< Previous20 Food & Drink International www.fdiforum.net END OF LINE PACKAGING As the food industry faces increasing pressure to balance product integrity and environmental responsibility, the drive for sustainable end-of- line packaging solutions intensifies. E nd of line packaging can be responsible for maintaining the integrity of many different types of products, including fresh produce, frozen food, dairy products and beverages. Amongst all this variety, packaging for transport must consider the unique characteristics of each product, as well as mitigating the environmental impact of the food industry. In both global and British food production, several types of end of line packaging are commonly used to ensure the safe and efficient distribution of food products. One prevalent method is the use of cardboard boxes or cartons, which are gifts for being easy to store flat and build as needed, as well as the ease and availability in using recycled and recyclable materials for these storage solutions. Boxes are also endlessly versatile, coming in various sizes and shapes. Often used for packaging bulk quantities of products such as fruits, vegetables, cereals, and canned goods, cardboard is also sturdy and cost- effective, making them an ever-popular choice for transporting food items from manufacturers to retailers. Whereas boxes alone are ideal for Rethinking food packaging © stock.adobe.com/Aleksandr MatveevFood & Drink International 21 www.fdiforum.net END OF LINE PACKAGING Looking for assistance labelling your product? HERMA are committed to meeting your requirements With over 110 years’ experience of manufacturing labellers and labelling machines HERMA have a wealth of knowledge in providing both local and international customers with labelling solutions. Visit HERMA to see how they can help with your labelling requirements. Labelling Systems high volumes of less breakable or perishable items, they won’t keep everything safely contained, no matter their convenience. Another common form of end-of-line packaging that comes in useful here is shrink wrap or stretch film. This type of packaging involves wrapping individual or multiple food items tightly in plastic film to protect them from damage, contamination, and tampering. Shrink wrap is particularly popular for packaging items like meat, poultry, seafood, and dairy products. It helps extend the shelf life of these products for quality, health and safety, sealing in freshness and preventing exposure to the air, moisture, and external contaminants which can kickstart harmful bacterial growth. The use of trays and clamshells is widespread in the food industry for © stock.adobe.com/Itsanan 22 Á22 Food & Drink International www.fdiforum.net END OF LINE PACKAGING 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 packaging many kinds of fresh produce, baked goods, deli items, or ready-to-eat meals. These containers provide a convenient, hygienic, and simple way to display and transport artisanal, visually attractive and individually portioned products, while also offering protection against physical damage and contamination. Trays and clamshells can be made from various materials such as plastic, foam, or compostable materials. The materials will depend on the specific requirements of the product, but quality and eco-friendliness often rely on the sustainability goals of the manufacturer, and so certain assets can vary drastically. The urgency of seeking out more sustainable packaging has reached fever pitch in recent years. While certain common packaging types, such as cardboard and several types of plastic, are at least recyclable, not all end of line solutions are equally made for eco-friendly efforts. Shrink wrap is one of them, as it’s typically made from polyethylene (PE), a type of plastic polymer. Polyethylene is widely used in packaging due to its flexibility, transparency, and ability to shrink when heated, and there are two main types of polyethylene used in shrink wrap production. Low-density polyethylene (LDPE) boasts superior clarity and ease of use, with polyvinyl chloride (PVC) falling out of favour due to its tendency to leak plasticisers. PVC also has a worse environmental impact even in comparison to other single-use packaging, due to the hundreds of years it can take to decompose, as well as the chlorine used in its manufacture. While shrink wrap is effective for packaging items and protecting them from moisture, dust, and damage during transit or storage, it’s usually not recyclable for several reasons. Often contaminated with other materials such as adhesives, inks, or residues from the products it covers, these contaminants can make it difficult and costly to separate and process shrink wrap for recycling. Many recycling facilities do not have the necessary equipment or capabilities to effectively recycle shrink wrap in the first place, as these materials are typically thin and lightweight, which adds extra economic and functional difficulty to recycling processes. As a result, even if shrink wrap is technically recyclable, it may not be accepted by local recycling programs due to logistical constraints. As a result, alternatives to traditional plastic packaging, such as compostable materials, biodegradable plastics, and circular packaging, are becoming increasingly popular. Manufacturers are exploring innovative packaging options that minimise environmental impact while still ensuring the safety and quality of food products, various eco- friendly end-of-line packaging solutions being developed and tested. These solutions encompass a range of innovative materials and approaches aimed at reducing the environmental impact, and promoting the sustainability, of individual manufacturers. Furthermore, they align with consumer preferences for eco- friendly products, and support global efforts to reduce plastic waste and promote recycling initiatives. One such solution involves the use of biodegradable and compostable materials derived from renewable resources. Packaging made from biodegradable polymers, such as corn starch or sugarcane, breaks down into natural compounds when disposed of properly, offering a more environmentally