< Previous20 Food & Drink International www.fdiforum.net END OF LINE PACKAGING E nd of line packaging is commonly used to ensure the safe and efficient distribution of food products, and the market is poised for significant growth over the next few years – even as tariffs from the US threaten to impact global trade. The EOL market is currently worth a little over $6.4 billion, which is expected to grow to $10 billion by 2034. A big reason for this increased drive is that more and more food and drink manufacturers are taking up automated production facilities and Industry 4.0 and also incorporating artificial intelligence into their operations. EOL packaging systems slot well into both given their modular adaptability, and the ability for vision systems to read barcode labels on larger boxes easier than individual products. Additionally, labour shortages are further pushing manufacturers toward automated systems, with many taking example from how Amazon organise their distribution systems. Food and drink deals with mostly perishable goods so quick and efficient transport is a necessity, meaning more focus on EOL packaging than in many other sectors. The use of trays and clamshells is widespread in the food industry for 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. 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 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 End of the line As more manufacturers move toward automated systems, the end of line packaging industry stands in a position to reap the benefits. Food & Drink International 21 www.fdiforum.net END OF LINE PACKAGING 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. 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 BENCHTOP BAG SEALING MACHINE IMPULSE BAG SEALING MACHINE HORIZONTAL BAG SEALING MACHINE VERTICAL BAG SEALING MACHINE © stock.adobe.com/stormy 22 Á22 Food & Drink International www.fdiforum.net END OF LINE PACKAGING 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. 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. A recent example in late 2024 involved development of biodegradable adhesive solvent for EOL packaging, showing a renewed focus on less expected parts of packaging. Solvents and glues often contain chemical components that can be dangerous both to the environment and to animals and ecosystems when some of them are inevitably dumped in rural areas. Power Adhesives brought a first-to-market biodegradable hot melt adhesive which can break down when exposed to oxygen leaving no harmful chemicals and also no microplastics. The adhesive could see use in corrugated EOL packaging, especially those also used as point-of-sale packaging. LEIBINGER’s nozzle sealing technology: the game changer in product marking LEIBINGER’s fully automatic nozzle sealing technology is the gateway to maximum productivity in product marking. While conventional CIJ printers often suffer from dried nozzles and delayed start-ups after downtime, LEIBINGER takes a different approach: the ink circuit is automatically sealed airtight when the printer is not in use, preventing the ink from drying out. The result? Instant start-up without cleaning – even after long shutdowns. This ensures maximum availability, minimal maintenance, and reliable marking performance at all times. The innovative nozzle sealing technology comes standard in every LEIBINGER CIJ printer. Engineered and manufactured in Germany, LEIBINGER stands for precision, reliability, and innovation. With automatic nozzle sealing, the company delivers smart solutions that keep production lines running and businesses ahead. Discover how this groundbreaking feature keeps your production lines moving – and why it’s changing the game in coding and marking. To find out more about LEIBINGER’s nozzle sealing technology, visit: https://leibinger-group.com/cij-products/automatic-nozzle-sealing-technology © stock.adobe.com/I ViewfinderFood & Drink International 23 www.fdiforum.net T FREEMANTLE CASE STUDY Sausage culture shift Since Heck’s launch in 2012 they have earnt their reputation in the sausage & burger category as the positive ‘disruptor brand,’ claiming majority share and abolishing stereotyped sausage eating customer bases and targeting a new younger, more health conscious consumer. Heck were one of the first brands to look at the market differently, squashing the dullness of category norms and shaking it up by bringing a confident new pastel coloured sleever to the shelf, that captures attention. The brand sends out a bold spontaneous message, no gimmicks just attractive innovation that aims to be real and delicious. Innovation & Investment One may ask how Andrew Keeble, owner of Heck, has taken his family run business from nothing but an idea back in 2012, to 130 employees and a turnover of 30 million this year, well Andrew had this to say: “It’s all customer led and data driven. We are all about efficiency here at Heck. We want a range that delivers and we also want a process that is always forward thinking. Reinvesting is a vital part of driving the family business and growing our brand.” Customer led innovation always means Heck have a market for what they produce. Their innovation has a direction. It’s inclusive and it’s expanding in more ways than one, especially with their end of line packing and their drive to be the most efficient they can be. Efficiency - Automated solutions partner T Freemantle High speed packing solutions for sleeved products haven’t been mastered by many British manufacturers but T Freemantle managed to guide Heck towards a solution that fitted perfectly with their efficiency initiatives. When Andrew was asked why he chose T Freemantle this is what he & his son Roddie had to say: “It’s important that you like who you are working with. From meeting Freemantle at a trade show we easily struck up a relationship and they were instantly amenable. Roddie and myself both felt the machines were mechanical enough for us without being too robotic. Easy to use and train the team on, local to us and British manufacturing. They continue to support us on our journey.” Heck have just had their 3rd machine