< Previous30 Food & Drink International www.fdiforum.net PACKAGING A sustainable approach 30-35.qxp_Layout 1 29/06/2020 11:31 Page 1Food & Drink International 31 www.fdiforum.net PACKAGING 32 Á With environmental impact becoming more and more important, especially in the wake of coronavirus, now is perhaps the best time to invest in new initiatives. Sustainable packaging is simpler than it has been in years past. © Shutterstock /SewCream There is a misconception for many that sustainable packaging is an expensive process, often using unusual and new materials such as plant-based fibre, which requires a complete overhaul of a manufacturer’s processing line. Investing in sustainable packaging must therefore be an investment, often with a large price tag and no tangible benefit other than the potential for increased branding with environmentally-conscious customers, and the chance to reduce their carbon footprint, which admittedly can save costs. All of this is not necessarily the case. While it can be, and those who wish to embrace it more fully than others certainly can look into unique packaging materials, it’s worth pointing out that there is another modifier which can influence the sustainability of the packaging process – efficiency. If a company’s packaging needs can be handled in a manner which reduces manpower, wastage or material used, 30-35.qxp_Layout 1 29/06/2020 11:31 Page 232 Food & Drink International www.fdiforum.net PACKAGING then there is an environmental and sustainable benefit to that change. What’s more, there is a financial and manpower saving as well. In this regard, sustainability and the desire to create a leaner packaging process go hand in hand. Many packaging specialists have boosted their research and development departments to emphasise this new approach, and focus is now on packaging that minimises material or waste, as opposed to redesigning or retro-fitting lines to accommodate a unique new packaging solution. This allows companies to reap the rewards of such initiatives, but also implement changes to their systems on a one by one basis – investing in individual pieces of machinery, and thus higher quality ones, rather than budgeting for a complete overhaul, which might require less-effective choices that cost less to be used. One packaging concept that has proven particularly popular for a while now is that of corrugated cardboard. With a wide range of benefits, including an inherent flexibility, corrugated can be modified for different crops and misshapen produce, thereby reducing the potential for bruising and skin damage that can sometimes occur with rigid packaging. Because over 80% of corrugated is recycled, while new boxes are made from recycled material, the environmental footprint is very low. Where new fibre is used, it comes from sustainably managed forests. This commitment to responsible forest management has made a huge contribution to the increase in the size of Europe’s forests – up by 30% since 1950. Although it has been used in one form or other for many years, the corrugated packaging industry is continually investing in new technologies to ensure it retains its top table place. Innovative technology is improving in-store performance as well through better print capability. High Quality SICK’s Advanced IO-Link Encoders Streamline Machine Controls SICK has released advanced variants of its AHS36 and AHM36 IO-Link absolute encoders that can harness valuable diagnostic insights for better machine control and availability. With versatile programming options, they make it easy to integrate data from encoders into localised and ‘edge computing’ configurations to improve the efficiency of food and drink processing and packaging plant. All SICK’s AHS36 14-bit (singleturn) and AHM36 26-bit (multiturn) IO-Link absolute encoders achieve quick, easy and economical higher-level fieldbus integration via an IO-Link Master. Now, the AHS36 and AHM36 IO-Link Advanced variants enable machine designers and end users to use diagnostic information, such as temperature values, to streamline machine control and optimise maintenance regimes. With IP66 and IP67 ratings, SICK’s AHS36/AHM36 IO-Link Advanced are suitable for tough ambient conditions, while the Inox variant provides a stainless-steel IP69K-rated housing for process environments with stringent chemical or high- temperature washdown regimes. For more information, visit www.sick.co.uk. 30-35.qxp_Layout 1 29/06/2020 11:31 Page 3PACKAGING © Shutterstock /Kichigin 34 Á Essentra launches ‘industry first’ recycled PET tear tape Essentra Tapes has launched the first tear tape for flexible packaging to combine the sustainability of recycled polyester (rPET) alongside the benefits of easy-opening and brand enhancement. Responding to both consumer demand for packaging sustainability and the latest legislative requirements