< Previous30 Food & Drink International www.fdiforum.net SLICING, DICING & CUTTING reduced damage to products, and reduced waste due to mishandled, misshapen or otherwise spoiled food items. However, there are also a few disadvantages to consider before you decide, such as the higher cost of ultrasonic equipment compared to traditional cutting equipment, and the need for additional training and expertise to use and maintain ultrasonic cutters properly. Just as ultrasonic cutting may not be suitable for all types of foods, often requiring adjustments to cutting speeds and temperatures to achieve optimal results, it may not be suitable to all types of businesses. If the staffing space or spare funds for training aren’t available, it may be worth keeping a manual unit on hand for certain more delicate tasks a while longer – if nothing else, these are reliably low-demand where operation is concerned. The upper echelons of food processing come with the addition of robotics. Robots are increasingly being used to perform slicing, dicing and cutting tasks, as their effectiveness has been developed over many years and proven by a multitude of large factories in a broad range of sectors. Robotic slicers and cutters offer several benefits over traditional equipment, including greater precision, consistency and efficiency, a significant plus of the elimination of human error. These machines can work quickly and effectively with minimal monitoring; this lack of need for intervention brings the added pro of workers being at the lowest level of health risk when working with or around them. Robotic slicers, dicers and cutters reduce the need for manual labour across the board, increasing the overall safety of operations and making them more hygienic. However, the use of robotics can be costly, and they aren’t made equally easy to clean. While some will be designed for ease of dismantling © stock.adobe.com/ ドンピエロ © stock.adobe.com/salomonus_ 28-31.qxp_Layout 1 24/04/2023 11:53 Page 3Food & Drink International 31 www.fdiforum.net SLICING, DICING & CUTTING or removal of components, others may have more intricate designs that require more effort to clean thoroughly, while still others are more susceptible to damage from cleaning agents or water. This factor ultimately depending on the specific design, materials and features of each machine, as well as its intended use. In addition to the potential problems of cleaning, there may be more compassionate concerns about the loss of jobs for human workers. Still, the adoption of robotics in the food industry continues to be a growing trend, which looks set to take large-scale food production into a new norm in the years to come. With so many options available, the key to making the right choice is keeping in mind which functionalities and production level will serve your business best. Thankfully, trustworthy manufacturers will make design, function and usage parameters explicit in their descriptions and instructions for each unit. Many machines will also be designed in such a way that keeps spaces where waste matter or contaminants can gather to a minimum, preserving cleanliness and efficiency at the highest possible levels by having as little necessity for wash-downs as possible. All that remains then is to tailor your equipment to your needs and resources, with just some thought for how you can best provide for your workers, brand and customers. © stock.adobe.com/Sergey Ryzhov 28-31.qxp_Layout 1 24/04/2023 11:53 Page 432 Food & Drink International www.fdiforum.net FUNCTIONAL INGREDIENTS focus The popularity of functional ingredients continues to rise as consumers increasingly turn to food and drink that can help them improve health and wellbeing concerns. focus Functional 32-35.qxp_Layout 1 24/04/2023 11:55 Page 1Food & Drink International 33 www.fdiforum.net FUNCTIONAL INGREDIENTS © stock.adobe.com/sommai F unctional ingredients — those with enhanced nutritional properties that can be used to create products with additional health benefits — have gained significant attention and momentum over the past few years, with consumers becoming more health-conscious, reassessing their attitude to wellbeing, and developing a greater understanding of, and desire for, food-as-medicine. The pandemic saw food and drink turned to as a quick and easy way to boost health, and defend against COVID-19, with products containing functional ingredients that support immune health flying off the shelves, and pushing manufacturers to release more immunity-related products, while the stress of the pandemic impacted demand for products containing mood improving ingredients. With more consumers than ever connecting their diet to their health and wellbeing, taking action, and