Food safety is a critical part of food manufacturing and proper packaging is integral to complying with the many relevant rules and regulations. From preserving freshness to detailing ingredients, using the correct packaging helps to ensure the safety and quality of products from the production line until they reach the customer.

The importance of packaging in food safety

Packaging and food hygiene go hand in hand. To remain safe to eat, food must be protected from chemicals and toxins, such as bacteria and viruses, that can spoil food and cause illness. The right packaging acts as a barrier, preventing this and other kinds of contamination and preserving freshness. Perishable foods such as dairy or meat may need to be shielded from exposure to air, moisture and light to prevent deterioration.

In addition to protecting goods, packaging and labels provide important information to customers regarding ingredients, nutrition and allergens. Barcodes and batch numbers store further details that can be used to identify products in the case of a manufacturing issue or recall.

Different types of food packaging

Food packaging can take many forms and each brings different benefits.

• Plastic packaging is versatile, lightweight and cost-effective. Suitable for a range of food products due to its ability to be moulded into different shapes, it is especially good for items customers want to see clearly. Plastic packaging can include tamper-evident seals and oxygen barriers to prevent food spoiling.
• Glass is strong and impermeable, providing a durable yet transparent barrier that can also include tamper-evident lids. Because it is an inert and non-reactive material, it won’t alter the taste or quality of food, however it is heavy to transport, which can increase costs.
• Metal packaging is ideal for preserving food over long periods due to its strength and durability. Tin cans provide an effective barrier against light and oxygen, and because they are airtight, microbes are unable to grow.
• Paper and cardboard are a sustainable choice, often used for dry goods that need to breathe. Bags and boxes are easy to print and label, and can be coated with food-grade materials to provide a more substantial barrier – although be aware this may remove some of the environmental benefits.

An overview of UK food packaging regulations

In the UK, best practice dictates that food packaging must adhere to the range of regulations and standards in place to ensure customer safety and quality control throughout the supply chain. These include Food Standards Agency (FSA) regulations as well as relevant EU regulations. The Food Safety Act 1990 requires all food businesses to “not treat food in any way which means it would be damaging to the health of people eating it”, and The Materials and Articles in Contact with Food Regulations 2012 implements a number of EU rules. Within this, the Framework Regulation EC 1935/2004 requires that materials in contact with food be safe and not compromise food quality. Food packaging should be marked with the food safe logo or the words “for food contact”.

Introducing packaging machinery

We already know that automated machinery can help ensure quality control and consistency, but it has a role to play in food safety too. By streamlining the packaging process and enhancing precision the chance of contamination due to human error is reduced, containers are sealed effectively and moved efficiently, without damage to the packaging or its contents.

Sack-filling machines automate the filling of bags and sacks, reducing the need for human handling and ensuring consistent quantities are packed every time. Many include dust control systems to minimise the particulates released into the air and reduce the chance of cross-contamination whilst heat-sealing or stitching packages closed preserves the safety and quality of the foodstuffs within.

The food and drink industry is the UK’s largest manufacturing sector and introducing automation helps to keep it running smoothly, profitably and safely. Let’s get started! Get in touch.

The wellbeing of employees in the workplace is of utmost importance and as the start of October marks Backcare Awareness Week, it’s a good time to take a closer look at how automated equipment such as depalletiser machines can help to minimise workplace injuries, especially to the back.

Back injuries are among the most prevalent and debilitating types of workplace injuries: it’s estimated that 477,000 UK workers are suffering from a work-related musculoskeletal disorder. They frequently result from lifting, carrying, and manipulating heavy objects – often repeatedly – which are common tasks on the manufacturing floor. Back pain can range from mild discomfort to severe, chronic conditions, affecting the quality of life of workers and the productivity of businesses. Figures from the HSE show 36.8 million working days were lost due to work-related illness and workplace injury in 2020/21.

Types of injury and the causes

Two of the most commonly seen workplace injuries are repetitive strain injuries (RSIs), which affect muscles, nerves and tendons, mainly in the upper body, and musculoskeletal disorders, which are injuries to soft body tissues including muscles, nerves, tendons, ligaments, joints, cartilage and spinal discs.