for recycled content, the new SupaStrip® PCR is made from rPET and contains 70% post-consumer resin (PCR) in a single ply, 23micron film. Using recycled content supports a circular system where plastic is kept in the economy and out of the natural environment and is in line with the latest roadmap outlined by The UK Plastics Pact. Like all Essentra tear tape solutions, SupaStrip PCR is easy to implement within flexible packaging lines and intuitive to use, providing fast, safe, and immediate access to the contents. In addition, the ability to print the tape allows a diverse range of brand messages and logos to be added for enhanced on-shelf impact and consumer interaction. For more information, visit www.essentra.com/en/capabilities/tapes. Food & Drink International 33 www.fdiforum.net obvious, way to improve efficiency and reduce waste. As opposed to using lighter or more environmentally friendly material, it can improve sustainability by reducing human error that would reduce in products being unsuitable for sale. This accuracy is absolutely vital in the sector, where increasingly stringent regulations on labelling – not to mention the huge expense that can be engendered by excessive product giveaway. This has in turn led to an increase in the levels of traceability present within the manufacturing and supply chain – with companies able to find out exactly who the suppliers were of any ingredients used in a given batch of completed products – within a few hours. This improved accuracy, and the reduction in human error that comes with it, has proven itself very valuable for the bottom line as well. Traceability is a requirement for many supermarkets, who will want to know where something went wrong in the event of an accident or product recall – usually within 24 to 72 hours. Having a system in place for this will make a company more attractive to such customers. Of course, there are other ways to improve the sustainability of food packaging, and although it is expensive, it’s hard to deny the benefits of the more esoteric methods. In development we can see milk-based packaging, packaging created from plant extract Post Print has transformed corrugated packaging from protective transit packaging into multi-functional, colourful retail ready packs, without compromising product integrity. Liners and coatings are also being developed for corrugated material to provide even greater food freshness and, with the advent of modern corrugated processes, such as new flutings that offer up to 23% storage space saving, it also offers more efficient logistics management through better use of pallets, resulting in fewer vehicles on the road. Automation is another, perhaps 30-35.qxp_Layout 1 29/06/2020 11:31 Page 4and even packaging which degrades itself. Edible and environmentally friendly packaging options are another step in the right direction, but the next logical step is in creating fully biodegradable packaging for which to house and transport products. Using this method would help to create a closed-loop approach to packaging, where wasted and surplus food is used to create bio-packaging, which can then be turned into compost, potentially fertilising new fruit and vegetable products. Many such developments are likely to be highlighted at the PPMA Total Show this September. Though undeniably expensive, companies who can keep themselves at the forefront of this innovation often experience unprecedented success. To many manufacturers, this is the realm of the giants – companies that can afford the risk. To them, however, it is not something done for frivolous purposes, but because they have identified an opportunity to pull further ahead and stake their claim in the SIG opens state-of-the-art AutoStore warehouse for spare parts SIG’s newly built, state-of-the-art and fully automated AutoStore spare parts warehouse for SIG filling machines, implemented by Hörmann Logistik, has now been put into operation. Located at the company’s machine assembly site in Linnich, Germany, the new AutoStore warehouse plays an integral part in SIG’s global spare parts management. As food and beverage products continue to diversify, it is essential that production schedules run smoothly and to maximum capacity without downtime. The new AutoStore warehouse enables SIG to adapt and respond flexibly to changing customer needs in the quickest possible time, guaranteeing speedy delivery of spare parts to keep the versatile equipment running efficiently. This seamless service means continuous and optimum performance of SIG’s filling systems, maximum technical availability and precisely tailored maintenance. The new warehouse uses a modular system, where stockable box containers are loaded, stored and then unloaded by robots, guided by routing software. For more information, visit www.sig.biz. 34 Food & Drink International www.fdiforum.net PACKAGING © Shutterstock /KtD market. As ever, those who are successful do not take risks because they can afford to, rather they are successful because they take such risks. One thing is for sure, however. With trading conditions placed in jeopardy by coronavirus, and consumers becoming no less demanding when it comes to the environmentally friendly nature of what they eat and drink, now is not the time for manufacturers to sit idly as others capture the market. Opportunities will not make themselves available. They must be grasped. 