looking for buzzwords on packaging that match their lifestyle goals, there is a major opportunity for the industry to address their requirements. Food, drink and ingredients that can offer more than just sustenance and delicious taste (though this must be maintained for success), whether that be improved sleep, energy, focus, and gut health, immunity support or reduced stress, are set to be superstars in the years ahead, and may well be a key aspect in driving purchases as consumers spend less on non-essential items in the midst of rising interest rates, inflation and volatile financial markets. Research from Mintel indicates that the majority of US adults consume products that claim to have functional benefits. However, only 7.3% of food and drink innovations featured functional claims in 2022, highlighting vast market opportunities, with highly processed 34 Á 32-35.qxp_Layout 1 24/04/2023 11:55 Page 2FUNCTIONAL INGREDIENTS food one area of growing demand for food enrichment. With functional foods driven primarily by start ups, more established brands have a chance to get ahead of competitors and respond to consumer trends, implementing functional claims into new product development and emphasising it on packaging and in marketing. Younger adults sit as the most engaged with functional ingredients — unsurprising as they grew up in a time of increasing functional claims — but older consumers should remain an area of focus for marketers too, through nuanced messaging, with the audience an ideal match for popular functionalities including energy, heart health, antioxidants, electrolytes and digestive support that promote healthy ageing. As functional ingredients like adaptogens and botanicals, nootropics, prebiotics, and probiotics have gained recognition amongst the masses globally, manufacturers are continuing to innovate, incorporating functional ingredients into a wider variety of products. Adaptogens for instance have moved out of tea and into chocolate and sparkling water, while probiotics have jumped from yoghurt into granola and cheeses, and botanicals and CBD can be found in everything from beer to sweets to coffee. Which functional ingredients are selected for certain health and wellness benefits is also evolving. In one of the most in-demand segments of functional products — energy-boosting ingredients — moves have been made beyond caffeine to power up consumers with vitamins, MCT oil, and other ingredients as manufacturers innovate with energy claims for products from snacks to desserts to creamers. It comes alongside attempts to revamp the image of energy-boosting products, from their past associations with being over- processed, with cleaner formulations and free-from labelling now on shelves. Consumers are eager to see functional ingredients enter more shopping aisles, with particular potential amongst indulgent foods to attract more purchasers, who have long been trained to perceive the likes of desserts and baked goods as “bad for you.” Where formulators can add functional ingredients such as probiotics, fibre and protein to these products, a healthy offset can be achieved for consumers, seeing them more inclined to purchase such products. This is ideal in a time where consumers are seeking permissible indulgence to lift their mood, but are concurrently still keeping an eye on their health. While a proactive approach to health and wellness is driving forward demand for functional food and drink with specialised health benefits, and consumers are clamouring for novel products and ingredients, the public are also becoming more ingredient savvy. To stand out from competitors, meet consumer expectations, and secure repeat customers, manufacturers must source ingredients that deliver on their claims to reassure sceptical consumers that the products they are choosing do in fact provide the benefits advertised. Science-backed ingredients are preferred, holding research to endorse claims, thus when developing new products selecting functional ingredients that are supported by peer-reviewed studies is vital. There is however also confidence behind ingredients that have long been associated with delivering a function, like turmeric and ginger, which are not always clinically proven, due to historically positive perceptions amongst consumers. With this, the best choice can often be utilising these ingredients alongside science-backed ingredients so that clinical claims can be supported, while gaining a wider consumer reach Apply Now… 0044 (0) 20 8446 7127 info@halalfoodauthority.com www.halalfoodauthority.com London - Ireland - Belgium EXPLORE OPPORTUNITIES Get Halal Certified Halal Food Authority is an industry leading Halal Food Certification Company. We specialise in Halal Certification of Food and Non-Food items including cosmetics, logistics, chemicals, additives & aromas, cleaning substances, packaging, pharmaceutical, ingredients and much more. Our certification is globally recognised including GCC countries and other developing markets such as Saudi Arabia, UAE, Qatar, Oman, Bahrain, Kuwait, Jordan, Egypt, Malaysia, Indonesia, Singapore, Turkiye, Pakistan and rest of the world. 