< Previous30 Food & Drink International www.fdiforum.net MICROBIOLOGY AND TESTING From preventing foodborne illnesses to combating contamination, we explore the importance of laboratory testing and burgeoning technologies like cold plasma. T he importance of maintaining health, safety and hygiene throughout food supply chains is now well known by many a layperson. However, what can go unrecognised are the many reasons behind this necessity, and how it’s managed on a practical level. Microbiology plays an unseen but vital role in this aspect of the food and beverage industry, directly impacting consumers although they’ll rarely, if ever, think about it. As long as the food and drink products they purchase are safe, most times they don’t let it worry them further. But the flipside of this blissful ignorance is the precise motive of microbiology in mass market food production – the prevention of negative impacts on consumer health and satisfaction. Food manufacture, safety and quality assurance personnel concern themselves with these matters so the average customer doesn’t have to. Meanwhile, ignoring microbiology can have serious consequences. Microorganisms such as bacteria, Safeguarding the supply chains Food & Drink International 31 www.fdiforum.net MICROBIOLOGY AND TESTING viruses and parasites can invade food and cause a vast array of unpleasant illnesses. Paying due attention to the microbial health of all foods decreases the risk of contamination, which can lead to outbreaks of diseases like salmonella, E. coli, listeria and norovirus. If left unchecked, harmful bacteria may be taken in by consumers along with the carrying product. Vulnerable populations, such as the elderly, pregnant women, children, or individuals with weakened immune systems, are particularly at risk of foodborne illness. These can range in symptoms from mild discomfort to severe health complications and, in some cases, even result in death. Discovering microbiological contamination after food products have been distributed to the market may then necessitate costly and disruptive product recalls. There are multiple reasons why a product may be removed from store shelves. Sometimes, this action is taken voluntarily as a precautionary measure when a manufacturer discovers the potential presence of substances like metal, rubber or plastic. The most common reasons for product recalls revolve around the existence of undeclared allergens, which pose a severe risk to consumers with food allergies. But detecting and addressing food poisoning can be challenging, often leading to recalls after consumers have already become ill. Food manufacturers can and do implement strategies to combat microbial threats such as campylobacter, which causes gastrointestinal infections, and E. coli and salmonella, the bacteria which trigger their eponymous illnesses. While implementing thorough washdown procedures is crucial, this alone cannot guarantee complete protection. Companies may therefore rely on laboratory testing facilities to examine food and beverage products, as well as production lines, for any signs of Food Care Solutions aims to help our clients achieve their aims. We have helped food businesses throughout the UK since 2003 with our services, including: • Food Safety and Food Quality • BRC and FSSC 22000 certification • Supplier Auditing • Training • Hygiene Inspections & Internal Audits • Complaints & Incidents Management Tel: 01933 276 400 • Mob: 07811 192545 • Email: victor@foodsafeconsult.co.uk • Web: www.food-care.co.uk FOOD CARE SOLUTIONS FOOD CARE SOLUTIONS 32 Á © stock.adobe.com/analysis12198032 Food & Drink International www.fdiforum.net MICROBIOLOGY AND TESTING contamination. Although this procedure is not considered mandatory, manufacturers can gain confidence in the fact that their products are free from contaminants and that their production environment maintains high hygiene standards. Laboratory testing serves another important purpose in the authentication of food products, verifying that the listed ingredients match what consumers are really eating or drinking. This measure acts as a safeguard, particularly in the ongoing fight against counterfeit food products that continue to flood the market. The testing process involves taking controlled samples of food products, either from a specific batch or a variety of sources. These samples are then processed to create a consistent and precise slurry for analysis. The slurries undergo thorough examination and processing, and the results are provided to the respective food companies, allowing them to see the quality of their products in fine detail. While testing products is a crucial step, simply identifying contamination does not solve the issue of eliminating it. Although maintaining hygiene is vital in this regard, advancements in preventive and defensive measures are continually being made. Cold plasma has been a topic of discussion for years, particularly in the context of food manufacturing, where it utilises reactive gases to neutralise microbes present on meat, fruits and vegetables. What sets this method apart from others, like ultraviolet treatment, is its ability to effectively eliminate a high percentage of microbes without causing any damage to the food or altering its properties. In fact, one study discovered that cold plasma eradicated 99.9 percent of norovirus while preserving the integrity and flavour of fruit. Although the use of cold plasma technology is not yet widespread, it is on the verge of becoming more commonly adopted. Its advantages extend beyond treating microbes on the surface of food products alone. Cold plasma can also be employed on contact surfaces and in processing and packing equipment, ensuring a sterile and contaminant-free production line. This versatile application further Allergen Services, Meat and Fish Species Detection, GMO Screening, Nutritional Values, Acrylamide, Pesticides, Heavy Metals, Vitamins and Minerals, Mycotoxins, Authenticity and Isotopic Analysis, Challenge Testing, Microbiological Assessment, Rapid (24hr) Pathogen Detection. UKASAccreditedServices