficult for brands in the near-term. This requires them to have diligent inventory planning and improving production efficiency. We can collaborate with brands to creatively mitigate impacts on shoppers, by consulting on nuanced pricing strategies or selective investment trade-offs.

Whatever revenue management approach brands take, transparency around supply chain realities can help them stabilise prices. While 2024 will once again test FMCG brands, cooperation can fortify consumer loyalty later. With careful navigation and pricing strategy planning, brands can ease the burden on household finances while continuing to move forward.”

CAMRA wants Welsh Government re-think on business rates help to protect pubs from closure Consumer group warns that reducing help with business rates could lead to more pubs being lost as community hubs Responding to the publication of the Welsh Government’s draft 2024/25 Budget which sees a reduction in help with business rates for pubs and other hospitality businesses from 75% down to 40% from April 2024, Director of CAMRA Wales Chris Charters said:

One in five UK adults have confused plant-based products with real animal products, according to new report New findings from a report conducted by Opinium, on behalf of UK & Ireland law firm Browne Jacobson add support to the position that plant-based products should be described using terminology unconnected with other animal products, with one in five UK adults having confused plant-based products with animal products due to branding or labelling.

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Moreover, nearly two fifths of adults in the UK (38%) believe plant-based producers should be prohibited from naming plant-based food products after their animals or animal product counterparts.

This comes after much controversy in the EU and UK about the banning of animal product terms to describe plant-based food.

It is already a requirement for food producers and other food business operators responsible for food labelling to ensure that the labelling and marketing of their products is not misleading, otherwise these companies risk incurring hefty fines and legal proceedings with damaging reputational consequences.

The findings also demonstrate that the way food producers present, label

Latest News Our locals are at the heart of community life across Wales, bringing communities together, helping to tackle loneliness and providing a safe social space to enjoy a drink with friends and family.

“Pubgoers will be disappointed to see support for business rates bills for pubs, social clubs and breweries being cut – despite money from the UK Government being made available to keep the discount at 75%.

“Our locals are at the heart of community life across Wales, bringing communities together, helping to tackle loneliness and providing a safe social space to enjoy a drink with friends and family. They deserve help so they can survive and thrive in the months and years ahead.

“That’s why I am urging the Welsh Government to think again and keep the business rates discount at 75% as it is in England. At a time when customers are tightening their belts and businesses are grappling with rising costs, this help is desperately needed if we are to avoid more pubs, clubs and breweries being lost for good to communities across the country.”

and market plant-based products has an impact on consumers’ purchasing behaviour, with three in ten UK adults (31%) saying they are less likely to buy plant-based products if they resemble animalbased food and half of those who follow a vegan diet (49%) would prefer plant-based foods to differentiate from animal-based products.

Restocking squeeze easing as input costs fears abate Pressures on Welsh flock numbers appear to have lifted slightly in recent months after results from HCC’s survey reveals farmer fears over input costs are easing.

In-depth analysis by Hybu Cig Cymru-Meat Promotion Wales’ (HCC) experts of Phase 2 of the Farmer Intentions Survey – a survey conducted by HCC and completed by sheep and beef producers across Wales - shows a considerable improvement in producer intentions, despite the annual June survey results showing a notable fall in Welsh flock numbers. Some 75 per cent of Welsh farms are now expected to maintain or increase stock numbers in the short term according to the results from Phase 2, and therefore lamb numbers are estimated to stabilize somewhat from the low recorded in June 2023.

The survey was conducted over three days (from 24 – 28 of November 2023) to a nationally representative sample of 2,000 UK adults, weighted to Office of National Statistics (ONS) criteria.

HCC believes this to reflect a positive shift in confidence, compared with the same time last year, when uncertainty over high input costs influenced 43 per cent of Welsh livestock farmers to consider reducing stocking levels during Phase 1 of HCC’s survey conducted in September 2022.

The built-in demographics were by gender, age, region and city.

The Welsh Government survey findings mean the 8.7million Welsh

flock was 26 per cent below Wales’ peak of 11.8million head in 1999.

2023 figures from England show the flock declined by 3.2 per cent year-on-year to 14.5 million head, the lowest recorded population since 2011, while in Scotland sheep numbers fell by two per cent when compared with the 5-year average to 6.6million head.

Glesni said HCC’s Phase 2 of the survey had indicated lamb producer concerns over input costs had been overtaken by other challenges within the sector such as changes to direct payments, agricultural policy and government support schemes.

Looking at the beef sector, the Phase 2 of the survey had revealed a similar positive stocking position for beef farmers, where 65 per cent now say they will maintain or improve stocking levels compared to last year’s 47 per cent considering reducing stock.

The June survey data shows there was a small one per cent fall in the Welsh herd size, with total cattle and calves falling from 1.13million to 1.12million head. The beef breeding herd was down 4.7 per cent on the year to 149,290 head, and the dairy breeding herd was down 0.5 per cent to 254,700 head.

