< Previous20 Food & Drink International www.fdiforum.net TEMPERATURE CONTROL SPOTLIGHT occurs in-house, typically a production line in an enclosed warehouse or other facility. Though there are many options open to manufacturers for ensuring a consistently cold production line or storage facility, it’s counterproductive to invest in subpar technologies. Even tiny changes in temperature can lead to micro-thawing and the crystallisation of goods. Insulation is crucial in maintaining a cooler temperature as the heat outside a facility will be constantly trying to work its way inside. Heat can work its way through even the smallest breaches in a manufacturer’s temperature defences, be that a wall, window or door. Of course, where cool air is present, there also exists the possibility of moisture build-up which can lead to all manner of issues such as damp or a build-up of ice. This not only presents a safety hazard for workers but can also severely limit the functionality and efficiency of processing equipment and lead to costly repairs. Ensuring a thorough washdown can help, as can investing in dehumidifying technologies. The transport and distribution of frozen goods presents a more challenging situation as it involves moving goods from one strictly controlled environment to another. To facilitate this changeover, manufacturers will likely have temperature controlled loading bays, ensuring a constant Gressenhall | Dereham | Norfolk | NR20 4DT | +44 (0)1362 861066 | www.premierpalletinverter.co.ukFood & Drink International 21 www.fdiforum.net TEMPERATURE CONTROL SPOTLIGHT temperature from the production and packing lines. Curtain walls will help to maintain this consistency, creating a barrier to ensure that cold air stays inside its designated area whilst also allowing workers, forklift trucks and other vehicles to pass easily through. Loading bays themselves, however, are literal openings into the outside and so could quite easily scupper this carefully controlled environment. To compensate for this and maintain the cold integrity, manufacturers and logistics companies rely on hoods around the bay door opening. This means a truck or lorry can back into the bay and open its doors, creating a seal and ensuring that the exterior and interior temperatures don’t have a chance to meet and mingle. Frozen and chilled goods can then be loaded without fear of thawing. These same hoods will likely be in place at the retailers and distribution centres where food and beverage products will be dropped off for supply and sale, ensuring one continuous chilled environment. Bay doors form a key part of defending temperature controlled environments, as they could elsewise be a liability. They must balance adequate insulation whilst also boasting the rugged design and defence required to fend off the elements and possible forced entry. © stock.adobe.com/chesky© stock.adobe.com/adisaSUSTAINABLE PACKAGING 22 Food & Drink International www.fdiforum.net T he vast amount of packaging waste generated by the food industry poses significant environmental challenges, from resource depletion to pollution. Sustainable food packaging offers a promising solution by reducing the environmental footprint, conserving resources, and ensuring the preservation of food quality. Consumers are increasingly aware of the food industry’s environmental impact and are actively searching for products which seek to lessen this impact. Conventional food packaging, often made from non-recyclable or hard-to- recycle materials such as plastics and metals, contributes significantly to the global waste crisis. Plastic packaging, in particular, is a major concern due to its non-biodegradable nature and the alarming accumulation of plastic waste in landfills and oceans. Plastic drinks bottles are of particular concern, as bottles and bottle caps contribute to approximately 6 and 9 percent of oceanic pollution respectively. Yet, modifying or completely redesigning existing packaging incurs astronomical costs for manufacturers, hence the slow progress in this area. Yet, the socio-political climate is forcing companies to re-evaluate their approach. As part of its single-use plastics directive, the European Union mandates the attachment of caps to plastic bottles with a capacity of up to 3 litres, with a deadline for compliance set by the end of 2024. Furthermore, charities such as Greenpeace are stepping up their name and shame campaigns to promote consumer awareness of corporate waste. This is in addition to the simple fact that the sight of a company’s products ending up as pollution reflects negatively on the company’s reputation. In other words, it no longer pays to use unsustainable materials. Understanding the risks of not acting, what are some benefits of acting sooner? Sustainable food packaging Increasing the sustainability of food and drink packaging In today’s world, where environmental concerns are becoming increasingly prominent, the need for sustainable practices in all aspects of life has never been more urgent. A key area that demands immediate attention is food packaging. SUSTAINABLE PACKAGING Food & Drink International 23 www.fdiforum.net © stock.adobe.com/VICUSCHKA provides a range of advantages that help address the environmental effects associated with conventional packaging. Firstly, it promotes resource conservation by utilizing renewable or recycled materials, thereby reducing the need for raw materials, and lowering energy consumption. Secondly, sustainable packaging emphasizes waste reduction through inventive design, lightweight materials, and efficient manufacturing methods. It encourages the adoption of biodegradable and compostable materials that