The power of sustainability in reaping productivity and environmental gains

Responding to the global agenda for greater levels of environmental awareness and delivering on climate impact reduction has increasing dominated headlines across industries in recent years.

From the raft of global events including the COP conferences between nations, through to a host of more bespoke showcases such as our own World Confectionery Conference and other industry gatherings, there’s little doubt that it is continuing to rightly dominate corporate policies around the world. The sweets and snacks market segments are no exception to that in terms of how companies delivery machinery and systems, which are ever-more efficient and point clearly to reductions in energy consumption that are collectively playing their part in creating a manufacturing landscape that has one eye on the future.

Some of those goals are achieved through capital investment into new, advanced packaging and processing lines, which we have reported on many occasions in recent years, or through making firm commitments to global environmental certification schemes to operate in a physically more sustainable manner.

But with a wealth of challenges facing many countries in terms of uncertain economies, high levels of inflation and supply chain instability, it is also understandable that companies on an individual level are in many instances finding it tough to engage with environmental best practice regulations and codes that are fast becoming the norm across industries. Within the UK one of the most significant factors has been additional regulatory burdens brought in since the Brexit vote of 2016, which, as the UK’s Food and Drink Federation recently noted, have proved a barrier to swifter economic recovery, with the nation slipping into recession at the end of last year amid high food inflation.

According to the organisation’s latest analysis, in the wake of additional issues including Covid-19, the war in Ukraine and extreme global weather conditions – companies are starting to refocus on investment, as a cautious optimism returns. The organisation said that companies are firmly focused on growth during 2024, with three-quarters (73 per cent) of manufacturers determined to grow UK sales, as supply chain pressures such as global agricultural commodities and energy prices have continued to fall in recent months. Two-thirds of food and drink manufacturers were looking to new product development and innovation to drive sales.

As the organisation observed, challenges remain, particularly for SME’s, which have been disproportionately impacted by the fallout from events the industry has faced since 2020. In the last quarter of 2023, half of SME’s reported that business conditions have deteriorated.

Research has found that as productions costs continued to rise throughout the year – by as much as 12.8 per cent, a significant proportion (25 per cent) of smaller business were unable to recoup this cost or redress this imbalance. Instead, companies have suffered sustained decline, where they have had to postpone or cancel vital investment projects and divert funds towards day-today operations to keep their businesses viable. FDF director for growth, Balwinder Dhoot, said: “Food and drink manufacturers are cautiously optimistic about 2024.

The global supply chain challenges the food sector has had to face, along with the cost-of-living crisis, has had a negative impact on businesses’ ability to plan and invest in the long-term future. “Innovation is key to maintaining competitiveness, so it is encouraging to see that UK manufacturers are looking to develop new products for consumers, and to take advantage of full expensing to increase and modernise plant and machinery expenditure. It is also necessary if we are to build a sustainable and resilient food supply chain, which supports the economy and feeds the nation.”

Equipment investment

Making such capital investment in machinery that has been custom-made with sustainability credentials in-built in terms of energy and productivity enhancement remains of critical importance.

As dairy-free vegan chocolate supplier Moo Free explains, it recently replaced its packaging line, with the business asserting that environmental performance of any new line would be of critical consideration.

Hence, the Devon-based business turned to Ulma Packaging UK for its innovative FR 200 flow pack wrapper. Being renowned as an environmentally friendly company, Moo Free uses nonsingle-use and recycled plastics for packaging alongside paper, to ensure zero waste to landfill. So, a solution that met a number of its key sustainability requirements was sought.

Speaking on the project, Nick Ghent, regional sales manager at Ulma Packaging UK, said: “When Moo Free told us their needs, it became clear that the FR 200 was the perfect machine for them. The recurring issue of film becoming misaligned was clearly a concern and something we needed to resolve “The FR 200 was able to resolve this problem using three simple steps. The first was the motorised unwind on the film reel holder – this maintains the correct tension in film at all times and is especially useful with more tricky and quite often newer sustainable films.

