< Previous20 Food & Drink International www.fdiforum.net a cohesive brand identity, which customers can easily understand and invest in. All products will have the same dimensions and weight. Aside from this simply being more visually appealing, it means that profit margins will stabilise, as companies are not either undercharging for too much product or overcharging for too little. Sensors and other software can also be easily installed to work with, around or instead of robotics to monitor any stage of production, ensuring quality control while catching flaws as they arise. For example, temperature sensors can monitor the temperature of a heating element, and then adjust as needed to maintain consistent conditions. Separate vision systems can inspect products for defects or anomalies and take action to correct them. Inventory management can also be maintained by tracking inventory levels and automatically SugaTrak revamped to make real-time data capture on food manufacture waste even easier and more detailed SugaRich is delighted to announce a major update to SugaTrak, its cutting-edge waste management tool; it streamlines waste tracking, optimises resource allocation, and enhances sustainability efforts for food manufacturing businesses of all sizes. Its new features now include: • Enhanced visuals as a sleek and contemporary interface has been designed to elevate the user experience. • A new dynamic dashboard has been re-designed to provide deeper insights and smoother navigation. • Easier search function to support analysis, with more filtering choices, so data can now be streamlined and detailed. Alex Keogh, Managing Director of SugaRich says, “…SugaTrak is helping our customers to comply with the waste hierarchy by providing a tool to help eliminate waste throughout production. As with all the technological innovation and growth at SugaRich, we owe a huge debt of gratitude to all our clients who have provided invaluable feedback as their insights have played a pivotal role in shaping SugaTrak into its latest high-performance iteration.” For more information visit www.sugarich.co.uk © stock.adobe.com/asayenkaFood & Drink International 21 www.fdiforum.net PROCESSING SPOTLIGHT ordering supplies through smart software or watching any item through the production process with the use of RFID tags. Another common usage of automation is to provide enhanced end to end traceability. It is crucial to keep exacting records of facilities and packaging processes that food products have gone through. In the event of an urgent recall, it is necessary to quickly identify affected batches. A scanner and barcode system is an easily implementable way to provide detailed product information, without needing to trawl through extensive logs. Although barcodes will be allocated to the finished product, they can be used to track products whilst at the manufacturing facility too. Barcodes could be allocated based on facility, batch code, or recipe type. This can easily be changed based on data upon rollout, making it a versatile investment. A barcode system could be a steppingstone to more sophisticated tracing systems. Software can be integrated within machinery to provide a user interface into the operation of the machinery, thus giving increased insight into operational efficiency. For example, beverage bottling machines are ahead of the game on this technology. Monitoring software within newer versions can give 24/7 oversight of productivity (speed of output, running efficiency of the machinery, and any jams or other issues). This means that operators always have access to the most up to date data, and can react quickly to any problems. These systems also store necessary data on recipes, product traceability and batch codes. This means that products can be searched by code rather than scanned, which is useful in the event of lost items. ʴˈˇ˂ˀʴˇʸ ˀ˂ʼˆˇˈ˅ʸ ʶ˂ˁˇ˅˂ʿ %RI\GIWWSJQSMWXYVIGERLEZIPEVKIMQTEGXWSRJMREPTVSHYGX UYEPMX]TVSHYGXMSR IUYMTQIRXJYRGXMSR1SMWX8IGLƅWRIEV MRJVEVIHQSMWXYVIWIRWSVEPPS[WQERYJEGXYVIVWXLIEFMPMX]XSEHNYWX QSMWXYVIPIZIPWFEWIHSRVIEPXMQIMRJSVQEXMSRPS[IVMRKVE[ QEXIVMEPGSWXWERHSZIRYWEKITVSPSRKMRKIUYMTQIRXPMJIG]GPIERH MRGVIEWMRKTVSHYGXUYEPMX] TVSHYGXMSRIJJMGMIRG] ˪˪˪ʡˠˢ˜˦˧˧˘˖˛ʡ˖ˢˠ ʞʧʧʤʤʦʫʠʩʫʣʧʤʦ © stock.adobe.com/Retan22 Food & Drink International www.fdiforum.net POUCH PACKAGING In the pouch The widespread deployment of pouch packaging demonstrates the demand for convenience, ease of use and products that align with the growing environmental agenda. Food & Drink International 23 www.fdiforum.net POUCH PACKAGING © stock.adobe.com/VRTX 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 saleable 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. 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 encourages 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 24 Á24 Food & Drink International www.fdiforum.net POUCH PACKAGING 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 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 incredibly durable as 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.ukFood & Drink International 25 www.fdiforum.net POUCH PACKAGING 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. © stock.adobe.com/Itsanan © stock.adobe.com/Annartlab BENCHTOP BAG SEALING MACHINE IMPULSE BAG SEALING MACHINE HORIZONTAL BAG SEALING MACHINE VERTICAL BAG SEALING MACHINE26 Food & Drink International www.fdiforum.net MATERIALS HANDLING Materials Handling © stock.adobe.com/paulacobleighFood & Drink International 27 www.fdiforum.net MATERIALS HANDLING T he most obvious benefit of a materials handling system is it eliminates the damage and loss caused by human error. Yet, beyond this, a truly well managed system can increase efficiency, reduces handling costs, and facilitates stock management and process flow. Understanding how to increase efficiency with materials handling is useful to know, even if you intend to use a third-party warehousing partner, so as to make an informed investment. Key efficiency indicators include time sensitivity, storage temperature, the