< Previous20 Food & Drink International www.fdiforum.net PACKAGING SPOTLIGHT profitable move. This is at odds with the fact that the same companies regularly claim and boast of sustainable packaging and environmental concern, showing that while they do believe appealing to those demographics to be a profitable business decision, they for some reason don’t believe it enough. Sustainable packaging remains a secondary concern for many in the industry – and the fault does not lie on designers and manufacturers of packaging machines, who have been pushing technology further and further toward lower emissions. The technology is very much out there and very much in use by some, but many food manufacturers, especially in the UK, are lagging behind their European competitors. This combined with bans for single-use and certain types of plastics commonly used in packaging across the world will force the issue for many businesses. Taiwan banned PVC as a food packaging material, after South Korea did so in 2020 and New Zealand in 2022. The true shock is that change might come by way of government interference at all, and whether it should need to. Governments are naturally slow to react and force change for fear of upsetting the economy, and it is mostly assumed in a capitalistic environment that businesses themselves will drive change in a competitive effort to corner more customers. That food packaging has stagnated and fallen behind despite clear trends and consumer buying habits showing a preference for environmentally conscious goods, highlights an odd antipathy in the packaging sector, one where it is good to claim to care about the environment but not worth investing in being so. If food manufacturers are so slow to change that governments beat them to the punch, how then can they expect to remain competitive BAG SEALING MACHINES RM Sealers remain a leading British manufacturer and supplier of high quality Bag Sealing Machines, also known as Rotary Band Sealers and Impulse Sealers. Call 01442 843387 to speak to a member of our team SEALERS © www.rmsealers.co.uk © stock.adobe.com/ArtCookStudioFood & Drink International 21 www.fdiforum.net in today’s ever more global world? And when will it be time to stop harping and promoting about being environmentally conscious, and start actually being so? The packaging industry is ready and willing, and any visit to one of many trade shows will see seminars and talks on environmental packaging and the numerous innovations in the sector. The packaging industry well understands the challenges and advantages of investment in new technology, but it seems food manufacturers are struggling to see the same. Flexible packaging – used for many single- use products which are most non- recyclable – is a particular bugbear for British consumers, with one in five admitting to throwing flexible packaging in the recycling bin because they didn’t know it can’t be recycled. It’s little wonder that as well as clear labelling, almost four in ten consumers think retailers should be made to have a plastic-free aisle in every store. But replacing plastic is by no means easy. New product development has yielded a number of worthy contenders with plastics produced from renewable sources such as the aforementioned sugarcane, as well as cellulose and starches. However, it’s a more complex issue than simply swapping petroleum produced plastics for those made from plant matter. For example, what good is plant-based packaging if vast swathes of endangered rainforest must be cleared to grow the crops to produce it? Yet it’s clear that there is a massive shift taking place in the industry. Boosting recyclability, switching to more sustainable materials and improving labelling will all help to improve the environmental impact of food and drink packaging and create a green supply chain. BENCHTOP BAG SEALING MACHINE IMPULSE BAG SEALING MACHINE HORIZONTAL BAG SEALING MACHINE VERTICAL BAG SEALING MACHINE © stock.adobe.com/Seventyfoure22 Food & Drink International www.fdiforum.net KITE PACKAGING Q&A Can you tell us a little about Kite Packaging and what you do? Kite Packaging is a leading UK packaging distributor supplying a wide range of industries across the country. We were established in 2001 with a vision of offering exceptional service and sustainability in the packaging sector and have since become a trusted partner for thousands of businesses. From boxes, tape and pallet wrap to production line and pack room equipment like conveyors and pallet trucks, we offer everything you need to keep your operations running smoothly. What makes Kite Packaging stand out in the food and drink industry? Sustainability isn’t just a buzzword or box-ticking exercise for Kite Packaging; it’s one of our core values. Since our founding, we’ve championed sustainable practices within the industry, taking responsibility for educating and empowering businesses to ‘love the planet [and] use less packaging,’ as is proudly displayed on our delivery trucks. Our environmental commitment earned us Packaging of the Year at the UK Packaging Awards, with judges praising our functional, eco-friendly packaging solutions and efforts to reduce our environmental