< Previous30 Food & Drink International www.fdiforum.net LOADING BAYS AND DOORS scenario that could have devastating consequences for the entire supply chain. The design of robust security doors should extend beyond weatherproofing to encompass water and airproofing measures, along with good thermal transmittance. Recent advancements involve using wood fibreboard, such as MDF treated with polyurethane-based insulators, as a waterproofing solution. These doors are then reinforced with heavy-duty metal armours, like stainless steel, creating a robust defence against external elements. For temperature-sensitive products, additional security and cold chain solutions must be incorporated to restrict access and prevent temperature fluctuations. Loading bays are not one- size-fits-all; the requirements for ambient products may be detrimental to frozen goods. The variation in temperature requirements across the food and beverage spectrum necessitates careful consideration of the loading docks. The loss of even a fraction of a degree can lead to disastrous consequences, making the establishment of an unbreakable cold chain a top priority. A four-sided vehicle seal ensures that the vehicle is only opened from inside the facility, maintaining controlled temperatures and safeguarding the integrity of the goods. Additionally, loading bay doors should incorporate security features for both hygiene and access control. Security measures like electronic key cards, iris recognition, and keyless entry devices deter thieves and forced entry, eliminating vulnerabilities associated with traditional lock-and-key mechanisms. Careful selection of materials, such as non-porous surfaces and stainless steel, further supports cleanliness and ease of maintenance. These are brought together to meet meticulous hygiene standards, ensuring the safe and uncontaminated handling of food and drink products throughout the supply chain. Modular loading docks and mobile platforms are gaining popularity for their flexibility and practical advantages over fixed raised loading docks. This trend aligns with the industry’s shift toward more flexible solutions. These modular technologies offer a wider variety of uses compared to traditional stationary docks, enhancing their overall benefits for businesses. Incorporating smart design elements, such as durability-focused materials like steel, anti-skid floor coatings, and bumper supports, strengthens safety measures and protects companies from potential litigation arising from worker injuries. Adjustable ramps known as dock levellers are the go-to solution for closing the gap between a vehicle’s storage and the loading bay platform. To keep the ramp at a safe gradient, these can unfold and extend as far as necessary to meet the height of any vehicle. Levellers are often connected to the vehicle load platform by a hinged lip, so that the two ramps can be securely linked without instability at the joining point. Attention must be given by anyone operating this Food & Drink International 31 www.fdiforum.net LOADING BAYS AND DOORS © stock.adobe.com/Katrin_Primak equipment to keep the area clear of other workers and debris, ensuring the lip does not trap anything that will make the centre connection between ramps uneven or insecure. Reinventing the door itself may not be necessary, but the materials and processes used in its manufacture are certainly not sacrosanct. Unseen technologies, such as modelling software and innovative materials, are shaping loading bays to minimise downtime and contribute to a more efficient supply chain. The integration of 3D modelling software in particular allows for detailed digital mapping of loading bays. This digital representation enables businesses to address specific variables ahead of time, troubleshoot potential issues, and explore new ideas. The use of such software not only enhances operational efficiency but also provides workers with a greater understanding of their working spaces, potentially reducing workplace casualties. Behind the scenes, loading bays are quietly developing so that they can keep doing their subtle work to ever higher standards. Complacency cannot be excused— staying abreast of technological advancement is what keeps your business ahead of the curve in every way that counts towards public satisfaction and safety, no matter how understated. Considering the multifaceted challenges and responsibilities shouldered by loading bays, it becomes increasingly apparent that these pivotal points serve as the backbone of a seamless and secure supply chain. Cleanliness, security, and temperature control within loading bays is not merely a logistical necessity, but a fundamental safeguard against the potential compromise of product quality and safety. The holistic approach to hygiene, advanced security measures, digital mapping, modular technologies, and innovative loading dock solutions collectively ensure the safe and hygienic delivery of products to consumers. For these ends, and for the continued safety of your business and its products, as much time and attention should be given to loading