With the world’s population set to exceed 8bn by 2030, securing a sustainable food supply is a significant global challenge. Refood’s Philip Simpson discusses the requirement for a radical change in the way we manufacture, sell and consume food.
WRAP’s Food Futures report outlines a groundbreaking new approach to how the food system operates, detailing the benefits that data-enabled technology could bring to reducing resource use and waste while also improving productivity.
The benefits of Industry 4.0 and the so-called “smart factory” feature heavily in the report. The idea is simple – factories of the future have the opportunity to increase manufacturing profitability and reduce food waste through intelligent equipment, which can interact with the real-world conditions they operate in.
Industry 4.0 & smart technology
Also known as the fourth industrial revolution, Industry 4.0 is a name given to the current trend of automation and data exchange that is seeing an upsurge across all areas of manufacturing. It essentially brings technology we are all using in everyday life, such as wearable technology and smart phones, into a manufacturing environment.
By combining the internet of services (automated communication and control of request) with the internet of things (connected devices influencing and responding to each other), smart technology has the propensity to eradicate food waste in the manufacturing sector.
When it comes to smart factories, recycling unavoidable food waste in this way, rather than sending it to landfill or incineration, can create the energy needed to power the factory, closing the loop and fulfilling zero waste ambitions. This approach to food waste recycling is critical in helping delivering a more circular and secure food system.
Here’s an idea of how the process could work:
- Delivery – Sensors recognise and prioritise raw materials based on their freshness. Stock is automatically controlled and ordered
- Cooking – More precise and personalised cooking means perfect timing and minimal waste
- Storage – Automatic control of temperature means less product spoilage
- Packing – Products are made and packaged on demand to customer order
- Distribution – Automated robotics are used to pick and pack products, which are then delivered according to customer requirements, using routing technology
While the food manufacturing industry has been slower to incorporate smart technologies than other sectors, such as the automotive industry, we are starting to see more rapid adoption with almost 10,000 food manufacturing robotic units now operating in factories across the UK. It’s clear to see why – the potential benefits include improved safety and hygiene, efficient processes, minimal maintenance, lower energy use, zero waste and personalised produce.
Smart technologies & food waste
Nearly five years ago, ReFood launched the Vision 2020 report, which set out clear guidelines for the supply chain to eradicate food waste to landfill. Since then, we have continued to lobby the government to support initiatives to minimise waste and improve efficiencies across the supply chain.
The idea of a smart factory is a perfect example of how technology can help manufacturers work towards zero waste and we fully support WRAP’s recommendations. However, one of the main waste reduction challenges facing factories is the unavoidable food waste that technology cannot eradicate (fat and gristle, tomato ends, bones, shells etc).
The WRAP report points to the fact that unlocking the value from food waste will be critical to delivering a circular food and drink system in the next decade. We couldn’t agree more and we are already helping food manufacturers and service companies to recycle unavoidable food waste through anaerobic digestion (AD).
The WRAP report points to the fact that unlocking the value from food waste will be critical to delivering a circular food and drink system in the next decade.
This process harnesses the natural rotting of food by capturing the biogas produced and using it to generate heat and electricity. Meanwhile, the resulting residue can be used as a nutrient-rich fertiliser; enabling beneficial nutrients to be retained and reinvested right back to the beginning of the food chain.
One food producer already successfully using AD to recycle its food waste is Mustard Foods, which develops and delivers bespoke sauces, soups, fillings and marinades to more than 400 restaurants across the UK. Mustard Foods partnered with us to implement an integrated food waste recycling solution, which sees full-size sanitised bins supplied for food waste disposal in kitchen areas.
These are swapped with clean sanitised bins and the food waste is taken away to our AD plants for recycling. Crucially, it is the collection and recycling of both packaged and non-packaged foods that has helped Mustard Foods towards zero waste and a 100% non-landfill solution.
When it comes to smart factories, recycling unavoidable food waste in this way, rather than sending it to landfill or incineration, can create the energy needed to power the factory, closing the loop and fulfilling zero waste ambitions. This approach to food waste recycling is critical in helping delivering a more circular and secure food system.
According to the WRAP report, population increases mean that it will take another 5 million tonnes of food to feed the UK population in 10 year’s time. The incorporation of smart factory principles, alongside food waste recycling measures, means food manufacturers can have the flexibility to adapt to growing and changing demands, at the same time as improving resource efficiency, eradicating waste and creating a more sustainable food supply.
