< Previous20 Food & Drink International www.fdiforum.net FROZEN AND CHILLED FOODS powerful selling point. The popularity of global cuisine has broadened offerings to a society craving new flavours, ready-to-eat meals ever more inspired by food from around the world. Healthier options such as low-calorie and gluten-free options are widely available, alongside fast foods made with high-quality ingredients, including gourmet frozen pizzas and chef-prepared meals. This mindful bounty of options in both the chilled and frozen aisles—catering to numerous tastes, dietary preferences, and lifestyle needs—is underpinned by regulation-required information on where ingredients have been sourced from, and the production journey they went on to reach store shelves. Contrary to popular belief, frozen foods don’t necessarily lean on high levels of preservatives. While some budget-oriented options may still contain additives, many frozen products bypass the need for such ingredients altogether. Quick freezing, often employed immediately after harvesting, preserves the nutritional integrity of fruits and vegetables while locking in essential nutrients. In fact, studies have shown that frozen produce can sometimes outperform their fresher counterparts in terms of nutrient content, highlighting their health benefits. Advancements in food preservation technologies have further bolstered the appeal of chilled foods, enabling manufacturers to offer a wider variety info@rubbuk.com | +44 (0) 191 482 22 11 | www.rubbuk.com Building Systems Flexible cold storage solutions © stock.adobe.com/adisaFood & Drink International 21 www.fdiforum.net FROZEN AND CHILLED FOODS of options without compromising on taste or freshness. Modified atmosphere packaging (MAP) techniques and temperature-controlled logistics have ensured that products maintain their quality throughout the supply chain, from farm or factory to plate. Consumers increasingly see chilled foods as viable alternatives to fresh produce, particularly for items with shorter shelf-lives such as dairy products and fresh meats. The chilled food industry has been built on innovation, and continues to break through boundaries of convenience and quality. Retailers are responding to social trends by offering items like pre-peeled avocados and packaged pomegranate seeds, catering to time-pressed people seeking healthy options. Premium frozen fare has become a universally accessible, highly desirable luxury, even in discounter chains such as Aldi, Lidl and Iceland; an extra added benefit of the cost- effectiveness of quick freezing to preserve otherwise fragile or unstable foods. Market savviness and forward thinking yield endless opportunities, for those who can find and fill the gaps in demand. Perceptions of chilled foods have shifted again in even more recent years, driven by evolving consumer preferences and technological advancements. Traditionally favoured for their perceived freshness and premium quality, chilled foods are now gaining traction as convenient and health-conscious options. The rise of ready-to-eat salads, pre-packaged sandwiches, and fresh meal kits reflects a growing emphasis on convenience and quality in the chilled food sector. The frozen section undergoes a parallel evolution in response to growing concerns about food waste and sustainability. Once associated primarily with convenience and affordability, it is now being rebranded as a solution to the food waste crisis. By freezing produce at its peak freshness, manufacturers can extend its shelf-life and reduce the amount of food that ends up in landfill. Ever since their invention, frozen foods have been in a steady position as sustainable alternatives to fresh produce. Offering year-round Gressenhall | Dereham | Norfolk | NR20 4DT | +44 (0)1362 861066 | www.premierpalletinverter.co.uk 22 Á Signatrol’s new nifty FDI-Approved button-style data loggers Signatrol, the data logging experts, has launched SL60 dLog, a new range of low cost, miniature button-style temperature or temperature and humidity data loggers, ideal for the food industry, to replace the company’s SL50 range. The next generation SL60 data loggers work with Signatrol’s TempIT5 software and offer several improvements on the SL50 including more readings with a wider range of accuracy and resolution, increased battery life of up to three years and a cheaper price. The system also allows users to read data even if the battery is exhausted. All SL60 products are self-contained and easy to use. As a result, they are suitable for food production, distribution, and storage. Both the SL62T (£149) and the SL63T (£180) are made with FDA-approved food safe material and are fully sealed to IP68 meaning they can be fully submersed without the need for protective enclosures. Communication to the data logger is provided by the latest NFC technology. The SL63T has an improved operating range of -40°C to +125°C making it ideal