friendly alternative to traditional plastics. Recycled content packaging is also gaining traction as a sustainable option, by innovating how and where recycled materials like paper, cardboard, or plastic can be used and processed. This rethinking has led to water-based coatings which make paper and card harmlessly water resistant, moulded pulp packaging made from recycled paper fibres, and advanced chemical recycling or pyrolysis, which break down plastics into their original building blocks ready to be reused. Food & Drink International 23 www.fdiforum.net END OF LINE PACKAGING © stock.adobe.com/Pixel_B BENCHTOP BAG SEALING MACHINE IMPULSE BAG SEALING MACHINE HORIZONTAL BAG SEALING MACHINE VERTICAL BAG SEALING MACHINE Mushroom packaging is using agricultural waste combined with mycelium to create biodegradable and compostable packaging materials. Groundbreaking packaging solutions are combining cardboard with polymer coatings or reinforcements to improve strength, durability, and moisture resistance, while still maintaining recyclability. These clever fixes are all offering similar if not equal functionality to traditional end-of-line packaging, maintaining or even boosting the strength and protection needed to ship products, while facilitating lightweight and easy loading and unloading. Consumer demands and environmental concerns simply do not allow for a lacklustre approach, even to the most basic and practical packaging needs. These innovations reflect a broader shift toward more sustainable and environmentally friendly materials and practices in the paper, cardboard, and plastic industries, driven by the need to stay relevant in the consumer market, and comply with regulatory pressures to reduce waste and pollution. The good news is that, if sustainable and accessible solutions to any business’s end of line packaging don’t exist today, ongoing research assures that in good time, they will. 24 Food & Drink International www.fdiforum.net GEARS, DRIVES & CONTROLS Tel: +44 (0)1707 331111 info@welwyntoolgroup.co.uk www.welwyntoolgroup.co.uk Hot Air delivered direct to the point of application HOTWINDMISTRALVULCAN G ears, as the mechanical components responsible for transmitting power and torque, work in tandem with drives to regulate the speed and force applied to various machine parts. For example, gears in a meat grinder not only transmit power to the grinding blades but also ensure that the blades operate at the appropriate speed and force to effectively process the meat. Drives, such as variable frequency drives (VFDs), provide precise control over motor speeds, allowing operators to adjust the machinery to meet the specific requirements of different food processing tasks. Controls complement the gears and drives by monitoring and adjusting equipment parameters in real-time. By continuously monitoring factors like temperature, pressure, and speed, controls ensure that the machinery operates within safe and optimal conditions. Additionally, controls can automate processes and detect potential issues early on, which contributes to preventing downtime and ensuring consistent product quality. As well as providing the power needed to cut through tough ingredients, gears also provide the assurance of making blades or mechanisms move with only the amount of speed and force necessary to properly prepare ingredients. This can manifest in many preparation needs, including mixing, blending, and slicing. Found in every machine that might provide these functions, their main purposes may be power and torque, but elsewhere, gears can perform subtly different functions. For instance, they could be used in extruders to power the screw which pushes product through the extrusion die, or work together in conveyors to ensure that items are moved from one location to another steadily, safely and in a timely manner. By regulating these forces so only the required energy is expended, drives can help to reduce wear and tear that would otherwise be caused by equipment absorbing the shock from high speeds, increasing its lifespan sometimes by significant amounts. Precision-oriented drives such as VFDs give reassuring levels of control over efficiency Integral to In an industry that relies heavily on its machines to get the job done, the small components that make them work are no less important for being less visible. Gears, drives and controls are integral to efficient operation, reliability and safety in food and drink, bringing these critical aspects to every operation on any production line. Food & Drink International 25 www.fdiforum.net GEARS, DRIVES & CONTROLS Our extensive product range includes: Innovative, system-compatible air heaters Powerful, robust blowers Compact, flexible hot-air blowers Comprehensive range of accessories 3 Heat output & air volume steplessly adjustable with potentiometers 3 Integrated temperature controls 3 Integrated temperature probes 3 Protection against heating elements or devices overheating 3 Brushless power motors 3 Integrated power electronics the quality of output too, as regulating to consistent speeds and torques also mean consistent texture, flavour, and overall quality and uniformity of all products leaving the production line. When teamed with gears which carry out power transmission efficiently, energy consumption and equipment wear can be reduced to a minimum, making all processes easier on the pocket. Here’s where the benefit of these components to industry performance in general comes in. Using drives made for energy efficiency may also prevent the motor from running at full power when it isn’t necessary. This can result in significant energy savings, which is important for the food industry where energy costs run high, especially in heavy demand or mass-market production. Even focusing on productivity alone, drives can help to extend the life of food processing equipment by precisely controlling motor speeds. Running equipment at 26 Á © stock.adobe.com/Surasak26 Food & Drink International www.fdiforum.net GEARS, DRIVES & CONTROLS high speeds and torques for extended periods of time will inevitably lead to earlier breakdowns and costly repairs. Once speed and force have each been