impact. By partnering with us, businesses benefit from a supplier whose values align with their sustainability goals. Whether it’s through our accessible range of biodegradable, recyclable, or reusable packaging, or our initiatives to drive down waste, we offer practical, environmentally conscious solutions tailored to their needs. Working with Kite isn’t just about packaging – it’s about collaborating to make a positive, lasting impact on the planet. What challenges do you find food and drink manufacturers are facing today? Many of them are still experiencing the same challenges they did in 2024. For example, the energy price cap increase in October 2024 and again in January 2025 has hit the industry hard due to the energy-intensive nature of production, refrigeration and packaging processes. Disrupted global supply chains, political uncertainty and climate-related events continue to impact raw material costs, adding financial strain. Additionally, the industry faces significant pressure to reduce its environmental footprint. Key concerns Q&A Specialists at packaging We speak to Kite Packaging, specialists in packaging across numerous industries, to find out how they are supporting their food and drink customers. Food & Drink International 23 www.fdiforum.net KITE PACKAGING Q&A using minimal energy, made from renewable or recycled resources, and are fully recyclable, biodegradable, or compostable. These include takeaway packaging such as bowls, boxes, paper bags, coffee cups, and wooden cutlery – perfect alternatives following the single-use plastics ban introduced in October 2023. By combining innovative products with eco-conscious designs and efficiency-boosting equipment, we provide tailored solutions to support food and drink businesses in overcoming today’s challenges. How do your industrial food packaging products comply with food safety regulations and industry standards? We ensure compliance by adhering to best practices, earning an AA rating for BRCGS accreditation in our warehouse. Regular unannounced BRCGS audits demonstrate our commitment to maintaining robust food safety standards, providing customers with reliable, compliant packaging solutions. What options do you offer for bulk ordering? As a wholesale packaging distributor, all our products are available for bulk purchase, with discounted prices for larger pack and pallet quantities. With 40,000 pallet spaces at our Coventry site and ample stock, we offer next-day delivery on most orders. Businesses can also apply for a credit account, providing them flexibility to purchase as needed and pay later. For companies with multiple UK sites, our key account managers and packaging technologists work together to ensure seamless supply chain support and the highest-quality packaging solutions. For more information or to get in touch with Kite Packaging, visit www.kitepackaging.co.uk, email enquiries@kitepackaging.co.uk or call +44 (0) 24 7642 0065 include managing packaging waste, lowering carbon emissions, and addressing food miles. Compliance with Extended Producer Responsibility (EPR) regulations also poses a challenge, as manufacturers must now absorb the cost of end-of-life packaging disposal, impacting their profit margins. How can your packaging help businesses overcome these challenges? For those navigating rising energy costs, some of our packaging machinery and equipment enhances efficiency without using extra energy or incurring costs. Our gravity conveyors, for example, require no electricity and improve the flow of goods so that manual labour can be focussed where it is needed most, making them ideal for energy conscious operations. Meanwhile, our carton sealing and bagging machines speed up packaging processes, significantly increasing output compared to manual processes whilst reducing labour costs. However, they do require electricity to operate. We can help businesses optimise their packaging and achieve cost savings, better preparing them financially for when unexpected challenges arise. On the sustainability front, our eco- friendly products enable businesses to meet their environmental goals and comply with regulations such as the Extended Producer Responsibility (EPR) initiative. Many of our materials are crafted 24 Food & Drink International www.fdiforum.net READY MEALS Ready meals are here to stay and are fast becoming the food of choice for every working adult and student. F rom 2020 – 2027, canned meals are expected to expand the fastest. This is due to the convenience and longevity of the product, whilst having the ability to retain healthy protein, carbohydrates, and fat that other ready meal types do not have. A traditional favourite of students, instant pasta and noodles are the biggest offering from the dried foods segment. The U.S., China, India, and the UK provide the largest demand for these products. In the UK and US, a rise in demand for Korean and Chinese dried products such as ramen has been seen amongst teens and young adults. Important to this trend is the notion of authenticity, so those looking to expand their ranges must source and manufacture these products similarly to the © stock.adobe.com/ weyo Food madeFood & Drink International 25 www.fdiforum.net READY MEALS © stock.adobe.com/photka country of origin in order to truly take advantage. Food on the go has become a staple of our diets in an increasingly busy world. Ready meals have gone from being TV Dinners served when no one is available to cook, to microwaved meals cooked in long queues in the office, so it’s no big surprise the market has boomed and expanded, be it in terms of value, variety or method. The ready meals market is expected to be worth $225 billion by 2030, experiencing a 6.8% annual growth over a decade. That’s not to say there aren’t challenges, however. Ready meals, while convenient, are notoriously unhealthy, often packed with preservatives, salt and carbs, and increased transparency on labelling has left many balking at the high % of rda in each meal. This has led some brands to diversify into healthier options, led in no small part by entrepreneurs selling meal packs online and making quite the profit doing so. Research suggests that consumers prefer to shop for food from stores rather than online portals, due to the ability to physically choose based upon individual item appearance. This is important for manufacturers looking to diversify their suppliers – do not overlook stores, and the value of eye-catching ready meals with easily accessible packaging that lets the consumer see the food inside. This highlights the continued importance of packaging in terms of catching the eye and drawing attention and 26 ÁExpandyourbusiness, attractnewcustomers, andmakeapositive impactbyofferinghalal- certifiedproducts.Contact ustodaytolearnmore abouthowwecanhelp youtosuccessfully integratehalalproducts intoyourbusiness. GLOBALLYRECOGNISED HALALCERTIFICATIONBODY GetHalalCertified info@halalfoodauthority.com 0044(0)2084467127 ISED anmaeaposstve impactbyofffeeringhalal- certifiedpprroducts.Contact ustodaayytolearnmore abouuthowwecanhelp yyooutosuccessfully integratehalalproducts intoyourbusiness. Expandyourbusinesss, attractnewcustommeers, andmakeapossiittive NBODY GeteeHalalllCertrrififfed www.halalfoodaut info@halalfooda 0044(0)208446 thority.com authority.comm 67127 26 Food & Drink International www.fdiforum.net READY MEALS stands in stark contrast to consumer claims that “packaging has no effect” on them, and that it’s the quality of the food that counts. Typically speaking, ready meals make use of cartoning and sleeving for their packaging, usually with the cooking instructions and labelling on the sleeve itself while the food is served in a carton with a film topping – important for allowing the consumer to see the meal itself. Visual confirmation remains key but this method of packaging is not particularly conscientious on the environmental front, leading to questions on how to both satisfy consumer demands to see the product but also have a lower impact on the environment. With the market continuing to expand, the main focus – especially in the UK with the cost of living – will be on affordability combining with health benefits. Healthier options, a reduction in salt, and changing up recipes to offer healthier alternatives will put brands in a better position to corner the market. A failure to do this not only risks turning off potential customers, but also opening a niche for a competitor to start targeting your own. After all, ready meals are already accepted to be less tasty than freshly cooked meals, so how much of a difference is there between one ready meal and the next, if the price is the same but one has half the carbs, fat, salt and sugar? Convenience meals eaten in a rush in a busy work environment won’t be savoured as they might be in a restaurant, so the reduction in taste is unlikely to be noticed, if perceived at all. © stock.adobe.com/WilliamFood & Drink International 27 www.fdiforum.net RIGGS AUTOPACK L eeds based L éclair Patisserie was born from a passion of French cooking, especially the sweet side, and the realisation that everyone needs an eclair in their life. With a small team of pastry chefs all sharing the same obsession for French patisserie and perfection, L éclair Patisserie was born! Their story began in lockdown. They took what was an old gym in West Leeds and converted it into a huge all singing, all dancing kitchen perfect for creating their patisserie. Then came the shop. They wanted to bring a little bit of Paris to Leeds so got a real-life Frenchman (Frank the Machine) who could see their vision. Armed with a drill and a paintbrush, off he went waving his magic wand of wonder and created their little shop. Since the early days of the little bakery shop, they’ve substantially grown and become a contract supplier producing 1000’s of bespoke products each day for national hotel groups. Their skilled team create a huge variety of tarts, macarons, gateaux and cheesecakes to name just a few products each week on a bespoke basis to meet each client’s specific requests. As production has grown over the years, they realised that to keep up with demand they would need to look at a suitable semi- automatic depositor. Co-founder Stephen Thompson approached depositor manufacturer Riggs Autopack to discuss their potential depositing