naturally decompose, thereby eliminating the persistent pollution caused by conventional packaging. Moreover, sustainable packaging aligns with the principles of a circular economy, where materials are reused, recycled, or composted, reducing the reliance on virgin resources, and minimizing waste generation. Ultimately, using sustainable materials can reduce production costs in the long term, as the cost, quality, and availability of recycled materials increases. Given that bottle caps are more polluting than the bottles themselves, new designs are attaching the cap to the bottle with a plastic tether. This requires the cap and bottle to be disposed of together, increasing the chances that both will end up in a recycle bin. This has prominently been adopted by Coca Cola, but many beverage manufacturers are following suit. Coca-Cola’s recent bottle cap rollout action aligns with its global initiative called “World Without Waste.” Coca- Cola aims to assist with collecting and recycling empty bottles or cans for every unit it sells by 2030. Furthermore, Coca-Cola plans to incorporate 50% recycled material into its cans and bottles by 2030, while aiming for 100% recyclable packaging by 2025. This initiative has been widely lauded, as an example of industry wielding power to incite genuine action. Furthermore, 24 Á24 Food & Drink International www.fdiforum.net SUSTAINABLE PACKAGING Coca Cola’s targets are shorter term than many government ones, increasing the long term benefits seen from the work. But this is not enough. Further development of innovative approaches and materials is crucial to achieving sustainable food packaging. Bioplastics, derived from renewable sources like corn-starch or sugarcane, offer a viable alternative to petroleum-based plastics. These bioplastics are biodegradable, compostable, and can be recycled alongside organic waste. Plant-based and edible coatings, such as those derived from seaweed or beeswax, provide an eco-friendly option for preserving food and replacing conventional plastic films. As these materials are naturally derived, there is also less concern around degradation and subsequent release of toxic chemicals, as will happen with many petroleum-based plastics. This therefore not only increases the products’ green credentials, but it also appeals to health-conscious consumers who are concerned about the quality of their products. Furthermore, the concept of active and intelligent packaging is gaining traction. Active packaging uses integrated systems, such as moisture control or antimicrobial agents, to extend the shelf life of food, reducing waste caused by spoilage. Intelligent packaging incorporates sensors and indicators that monitor freshness and temperature, ensuring optimal storage conditions and reducing food waste. Another emerging trend is the use of recycled and upcycled materials for packaging. For instance, recycled paper or cardboard can replace plastic trays or containers. An economical, yet effective packaging solution is to use recycled paper padding when transporting goods. This is being widely adopted instead of bubble wrap, which whilst recyclable, must be subject to extra restrictions. Using non-coated paper ensures that this can be disposed of at any recycling location, in addition to being cheaper. Education and awareness campaigns are vital in promoting consumer understanding and driving demand for sustainable packaging. By providing © stock.adobe.com/ChayTeeFood & Drink International 25 www.fdiforum.net SUSTAINABLE PACKAGING information about the environmental impact of packaging choices, consumers can make more informed decisions and actively support sustainable practices. These campaigns should emphasize the importance of reducing waste, conserving resources, and mitigating environmental harm through sustainable packaging. In addition to education, retailers can play a proactive role in promoting sustainable packaging. For example, implementing incentive programs that encourage customers to bring reusable bags or containers, reducing the reliance on single-use packaging. Whilst redesigning packaging could set a business back £5-15,000, the increased awareness from marketing campaigns is sure to make a fantastic return on this investment. In the face of governmental organisations cracking down on waste, it also secures the products’ long-term future. © stock.adobe.com/David Fuentes26 Food & Drink International www.fdiforum.net FLOW MEASUREMENT AND CONTROL precision The power of © stock.adobe.com/SurasakFood & Drink International 27 www.fdiforum.net FLOW MEASUREMENT AND CONTROL W hen you’re precise in your food business’s flow measurement and control, safety and efficiency naturally fall into place. But it’s also a matter of quality, vital to maintaining consistency in your product’s taste, attractiveness and value to consumers. By accurately measuring and controlling the flow of ingredients, such as liquids, additives and flavourings, food manufacturers can ensure that each batch of their products adhere to the intended recipe, allowing them to meet expectations every time. This is also a weight off the quality assurance process because, when done properly, these primary quantifications reduce the risk of production errors being discovered further down the line. In these ways and more, managing flow can be a lifesaver in making the most of ingredients and bringing the best out of your products. To ensure you reach this high efficiency level, there are several areas in which you can plan, tighten up and improve, no matter how long you’ve been running your business. Begin by understanding the specific needs and requirements of your process. Determining the critical