30-35.qxp_Layout 1 29/06/2020 11:31 Page 5w: www.dynascan.co.uk e: info@dynascan.co.uk | t: +44 (0)1480 462142 Is your packaging leaking? Use Dynascan leak detection products as part of your quality control to identify packaging leaks and avoid costly production downtimes. User-friendly and low maintenance, the Dynascan instruments provide instant test results to help improve your packaging processes. All test systems are designed and manufactured to the highest quality. Both standard and made-to-order products are available to provide complete solutions. Manufacturer of seal integrity and leak detection solutions Various test methods available Social distance products businesses safely 02476 420065 30-35.qxp_Layout 1 29/06/2020 11:31 Page 636 Food & Drink International www.fdiforum.net MEET THE EXPERTS © Shutterstock /Sorn340 Studio Images ‘From field to fork’ is a buzzword beloved of the media for its seeming ability to capture the length and breadth of the food and drink supply chain in one term. While undoubtedly easily applicable, the phrase does the industry a disservice, downplaying the complexity of the supply chain and the massive number of players working within it. There are many moving parts tessellating together to ensure that the journey from field to plate is as smooth, safe and efficient as possible. That’s why our ‘meet the experts’ pages look to highlight all the players that enable the supply chain to function and have them share their expertise and insight. Almost all stages of this supply chain depend on water, either to grow products, for washdowns or as an integral ingredient in its own right. All of that water needs to be responsibly managed, disposed of and measured with companies working tirelessly behind the scenes to do so. One can’t help but use the metaphor of the iceberg. The tip is what most consumers see or realise takes place when they purchase food and drink products, while the majority is hidden under the surface. Flow measurement is another important aspect of the production and processing process as without this crucial element, manufacturing could be plunged into chaos. Experts in their field Food and Drink International’s semi-regular ‘Meet the experts’ feature is a great way for companies across the food and drink industry to share their expertise. 36-37.qxp_Layout 1 26/06/2020 12:46 Page 1Food & Drink International 37 www.fdiforum.net MEET THE EXPERTS Rotronic Instruments (UK) Ltd Crompton Fields, Crompton Way, Crawley, West Sussex RH10 9EE. Tel: +44(0) 1293 571000 Email: instruments@rotronic.co.uk Web: www.rotronic.co.uk Company profile: Rotronic is a global company manufacturing instruments for the precise measurement of water activity, humidity, moisture, temperature, CO2 and differential pressure. Rotronic devices are specified throughout the food and other industries. Experienced engineers can provide measurement solutions for any application. Rotronic has UKAS / ISO 17025 accreditation for Temperature, Humidity and Dew Point calibration. Product profile: Rotronic manufactures water activity analysers to determine the free moisture within food products - a good indicator of product stability and shelf life. Controlling the moisture present improves product quality. Analysers provide measurements in typically less than five minutes. The wide product range includes the AwTherm analyser with full temperature sample control; the HygroLab laboratory analyser for up to four probes, handhelds for making spot-checks and a PC-based solution which is ideal when visiting suppliers’ sites. The sensors can be calibrated to confirm performance. Full technical product information is available on the website. WATER ACTIVITY Detection is critical in ensuring that food and drink products are free from contaminates, pathogens and any other harmful additives that may have entered along the supply chain. Metal is a common contaminated and companies must utilise metal detection methods to ensure their products are safe. Magnetic separation is a reliable means of maintaining product integrity and safety. As well as testing food, laboratories are also at the cutting edge of food trends, with the rise in nutraceuticals and nutrition-added ingredients. Ensuring that food and beverage makers stay up to date with the