< Previous30 Food & Drink International www.fdiforum.net READY MEALS 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 © stock.adobe.com/William Automated Tray denesting solution for meat free range of products Quorn Foods have been on a mission to produce vegetarian and vegan products since long before it ever became popular. Recently, Quorn have been focused on reducing labour costs and increasing production speeds and looked to the UKs leading manufacturer of Pick and Place Tray Denesting solutions, Partners in Packaging (Machine Systems) Ltd for a solution which would handle a range of different trays, and work with an existing high speed tray sealer and an automatic product loading system. “What attracted us most to the A Series, is the ease of which trained operators can change from tray to tray in a matter of minutes without the need for any fine tuning” said Shirley Vassallo, Quorn’s Senior Process Technologist. “it’s a simple job of changing the dedicated product magazine mask, which is set up by Partners to optimum settings for each tray and tub. The A Series also offers us the flexibility of using trays and tubs made from different materials such as card in the future, which will only require a new product mask.” For more information visit www.partnersinpackaging.com Food & Drink International 31 www.fdiforum.net READY MEALS 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 cartoning 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 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. Despite this there is still room for threats to the market from health-conscious consumers, as there’s plenty of talk and research around the potential dangers of ultra processed food (UPF) and the impact it can have on people’s waistlines, heart health, and even mental faculties. Ready meals naturally contain a lot of additives that would not be used in fresh foods because they need to sit on shelves for several days, so while the convenience is still there, some consumers are choosing to steer clear and look for fresher alternatives. www.halalfoodauthority.com - info@halalfoodauthority.com - 0044 (0) 20 8446 7127 Meat, Food Processing, cosmetics, logistics, chemicals, additives & aromas, cleaning substances, packaging, pharmaceutical, ingredients GETHALALCERTIFIED GOBEYONDBORDERS © stock.adobe.com/ weyo32 Food & Drink International www.fdiforum.net MICROBIOLOGY AND TESTING © stock.adobe.com/ParilovFood & Drink International 33 www.fdiforum.net MICROBIOLOGY AND TESTING M icrobiology is vital in the food industry, in production, processing, preservation, storage and shelf life, as well as food safety. Microbiologists perform critical work, from studying foodborne pathogens and evaluating whether products comply with health and safety regulations, to working in product development and quality control for manufacturers. While microbes including bacteria, molds, and yeasts are utilised for the production of foods and food ingredients, for instance for beer, bakery, and dairy products, here Food and Drink International focuses on microbiology in relation to manufacturers preventing and addressing microbial contamination and foodborne illness, which can quickly ruin a brand and its reputation, halt production, see major fines, costly recalls, and even lead to death for consumers. One need only reflect on a Listeria outbreak in England in 2019, traced to sandwiches, that killed six people as an example, with the supplier of the chicken sandwiches, Good Food Chain, meat producer, North Country Cooked Meats, and distributor, North Country Quality Foods, all ultimately going into liquidation and ceasing trading. Consumers expect that the food industry uses effective control measures to ensure products are free of pathogens. Alongside actions such as a thorough cleaning and sanitising routine and seeking out any errors in these practices to fix them immediately, a solid continual regimen of microbial tests is essential to ensure products are safe for consumption. This acts as one of the most important elements of quality control and pathogen prevention. Facilities should make use of an environmental testing programme for pathogens, while routine product testing, and ‘search and destroy’ are also effective, with the latter seeing teams swab everything in a facility in search of pathogens, and upon finding an area with a pathogen, swabbing everything within a gradually expanding radius until all major contamination points are found. These areas can then be noted as hot spots for continual checks. An important aspect of microbial testing is deciding whether to use external labs or to conduct microbial testing onsite. For smaller businesses, third party labs tend to be the more accessible option, with ease of use key, as the manufacturer simply ships samples and swabs away to be tested. These labs are usually associated with stringent standards and can access expertise, while being preferable during a time of labour shortages, allowing for increased productivity. Using an external lab also overcomes concerns of handling pathogenic samples in the same facility that food is made and incorporates less initial outlay, with no testing equipment being invested in. Meanwhile no additional floorspace is required to accommodate an onsite lab. Conversely, over time the expense of sending out samples can be high, whereas by bringing testing onsite, it can be completed at a lower cost. With a lower cost per test, testing can be conducted more frequently. In addition, testing can be completed quicker in-house, preventing a hold up of products until they are cleared by the results, reducing times from up to around 72 hours to an under 24-hour turnaround. Of course, as noted, investing in the equipment can involve significant expenditure, as can hiring, and training employees to collect swabs from products and surfaces. Space must also be allocated for a secure area that does not allow for cross contamination, with isolation, adequate ventilation, food safety Food safety expectations and awareness are only rising. As a result, microbiology and testing will only become more crucial to the food industry. 