< Previous20 Food & Drink International www.fdiforum.net MACHINERY AND EQUIPMENT SPOTLIGHT inspection and maintenance can sustain efficiency and identify causes for concern before they result in extended disruptions. This will also ensure that machines are running at optimum levels and, thus, at their most environmentally friendly. As well as the ongoing issues that producers and processors have been facing for many years now – including staff shortages and the continuing skills gap – more challenges have arisen over the last twenty-one months. Namely, social distancing measures and self-isolation. The impact COVID has wrought on the industry cannot be overstated. Despite a relative return to normal, businesses are still feeling the economic impact of the pandemic, and news of Mpox has many fearing what the return of another infectious disease (if not Mpox then something else) might do to the industry. It should go without saying that replacing old and outdated machinery will not only boost a company’s efficiency and output but will also reduce carbon emissions, but too Tennant RUBBER Tennant Rubber Ltd is a family run business with 70 years of experience in the Rubber Industry. T 0115 985 2300 E sales@tennantrubber.co.uk W www.tennantrubber.co.uk © stock.adobe.com/Leyla RamazanovaFood & Drink International 21 www.fdiforum.net MACHINERY AND EQUIPMENT SPOTLIGHT many producers still rely on old machinery rather than investing in new or refurbished replacements. It’s a false economy and counterintuitive besides, yet worryingly commonplace. A McKinsey report found that the average food processing plant, for instance, is more than two decades old. With the continuing market proliferation of smart technologies, companies risk making themselves obsolete. Investing in machinery and equipment that can deliver cost savings will, of course, be a motivation alongside efficiency gains, but part of the criteria also needs to be environmental impact. Declining labour availability is also a continuous issue for manufacturers, which automation and AI are being touted as a possible solution to. Using robots can streamline process, reducing the need for labour. Furthermore, the drive for sustainability is increasing across the sector. Automated monitoring processes give oversight into equipment efficiency, so outdated equipment can be replaced to use less heat. Packaging is the most common area of manufacturing in which to find automation. A consistent and sterile environment needs to be maintained to preserve the safety of consumable products. Packaging machinery is easy to clean and lessens the chance of product contamination from unscrupulous handler hygiene practices. Furthermore, there is less down time from cleaning machinery, than from continual hand washing. Automating solutions are varied, Our experienced team supplies rubber and many other polymer products into a range of markets in the UK including food, pharmaceuticals, locomotive, quarries and mines, bulk processing, engineering, utilities, construction, chemical and many more. 70 YEARS 22 Á © stock.adobe.com/moodboard22 Food & Drink International www.fdiforum.net MACHINERY AND EQUIPMENT SPOTLIGHT with the most common in packaging being can sealing, pouch making, and pick up and drop off robots. 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. These management systems could significantly decrease operational costs. Having insight into the energy consumption of the machinery means that inefficient equipment can be identified and replaced before having a detrimental impact on energy and operating costs. Furthermore, inefficiently running machinery can be an early indicator that equipment is likely to break down. This allows manufacturers to run repairs, or even purchase new equipment pre-emptively, meaning that down time due to machine expiry can be mitigated. Taking steps to reduce energy consumption has the dual benefit of decreasing the carbon footprint of the business, meaning that manufacturers can be one step closer to achieving sustainability goals. This is a benefit that is passed onto the consumer, as many are increasingly looking to invest in companies which seek to enact widespread positive change. © stock.adobe.com/asayenkaShady Lane, Great Barr, Birmingham, B44 9EU England Tel: +44 (0)121 360 0155 For all your Power Transmission Solutions • Roller Chain • Gears & Sprockets • Timing Belt Drives • V Belt Pulleys • V Belts • Clamping Elements • Inverted Tooth Chain • Inverted Tooth Sprockets • Sealmaster Bearings • Shaft Couplings • Freewheel Clutches • Torque Limiters • Overload Clutches • Sheargard Clutches • McGill® Cam Followers • Gearboxes The Driving Force In Power Transmission sales@crossmorse.com www.crossmorse.com Power Transmission Solutions Reliable & Easy-to-Use Eriez Metal Detectors Offer: • Dependable Consistent Detection • Large Capacitive Touchscreen • Rugged Washdown Construction Bulk Flow Liquid Line Conveyor www.eriez.eu | +44 (0) 29 2086 8501 Metal Detection 24 Food & Drink International www.fdiforum.net DUST CONTROL F ood manufacturing facilities are required to adhere to strict food safety regulations in order to produce safe, high-quality products. One important aspect of these regulations is the control and maintenance of clean air in the factory and the control of dust particles. Whilst this might sound like a no brainer, there is actually considerable