for food producers who wish to log the temperature of finished products during the freezing process post-cook. For more information www.signatrol.com Your Container... Your Way Delivery UK or Worldwide Call +44 1472 433101 ext 200 sales@hscinternational.co.uk www.hscinternational.co.uk www.flatpax.co.uk 20’ CONTAINERS IN STOCK NOW AT UK DEPOTS NEW & USED CONTAINERS FOR ANY INDUSTRY • Inspected & Tested • CSC Certified • Standard & Bespoke MULTI-PURPOSE STORAGE CONTAINER FOR ANY LOCATION • Flatpack tool-free assembly • Robust and moveable • Forktruck runners and jack rings • 10 year anti corrosion 22 Food & Drink International www.fdiforum.net FROZEN AND CHILLED FOODS availability without sacrificing nutrition or quality, further innovations only build up from this perfect founding principle. Looking ahead, the chilled and frozen food market is likely to be shaped by the continued demand and pursuit of evenly matched convenience, quality, and sustainability. Manufacturers and retailers will need to adapt to these trends by investing in technology and infrastructure to enhance the shelf-life and quality of their products. Additionally, there will be a greater emphasis on transparency and traceability throughout the supply chain, as consumers expect detailed reassurance regarding the origins and production methods that go into their food. Concerns about environmental sustainability continue to grow, and so the promotion of responsibility will bring even greater focus to reducing packaging waste and improving the eco-friendliness of chilled and frozen food packaging. The development of fully recyclable or biodegradable packaging materials is a matter of when, not if, and cartoning and sleeving become more commonplace, helped by their greater freedom of enticing design possibilities. Expect efforts into more effective initiatives to minimise food waste, to be implemented at all stages of the production and distribution process. And as manufacturers and retailers continue to respond, adapt, and compete with now-unavoidable demand for greater choice and variety, we’re bound to see yet more convenience, higher quality, and reinvention of chilling and freezing possibilities in years to come. © stock.adobe.com/hedgehog94Food & Drink International 23 www.fdiforum.net SLICING, DICING AND CUTTING T he growing demand for pre- cut packaged foods and convenience meals containing sliced and diced foods have significantly increased the demand for cutting machines. In order to meet this demand, manufacturers have to turn to automation and other innovative options to maintain product integrity whilst also scaling up output. Consumers have come to expect uniformity in the food and beverage products they buy. A product they purchase from a store should be identical to one purchased in a different branch on the other side of the country. This is as true for the finished products and their packages, as the ingredients and goods inside. If there are varying sizes of meat or vegetables within a product mix, or if a blade isn’t adequately cutting, it risks contradicting the weight printed on its packaging. This can result in costly recalls, the fallout from which manufacturers can suffer from for years. Consistency of cuts and portion size is largely dependent on the sharpness of a cutting tool. Regular use renders any blade dull over time, and so it’s paramount that manufacturers regularly change, sharpen and replace their cutting tools. It’s as much to do with hygiene, with a dull blade more likely to harbour matter and risk contaminating other products. Dull blades can also damage products, crushing, denting or bruising them. In any case, a manufacturer can be left with entire batches compromised and/or an expensive clean-up bill. Better to regularly replace and service cutting The right slice © stock.adobe.com/Sergey Ryzhov In a world where clear packaging is used to reveal the quality of the food inside, getting the right cut is paramount to a visually appealing meal. 24 Á24 Food & Drink International www.fdiforum.net SLICING, DICING AND CUTTING tools than risk extended periods of downtime. Hygiene is critical right across the supply chain but is of particular concern in the production line where products are directly exposed to conveyor belts, weighers and, of course, cutting tools. As we’ve already explored, the tools themselves must meet stringent hygiene levels, but so too does the surface on which the foods are placed and the cuts are made. Constant cutting will inevitably lead to dullness of the blade, which in turn can result in less than ideal precision for food products, while rendering others completely unsuitable for the customer. A blunt blade will leave ragged edges which can lead to the product, particularly meat, spoiling. This can result in it becoming unstable or unsafe during distribution, something that might only be discovered by the end user. Likewise, a blunting blade