Causes may include:

• Moving and lifting boxes on and off racks
• Gripping bulky items that may not have handles
• Bending and twisting to lift heavy materials
• Twisting and reaching overhead to get materials from racks and bins
• Reaching down or stopping to load and unload boxes
• Pushing or pulling heavy objects
• Using excess force

How can automation help?

Automatic handling systems eliminate the need for heavy lifting and minimise the awkward bending and stretching movements that can strain the back, helping to reduce injuries and promote a safer working environment.

Depending on the types of injuries workers are sustaining, equipment such as palletisers, depalletisers and sack-filling machines may all be beneficial.

• Automatic palletisers stack and load goods onto pallets quickly and efficiently, removing the need for items to be moved by hand. They can handle heavy packages and move consistently, reducing the risk of injuries caused by repetitive motion or sudden exertion.

• Automatic depalletisers unload packages from pallets efficiently, transferring them onto the production line. Goods of all types are moved without the need for manual intervention, reducing the risk of accidents and allowing workers to be deployed on more interesting tasks.

• Sack-filling machines efficiently fill bags with bulk materials from foodstuffs to aggregates, reducing the need for employees to lift and handle heavy bags manually. Dust containment systems also protect workers from any respiratory conditions caused by dust and debris generated during the filling process.

Enhancing workplace safety

The integration of automatic handling systems extends beyond reducing back injuries alone. It also fosters a culture of safety and wellbeing in the workplace by:

• Boosting efficiency. Employees can focus on tasks that require human skills and judgement – and deliver higher value – rather than repetitive, injury-prone activities.
• Minimising human error. Automation reduces the risk of accidents caused by human error, improving overall workplace safety.
• Enhancing job satisfaction. A safer, less monotonous work environment contributes to higher job satisfaction, greater motivation and better mental health amongst employees, improving employee retention and further benefiting businesses in the long run.

As manufacturers strive to maintain competitive advantage, many are investing in automation as a way of streamlining production and making it more cost-effective.

But adding robotics into a production line doesn’t just improve efficiency, it brings other benefits too, by creating a safer work environment and reducing workplace injuries.

1. Reducing manual handling injuries

One of the primary benefits of automation is that it can take over the most physically demanding tasks of heavy lifting and repetitive motions. These put individuals at risk of developing manual handling injuries such as musculoskeletal disorders, back pain or repetitive stress injuries which not only cause pain and suffering for workers but can result in decreased productivity and higher costs for employers.

One such job is palletising, the time-consuming, labour-intensive and often monotonous job of sorting, transferring and stacking goods onto a pallet. Automatic palletisers make the process quicker and safer by handling heavy or awkwardly-shaped packs that can be difficult for an individual to move. Europack’s range of palletisers can be supplied with picking-up heads for bags, boxes, cans, reels and bundles, so they can handle a wide range of packages of all sizes with ease.

Many automated systems can also be designed with ergonomic features such as adjustable height and easy-to-use controls, which can help to reduce physical strain on workers and improve the overall comfort of the work environment.

2. Preventing workplace accidents

It goes without saying that when fewer workers are required, fewer people are exposed to the hazards of the production line. This, in turn, leads to a decrease in the number of workplace accidents, as well as a reduction in the severity of accidents that do occur.

Automated machines can also perform tasks faster and more consistently than human workers, which can not only reduce the risk of fatigue and boredom-related accidents but leaves less room for human error, which can often lead to accidents and injuries.

Sack-filling machines bag grains, pellets and aggregates, sealing them in medium to large sacks ready for palletising and transportation. The technology means that what would take several people minutes to complete can be accomplished in just a few seconds, with far greater precision and accuracy.

3. Improving employee wellbeing

Automation can also lead to increased employee morale and contentment. When employees are not exposed to monotonous or physically demanding tasks, they are more likely to feel safe and secure in their work environment, to be more motivated and to have higher levels of job satisfaction. Not only does this help to reduce the risk of accidents and injuries in the workplace, but it also improves mental health and wellbeing overall.

Investing in safety

It’s important to note that machines alone cannot reverse a poor safety record or create a healthy and safety-conscious culture. Companies must properly train workers on how to operate and maintain automated systems and regularly assess the safety of their processes to ensure that they are functioning correctly.

However, with those processes in place, automating manufacturing processes has the potential to greatly reduce the number of workplace injuries and create a safer work environment for all employees.