installed. The automatic pre-glued sleever has allowed Andrew to make strategic steps to increase production efficiency, deploying valued members of the team to other areas of the business and reducing the unnecessary manual labour at the end of the line. The sleeving machines installed at Heck running at 80 ppm create this efficient output, allowing them to put their focus on more important areas of the business. The automation means they can keep up with demand, as well as guaranteeing a more consistent quality of product. T Freemantle support forward thinking customers like Heck on projects that structure automated change, as part of their long term goal to get a return on investment, in as shorter time possible. Freemantle’s machines make this happen with their competitive pricing and aftersales care. Heck of an investment Market Leaders in Cartoning and Sleeving Machinery Tel: 01724 276908 www.tfreemantle.com 24 Food & Drink International www.fdiforum.net GEARS, DRIVES AND CONTROL More focus onFood & Drink International 25 www.fdiforum.net GEARS, DRIVES AND CONTROL Labour shortages and advancing technology are pushing manufacturers to embrace greater levels of automation. Now the focus is on the gears and drives that propel these processes, and how to get the most out of them. A s food and drink manufacturers move towards increasing levels of automation, the gears and drives that power these systems become increasingly important. As well as providing the power needed to cut through tough ingredients, gears provide the assurance of making blades or mechanisms move with only the amount of speed and force necessary to properly prepare ingredients – and this is integral in an automated system. 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 26 Á © stock.adobe.com/Jelena26 Food & Drink International www.fdiforum.net GEARS, DRIVES AND CONTROL 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 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 high speeds and torques for extended periods of time will inevitably lead to earlier breakdowns and costly repairs. 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 quality makes will NEW AIR HEATER SERIES LHS 210 / 410 COMPACT & POWERFULFood & Drink International 27 www.fdiforum.net GEARS, DRIVES AND CONTROL 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. Tel: +44 (0)1707 331111 info@welwyntoolgroup.co.uk www.welwyntoolgroup.com EASY CONNECTION HOT AIR RECYCLING ECONOMICALCOMPATIBLE NOZZLES HIGH AIR VOLUME OVERHEATING PROTECTION © stock.adobe.com/nordroden28 Food & Drink International www.fdiforum.net MIXING AND BLENDING F ood factories face tough challenges: keeping products consistent, safe, and efficient, while also protecting the environment. Mixing and blending are key, and these processes are changing fast. New technology is bringing more automation, better hygiene, and improved energy use. Adaptive blending, a key advancement, utilises sensor fusion to dynamically adjust mixing parameters. By combining inputs from viscosity, temperature, pH, and particle size sensors, algorithms can optimise the process in real-time. Waters Corporation’s development of advanced, user-friendly rheometers plays a crucial role in this. These instruments provide accurate and immediate viscosity measurements, eliminating batch- to-batch variations, which are particularly critical for products like sauces and emulsions where texture and consistency are paramount. Artificial intelligence is also reshaping maintenance and process optimisation. By analysing historical data from sensor readings and maintenance logs, AI models can predict equipment wear and potential failures, minimising downtime and reducing costs. Bühler Group, for example, has implemented AI-driven predictive maintenance in their grain processing and milling systems, using machine learning to anticipate maintenance needs and ensure consistent product quality. Moreover, AI algorithms optimise blending parameters based on predicted outcomes, while digital twins provide a safe haven for experimentation and refinement. Nestlé has explored the use of digital twin technology in their food manufacturing processes, particularly for simulating and optimising processing parameters in complex systems like coffee production. This allows them to test different scenarios and optimise production without disrupting actual operations, fine-tuning for the most efficient Automation and hygiene lead the way in next- generation food blending From AI-driven precision to enhanced hygiene and sustainability, food factories are transforming mixing and blending to meet rising consumer expectations and industry demands. Food & Drink International 29 www.fdiforum.net MIXING AND BLENDING mix. In an era of heightened food safety concerns, advanced digital recipe management and traceability are essential. Cloud-based platforms offer secure access control and seamless integration with inventory systems, while automated logging and blockchain technology ensure end-to- end transparency, building consumer confidence. IBM Food Trust has partnered with numerous food companies, including Walmart and Carrefour, to implement blockchain-based traceability solutions, allowing consumers to track the journey of food products from farm to shelf. Food safety remains paramount, driving the demand for mixing equipment with enhanced hygienic design and CIP capabilities. Minimising biofilm formation is crucial, and advanced surface treatments, such as electropolishing and antimicrobial coatings, create smooth, easily cleanable surfaces. The use of advanced alloys further enhances corrosion resistance and durability, extending the life of the machinery. Enhanced CIP systems, featuring optimised spray nozzles, automated monitoring of cleaning solutions, and sensors that detect residual contamination, ensure thorough cleaning with minimal human intervention. UV-C light sanitisation is being integrated into CIP cycles for added protection, providing an extra layer of defence against pathogens. For high-risk applications, aseptic mixing systems, with sealed chambers, steam 30 Á © stock.adobe.com/AlienmarshNext >