merit to giving some thought to optimising factory ventilation systems with a view to improving the productivity of employees. There are several ways that food manufacturers can maintain clean air in their factories. One of the most effective methods is through the use of air filtration systems. These systems work by pulling in outside air and running it through a series of filters to remove dust, dirt, and other contaminants. The cleaned air is then circulated throughout the factory, helping to keep the air inside the facility clean and safe for both workers and products. Air filtration systems are well suited to large factory spaces, and for especially dusty environments. Another way that food manufacturers can maintain clean air in their factories is through the use of air purification systems. These systems use advanced technologies such as ultraviolet (UV) light and ozone to kill bacteria, viruses, and other microorganisms that may be present in the air. This is especially important in areas of the factory where food is being processed or packaged, as these microorganisms can pose a significant risk to the safety of the finished product. UV air dust Dust control and air filtration are necessary not only for hygiene reasons, but also for productivity of employees. Controlling © stock.adobe.com/ElnurFood & Drink International 25 www.fdiforum.net DUST CONTROL © stock.adobe.com/aviavlad purifiers are generally best for localised use, such as near workstations, and therefore should be considered when working with potential contaminants (such as raw meat). As these emit UV light, which can cause damage to the eye, face shields may need to be considered for those working closely alongside them. In addition to air filtration and purification systems, manufacturing facilities should also be taking steps to reduce the amount of dust and other contaminants that are generated within the factory. This may involve implementing good housekeeping practices, such as regularly sweeping and cleaning floors and equipment. It may also involve investing in specialized equipment, such as dust collectors and ventilation systems, to help control the spread of dust and other contaminants throughout the factory. Common cleaning tasks like vacuuming can help remove dust from surfaces, but to fully address the threat of dust, a properly designed and installed industrial dust collection system, such as involving cartridge dust collectors, is required, working to collect dust from the air and constantly cycle it through filter cartridges while putting clean air back into or sending it out of the facility. Pressure from dust build-up on the filter meanwhile is relieved as the system pulse cleans the filters, by sending a blast of compressed air through the centre of the filter, ejecting dust to fall into the hopper. It should be noted that when a dust collector pulls combustible dust from the air, the system itself is also a source of dust explosions if not properly protected. Additionally, the location of a dust collector must also be considered (usually in food production being placed outside to stop dust recontaminating a facility in filter changes) and what the best filter for the application will be. For instance, hygroscopic dusts, absorbing moisture from the air, can mean dust reaching filters is wet when the surrounding environment is humid or water vapour is released to the air from production processes, leading to a crust or caking on a filter. In this scenario, a washable filter material will lengthen filter lifespan. Modern networkable or cloud-based control systems can also be integrated for predictive maintenance and remote monitoring of dust collectors. A clear way to mitigate dust and its potential to cause health and safety issues is to prevent accumulation and spread in the first place. In doing this one can remove any potential ignition sources and reduce health risks for workers. Many companies use food- grade extraction arms (telescopic and flexible), designed to capture dust particles and contaminants before they get the chance to enter the breathing environment of staff. These typically involve a flexible hose connected to a powerful vacuum system placed near the source of dust with an extraction hood. The vacuum system extracts the particles into the ducting system to be captured. Enclosures around dust creating processes and transfer points and conveyors can also be beneficial. Clean air and ventilation maintenance is not just desirable – it is entirely necessary. Primarily, this is for the safety of the workers, and ultimately, of the consumers, as it removes the legitimate threat of consumable products being contaminated by dust or other airborne particles. Which system is chosen depends on the nature and scale of manufacturing, but all manufacturers could benefit from implementing a basic air quality testing regime (the frequency of which can be determined by how hazardous the products are – dusty products such as spices will require more frequent testing due to their irritant nature) to prevent employee health risks and generally improve factory working conditions. 