34 Á Ensuring 34 Food & Drink International www.fdiforum.net MICROBIOLOGY AND TESTING secure entries and more required. Moreover, to be worth the investment, it should be considered whether there will be enough testing volume. Considering the future of the industry, as labs turn to automation technology, the development of modern sequencing technologies is revolutionising food microbiology and safety, with high throughput sequencing, or next generation sequencing, allowing specialists to sequence marker genes, whole genomes, and transcriptomes of microorganisms in close to real-time. In dealing with pathogens, the data can uncover a pathogen of concern’s identity as well as its virulence potential and functional characteristics. Within this, whole genome sequencing has been hailed as the best-in- class genomic sequencing solution for the investigation of foodborne outbreaks - a rapid process of determining the complete DNA sequence of an organism’s genome, helping to trace source of outbreaks quickly. Applauded for its efficiency and specificity, it takes over from more tedious molecular methods for typing pathogens. The technique is being used to compare the genomes of pathogens isolated from food samples to clinical samples from ill patients. When there is a match between these, food safety experts can use this information to pinpoint the source and extent of an outbreak. A further key benefit of whole genome sequencing in investigating outbreaks is the ability to match the genome sequence of a foodborne pathogen with its geographic origin, with genome sequences from pathogens in the same location sharing more common features. This is useful when needing to nail down the contamination source in complex food, containing ingredients from countries across the world. In understanding and identifying the sources of foodborne illness consumers can be protected and global food safety measures enhanced. The evolution of machine learning, algorithms and new bioinformatics tools and availability of data, meanwhile, is allowing the formation of novel models for predicting, preventing, and addressing outbreaks of foodborne diseases. Predictive diagnostics for instance uses customised data and diagnostic tools to present real-time insights and uncover possible issues. Utilising a combination of molecular innovations and genomics applications, predictive diagnostics can help create impactful and measurable improvements to operations. While technologies like whole genome sequencing are in use by governments for food safety inspections, outbreak investigations and disease diagnostics, integration is at present limited amongst food firms themselves. One reason for this is the investment and training involved. 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/GorodenkoffFood & Drink International 35 www.fdiforum.net SOFTWARE AND HARDWARE © stock.adobe.com/Frenchiebuddha T he food and drink industry faces a constant struggle to boost efficiency, reduce downtime, and find cost savings. However, by exploring and integrating automated hardware and emerging software solutions, manufacturers can take their operations to the next level. It is crucial to keep software up-to-date and stay current to keep up with competition. For these reasons, it’s well worth adopting cloud computing, big data, and analytics to gain insights and improve efficiency. Cloud computing has become increasingly popular in the food and drink industry, as companies seek to consolidate their various branches into a single enterprise platform. The cloud refers to software and services that run on the internet rather than locally on a single computer, enabling multinationals and other major players in the food and drink sector to conveniently widen their net of owned companies. This is because the cloud allows companies to oversee all infrastructure from a central location and integrate resources more efficiently. The growth in digital technologies, including big data and analytics, has brought about significant changes in the industry and will continue to do so in the years to come, not least in ascertaining trends in customer preferences. Big data allows companies to gain insights into the behaviour and spending habits of consumer groups in large numbers creating invaluable insights when forging new strategies in areas such as marketing or packaging. Even on the internal level, operational efficiency can be analysed smart business Embracing 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. 36 Á36 Food & Drink International www.fdiforum.net SOFTWARE AND HARDWARE through data streams, zeroing in on specific areas that require improvement. Information unlocked with analytics may reveal that most inefficiencies occur because of a single unit or component. As a result, rather than replacing an entire processing line and causing potentially vast expense, smaller areas can be focused on to save money, and labour besides. Such solutions can also lead to cost and efficiency savings beyond the production line, by automating inventory management using sensors, for instance. Regardless of whether a company produces bottled soft drinks, confectionery, or food grade lubricants, it will undoubtedly have inventory requirements that range from raw ingredients to packaging materials. Previously, the industry standard for managing inventory involved the use of a clipboard, pen, order forms, and telephones. As desktop computers became more prevalent, this process transitioned into the digital age, and subsequently evolved again with the advent of smartphones and tablets. However, advancements in software and smart technology, such as sensors, have made it possible to automate this process to a great extent. Essentially, a manufacturer can now