34 Food & Drink International www.fdiforum.net 32-35.qxp_Layout 1 24/04/2023 11:55 Page 3Food & Drink International 35 www.fdiforum.net FUNCTIONAL INGREDIENTS through familiar ingredients. As manufacturers select ingredients further challenges then follow, in overcoming formulation issues that arise when functional ingredients are added to recipes. Many functional ingredients have off-notes that influence flavour and aroma, requiring masking, while mouthfeel can be affected too. There is also great importance in choosing the right flavour to complement an ingredient to resonate with consumer associations — lavender for stress- reduction ingredients for example. Working with experts is key to overcoming these issues. Interest in functional foods is accelerating, especially in the wake of COVID-19. With 69% of consumers buying or saying they would buy products fortified to increase health/wellness, according to Kerry, the audience for functional ingredients and opportunities for new product launches is vast. WORLD RENOWNED SHAKERS AND SIEVES ENDECOTTS.COM 9 Lombard Road ƒ London, SW19 3UP ƒ UK ƒ Tel.: +44 (0)208 542 8121 ƒ sales@endecotts.com Endecotts Ltd ƒ 9 AND MORE...! Consistometers Sample Dividers Laboratory Shakers & Sieves © stock.adobe.com/_KUBE_ 32-35.qxp_Layout 1 24/04/2023 11:55 Page 436 Food & Drink International www.fdiforum.net CLEANING & MAINTENANCE Proper cleaning and maintenance of industrial food manufacturing equipment is essential for creating safe and high-quality products and protecting investments. practice Best © stock.adobe.com/Seventyfour 36-39.qxp_Layout 1 24/04/2023 11:57 Page 1Food & Drink International 37 www.fdiforum.net CLEANING & MAINTENANCE © stock.adobe.com/rh2010 T he cleanliness and efficacy of industrial food manufacturing equipment sits at the core of manufacturers’ operations. With audits carried out anywhere between six months and two years, regular maintenance of machinery is paramount to straightforwardly passing these checks. Clean and well-maintained equipment is vital for creating safe and high-quality products. Establishing a robust cleaning and maintenance routine should therefore be viewed as part of a business’s long-term strategy for protecting their significant investment in high-performance equipment, and brand consistency. Due to their enclosed nature, two machines that are notoriously complicated to maintain are piping systems (used to transport raw materials, finished products, and cleaning solutions throughout the facility) and food processing equipment (multi-part machines designed for turning raw materials into the desired product). In this article, we will discuss industry recommended practices for the cleaning and maintenance of these systems, and some common cleaning mistakes to avoid. Best practice for cleaning industrial piping systems is a multi-step process that must be performed regularly to ensure that the system remains clean and free of contaminants. To clean a piping system, at least five steps are involved. Firstly, a pre-rinse is performed to flush the system with water and remove any loose debris or residue. Next, a chemical cleaning solution (such as caustic acid) is 38 Á 36-39.qxp_Layout 1 24/04/2023 11:57 Page 238 Food & Drink International www.fdiforum.net CLEANING & MAINTENANCE introduced into the system to break down any organic matter present, and it is allowed to circulate for a period of time to thoroughly clean the pipes. Once the chemical cleaning solution has been circulated, a post-rinse is conducted with water or a neutralizing solution to eliminate any remaining chemical residue. Following this, the piping system is sanitized with a sanitizing solution, which is also circulated for approximately 12 hours to eliminate bacteria or other microorganisms. Finally, a final rinse is performed to eliminate any remaining sanitizing solution or residue. Performing a process known as Pigging prior to cleaning will significantly reduce equipment down time, as it removes residual product within the pipe. Pigging can be done by propelling a solid projectile slightly wider than the pipe, pressurizing the pipework behind it. Liquid residue will be forced to the destination tank, or returned to source. Maintaining the cleanliness and functionality of industrial piping systems is essential