parameters that need to be measured and controlled, such as flow rates, pressure, temperature and viscosity, will help you optimise your equipment’s energy consumption and minimise waste. Assessing the desired accuracy, range and response time for each parameter in advance will also save operatives from having to intervene and alter processes on the fly, saving valuable time in your working day. Selecting appropriate measurement technology is your next best move from here, as this will affect how ingredients move through the equipment you’ve optimised for requirement. There are choices to be made here too, with different technologies available for a wide variety of needs. Electromagnetic flow meters, for instance, are ideal for measuring the flow of conductive liquids such as juices, milk and sauces, because of their range of modification for accuracy and ability to handle fluids with high solids or particulates. But if you’re more varied in your © stock.adobe.com/9dreamstudio We explore how accurate flow measurement and control in the food industry not only ensures safety and efficiency but also maintains product quality and consistency. 28 Á28 Food & Drink International www.fdiforum.net FLOW MEASUREMENT AND CONTROL range of products and looking for a good all- rounder, coriolis meters are versatile enough to handle both liquids and gases, while being hardy enough to measure high-viscosity fluids like syrups, oils and cream. It’s important to note that the suitability of a specific flow meter technology may also depend on other factors such as pressure, temperature or flow range, as well as the level of cleanliness needed. It may be best to consult with flow meter manufacturers or experts to select the most appropriate technology for a particular food or ingredient application. In any case, it will be crucial to make sure any flow measurement instruments are properly installed and regularly calibrated, if your new equipment is to make accurate measurements and control the flow of any ingredients reliably. Thinking ahead about maintenance requirements, and the resources necessary for these, is equally important for the long-term cashflow and time management of your business. As long as operators and maintenance personnel receive proper training on the use and troubleshooting of equipment, waste of either resource should remain minimal. Developing and implementing preventive maintenance programs, including regular cleaning, inspections, and replacement of worn-out components, will significantly reduce the downtime that would otherwise become necessary for equipment left to fail. Even with every precaution taken however, a food business director can never be too careful. Setting up alarms and alerts to notify operators of any deviations or abnormalities in flow will minimise disruption even in unforeseen circumstance, guiding staff to identify and address issues as quickly as possible. By preventing deviations and detecting them as they arise, proper flow measurement and control maintain the strict hygiene standards which are always foremost, especially when serving the public. Just for one example, in a dairy processing plant, anomalies detected in milk flow may indicate potentially harmful issues, whether with sanitation or equipment malfunction. In dairy’s specialised processing stages, such as pasteurisation and sterilisation, precise flow measurement and control are essential to ensuring the effectiveness of thermal treatments. Staying alert to warning signs for contamination in the product itself, or cross-contamination from equipment or machinery, could mean the difference between shipping out a safe product and a recall situation. The issue could be as simple as a leak or blockage, or incorrect ingredient amounts filtering through the processing system. But where health and quality are paramount and susceptible to pollution, each method of quantifying and assessing your ingredients is a defence against risks that may otherwise pass unnoticed on a busy factory floor. By continuously monitoring flow rates, operators can identify anomalies that may compromise consistency and hygiene at any point during a food or drink item’s production. But to go that extra mile, flow measurement systems can benefit from integrated traceability as an added measure of quality. If any incoming ingredients are found to have an unexpected flow, perhaps due to poor consistency or contamination by foreign particulates, these flaws can then be tracked down, secured and rectified at the source through flow measurement data. Regulatory bodies often require precise records of this data as proof of adherence to safety protocols. But as a conscientious and forward-thinking member of the food industry, you can go beyond ensuring your place of work passes regulation standards, paying attention to where your ingredients are coming from, and assuring customers can feel confident in your responsibility when investing in any of your products. As simple and minor as flow from one process to the next may seem, it’s much more than getting ingredients from start to finish. The foresight and attention to detail involved in correct measurement and control are barriers against ingredient level discrepancies and contamination. Meanwhile, continuous monitoring and analysis of your data is a ripe opportunity to find areas for improvement. Flow is part of keeping regulatory bodies and customers alike satisfied. But beyond that, it’s another tool for growing your business in its efficiency, high-quality output, and all-round commitment to excellence.Food & Drink International 29 www.fdiforum.net FLOW MEASUREMENT AND CONTROL © stock.adobe.com/Quality Stock ArtsNext >