will likely retain residue and matter from the previous products which will then © stock.adobe.com/salomonus_Food & Drink International 25 www.fdiforum.net SLICING, DICING AND CUTTING become entrenched in others, allowing for contaminates to spread with greater ease. It’s something as simple as ensuring equipment is at its best, but the consequences otherwise can result in an entire batch deemed unsuitable for sale or may even result in a recall at a later stage. It comes at the cost of a company’s profits and its time, not to mention its reputation. Given the constraints of any given technology, there is only so far a process can be streamlined, meaning a producer is only able to become efficient and time effective to a certain point. By the same rationing, adopting equipment designed to minimise wasted time and damaged goods is the next logical step. Ultrasonic slicing might be widely used across the industry for use with foods of a sticky, delicate or soft structure, but extension across more food types is combatting yield loss and boosting profit. Many food equipment manufacturers and retailers are adopting ultrasonic slicers and cutters, and the uptake among producers is rising. The advantages over traditional blades extend beyond the obvious boon to hygiene, with greater precision, functionality and reliability. Robots have become commonplace on the factory floor and production line, providing untold benefits to industry and consumer alike. In fact, a survey undertaken by The International Federation of Robotics identified ten reasons why manufactures should invest in robots. Some of the benefits include reducing operating costs, improving quality and consistency and reducing material waste as well as increasing yield. In a slicing, dicing and cutting context, robotic advancement has come in leaps and bounds, replacing human workers on the production line altogether. Of course, robots will have to be washed and serviced like any other piece of processing equipment. With the startling development of robots, the human workforce is likely to further decrease. For the slicing, dicing and cutting industry, imagine the speed, efficiency and safety of a robot workforce with the ability to handle food with minimal risk to product integrity, in an environment that is more hygienic and more cost effective. As efficiency and hygiene are the heart of this industry, robotics and advanced cutting equipment are ensuring the changeover from traditional processing machines to more modern fare goes smoothly.26 Food & Drink International www.fdiforum.net CAPS AND CLOSURES Tethered and glass caps are the packaging of the future Food & Drink International 27 www.fdiforum.net CAPS AND CLOSURES © stock.adobe.com/ChiccoDodiFC T he European Union (EU) has moved forward with the adoption of the Single-Use Plastics Directive, signalling a concerted effort to combat environmental pollution and promote the recycling of caps and closures. Effective from July of this year, the directive mandates that plastic caps on single-use beverage containers up to three litres must remain tethered after opening. Notably, exemptions are granted to metal and glass containers. Although the most popular drinks manufacturers have had them in place for a few years, this will become a legal requirement for all future bottled product offerings. The rationale is rooted in the prevalence of plastic closures and lids as pervasive litter found on European beaches and is part of a wider set of EU initiatives (such as the Paris climate agreement) to tackle climate change. When first proposed, industry leaders advocated for a greater focus on enhancing current recycling systems in lieu of immediate implementation. With many deeming it a more pragmatic approach to addressing environmental concerns, their perspective is bolstered by a comprehensive 2023 study commissioned by the European soft drinks industry (UNESDA) and the European Federation of Bottled Waters (EFBW), which underscores the substantial environmental and economic implications of mandatory tethered caps. In response to this call, Latvia, Lithuania, Slovakia, and Malta have now implemented national Deposit Return Schemes to discourage single-use drink containers. Responding to the mandate, the European Commission tasked CEN, the standardisation body, with establishing rigorous standards to ensure caps and lids maintain adequate strength, reliability, and safety while remaining tethered. This catalysed collaboration amongst brands, packaging producers, and equipment suppliers to devise compliant solutions, showcasing a collective commitment to environmental stewardship and regulatory compliance. Manufacturers of caps and closure systems have explored various avenues to meet these stringent standards, with hinged tops and lasso closures emerging as the forerunners. The collaborative process ensured that different production machineries and ability to absorb