< Previous20 Food & Drink International www.fdiforum.net PROCESSING SPOTLIGHT the food industry is its ability to contribute to reducing food waste. Unlike traditional mass production methods, where surplus materials often become discarded, 3D printing ensures precise control over the number of raw materials used for each product. This means only the necessary edible ink is utilized, significantly minimizing waste. Furthermore, 3D printing enables on- demand food production, eliminating the need for extensive inventory storage. By producing food precisely when and where it is required, transportation and storage costs are reduced, and the final product’s freshness is ensured. This streamlined approach holds great promise for enhancing food processing efficiency and sustainability. In response to the growing concern for sustainability and environmental impact, manufacturers are prioritizing the development of energy-efficient food processing machinery. This includes the integration of advanced thermal insulation, heat recovery systems, and smart energy management solutions into processing equipment. By adopting energy- efficient machinery, food processing plants can effectively reduce their carbon footprint and realize substantial cost savings. The incorporation of heat recovery systems is a key feature of energy-efficient machinery. Food processing operations often generate significant amounts of heat as a byproduct. Instead of allowing this excess heat to dissipate into the environment, heat recovery systems capture and reuse it. The recaptured heat can be redirected to preheat incoming water or air, thus reducing the overall energy required for heating processes. To maximize energy efficiency even further, some food processing plants have adopted cogeneration systems, which utilize excess heat to generate electricity. With consumers having to be more discerning than ever with their product choices due to the cost-of-living crisis, manufacturers are on the hunt for technology which balances consumer experience with operational efficiency. High-Pressure Processing (HPP) represents a cutting-edge method for preserving food without relying on heat or chemical additives. It is an innovative and non-thermal technique that utilizes high hydrostatic pressure levels to enhance the shelf life and safety of various food products. HPP has been gaining widespread acceptance throughout the food industry, as it effectively maintains the freshness and nutritional quality of foods while ensuring they remain safe for consumption. By subjecting food items to extreme pressures ranging from 300 to 600 megapascals (MPa) for a duration of a few seconds to several minutes, HPP effectively eliminates harmful microorganisms while retaining the food’s original flavor, texture, and nutrients. This approach aligns with consumer demands for minimally processed, fresh-like foods with an extended shelf life. HPP finds extensive use in beverages, deli meats, and ready- to-eat meals, making significant contributions to a safer and more sustainable food supply chain. Similarly, Pulsed Electric Field (PEF) is a state-of-the-art technique employing short, powerful bursts of electrical energy to treat a variety of food products. As a non-thermal and non- chemical process, PEF has garnered significant attention in recent years as a promising alternative to conventional Food & Drink International 21 www.fdiforum.net PROCESSING SPOTLIGHT food preservation methods. PEF’s capability lies in its effective inactivation of microorganisms, enzymes, and spoilage agents, while simultaneously preserving the food’s nutritional quality and sensory characteristics. By creating pores in cell membranes and enhancing mass transfer rates during processing, PEF treatment brings about several advantages. These include extending the shelf life of food, improving nutrient retention, and enhancing flavours, all achieved without the use of high temperatures or additives. Particularly valuable for processing liquid foods like juices and dairy products, PEF technology ensures that the natural qualities of these products are maintained, while also enhancing safety and prolonging freshness. As PEF technology continues to evolve, it holds immense potential to offer more efficient and sustainable methods for food preservation and treatment. Although somewhat sci-fi sounding, nanotechnology has made its way into the food industry. By utilizing nano- scale particles and structures, the functionality of food additives like stabilizers and emulsifiers can be greatly enhanced, resulting in improved texture and taste of food products. Additionally, nanosensors offer real-time detection of spoilage and contamination, promoting food safety and quality. One of the key benefits of nanotechnology in food processing is the development of smart delivery systems. These systems can respond to specific triggers, such as changes in pH, temperature, or moisture. As a result, they release bioactive compounds or flavours only when necessary, enabling targeted and controlled release. By implementing smart delivery systems, the flavour and nutritional content of processed foods can be significantly enhanced, while reducing the reliance on excessive additives and preservatives. This not only improves the overall quality of food products but also ensures their safety for consumers. © stock.adobe.com/moodboard22 Food & Drink International www.fdiforum.net READY MEALS food Convenient Ready meals are here to stay and are fast becoming the food of choice for every working adult and student. Y oung consumers typically dominate the ready meal market, which has increased demand for canned and dried product ranges. From 2020 – 2027, canned meals are expected to expand the fastest. This is due to the convenience and longevity of the product, whilst having the ability to retain healthy protein, carbohydrates, and fat that other ready meal types do not have. A traditional favourite of students, instant pasta and noodles are the biggest offering from the dried foods segment. The U.S., China, India, and the UK provide the largest demand for these products. In the UK and US, a rise in demand for Korean and Chinese Food & Drink International 23 www.fdiforum.net READY MEALS © stock.adobe.com/ weyo dried products such as ramen has been seen amongst teens and young adults. Important to this trend is the notion of authenticity, so those looking to expand their ranges must source