latest innovations in processing and packaging equipment is critical. To that end, suppliers of such equipment perform a key role in the supply chain, ensuring companies keep up with the times and remain competitive. In this edition of ‘Meet the experts’ we’ve got a leader in water activity who showcases the very best the supply chain has to offer, truly from farm to fork. Laboratories are also at the cutting edge of food trends, with the rise in nutraceuticals and nutrition-added ingredients © Shutterstock /Marco Ossino 36-37.qxp_Layout 1 26/06/2020 12:46 Page 238 Food & Drink International www.fdiforum.net ENGINEERING AND COMPONENTS © Shutterstock /asharkyu automation Engineering 38-41.qxp_Layout 1 26/06/2020 12:48 Page 1Food & Drink International 39 www.fdiforum.net ENGINEERING AND COMPONENTS As demand rises, tastes change rapidly, and companies scale up operations, heightened focus is being placed on engineering, and individual components, to bolster efficiency in food production. Automation remains a key area in regard to this and is only gaining more consideration as companies handle COVID-19 and look to support social distancing. Facility wide automation is considered a necessity to boost quality control, improve performance, production speed, precision, consistency, agility, and profitability. Furthermore, many new automation systems are centred on flexibility to adapt to customer demand and can retool quickly. More automation is being designed into processes as labour becomes harder to find, especially at present when an already limited worker pool has been diminished by a pandemic cutting half of staff from production lines. Robots are increasingly sought after, bringing benefits of high precision movements, minimised error and contamination, past what is possible with human employees, while removing workers from unsafe environments (from cold stores to those involving sharp tools) and monotonous roles to be transferred to and retrained for tasks with added value. Moreover, with automated robotic processes, manufacturers can reduce costs associated with injuries like ever- common repetitive strain. Robots are being invested in to raise productivity, address quality and output issues and boost operational efficiencies, and as they do not need breaks, are permitting cost savings and increased throughput. An important evolution in engineering robots for the food industry can be seen with advanced grippers and vision systems, which are allowing the quick and gentle handling of sensitive products, and faster, sophisticated, and detailed processing of images. These grippers are overcoming problems in which duties requiring a delicate touch and dealing with irregular shapes were previously difficult to automate. Now, however, soft gripper technology can mirror human touch and ensure goods are not damaged while completing tasks more efficiently than flesh and blood workers. Advances in hardware and software have enabled these improvements with machine learning facilitating better decision making. Today, robots - which are performing almost a third of food processing and over ninety per cent of packaging operations, from weighing to palletising - are being designed to work cohesively alongside humans and products to be consumed, as well as to handle cold, heat and water and withstand rigorous cleaning and corrosive chemicals required within the food industry, utilising corrosion resistant surfaces, stainless steel, improved seals, new materials, and lubricants that are compatible with food. Food companies and automation and robotics partners are coming together to refine and develop novel technologies for optimised precision with new sensors, vision tech, grippers, and AI. Boosting a robot’s ability to touch, feel, see, and grip, they now hold more intelligence to be flexible and take on complex roles. Meanwhile cobots have been engineered to bypass cages and protection necessary for typical robots, to work in harmony with humans, programmed to stop when encountering obstructions and use proximity sensors to adjust speed when people get close. Reducing costs of robotics and installation, simplified programming, and decreasing sizes are pushing adoption further, however more work remains essential to truly progress the next generation of robots that can be employed across the entirety of food production. It is impossible not to highlight Industry 4.0 and the Internet of Things (IoT) when considering the development and advancement of robots and automation for the food industry, with firms looking for connected and intelligent automated systems and machines. The digitisation of the manufacturing process is vital to Automation remains central as food and drink companies look to engineering for solutions to rising demand and complex desires. 40 Á 38-41.qxp_Layout 1 26/06/2020 12:48 Page 2Next >