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Software & Technology

The Key to Success in the Food and Drink Industry: Striking an Effective Balance Between Automation and Human Labour Automation and AI: the undeniable benefits Increased efficiency, consistency and production capacity are just some of the most well-known benefits to automating food factories. Streamlined production, higher production capacity, faster turnaround and reduced reliance on manual labour also result in cost savings, a particularly appealing benefit to manufacturers. But there’s many more advantages.

With the continued advancements in automation and AI being painted as the future in the media, many seem to be forgetting that human labour continues to play a vital role across a range of industries, and will do so in years to come.

New technologies offering visualisation and remote visibility, automating procedures such as food inspections, or barcode and date code inspection, make data available that helps improve traceability. User monitoring, historical trends, and tracked user changes have become vital in an industry where traceability and security are of utmost importance.

There is no doubt that there are extraordinary benefits to integrating new technologies in food factories and the food industry as a whole. Automation and AI can take away the burden of unappealing repetitive tasks and improve efficiency in a variety of ways, yet human beings cannot be completely replaced.

Automated data collection has long been seen as a significant asset to the industry, and new tools are being developed to allow for even better opportunities. Having the ability to more easily identify potential issues, process ingredients and products, make predictions and meet specifications, facilitates a range of processes, and makes it easier to cope with increases in demand.

Here, Ian Hart, business development director of adi Projects, a division of multidisciplinary engineering firm adi Group, discusses why the key to success in the food and drink industry involves creating an environment where human beings and AI can work hand in hand, maximising the benefits across the board.

In environments like food factories, where maintaining the highest standards of cleanliness and hygiene is paramount, automated material handling can play a significant role in elevating these standards to unparalleled heights. With humans being the source of contamination, reducing the amount of people coming into contact with ingredients and products can have a particularly positive impact.

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What makes human beings irreplaceable in food and drink factories?

In a nutshell, AI lacks the emotional and creative intelligence that humans possess, as well as the ability to predict and handle unexpected situations – essentially the quality of adaptability, and the ability to act in a reactive manner.

Whether dealing with changes in production processes or troubleshooting problems, which human beings are naturally equipped to handle thanks to our critical thinking and decision-making skills, automated systems use preprogrammed algorithms that wouldn’t be able to automatically respond to new circumstances.

And while AI can analyse data and make suggestions, creating new recipes, flavours, and food products involves creativity and innovation that remain exclusive to humans.

Software & Technology Tasks requiring cultural understanding, aesthetic judgment and ethical or moral decisions can’t be assigned to AI systems.

Tasks requiring cultural understanding, aesthetic judgment and ethical or moral decisions can’t be assigned to AI systems.

Humans are also instrumental in ensuring compliance with safety standards and regulations, making real-time decisions based on intuition and experience to maintain the highest levels of food safety. Automated systems can be entrusted with quality control processes thanks to tools that can monitor production lines for potential defects or errors; however, trained individuals should also be available to intervene in the case of issues presenting themselves that need to be resolved with appropriate

judgment calls. Ultimately, AI needs the aid of human experience and feedback to be able to work effectively.

Security has long been a topic of concern when it comes to automation and AI. Data can easily be targeted by cyberattacks, and yet human beings could also be the cause of – accidental or otherwise – data leaks. The realtime data that new technologies are capable of offering is becoming irreplaceable, but equally, protecting network infrastructure by ensuring those who use it do so in the right ways is vital, showcasing that yet again, an effective balance between humans and automation is fundamental.

Creating an environment where human beings and AI can work together While AI and automation can streamline processes, enhance quality control, and optimise crucial aspects of food production, their value is enhanced when they are employed to complement human efforts rather than replace them entirely.

For instance, simple, repetitive routine tasks can effectively be handled by AI systems, allowing human beings to focus on more complex tasks. And though automated data analysis allows for trends and patterns to emerge that

would be near impossible for humans to identify, human beings are still required to look at this data, interpret it and make informed decisions as a result.

Human beings and AI should work in synergy to create safer, more efficient, and innovative food production environments. The strengths of both can and should be harnessed to achieve higher levels of productivity, efficiency, and innovation in the industry, and being aware of the unique capabilities of each is vital in building the right environments.

About the Author Ian Hart – adi Projects Business Development Director As a Director and Chartered Engineer, Ian has 25 years Executive Board experience, successfully establishing and developing customer focussed, engineering-based business and delivering high value investments in both private and public sector organisations throughout the world.