bays and doors as any other area in food production. info@rubbuk.com | +44 (0) 191 482 22 11 | www.rubbuk.com Building Systems Flexible cold storage solutions32 Food & Drink International www.fdiforum.net CONTAINERS AND PALLETS C ontainers and pallets play a vital role in the efficient storage and transportation of goods, ideal for moving products seamlessly from production facilities to consumers. They’re one of the last stops your products will make before they ship, but that doesn’t mean decisions around them can afford to be rushed or glossed over. Though it’s easy to overlook boxes and vessels against the high-octane tasks of the factory floor, these finer details are just as important as any other to providing desirable food and drink. Containers, designed to accommodate a range of items, act as a first line of defence in the logistical process. They safeguard products, maintaining their freshness and quality during transit, while pallets provide the foundation for efficient handling and transport, organising goods for easy loading and unloading. In busy warehouses, containers and pallets streamline operations, optimising storage space and reducing the risk of damage. Their ability to stack further ensures goods are easily accessible while being moved for transit, and minimises the potential for mishandling. Once items have been given their primary, secondary and any attractive retail packaging, this latter stage shows a commitment to delivering the best to shelves, and finally to consumers. Packaging safety and operational efficiency are given their final security measures here, with specific design to prevent contamination and damage, ensuring goods remain in the same optimal condition as when they left the production line. Different materials, such as plastic, wood, or metal, offer varying benefits to food logistics. Plastic pallets are the stalwart choice for many, and for good reason. Their non-porous surfaces create an environment inhospitable to bacterial growth, ensuring a robust defence against contamination. However, the picture isn’t entirely flawless. Plastic may be susceptible to damage under heavy loads or when subjected to high impact. The initial investment might also be higher compared to other materials, prompting businesses to weigh the long-term benefits against immediate costs. One way to offset cost concerns is to opt for wooden pallets, their repairability and lower initial cost an attractive option for businesses with budget constraints. However, these can absorb moisture, potentially leading to bacterial growth in a material that’s already resistant to thorough cleaning. Cleanliness is a non-negotiable attribute in the food industry, where meticulous hygiene practices are imperative. The difference between In the dynamic world of food logistics, containers and pallets seamlessly bridge the gap between production and consumer shelves. A quiet Food & Drink International 33 www.fdiforum.net CONTAINERS AND PALLETS plastic and wood shows that across different types of containers, cleaning processes can vary widely, influencing not only their effectiveness in handling food but also the overall longevity of the containers and pallets. It’s also easy to see how what first appears to be a cost-effective measure when buying can backfire, requiring you to shell out for replacements and spend more than if you’d settled for the extra expense to begin with. Ensuring the structural integrity of containment solutions is often worth a greater financial investment. Plastic pallets, despite their liability to break under pressure, are sufficiently durable under most circumstances. They can also weather the elements and are less susceptible to the wear and tear that can plague their wooden counterparts, which become © stock.adobe.com/Kadmy © stock.adobe.com/michaeljung 34 Á34 Food & Drink International www.fdiforum.net CONTAINERS AND PALLETS especially vulnerable to damage in wet conditions. Metal pallets, on the other hand, boast unmatched strength to offset their heftier price tag. They can withstand heavy loads and harsh conditions, but their weight may pose challenges in terms of transportation and handling. Particularly where product volumes are lower and the items themselves are lighter, metal is undeniably the most robust choice, but may still need to be rounded out with extreme care whenever staff are moving, loading and unloading them. The substantial weight of metal pallets might also impact fuel costs. In an era of growing environmental consciousness, the sustainability of materials used in containers and pallets comes under scrutiny. Plastic pallets, often made from recycled materials and recyclable themselves, present a more environmentally friendly option. Being lightweight, they contribute to ease of manoeuvrability and fuel savings, perhaps making them the greenest choice in terms of balancing long-lasting use with the limited resources needed to move them. Despite the many benefits of plastic, concerns about the environmental impact of plastic waste persist. Wooden pallets, being a natural material, are