distributed and regulated within a machine, controls take over the monitoring and adjustment of equipment parameters, such as temperature, pressure, and speed. Controls can be equipped to monitor much more than the effective handling and processing of ingredients and products. Sensors and instruments that collect data on a multitude of machine functions have added value in monitoring equipment performance, identifying trends, and troubleshooting issues as soon as they arise, preventing stress and time that can be wasted in identifying where an error in function or contamination lies. By catching maintenance or line shutdown needs as soon as they require attendance, the diagnostic information provided by control units helps to prevent breakdowns, prolong equipment life and prevent public health hazards. In some cases, the controls themselves may even be relied upon to automate processes, such as weighing and sorting, which reduce labour costs and even further improve efficiency, especially when all care has been taken to install energy efficient components elsewhere. Dedicated monitors linked with some control systems can detect needs for changes in operation parameters, so operators may then adjust accordingly. This variety of function makes controls invaluable for ensuring optimal performance throughout every stage of production. However, because controls enhance and action the monitoring and maintenance of safe machinery processes, control mechanisms themselves must meet strict standards ensuring that equipment operates safely and doesn’t pose a risk to human health. The same standard goes for all components, including gears and drives, as these all work together for high standards of product quality, health and safety for consumers as well as machine operators. Proper preservation of all these parts is equally crucial to sustaining the reliability and efficiency they provide to food and drink production processes. The resilience of your machinery is also important if it’s to withstand the harsh conditions of the food processing environment, and they must also be able to tolerate high loads, shock and vibrations without failing. To manage routine wear and tear, even the highest © stock.adobe.com/ Ян ЗаболотнийShady Lane, Great Barr, Birmingham, B44 9EU England Tel: +44 (0)121 360 0155 For all your Power Transmission Solutions • Roller Chain • Gears & Sprockets • Timing Belt Drives • V Belt Pulleys • V Belts • Clamping Elements • Inverted Tooth Chain • Inverted Tooth Sprockets • Sealmaster Bearings • Shaft Couplings • Freewheel Clutches • Torque Limiters • Overload Clutches • Sheargard Clutches • McGill® Cam Followers • Gearboxes The Driving Force In Power Transmission sales@crossmorse.com www.crossmorse.com Power Transmission Solutions Food & Drink International 27 www.fdiforum.net GEARS, DRIVES & CONTROLS quality makes will require maintenance, to ensure that they continue to operate efficiently and safely. This includes regular cleaning, lubrication, and routine upkeep of inspections to detect the early signs of damage. Working together in a multitude of useful ways, gears, drives, and controls create a seamless operation where power transmission, speed regulation, and equipment monitoring are carefully coordinated. This integrated approach builds on the efficiency, reduction of energy consumption, and efforts towards product consistency which any responsible food business operative will be striving for already. To be fully comprehensive in all of these contributions to eco-friendliness, consumer care and delivering a great product, the fact is that gears, drives and controls need to be working away at their best. But as long as you don’t take any shortcuts in selecting, installing or maintaining your machinery, you’ll get the best possible life and satisfaction out of every little component. © stock.adobe.com/Jelena28 Food & Drink International www.fdiforum.net MIXING AND BLENDING © stock.adobe.com/chaiwat Mixing things up Food & Drink International 29 www.fdiforum.net MIXING AND BLENDING E ven in a finished product that isn’t smooth or liquid in consistency, one or several elements may have met with a mixing or blending machine at some point during processing. Hygiene, efficiency and end product quality are already crucial concerns for the food industry, but the ubiquity of this process makes the need to choose suitable machinery paramount for many products. For a start, one must prioritise the consideration of whether mixing or blending is required. They might seem similar at a glance, and can even be used to describe the same end goal of smoothly combining ingredients, but are ultimately different processes. Mixing involves using an agitator to break down and combine disparate materials for a uniform result, often combining wet and dry ingredients as in baking. Blending, on the other hand, is the gentler touch for much the same result, instead tumbling dry ingredients so that each component can be evenly distributed through a liquid. When a decision has been reached as to which of the two processes is required, all that remains is to choose the right machine for the job. There is a wide array of types available, each with subtle differences for tailoring the process to your products. Where mixers are concerned, many for food and drink production are high shear – or high in the opposing forces of mixing pushing materials against each other, so that even components resistant to blending can be incorporated together for an even and shelf- attractive result. One machine up to this task is the vertical mixer, which has reliable and versatile speed settings for handling many levels of ingredient viscosity. Another plus side is its gentle treatment of heat sensitive and fragile matter, and minimising of aeration. However, this also means it is especially well- suited for free-flowing ingredients, and may require specific anchor agitators for more difficult to mix media. 30 Á Mixing and blending are responsible for everything from texturizing and emulsification to incorporating powders, flakes and pellets into food products. Yet selecting the right option is paramount for process optimisation. Next >