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Software & Technology

Supply chain 4.0 – where preparedness and opportunity meet in the digital supply chain Supply chains matter. One break in the link and manufacturers can be left with costly disruptions that bring the entire operation to a standstill – and the problem isn’t going away soon. According to McKinsey research, disruptions lasting a month or longer now happen every 3.7 years on average. Whether it is issues securing raw materials, a steep rise in shipping costs, labour shortages, geopolitical conflicts, or sustainability concerns, the pressure is mounting on manufacturers to diversify their supplier partnerships and introduce more flexible operations. For manufacturers determined to create more resilient supply chains, Andrew Newton, Business Central Consultant at Columbus UK, argues that a digital transformation of supply chains will be integral to the industry’s ongoing survival.

Industry 4.0 has been the main driving force behind recent supply chain transformation with the introduction of IoT technologies such as cloud, data analytics, and AI throughout the manufacturing ecosystem. This includes smart factories that enhance manufacturing with Industry 4.0 tech and smart products offering internetbased services.

It’s now time for the supply chain to step up to the 4.0 digital plate. Market leaders, particularly in the automotive and electronics sectors, have already launched digital transformation initiatives to establish flexible and high-performing supply chains – and manufacturers of all sizes can learn from their example on how to achieve sustainable change.

When disruption is constant, an organisation’s preparation for supply chain changes will provide a significant competitive advantage.

From effective data connectivity to

reshoring operations, operationalising AI, and implementing a long-term sustainability agenda – successful manufacturers must be able to incorporate these factors into supply chains to drive innovation and redefine how products are created, developed, and delivered to meet evolving consumer demands.

1. Unearth actionable findings within the data haystack Many businesses now have extensive data archives spanning several years, including substantial sales orders and operational performance records but the ability to extract maximum value from this data remains a common challenge. Manufacturers want to establish robust connections with shop floor assets to unlock enhanced operational efficiency and make more informed decisions. However, many lack the data-related skills to successfully link their machinery or manage the influx of data streams from sensors.

This is where the introduction of business intelligence dashboards with Supply Chain 4.0 can offer realtime production insights to inform decisions, boost efficiency, cut costs, and refine product quality.

The convergence of operational technology (OT) and information technology (IT) adds to the data

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challenge, particularly where legacy equipment is still in use. It is important to recognise that the solutions being implemented require tailored approaches due to the unique demands of each manufacturing organisation.

Developing applications within a business can be tricky, with not every business having the in-house data skills to do this.

Custom applications that don’t require extensive coding expertise can address this digital skills gap.

Versatile solutions that combine lowcode services, self-service analytics, and automation for instance, can make it easier for manufacturers to create applications that precisely align with their specific needs, boost efficiency, and innovate in the process.

The establishment of a reliable data environment with Supply Chain 4.0 ensures that manufacturers can enhance decision-making and operational efficiency, all while reducing costly errors.

2. Operationalise AI to stay one step ahead AI has left a mark on every industry and when it comes to the manufacturing landscape, the story is no different. Already many businesses are using AI tools to process realtime data from shop floor sensors to provide manufacturers with immediate insights and action, especially if quality measures breach thresholds.

But the capabilities of AI don’t stop at detection.

Manufacturers must consider many factors in production and delivery, such as demand versus capacity and how much materials cost along the supply chain – and this is where unsupervised AI can be a useful tool for risk identification and market trend forecasting.

For instance, AI can suggest preferred suppliers to purchase from based on

Software & Technology and add another level of complexity, but they do allow for greater inventory control and bring the product closer to the end customer, which reduces overall lead times. This reduction with Supply Chain 4.0 ensures that manufacturers can promote higher customer responsiveness and allows for constant improvement and innovation based on consumer feedback.

AI has left a mark on every industry and when it comes to the manufacturing landscape, the story is no different.

their supply chain history or issue alerts for impending weather events affecting supply chains. Social media analytics enabled by AI can also be used to project patterns to better understand where the market is heading but it can’t fully predict the future. Instead, the role of AI with Supply Chain 4.0 is to help manufacturers identify shifting consumer interests and trends, spot market trends relating to offerings or brand, and forecast waning or growing interest in product types.

3. I want it now! Proximity sourcing can help meet customers’ changing expectations As supply chain disruptions become part of the new business environment, it’s time for manufacturers to end the reliance on disparate and siloed operations and instead look to nearshoring as the answer.

Customer expectations around delivery times are changing, with 62% of UK consumers now expecting next-day delivery when ordering online – an expectation that traditional offshoring business operational models now struggle to match. Yes, regional or local supply chains can be more expensive

Nearshoring also provides an opportunity to clamp down on miles covered and will help manufacturers introduce a circular approach to operations. With over 4 in 5 UK adults recognising their role in lessening their environmental footprint, it is clear that the manufacturing industry needs to mirror this popular attitude – and technology will play a key role here. Automation techniques for instance can improve traceability and visibility over the entire product line, highlighting how businesses use and waste materials, along with how they can reuse products for better forecasting and reduce fossil fuel usage and pollution.