26 Food & Drink International www.fdiforum.net BAKERY AND CONFECTIONARY Sweet simple The bakery and confectionary markets face their own raft of issues surrounding obesity, sugar taxes and rising inflation, proving that even food staples aren’t immune to rapidly changing conditions. but not soFood & Drink International 27 www.fdiforum.net BAKERY AND CONFECTIONARY In spite of the dreaded sugar tax, UK bakery and confectionary businesses are booming, and are even set to surpass pre- pandemic levels. The first reason why the UK is seeing a bakery boom is that businesses are commonly and cleverly combining their bakeries with a coffee shop. In fact, research suggests that 40% of consumers are more likely to buy a sweet treat to accompany a hot drink. With a return to office-based working, people love a break from the office hustle and bustle in a warm, calming, and aromatic environment. Ultimately, people often come for the coffee, and stay for the bakery. Survey results depict a romanticised image of bakeries, with many consumers saying they would prefer to purchase from artisan bakeries with fresh products. The key takeaway from this is that independent concerns should be ensuring that their establishment exudes uniqueness with an emphasis on fresh, artisanal options. Furthermore, increasing to-go offerings is likely to prove successful. With larger chains such as Costa and Starbucks opening new drive-thru sites in community and travel hot- spots, this is an indicator of the demand for food and drink whilst on the move. The sweets and confectionary industries have also tied themselves into this with a push toward chocolates and other sweets being offered as parts of “meal deals” by most supermarkets. While not exactly healthy (and that remains a concern for many consumers) this push toward sweets as a convenient source of sugar and energy has proven popular. In the realm of flavours, it’s a tale of seamless fusion. The culinary narrative blends the timeless essence of tradition with the vivacity of innovation. A staggering 34% of consumers seek more variety and novelty in their cake, pastry, and sweet goods consumption. Seasonal and limited-edition flavours also beckon, with 13% of individuals actively seeking these tantalizing options. American-inspired flavours continue to capture hearts, with toasted s’mores and salted caramel emerging as perennial favourites. The reign of cookies and cream in the realms of cheesecake and cupcakes remains unchallenged. Flavors, in all their glory, are more than just sensory delights – they’re an artistic expression. Buttercream has emerged as a medium through which bakers craft masterpieces that are equal parts nostalgia and “wow” factor. The intricate art of buttercream piping and painting resonates deeply with audiences, fuelled by a continued longing for nostalgia. 28 Á © stock.adobe.com/exclusive-design28 Food & Drink International www.fdiforum.net BAKERY AND CONFECTIONARY Bakery checkweighing compliance essentials Efficient weight controls and checkweighing systems on bakery production lines are integral to meeting consumer expectations and for compliance with net weight regulations. Daniel Shail, Applications Engineer at Fortress Technology Europe, explains why this is so imperative. By deploying smart checkweighers inline and at the end of a production line, processors prioritise and promote food safety, while simultaneously protecting their brand integrity. Additionally, weight controls help meet waste reduction targets, contributing to a more sustainable production process. Global weight regulations are in place to safeguard consumers from receiving products that do not meet the specified weight requirements. If processors are not using ‘regulatory-approved’ weighing systems, or using them incorrectly, it can result in costly penalty fines. Notably, knowingly distributing underweight products in some regions could be deemed fraud. Although automated food checkweighing is not currently as tightly regulated as HACCP inspection equipment, many processors now recognise the essential role these systems play in their wider quality control programs. To download a copy of the Fortress Technology Checkweighing Compliance Essentials whitepaper visit https://fortresstechnology.co.uk/checkweighing-compliance-essentials/ Inline dough checkweighing helps to mitigate the risk of a bread batch being out of tolerance before the baking process The trend of “kitsch cakes” embraces elaborate piping, vibrant hues, and fruit embellishments, creating visual spectacles that pay homage to the past while celebrating the present. Reflecting a desire to reconnect with nature, a growing fascination with foraged and wild tastes is on the rise. Flavors like rosemary, sorrel, elderflower, and orange blossom captivate adventurous palates. The allure of the tangy and sour has surged, with rhubarb, sea buckthorn, yuzu, sumo orange, and kumquat making their mark. The reach of flavours extends beyond borders, with unique Australian delicacies capturing British attention. This is a trend anticipated to span the next few years. Ingredients like saltbush, wattle seed, and myrtle are garnering attention, bringing with them a new dimension of taste and texture. While cost-consciousness has become a hallmark of contemporary shopping behaviours, consumers still yearn for novel experiences. This places the onus on bakers and sweet makers to strike a delicate balance – delivering value while exceeding consumer expectations. The symbiotic relationship between cost and value has become a pivotal factor for a significant 50% of consumers when making their food choices. © stock.adobe.com/monticelllloNext >