cost was considered for companies of varying sizes, as a primary concern was the potential hit to smaller businesses. Cost considerations are a must throughout the entire supply chain of the single-use beverage market, with customer surveys having underscored the already present aversion to passing additional costs onto consumers. Ultimately, a tethered closure solution was identified as the optimum cap type, as it ensured legal compliance without imposing significant additional expenses. Sacmi, an industry leader in compression technology for over 20 years, was at the forefront of the design overhaul. A streamlined manufacturing process was developed which involves post-press slit of tamper-evident bands, optimizing cap handling through precision knives and rotary spindles, resulting in straightforward molded caps that eliminate the complexity Drinks packaging is about to undergo a significant shift across Europe, one that has stirred both controversy and concern among industry giants. The proposal to mandate tethered caps on beverage containers has sparked a fierce debate, with household names such as Coca-Cola, Danone, Nestlé, and PepsiCo initially vehemently opposing the idea. 28 Á28 Food & Drink International www.fdiforum.net CAPS AND CLOSURES of traditional bands. When fulfilling orders to adhere to the new legislation, Scrumi has notably experienced particular demand for 26/22mm tethered closures. This is reflective of the sentiments expressed by corporations at the outset of the directive, where concerns were expressed regarding the monetary cost and carbon footprint involved in creating brand new bottle designs. Using Scrumi’s 26/22mm tethered closures will integrate the new requirements with existing bottle designs as closely as possible, reducing this expense. Furthermore, rival Retal, leveraging its design expertise and strategic Sacmi partnership, has introduced their EasyTether solution to the new requirements. This cap seamlessly integrates into existing production lines at no additional cost, ensuring compliance with EU legislation while also repurposing defective caps back into the production line. Despite minimal impact on bottle usability or drinking experience, the necessary new design adaptations have led to enhanced manufacturing efficiency and economy. Bottled drinks are not the only consumables undergoing a capping refresh in 2024. Driven by evolving consumer preferences and competitive dynamics, experts predict that supermarket own-brands are poised to embrace a new era of sophistication, with the adoption of premium jars featuring deep twist-off lids. This move is aimed at distinguishing brands from more traditionally “budget” packaging. With new offerings hitting the shelves daily, brands are increasingly focused on differentiation, endeavouring to captivate consumers through bespoke jars and custom printing. As the primary method of grabbing customer attention, supermarket brands are attempting to appeal to the increasingly squeezed middle-class Food & Drink International 29 www.fdiforum.net CAPS AND CLOSURES market, by presenting a premium covering to conceal its’ budget-friendly contents. Moreover, the sustainability of glass capping, despite its’ higher cost, is progressively seen as a method of garnering social capital. From the utilisation of 100% post-consumer recycled materials to the adoption of higher PCR content in glass production, carbon neutralisation is now a firmly embedded consideration in the DNA of packaging creation. Brands are turning to ever-more innovative strategies to gain a competitive edge, such as sourcing material closer to their point of origin to minimize environmental footprint and align with evolving consumer values. Glass manufacturers are at the forefront of this sustainability drive, with a concerted effort underway to align with carbon-zero targets and develop more sustainable processes. Government pressure (especially across the UK and Europe) and the imperative of continued industry survival are expected to further galvanize this movement, with the looming threat of future levies compelling manufacturers to accelerate their transition towards environmental responsibility. The recent design innovations displayed across consumables manufacturing promise an exciting future in product design, defined by elevated aesthetics and the increasing industry commitment towards sustainability. As governmental pressure increases on corporations to consider reusability in product design, the EU directive will evidently not be the last of its kind. As brands navigate this shifting landscape, those ready to lead the charge will be those who embrace change as an opportunity for growth and differentiation, setting the stage for a new era of innovation and sustainability. Companies who want to be seen as conscientious and forward thinking will reap the benefits in customer approval. © stock.adobe.com/ พงศพล วันดีNext >