and manufacture these products similarly to the country of origin in order to truly take advantage. Precooked offerings tick the convenience requirement for families, and they help save time and effort required for meal preparation. This has led to an increased demand for healthier ready meals, especially among the working population and students across the globe. Ready meals are a cost-effective alternative as they are precooked, but noticeably unhealthy. This has resulted in an upsurge in the number of delivery services available such as Hello Fresh, as delivering all the ingredients for your meal for the exact number of people you need (as specified by you at the point of ordering). This has increased 24 ÁREADY MEALS exponentially in popularity as it is convenient, and environmentally friendly in packaging (it comes in a brown paper bag without cellophane wrapping on the ingredients). Yet, it is fairly expensive, with packages priced at around £30, so many people choose to do this once or twice a week, rather than nightly. Given this trend, a noticeable gap is between convenient and cheap food delivery services (such as Deliveroo) and the desire for healthy, yet quick food. The ready meals sector is also expanding beyond the home cooking market. Many schools rely heavily on pre-cooked meals to cut costs and the time for cooking a meal from scratch. For instance, in September 2020, FiveStar Gourmet Foods ltd launched the Simply Fresh2GO ready meals product line to deliver both in retail and school food services channels. The meals are designed to meet strict national school lunch dietary standards. It maintains that each item in the line has a balanced complete meal including protein, grains, fresh vegetables, and fruits. Research suggests that consumers prefer to shop for food from stores rather than online portals, due to the ability to physically choose based upon individual item appearance. This is important for manufacturers looking to diversify their suppliers – do not overlook stores, and the value of eye- catching ready meals with easily accessible packaging that lets the consumer see the food inside. This highlights the continued importance of packaging in terms of catching the eye and drawing attention and stands in stark contrast to consumer claims that “packaging has no effect” on them, and that it’s the quality of the food that counts. Typically speaking, ready meals make use of cartooning and sleeving for their packaging, usually with the cooking instructions and labelling on the sleeve itself while the food is served in a carton with a film topping – important for allowing the consumer to see the meal itself. Visual confirmation remains key but this method of packaging is not particularly conscientious on the environmental front, leading to questions on how to both satisfy consumer demands to see the product but also have a lower impact on the 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. 24 Food & Drink International www.fdiforum.net © stock.adobe.com/photka စထထ ႅဈဈ င စဉထဓဇဒဇထဒဒ $ %&'( )( *+& *&'( )( *+& Food & Drink International 25 www.fdiforum.net READY MEALS environment. With the market continuing to expand, the main focus – especially in the UK with the cost of living – will be on affordability combining with health benefits. Healthier options, a reduction in salt, and changing up recipes to offer healthier alternatives will put brands in a better position to corner the market. A failure to do this not only risks turning off potential customers, but also opening a niche for a competitor to start targeting your own. After all, ready meals are already accepted to be less tasty than freshly cooked meals, so how much of a difference is there between one ready meal and the next, if the price is the same but one has half the carbs, fat, salt and sugar? Convenience meals eaten in a rush in a busy work environment won’t be savoured as they might be in a restaurant, so the reduction in taste is unlikely to be noticed, if perceived at all. © stock.adobe.com/William26 Food & Drink International www.fdiforum.net MATERIALS HANDLING Ensuring safety and efficiency Ensuring safety and efficiency Food & Drink International 27 www.fdiforum.net MATERIALS HANDLING P roper materials handling is not only essential for operational efficiency and cost- effectiveness, but also directly impacts food safety, product quality and regulatory compliance. This can be a challenging task to approach by its very nature, because of its varied applications. The food and drink industry operates within a complex network of suppliers, manufacturers, distributors and retailers, meaning that a single breakdown in the handling process can result in contamination, spoilage or delivery delays. Any combination of these issues could lead to financial losses and consumer satisfaction, or even potential harm. But this guide is here to reduce your overwhelm and provide clearly defined areas to implement correct materials handling. One of your primary focuses should be ensuring food safety. Strict adherence to hygiene protocols, proper sanitation of equipment and effective pest control are critical to minimising contamination risks. By applying hygienic procedures, such as using the proper storage methods for each product, the risk of foodborne illnesses and spoilage is reduced, safeguarding consumer health and maintaining any food business’s brand reputation. Implementing a HACCP (Hazard Analysis Critical Control Points) system in food processing facilities provides a checklist for identifying and controlling potential hazards at critical stages of the production process. From strict adherence to hygiene protocols – including cleaning methods and rotas – to regular monitoring schedules, systems such as these make excellent starting points in defining each action needed to handle food appropriately and safely. Efficiency is another core objective of materials handling in the food and drink industry. Streamlining production processes and optimising storage facilities help to reduce operational costs and minimise waste, improving the overall productivity of your business. Rethinking how and when materials move between these areas will create a smooth flow of goods throughout the production and distribution cycle. This means minimising unnecessary handling and reducing wait times between processes wherever possible. Optimising the layout of the production facility and storage areas will ensure materials are never handled or held in one place for too long, while reducing travel time between processes. Trying out automated conveyance systems or Safely and efficiently moving raw resources, ingredients and finished products requires careful planning in all materials handling. The same applies wherever you’re operating in the food and drink industry, encompassing the processes of transporting, storing, protecting, and controlling materials, from sourcing to consumption and at every stage in between. 