UKAS accredited food, swab and water analytical services • A range of turnaround times available DAKKS accredited services available through our group Laboratory, IFP Labs Unit 1b Moderna Business Park, Mytholmroyd, HX7 5QQ Tel: 01422 405678 Email: sales@micro-search.co.uk Part of IFP Laboratories Group TESTING WITH RESPONSIBILITY © stock.adobe.com/ luchschenFFood & Drink International 33 www.fdiforum.net MICROBIOLOGY AND TESTING enhances its appeal in the food industry. While more efficient methods are still being developed, checks for microbiological contamination should take place in any way a food manufacturer is able to provide. If not, incidents which may otherwise have been prevented can result in lawsuits and legal consequences. Companies may face litigation from affected consumers, regulatory penalties, and financial losses due to legal settlements, fines and decreased sales. No matter how swiftly reparations are made, the damage has reverberations in wounded consumer confidence and trust, which may make it difficult if not impossible to regain their loyalty. Despite the invisibility of microbiology testing outcomes, consumers have increasingly become more conscious of the food supply chain in recent years, largely due to the rise of social media. Since 2020, this awareness has intensified further as consumers delve deeper into concerns regarding potential contaminants in their food. Leveraging this growing trend, food companies are actively engaging with consumers through social platforms and adopting a more transparent approach to their processes. This creates an open loop for feedback and better practice. Consumers who feel assured in their ability to converse with businesses will provide valuable experiences, while this level of accountability fosters the best hygiene standards in any business that cares for its customers. Manufacturer of pre-poured culture media and associated products for microbiology. BOTTTLED & BAAGGEEDMMEDIAA BESPPOKEEMEDIA MMANUFACCTURRE PLATTEDMMEDIA Scan Heere to Browse Our Product Range Find out more at www..sglabb.com Email Us sales@sglab.co.uk © stock.adobe.com/ Марина Жукова34 Food & Drink International www.fdiforum.net POUCH PACKAGING BAG SEALING MACHINES RM Sealers remain a leading British manufacturer and supplier of high quality Bag Sealing Machines, also known as Rotary Band Sealers and Impulse Sealers. Call 01442 843387 to speak to a member of our team SEALERS © www.rmsealers.co.uk Here to stay Once reserved for pet food, pouch packaging could shake up the industry – ticking all the right boxes. Sustainability, affordability, and flexibility. Food & Drink International 35 www.fdiforum.net POUCH PACKAGING P ouch packages are highly versatile, offering an impressive degree of customisation that continues to make them an attractive option to producers and consumers alike. They come in several different formats, depending on the function and market for which they’re intended. For example, baby food often makes use of the spout pouch, in which a plastic cap can be twisted off and the food inside sucked out of a plastic spout. This also has the added benefit of being resealable, helping with portion control and cutting down on food waste. For pouch packaging, the baby food market has also yielded several breakthroughs including no spill technologies. Functionality is crucial to the popularity of pouch packaging, with heat sealable and flat-bottomed varieties available. Though most commonly found paired with ambient foods, pouch packages have become increasingly common in the freezer aisle. One of the biggest motivators in the development of new packaged goods concerns the environment, and with fresh heat waves and the recent conferences on the topic, this is a timely one. Pressure groups, campaigners, consumers and government ministers have all called on food companies and packaging producers to make their products more sustainable and more easily recyclable. BENCHTOP BAG SEALING MACHINE IMPULSE BAG SEALING MACHINE HORIZONTAL BAG SEALING MACHINE VERTICAL BAG SEALING MACHINE 36 Áencourages multiple uses by ensuring the product inside is kept fresh and improving the overall customer experience. Because of the lightweight nature and flexibility of pouch packages, producers can save on storage space and pack more product in one shipment, thereby saving fuel costs in transit. So, when it comes to logistics, pouch packaging is often a more environmentally friendly option than other more rigid forms of packaging. This also makes these packages ideal for mail orders, as their lightweight nature means producers can reduce postage costs compared to other materials. For all that, pouch packages are still a challenge when it comes to recycling. As the environmental agenda becomes of increased importance, doubtless the flexible packaging industry will continue to make gains with the recyclability of pouch packages. Although at present these 36 Food & Drink International www.fdiforum.net POUCH PACKAGING Pouch packaging, especially the aforementioned re-saleable pouch varieties, has an advantage here over many of its counterparts. While they’re still ultimately made from multiple layers of plastic – the primary raw material being linear polyethylene resin – these re-sealable pouches aren’t single use. Single-use plastics are rampant in the food and drink industry, especially in the food to go where packaging is discarded after a product is consumed. But with a re-sealable function on a pouch package, it © stock.adobe.com/Annartlab © stock.adobe.com/ ItsananFood & Drink International 37 www.fdiforum.net POUCH PACKAGING packages can be optimised for recycling, they are often thrown out with domestic waste. It’s worth noting, however, that niche and speciality recyclers are now accepting these kinds of plastics for recycling. Several pouch packaging makers specialising in recyclable and eco-friendly packages have also emerged over the last few years to improve the industry’s green credentials. For producers, the benefit of pouch packaging is first and foremost its versatility. As the