Particularly in the food industry, conscious consumers will base their buying behaviour on transport miles and the environmental impact of the product’s journey. If manufacturing businesses are able to clearly share this information with transparent supply chains, they will not only open themselves up to a larger customer pool but will also play a major role in tackling environmental challenges in the industry.

4. Long-term commitment to sustainability goals Nearshoring is certainly one way that manufacturers can become more sustainable but with customer sustainability expectations rising, companies now have to show a longterm commitment to creating greener supply chains.

Many businesses are making efforts to report on internal sustainable efforts such as energy consumption but extending reporting down the supply chain poses challenges, such as effectively reporting on a supplier’s energy usage. To achieve a comprehensive sustainability profile, this reporting must span the entire supply chain.

comprehensive tracking and analysis of environmental and social impacts, which will enable manufacturers to make informed decisions, ensure regulatory compliance, and communicate sustainable practices transparently. Manufacturers are looking to achieve this connectivity, particularly in linking shopfloor equipment usage with sustainability goals.

Leading organisations are pushing for data standardisation among their supply chain suppliers but this brings its own set of pros and cons.

Increased standardisation can make the supply chain more efficient and easier to review, potentially reducing a company’s risk. However, there’s more work needed to establish this standardisation.

As public and regulatory interest grows, having a clear view of supply chain processes will become even more important. In the short-term, expect leading companies to keep investing time and effort to better organise their supply chain data.

Supply Chain 4.0 – where preparation and opportunity meet in the digital supply chain Digital transformation is a long and complex journey but preparedness plays a key role in achieving optimal outcomes. Through the process of transformation, manufacturers can more effectively adapt to ever-shifting business conditions and evolving customer demands with Supply Chain 4.0, all while maintaining a competitive edge.

The issue remains that each manufacturer faces their own unique scaling challenges that require a calculated approach to processes, planning, and implementation to create a sustainable business model.

Often companies have growth ideas but lack a clear path to achieve them.

The identification of key supply chain trends will set apart the laggards from the market leaders.

Supply Chain 4.0 brings sustainability reporting tools that provide

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Sustainability

HRS welcomes progress on separate food waste collections

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

Along with others in the anaerobic digestion (AD) and biogas sector, HRS Heat Exchangers welcomes the recent announcement by the Government that weekly collections of food waste will also be introduced for most households across England by 2026. Defra’s ‘Simper Recycling’ plans also state that the ‘Government’s preference is for food waste to be collected for treatment by anaerobic digestion (AD), which presents the best environmental outcome.’

We recently commented on how a lack of consistency in policies, including around nationwide food waste collections, were preventing the UK from maximising the potential of AD to both generate renewable energy, mitigate emissions from organic wastes, and boost soil health. It is therefore extremely welcome to see the government recognise that, ‘Municipal food waste collections will reduce the amount of food waste going to landfill, where it releases harmful greenhouse gases, helping to achieve our Net Zero strategy target

to eliminate biodegradable waste sent to landfill from 2028. Instead, where food waste is collected separately, it can be reprocessed to create organic fertiliser and biogas, which can be used to generate electricity, bolstering our energy security.’

As Charlotte Morton of the Anaerobic Digestion and Bioresources Association (ADBA) points out, “Separate food waste collections are the cornerstone for an effective implementation of Defra’s Food and Drink Waste Hierarchy and now Local Authorities and AD operators can plan with confidence to put contracts and infrastructure in place to ensure inedible food waste goes to AD treatment as the first recycling option. The food waste collected will provide an invaluable new source of feedstock for AD plants to produce renewable gas for heat, electricity and transport fuel, and biofertilisers for soil health and improved crop yields.”

HRS hopes that these newly announced measures will unlock the considerable biogas potential in the country, allowing a number of proposed and planned AD plants to now proceed to completion.

However, as a number of industry observers have already noted, the increase in segregated food waste requiring treatment will exceed current treatment capacity unless new AD plants are built quickly.

The government also seems to have recognised this, and in another welcome announcement, has confirmed that the Green Gas Support Scheme (GGSS) will be extended until 31 March 2028 – ahead of the full response to the Mid-Scheme Review consultation.

HRS hopes that these newly announced measures will unlock the considerable biogas potential in the country, allowing a number of proposed and planned AD plants to now proceed to completion. As we have previously commented, it is imperative that AD plants maximise efficiency at every stage of the process, for both economic and environmental reasons, and doing so will require a multi-disciplinary approach including the use of heat regeneration through heat exchangers, as well as the use of bespoke systems such as the HRS BDS (Biogas Dehumidification System), DCS (Digestate Concentration System) and DPS (Digestate Pasteurisation System).

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R E E B S S A L C “WORLD DEMANDS A

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R E L L I F S S WORLD CLA Dan Carey, New

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