requirements. The initial remit was to speed up their production process by accurately depositing their range of ambient temperature cake batters, directly into trays, with a nominal single deposit range of 3ml - 40ml. Following the initial enquiry, Riggs Autopack Technical Sales Engineer Neil Pygott visited their premises to discuss their requirements in person and review their range of products and containers. To meet their specific production needs, Riggs Autopack recommended their Model 1000 Series 1 Micro Depositor and supplied L éclair Patisserie with a free of charge depositor for a 2-week period to conduct comprehensive product trials. Stephen Thompson said, “The support and guidance we received from Neil Pygott and Riggs Autopack was invaluable and perfect! We haven’t used depositors before and relied heavily upon their expert guidance. Within just a couple of days of running the machine in production, operators reported back how much easier and quicker the depositor had made their jobs. They loved it!” They were astonished with the increased production speeds, depositing accuracy and product presentation. Consequently, L éclair Patisserie placed an order with Riggs Autopack for the Series 1 Micro Depositor. The depositor has dramatically changed the company and transformed the cost of production; they are now producing 5 times the volume when compared to before the machine. 22 minutes of previous production time is now only 4 minutes! By purchasing the depositor, it has also opened new doors to undertake many larger contracts that they would previously have not been able to fulfil. Stephen Thompson added: “I contacted several companies that sell depositors, however from the first call to Riggs Autopack I knew these people had the experience, knowledge and support we would need in this new field to us. “At our first meeting there was no pressure to buy or ‘our machine is better than everyone else’s’ approach; they let the machine do the talking. Even on the set up of the trial machine, Neil Pygott and a service engineer came out to set up the machine and talked the team through every element. “The machine never left our premises. I called Neil and said send me an invoice, it’s staying! Buy this machine, it will save labour cost, portion costs, opens up NPD and the most important for me is ANYONE can use this machine…..and as a bonus you will get a great new friend called Neil.” Riggs Autopack Ltd Premier Buildings, Brunswick Street Nelson, Lancashire BB9 0HU Tel: 44 (0) 1282 440040 Email: info@riggsautopack.co.uk Web: www.riggsautopack.co.uk Léclair Patisserie Experiences Growth with a Riggs Autopack Depositor 28 Food & Drink International www.fdiforum.net LOADING BAYS AND DOORS Fundamental to food and drink logistics, loading bays and doors are evolving to meet greater consumer demand, resulting in efficiency and safety gains. T here has been a significant increase in technologies not only to make the process of arriving and backing up into a loading bay more efficient – therefore allowing goods to be loaded quicker and more deliveries to be made – but also safer for operatives. While slips and falls are the most common accidents to occur in loading bay environments, injuries can and do occur from trucks backing up, overexertion, and accidents involving forklifts. It’s believed that as much as twenty-five per cent of industrial accidents occur in loading bays, highlighting the pressing need to make these environments safer. Technologies such as sensors, which are being found increasingly in and around the loading bay area, not only lead to greater efficiencies and provide actionable data for operational improvements but provide a boost to worker safety. For example, sensors around the loading bay can demand Keeping up with Keeping up with Food & Drink International 29 www.fdiforum.net LOADING BAYS AND DOORS © stock.adobe.com/TTstudio alert operators when a truck is coming in too fast, too close or is out of alignment with the loading bay door, helping to prevent injuries and accidents (and reduce downtime that occurs in either occurrence). There’s also telescopic lips which provide an optimal range loading platform allowing for precise bridging for fast, efficient, and safe loading and unloading. Solutions such as these help to bolster existing safety measures such as buffers, to create a safer working environment. While worker safety is, undoubtedly, a priority, there is also the protection of goods to consider. Many products are temperature sensitive, making them vulnerable to the elements and changes in temperature. Where frozen products are concerned, even miniscule changes in heat can lead to spoilage and deterioration. It’s critical, therefore, to preserve a consistent temperature so products can be loaded from the warehouse onto the truck without any defrosting. In order to do that, solutions such as dock shelters and loadhouses are required, both which extend the loading area either to preserve the temperature controlled environment and/or to keep out the elements. While there has been a lot of development where the loading bay area is concerned, it’s important not to forget the door. As they must 30 ÁNext >