most flexible and adaptable type of packaging on the market, shape, size and materials can all be adapted to meet specific customer requirements. They also use fewer resources to produce than other common types of packaging such as plastic tubs and tins. They are also incredible durable as they’re often made from laminated polyethylene terephthalate (PET) that can stand up to high pressure and temperatures. This makes it ideal in transit, but also means it’s ideally suited to microwavable cooking, making it a popular choice for ready meal foods such as rice, pasta, cous cous and quinoa. High barrier pouches, meanwhile, employ a protective layer which keeps outside elements from entering the package. It’s also not just in terms of materials where pouches have an advantage over other types of packaging, but they boast reduced retort and serialisation time compared with glass bottles and metal tins. As well as the convenience inherent with flexible pouches, another big draw is the vibrancy of pouch packaging. Designed either to stand upright or hang, pouch packages are easy to pack and display on store shelves. Some might have a clear window allowing consumers to see the product inside, but typically the entire package is the label, offering producers a big canvas to work from. Pouch packaging offers full front image, rotogravure quality printing and improved print quality, but there’s no added cost for extra labelling, as everything is included on-pack. Because of its strong shelf appeal and immediate impact with consumers, these packages also mean that smaller producers and start-ups can compete with major industry players. The consumer demand and industry ubiquity of pouch packaging has led to manufacturers having to increase their production output to keep up. This, in turn, has meant machine makers have had to supply ever more innovative equipment. Some filling machines now boast speeds of 120 pouches per minute and this will only increase. Machine makers have also noted an uptick in orders for bespoke, integrated systems designed to suit their exact needs. 38 Food & Drink International www.fdiforum.net SOFTWARE AND HARDWARE In the fast-paced world of food manufacturing, embracing the power of automation to streamline production processes, enhance efficiency, and elevate food safety standards is becoming a must for manufacturers. © stock.adobe.com/Frenchiebuddha EmbracingFood & Drink International 39 www.fdiforum.net SOFTWARE AND HARDWARE A s the demand for quality and traceability grows among consumers, the integration of smart processes is imperative for manufacturers seeking a competitive edge. From IoT-enabled smart systems to AI-driven quality control and enhanced supply chain traceability, the impact of automation is moving the sector towards safer, more transparent, and customized food production. In the UK, food manufacturers are rapidly embracing the concept of smart factories, a notion already well- established in Asia’s thriving clothing industry. A smart factory, alternatively known as an intelligent factory or Industry 4.0 factory, represents a modern manufacturing facility that harnesses advanced technologies, automation, data analytics, and artificial intelligence to optimize production processes, achieving remarkable efficiency, productivity, and adaptability. These facilities leverage the power of the Internet of Things (IoT) by incorporating IoT-enabled sensors throughout the production lines. The IoT allows everyday objects to send and receive data to one another via the internet. These sensors facilitate real- time monitoring of critical parameters like temperature, humidity, and pressure, enabling seamless data exchange that allows manufacturers to optimize workflows and identify potential bottlenecks before they escalate into larger problems. The implementation of smart factories also involves real-time monitoring of machinery and equipment health, ensuring proactive maintenance to prevent unexpected breakdowns. By embedding IoT sensors in machinery, early signs of wear and tear can be detected, facilitating predictive maintenance schedules. This proactive approach significantly reduces downtime and extends the lifespan of equipment, ultimately leading to cost savings on maintenance. Additionally, AI-driven algorithms help optimize the use of resources, leading to reduced water and raw material wastage. Furthermore, automated monitoring processes give oversight into equipment efficiency, so outdated equipment can be replaced to use less heat. Smart systems can monitor energy consumption in real-time, allowing manufacturers to optimize energy usage and reduce wastage. By minimizing resource consumption and waste generation, smart factories align with sustainable manufacturing practices, making them more appealing to environmentally conscious consumers and investors. Even without creating a smart factory, packaging is the most common area of manufacturing in which to find automation. To maintain the safety of consumable products, it is crucial to uphold a consistent and sterile environment. Automatic packaging of items ensures a standardized product output, eliminating the risk of human error that could lead to less secure packaging. This reduces the chances of spoilage or damage during transportation and shelving, safeguarding product quality. Companies can avoid substantial losses due to product wastage and, more importantly, protect their brand image from being associated with inconsistent products, which could erode consumer trust in their quality and safety. Incorporating packaging machinery brings additional benefits, as it is easy to clean and minimizes the risk of product contamination compared to relying on human handlers’ hygiene practices. The automation of packaging processes also reduces downtime spent on cleaning, as opposed to frequent handwashing. Various automated solutions are available for packaging tasks, such as can sealing, pouch making, and pick up and drop off robots. Advanced robotic systems precisely measure and fill products, © stock.adobe.com/Laurentiu Iordache 40 ÁNext >