sealants utilised and accessibility of stock. All of these combine to determine the speed at which the materials can be processed, and the quality of the end product. Given that Unplanned Downtime, Yield, and Inventory Turnover are amongst some of the most common Key Product Indicators measured by food and drink manufacturers, it can be seen how efficiency with materials handling can improve these indicators. If outsourcing your warehousing is the best way to go, it is firstly important to ensure that your warehouse is accredited by the British Retail Consortium (BRC), as this is the gold- standard in ensuring that the warehouse is food grade. This means that safety and manufacturing processes are suitable for consumable products, meaning it is more likely that output will be at the desired pace and of the desired quality. Why is this important regarding materials handling? Their evaluation processes include the evaluation of Management of suppliers of raw materials and packaging and Layout, product flow and segregation, both of which cannot pass these stringent tests without quality materials handling systems. For raw materials and packaging, these could include a receptional unit which funnels into a pre-calibrated furnace to batch cook. This ensures the least possible amount of material waste, and consistency across cooking methods. The output would then feed onto a fully automated conveyor belt system, for transportation to packing robots, and from there a chute conveyor to transport the packaged products towards deposition departments. Alongside these processes would be a quality control system to ensure consistent output. Here, it is recommended that some human interface with the materials handling system occurs, to prevent system failure and outliers. It has been found that when workers are assigned purely for quality control roles, they are greatly efficient, as this is the subject of their undivided attention. The lack of human interference here would help to past the stringent sanitisation tests required for BRC accreditation and ensure a timely and continuous flow across the production process. This is especially required in the food and beverage sector, as it is subject to the ever-changing consumer preferences, and thus a requirement to keep up with change. Automated materials handling systems allow for flexibility within the supply chain, as when a new product is introduced, it is merely a case of recalibrating machinery. If flexible walls were installed in conveyor belts, this would allow for easy manoeuvrability around the warehouse if operations were to be moved, scaled up or scaled down, without significantly increasing downtime. Given the exponential demand for packaged snacks, ready meals, and In a modern world, the supply chain process in food manufacturing cannot survive without efficient and well-planned materials handling. 28 Á28 Food & Drink International www.fdiforum.net MATERIALS HANDLING flavoured drinks, this has necessitated efficiency within materials handling, as the long-lasting nature of these products means that businesses can expand their operations. With increased operations, increases the need for accuracy, food safety stringency, and cost-saving process. For example, frozen pizza is one of the best-selling pre-packaged food products. In fact, more than 350 million tons of frozen pizza is consumed yearly in the US. This requires finely tuned material handling of fresh dough, dairy and other common ingredients. Batch handling systems need to be employed, in a timely manner and without damaging the inventory, such as the automated system above. This is precipitated by a leading trend for convenience stores to provide fast-food services such as frozen food and ready meals. This increases the turnover required at manufacturing level. Once manufactured, the question turns to how to transport the packaged food (such as frozen pizza) around the warehouse. With the rise in mutli-product warehouses, so too has been seen a demand for Automatic Guided Vehicles (AGVs) to transport workers and products across the vast expanse of depot. They remove the requirement for manually operated forklifts, lessening costs for hiring workers who are qualified to operate such machinery. AGV’s can also operate for 24 hours a day. They utilise Artificial Intelligence to drive across pre-determined routes, pick up material, and transport it to another pre- determined destination. This decreases time delays, and the risk of misplaced goods, as a tracking system is integrated, which can be reviewed on a cloud-based system. AGVs are expected to reduce workplace accidents significantly, as driving automated paths and the ability to inter communicate with other AGVs reduces likelihood of collisions. It is estimated that 25% of injuries in the workplace are caused by contact with objects and equipment and reducing the need for manual handling across the production process, underscores the impact of automated vehicles in reducing these incidents. Although the above examples of materials handling may appear futuristic and out of reach, they are more common than ever. America’s leading drinks company, the Dr Pepper Snapple Group, has over 100 warehouses and distribution centres across the States, which is unmanageable without materials handling processes. These systems are increasingly being adopted by smaller businesses wishing to upscale, or simply improve efficiency. Whatever your businesses’ standing, it is undeniable that beginning to introduce materials handling systems will increase the efficiency, safety, and quality across your supply chain. In fact, given their effectiveness, they may become compulsory to install. © stock.adobe.com/standretFood & Drink International 29 www.fdiforum.net READY MEALS © stock.adobe.com/photka Young 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. P recooked 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 they deliver 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 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 above all 30 ÁNext >