receive notifications as soon as they need to order more of any given stock. More sophisticated solutions will automatically order inventory items as soon as they are running low. As long as there are no supply chain issues, there is no need to worry about running out of stock. By ordering only the necessary amounts, a manufacturer can ensure that they do not overspend on replenishing inventory. One of the most disruptive technologies developed in recent years has been blockchain. This technology is essentially a decentralised, distributed, and public digital ledger that can record transactions and supply chain information in a secure and traceable manner. Supporters of blockchain claim that it has the potential to increase transparency, collect more accurate data, and Food & Drink International 37 www.fdiforum.net SOFTWARE AND HARDWARE eliminate the need for intermediaries. However, there is still a significant lack of trust in the technology, both within and outside of the food industry, due to its relative newness and limited adoption. Despite this, proponents argue that widespread adoption of blockchain could lead to reduced prices for consumers and more equitable returns for farmers. Hardware is not exempt from digital disruption, and this can be seen in the development of the Internet of Things (IoT), which connects physical objects in an interconnected network. For manufacturers, the use of IoT technology can result in improvements in efficiency, logistics, and food safety, while also reducing waste and increasing transparency in the supply chain. Despite the initial cost, many manufacturers incorrectly assume that implementing these solutions will be complicated and troublesome. In reality, many smart technologies are designed to be easily integrated, with a plug-and-play nature that simplifies the installation process. Although adopting a fully automated production process can lead to significant cost savings in the long run, the initial investment required can be a significant hurdle for smaller producers. Therefore, a semi-automated process may be a more viable option, and in the short term, human labour may be more cost-effective. However, there are alternative options available, such as purchasing used and refurbished machinery. When considering this option, manufacturers should ensure that they source from a reputable supplier who can provide safety checks, quality assurance, and reviews from previous customers that can inform their purchasing decisions. Refurbished machines are typically rigorously tested and meet modern operational standards and can often be easily integrated into existing production lines. As a result, it is not uncommon for manufacturers to operate newer and refurbished machines side by side. © stock.adobe.com/sompong_tomACHIEVE PRINT SUCCESS AT WWW.LABELEXPO-AMERICAS.COM LABELEXPO AMERICAS, THE GAME-CHANGING EVENT FOR THE LABEL AND PACKAGE PRINTING INDUSTRY, RETURNS TO CHICAGO. 10-12 SEPTEMBER DONALD E STEPHENS CONVENTION CENTER, CHICAGO 3 DAYS 5 HALLS 400+ EXHIBITORS ALL UNDER ONE ROOF THIS SEPTEMBER > Engage with innovative suppliers and find the latest trends and technologies to give yourself the competitive edge. > Discover hundreds of live demonstrations and product launches from leading manufacturers. > Connect with industry experts and learn about the latest advancements in flexible packaging, automation, RFID and sustainability.Food & Drink International 39 www.fdiforum.net LABELEXPO AMERICAS 2024 A imed at label and package printing converters, brand owners, label/packaging designers, and suppliers, this year’s edition focuses on bringing the package printing community together and achieving print success. Covering five halls, over 400 exhibitors will be participating, including: ABG, Avery Dennison, Nilpeter, HP, Mark Andy, OMET, Xeikon, BOBST, Cartes, Heidelberg, Durst, SCREEN, Dantex. Complementing the exhibition includes the FlexPack@Labelexpo, a focused area for flexible packaging, which will allow attendees entering this high-value market to see the latest equipment and materials from leading industry suppliers in the flex pack sector. At the Innovation Stage, exhibitors will get the opportunity to promote their latest technologies. TLMI, the sponsoring partner for Labelexpo Americas 2024, will host an Eco Stage on the first two days of the show, presenting the latest developments in sustainability. The Label Academy will be presenting masterclasses on Shrink Sleeves and Flexible Packaging and a workshop on RFID Technology for Label Converters, aligning with the key trends to be seen at the show. This educational series will provide attendees with expert guidance into how they can enter or expand their label production into new, lucrative markets, add value and streamline their current operations. A one-day conference program will comprise of sessions including a global and regional market overview, redefining sales strategy, diversification into new segments such as flexible packaging and cartons, as well as a case study on the cannabis packaging market in North America. Also taking place, on the evening of 10 September, will be the Opening Night Party featuring the Label Industry Global Awards, which recognize key achievements and celebrates excellence in the label and package printing sector. Labelexpo Americas 2024 is again strongly supported and endorsed by trade bodies such as TLMI, Acoban, FPA and FTA. To register, visit: www.labelexpo-americas.com Labelexpo Americas 2024: Spring into action and achieve print success Registration for Labelexpo Americas 2024, the Americas largest label and package printing technology trade show, is now open. Returning to Donald E. Stephens Convention Center in Rosemont, Illinois from 10 – 12 September, the biennial show promises hundreds of live demonstrations, three new features, a one-day conference program, two educational workshops and a master class focusing on flexible packaging. Next >