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Food and beverage companies have the ability to make a difference in the reduction of waste, which occurs throughout the whole supply chain of their products. This has a positive impact on a company’s bottom line (since less waste means cheaper costs), but it also has a positive impact on the environment due to the conservation of natural resources and the reduction of greenhouse gas emissions. Waste can occur at any point along the value chain, and companies can take steps to decrease or even eliminate waste in their respective areas of the production process.
Food and beverage makers can begin addressing this issue by taking a close look at their processing and packaging operations, both of which offer potential to reduce waste. Here are some ideas about how to get started.
The processing side
Product losses can occur in large-scale food manufacturing operations as a result of inefficient lines, formulation changes, and facility maintenance. Manufacturing plant managers can reduce waste by implementing measures that avoid product loss while also increasing production efficiencies.
Their first order of business should be to deal with the most straightforward problem: inefficient industrial layouts. Milk losses in the dairy business can range from 2 to 3 percent on average from the moment the raw milk enters the production to the time the finished product is packed and transported out. Although this may appear inconsequential, it adds up to nearly 1.4 billion pounds of milk per year, and that figure more than doubles when cheese manufacturing is factored into the calculation.
There are a variety of explanations for these losses. In one instance, when large-scale equipment is used to prepare food, the machines must be thoroughly cleaned in order to ensure that the food is safe to consume. Milk is lost as a result of those cleanings. A typical factory processing 500,000 gallons per day can experience a 3 percent loss, or 15,000 gallons, each day in its operations. One approach is to use equipment that is built to function for a longer period of time between cleanings, thereby increasing efficiency while decreasing product loss.
Furthermore, inefficient equipment design contributes to additional losses, as does the vast range of items that consumers today desire, which puts pressure on manufacturing operations to create a large number of stock-keeping units (SKU). Producing products that require a variety of different components and format changes on a daily basis necessitates multiple line changes, which results in production stops and starts as well as additional cleaning cycles. Inevitably, this results in additional losses.
Construction of processing facilities should be done in the most efficient manner possible, which means that they should be small and contain technology that can perform multiple functions at the same time. Tetra Pak has created a number of technologies that are intended to increase the efficiency and compactness of liquid food processing operations. One of these is the OneStep technology, which allows processors to adjust the fat content of their products in a fraction of the time, so reducing processing time (and the loss associated with it) dramatically.
Consumption of water is another area in which food and beverage firms can lessen their environmental impact. Processes such as milk processing require 2 to 3 lbs of water per gallon, and inefficient plant design might cause this figure to rise even higher. This is water that is largely needed to clean and rinse the equipment, and it can be decreased by installing equipment that requires fewer cleanings and provides other efficiencies. It’s simple to see why it’s vital for the dairy industry in the United States, which produces approximately 23 billion gallons of milk each year, to reduce losses in order to conserve water.
The packaging side
When it comes to preventing food and beverage waste, packaging is equally crucial. Starting with the packaging, the environmental impact, shelf life, and resource consumption during transportation and storage are all influenced by the selection of the packaging method used. Milk in aseptic containers is one example. After packing, it is safe to consume for up to six months without refrigeration until it is opened. Cold milk has a shelf life of around two weeks and requires electricity during transportation, retail display, and storage at the consumer’s residence.. By avoiding the energy expenditure required for cooled transit and storage, containers that safeguard product without refrigeration save waste across the supply chain.
Achieving a balance between safeguarding the product to assure its sale and consumption rather than waste, as well as using an economically efficient quantity of material to manufacture the container, is another consideration for producers. Reduced packaging weight saves resources by reducing the amount of material used in transportation and by reducing the amount of material left over at the conclusion of a package’s life cycle.
It is also possible for producers to reduce waste that occurs after a product has left the store through the use of ergonomic packaging design. When designing packages, firms can reduce waste by addressing how people open and close them. By making packages easier to open and more efficient in their closure and storage, companies can ensure that unused pieces are not wasted. If they are capable of handling the packages, they are less likely to fumble, drop, spill, or otherwise squander merchandise.
Conclusion
Supporting in reducing and eliminating waste at every step of the food and beverage manufacturing process is a win-win situation for everyone involved: businesses, the environment, and society as a whole.
About The Author: Optymum SS is a networked, international pipeline-organisation of chartered scientists and certified laboratories. UK Chartered Scientists represent the best professional scientists working in the UK and abroad. We utilise our innovative business model to support the provision of the best, most cost-effective solutions to challenges within the broad life sciences –advancing well-being and quality of life. For more information about working with us or joining our partnership, please get in touch.