biodegradable and contribute less to landfill waste. However, the sustainability of wood sourcing and the energy-intensive production process raise environmental considerations. Metal pallets, while durable and recyclable, are energy-intensive to produce. Their environmental impact is mitigated by the potential for recycling, but businesses must weigh these factors against their specific sustainability goals. Wherever goods are being shipped to, the fourth industrial revolution is shaping industries worldwide, and brings the compatibility of containers and pallets with automated handling Gressenhall | Dereham | Norfolk | NR20 4DT | +44 (0)1362 861066 | www.premierpalletinverter.co.uk © stock.adobe.com/kokliang1981Food & Drink International 35 www.fdiforum.net CONTAINERS AND PALLETS systems into sharp focus. Plastic pallets, known for their standardised dimensions and durability, seamlessly integrate with automated systems. Because of their uniform size and weight, they passively reduce manual labour and enhance efficiency by being highly compatible with automation, and may prove the strongest choice overall when your business is transitioning to using more automated processes. Customisation, whether working with automation or not, plays a vital role in simplifying the use of containers and pallets in the food industry by tailoring these essential components to meet your business’s individual needs. Modifying designs to automated systems can unlock their full potential, containers with collapsible features optimising storage space when not in use, while pallets designed for easy robotic manipulation contribute to faster and more efficient handling. But in more general use, customised design can accommodate the varied shapes and sizes of food products, ensuring a secure fit that minimises movement during transportation and storage, thereby reducing the risk of damage and optimising space. Whether it’s temperature-controlled compartments or ventilation features, custom designs ensure that each food product is stored in an environment conducive to its preservation. By weighing the nature of your products against the ability to personalise containers and pallets, you can use what might seem on the surface a simple logistical decision as a powerful strategic move, aligning with unique industry needs for cleanliness, efficiency, safety, and sustainability. When you exemplify all these concerns in every detail, even down to the modest pallets that deliver your food and drink products, you not only protect their quality, but display the kind of care that consumers won’t fail to notice. D Davies Turner © stock.adobe.com/Kadmy36 Food & Drink International www.fdiforum.net MICROBIOLOGY AND TESTING F ood makers already have many measures at their disposal which can be utilised in-house, such as ever more sensitive sensors that can be easily fitted into existing production lines. With advances in portable sensors, food makers are better able to detect the presence of foodborne pathogens such as E.coli, listeria and salmonella. Although some food companies, especially major global operators, will maintain their own in-house laboratory facilities for food testing, the majority simply can’t afford that expense or don’t have the space to spare. In these cases, companies will outsource to specialist food testing companies. Ensuring food safety and regulatory compliance during the discovery of a pathogen is already a protracted process, but with added wait times between testing, it only draws the process out which could be difficult for food makers to mitigate in an increasingly competitive market. Advances in rapid diagnostics, however, have led to ever more efficient, accurate and swifter tests being developed to detect pathogens and contaminants and validate authenticity. Turnaround times are quicker, downtime for food producers and operators is reduced, and companies can implement recall plans and investigations quicker and more Test now to avoid disaster later Microbiological testing can be slow but the consequences of an outbreak are anything but. Though memories may have been dulled by COVID, the years before saw a number of startling outbreaks in food products with dire consequences, and consumer and media attention now is even more focused on food hygiene. Food & Drink International 37 www.fdiforum.net MICROBIOLOGY AND TESTING efficiently. This helps to protect customers, curb potential litigious action and reputational damage, and keep costs down. If a pathogen is detected in the test sample, then undoubtedly the batch that sample was taken from will be destroyed. Detecting that pathogen as early as possible means that the source can be more swiftly identified. Once that’s discovered, the source can be better ascertained. If, for example, environmental swab testing reveals that Food Care Solutions aims to help our clients achieve their aims. We have helped food businesses throughout the UK since 2003 with our services, including: • Food Safety and Food Quality • BRC and FSSC 22000 certification • Supplier Auditing • Training • Hygiene Inspections & Internal Audits • Complaints & Incidents Management Tel: 01933 276 400 • Mob: 07811 192545 • Email: victor@foodsafeconsult.co.uk • Web: www.food-care.co.uk FOOD CARE SOLUTIONS FOOD CARE SOLUTIONS 38 Á © stock.adobe.com/angellodeco38 Food & Drink International www.fdiforum.net MICROBIOLOGY AND TESTING the testing of ingredients and prototypes, companies can undertake shelf life determination and, as previously mentioned, discover nutritional information for labelling. Products are recalled for a variety of reasons, though most commonly because of the presence of undeclared allergens such as soya, peanuts and gluten. Rigorous testing before products hit shelves can help to prevent future recalls and they cost they incur. There are plenty of sources where contamination can occur, whether that’s raw materials coming into contact from soil, sewage and live animals, in the slaughterhouse where meat is concerned, or in transit where food is improperly cooled or heated. Improper storage temperatures are doubly concerning for high risk foods such as dairy products, seafood, cooked rice, meat and poultry and prepared fruits and vegetables. Contamination also occurs during production, where chemicals used to maintain machinery can mix with foods, or pathogens can develop on improperly cleaned machinery. There have been a surprising number of high-profile microbiology outbreaks within food products in the last few years, though the COVID pandemic has done a good job of making the the conveyor system was the source of the contamination, steps can be taken to ensure it’s thoroughly cleaned or replaced and tested again to confirm whether production can resume. There will of course be production downtime during this process, but steps can be taken to ensure that no further batches pass through the same conveyor. Though testing is used during investigations in existing outbreaks, many food chain operators use it as a precautionary measure. It’s not that food makers are hoping to find contaminates or pathogens in their products, but rather want the peace of mind of knowing their products are safe. Should a pathogen then be found, they’re already in a better position to act. Routine testing is therefore advised, not only for ingredients and finished products, but for the premises and production lines themselves. Swabs can be taken of the entire production environment, from equipment, machinery and trucks to the growers of raw ingredients. Testing is a key preventative measure for food makers, but it also has a valuable role to play in new product development. With EL-USB-1, temperature data logger The EL-USB-1 is a USB temperature data logger with a measurement range of -35 to +80°. The data logger can store up to 16,382 readings and is supplied with a long-life replaceable lithium battery, allowing the unit to log data continually for at least one year (depending on logging rate and temperature). The status of EL-USB-1 is indicated by flashing red, green, and orange LEDs. • USB temperature data logger • Configuration software • 2 Settable alarm thresholds • LEDs indicate logger status • IP67 protection Data logger configuration software is supplied, allowing the user to easily set-up the data logger. The logged data stored in EL-USB-1 is downloaded via the configuration software. Once downloaded or exported to other applications. The EL-USB-1 is suitable for a wide variety of applications, these include: • Pharmaceutical fridge monitoring • Transportation • Food & drink • Building & site monitoring Find out more at: https://www.labfacility.com/el-usb-1.html Scan for More InformationFood & Drink International 39 www.fdiforum.net MICROBIOLOGY AND TESTING © stock.adobe.com/analysis121980 consequences of them. Between September to December 2019, 167 people from twenty-seven states in the US were stricken with E. coli after eating contaminated romaine lettuce, resulting in eighty-five hospitalisations nationwide. Though no deaths were reported, fifteen of those sickened developed a type of kidney failure. This followed a similar one in 2018 from the same strain of E. coli from the Salinas growing region, and another the year before it. The issue arose because leafy greens like lettuce can become easily contaminated in the field by soil, water, animals and improperly composted manure. Contamination can also occur during handling, storage and transportation and after all that, consumers typically eat it raw and while washing at home removes some bacteria, it does not eliminate E. coli. Last year also saw the outbreak of listeriosis in Spain, the biggest in the country’s history. In all more than two hundred people were taken ill, of which three died, after eating branded chilled roasted pork. Though the outbreak began in mid-August, and was declared over in October, arrests were made after the Spanish Civil Guard and law enforcement agency Europol found individuals were aware since December 2018 that some food products contained listeria but did not inform authorities and continue to sell them. In the UK, six people died from listeria infection after 40 ÁNext >