28 Á © stock.adobe.com/Hakan Tanak28 Food & Drink International www.fdiforum.net MATERIALS HANDLING robotics are optional added extras, but can reduce human workload and speed up the entire process for those who can afford them. Effective materials handling also contributes to maintaining product quality throughout the supply chain. From the moment raw materials are received to the point of consumption, the careful handling of goods prevents physical damage and maintains a product’s freshness, taste and appearance. This aspect is especially important for perishable items, where any mishandling can lead to substantial losses in valuable ingredients. To avoid unnecessary waste, set up and be consistent with routine inspections and quality checks during stages such as raw material receiving, processing and packaging. Here too, machinery and robotics can be employed to ease the stress load on human workers, with automated sensors and quality control tools available to detect defects, and then remove these substandard products from the production line. Materials handling practices in the food and drink industry also play a pivotal role in regulatory compliance. Companies must adhere to many food safety regulations, quality standards and certifications, which all ensure that any products meet consumer expectations and legal requirements. These standards are put in place so that a business can ensure its outgoing products fulfil a high standard of quality and hygiene and avoid as many legal issues and instances of reputation damage as possible. Establishing standard operating procedures, and conducting regular internal audits and third-party inspections, are always the best courses of action for peace of mind regarding your business’s compliance. Proper documentation and traceability are just as essential for demonstrating compliance in the unfortunate event of audits or recalls. Assigning batch numbers or lot codes to each product during handling enables fast and accurate traceability, removing delays from this worst fear of any food and drink business proprietor or operative. Maintaining comprehensive records of the movement and processing of each batch will making it even easier to trace the origin of any quality issues and allow targeted recalls if needed. During the majority of occasions when quality checks catch every flaw, appropriate packaging and protection of products will ensure they survive transportation and storage to reach consumers in optimal condition. Selecting the correct materials and containers for every type of food, such as cushioning materials and temperature control for perishable items, will keep your products at their best as they wait for shipping, then travel to their destination. While ingredients and products are awaiting either transport or the next stage of processing, accurate inventory tracking avoids both overstocking and stockouts. Organisation at this static stage of handling shouldn’t be overlooked, as it reduces waste of surplus materials and ensures a steady supply of products to meet consumer demand. Barcode or RFID (Radio Frequency Identification) technology can easily and inexpensively track inventory levels accurately and in real- time, while implementing an inventory management system that integrates Food & Drink International 29 www.fdiforum.net MATERIALS HANDLING with production and sales data will forecast demand and prevent stocking errors. Finally, don’t forget about your workers. The values of ergonomics and safety intertwine with materials handling, as considering both reduces the risk of workplace injuries as well as improving the comfort and efficiency of your employees. Accidents can not only harm people, but also disrupt production and damage a company’s reputation. Training employees in proper lifting techniques and providing ergonomic equipment, such as pallet jacks or lift-assist devices, will reduce the physical strain associated with manual materials handling. When workers can see to their own safety, regularly conducting audits to identify and address potential hazards ensure a safe working environment, boosting employee morale and reducing downtime due to accidents. Attention to each of these areas will contribute to an efficient supply chain, smoothing materials flow all the way through to timely deliveries. Using this knowledge of how materials handling intersects with a multitude of crucial areas in safety, hygiene, quality and compliance, you can bring the best out of each material that makes your products, ultimately giving your business an enviable edge in this competitive industry. SICK Announces Major Upgrade to Colour Sensor Portfolio SICK has announced a major advance in its colour sensor portfolio, with its CSS high resolution and CSX and high-speed devices. SICK’s flagship CSS colour sensor leads the way with best-in-class colour resolution and the ability to distinguish even the slightest nuances in shade. Up to 15 colours can be output directly via the CSS’s four switching outputs, while up to 24 colours can be output using the IO-Link version. The SICK CSS’s unique distance regulation capability accommodates changing sensing distances automatically on a production line. With a switching frequency of 13.8kHz, the SICK CSX High Speed sensor works at double the pace of its predecessor device, while still offering full mounting compatibility for direct replacement. “These two devices now offer best-in-class performance, as well as combining unmatched colour recognition with ease of set-up and the ability to adjust the colour sensitivity precisely.” explains David Hannaby, SICK’s market development manager for presence detection. “The sensors are therefore ideal for wide-ranging colour sensing applications, such as colour verification for quality control, sorting and separation, as well as object and print mark positioning.” For more information visit www.sick.co.uk © stock.adobe.com/ItsananNext >