for food manufacturers to ensure the safety and quality of their products. Regular cleaning and maintenance can help to prevent contamination and ensure that the system operates effectively. While the cleaning process may be time- consuming and labour-intensive, it is a critical aspect of food safety requirements and should not be overlooked. Additionally, ongoing maintenance can help to identify and address issues before they become serious, helping to minimize downtime and prevent product recalls. Understanding that regular maintenance can prolong the life of the system (a considerable investment for manufacturers) it is vital to implement a rigorous maintenance routine, alongside routine cleaning sessions. During a visual inspection of piping systems, any defects or damages that are identified may require repairs or replacements. This could involve the replacement of valves, pipes, or fittings. Once repairs or replacements have been made, pressure testing is typically carried out to ensure that the system can withstand the pressures it will encounter during normal operation. Additionally, regular lubrication is necessary to ensure that valves and other components function correctly and do not incur damage. Another maintenance best practice is to carry out temperature monitoring to ensure that the system operates within a specific temperature range. Another staple of consumables manufacturing is food processing equipment such as mixers, grinders, and blenders. Whilst pipes can be flushed, these machines require extra attention due to their multi-part nature. This means that the first step in cleaning a food processing machine is to disassemble it. This may involve removing any removable parts, such as blades or screens, and separating any parts that are connected by clamps or bolts. Similarly to piping systems, a pre- rinse can be conducted to remove loose material prior to the deep clean. Once completed, scrubbing can commence. The machine is scrubbed to ensure that all surfaces are thoroughly cleaned. This may involve using brushes, sponges, or other cleaning tools to remove any remaining debris or residue. It is important to consult the 36-39.qxp_Layout 1 24/04/2023 11:57 Page 3Food & Drink International 39 www.fdiforum.net CLEANING & MAINTENANCE manufacturer on appropriate scrubbing materials, as some cleaning methods may be too abrasive for the equipment. For example, dishwashing internal parts such as blades may damage them, and using metal scrubbing pads is likely to remove any non-stick coatings. Best practice for scrubbing is generally considered to be using soft bristled brushes or sponges to apply a gentle soap, such as dishwashing liquid or baking soda. A little vinegar can be added for extra cleaning power. As disassembly is an essential step in the cleaning routine, visual inspections can be carried out during cleaning to ensure that the equipment appears to be in working order. Inspecting these machines periodically is also important to catch potential issues before they become more severe. This inspection process may include checking the condition of the FOLLOW US WHEN YOU SEE THE PERFORMANCE WHEN YOU SEE THE PRICE WW Versatile thanks to a wide performance range, intuitive and flexible user guidance, low-pulsation dosing, and energy-efficient during operation - all at an attractive initial cost. The new iSTEP XS offers XL performance at XS price ! iSTEP XS Now available iSTEPXS.sera-web.com More info: sales.uk@sera-web.com Tel. 01283 753400 machine or its components. In addition to this, some vital maintenance tasks are necessary to ensure all parts remain effective. In the realm of food processing, proper lubrication of the moving parts of machines is crucial for their effective operation. Neglecting to lubricate these parts can lead to malfunctions or damage. Furthermore, regular calibration of some food processing machines is necessary to ensure that they operate within the correct parameters, which may involve adjusting the machine’s speed, temperature, or pressure settings. If any damage or defects are detected during the inspection stage, repairs or replacements may be necessary, such as replacing worn or damaged parts or repairing broken components. Lastly, regular, and rigorous employee training should be considered a maintenance strategy. Training employees is crucial for ensuring the machines’ safe and effective use, which may involve instructing employees on proper machine use, maintenance, and safety procedures. Ultimately, creating and maintaining robust routines as above will protect your investment in the business, and customers’ investment in your products. © stock.adobe.com/franco lucato 36-39.qxp_Layout 1 24/04/2023 11:57 Page 4Next >