The second was the easy-to-thread double adjustable folding box, which offers full flexibility as well as ease-of-use to help the operators thread it through properly. “Finally, as the FR 200 has three pairs of rollers for longitudinal film pulling and sealing, it is ideally suited to correct this kind of problem and will therefore keep the film in position. Thanks to the machine’s design, the material will stay in place for the whole roll, drastically reducing the amount of waste and downtime that was hampering Moo Free’s operations.”

Sustainable packaging
As packaging specialist Gerhard Schubert has observed, sustainability is becoming increasingly important to consumers when shopping, and particular attention is being paid to packaging, including for confectionery. While the company’s focus is on modular, digital, robot-based packaging machines, it also leverages its expertise on the development of sustainable packaging concepts. This year, the Crailsheim-based company presented two environmentally friendly solutions developed in-house: Dotlock, a technology that enables cardboard packaging to be produced entirely without glue, as well as a cardboard-monofilm hybrid solution – also glue-free – that significantly minimises the use of plastic.

Brand owners, manufacturers of confectionery and snacks as well as consumers benefit not only in terms of sustainability, but also from many other advantages. Glue and other synthetics are being increasingly scrutinised in the packaging world. Production is resource- and energy intensive and the processing of glue calls for a never-ending supply of energy. In addition, plastics continue to make complete recycling very difficult.

Not surprisingly, Schubert, with its focus on creating innovation within the packaging industry, has embarked on a research journey to develop new solutions that can make automated packaging processes more sustainable. The new Dotlock process can be used to join several layers of cardboard, is based on clinching technology that is often used to join metals.

For clinching, parts are not joined with the help of a filler material, but only by forming. Schubert’s aim was to achieve at least the same stability and strength with Dotlock as with a glued joint. Manuel Schuster, the firm’s head of new component development, noted: “This was quite daunting, as Dotlock is based on other principles of operation. We therefore had to fundamentally rethink our understanding of the process.” With Dotlock, the strength that is usually provided by the glue is achieved by the number and arrangement of the perforations. For example, several holes can be made in corners that require greater strength.

The hole size also varies depending on the cardboard thickness. The geometry of the hole distribution is redefined for each new pack, as it is important to prevent the cardboard from tearing if the perforations are too closely set or if the joint is not strong enough should the perforations be too widely set. As a packaging solution that is 100 per cent glue-free, Dotlock is fully recyclable via the paper cycle. However, there are many other advantages for both companies and consumers. For example, Dotlock cardboard packaging cannot be resealed, which means that confectionery and snacks cannot be tampered with. As a result, there is no need for tamper-evident labels – another benefit in terms of environmental protection.

Furthermore, the storage space for the glue and the heat supply required for processing are eliminated. The cardboard box with perforations is also a winner in terms of marketing. Unlike the many different eco-labels on confectionery and snacks, which are difficult to identify, it offers strong recognition value for consumers seeking sustainable packaging. Companies can even use the distinctive look as a design element, for example in the form of a logo. “Depending on requirements, perforations can be concealed or highlighted in certain areas of the carton. In addition to the visual advantages, Dotlock also offers consumers an appealing acoustic and tactile opening experience,” added Manuel Schuster, of the system that was first seen at Interpack last year.

Sustainability achievements
While finding the right machinery or material for the job is of upmost importance to companies’ overall performance, another core area of sustainability lies in tangibly measuring environmental delivery. Danish liquorice specialist Lakrids by Bülow has celebrated gaining coveted B Corp status, which has highlighted its ongoing commitment to sustainable manufacturing within its operations. The international environmental standard, which is widely considered as a gold standard across industries for corporate social responsibility policies, which has now seen a number of companies with confectionery engage with the initiative, including Luker Chocolate, Valrhona, Love Cocoa, Koa cacao fruit business and Moo Free Chocolates.

In terms of its own focus for attaining B-Corp status, Lakrids noted that since 2020, 100 per cent of the power consumption for its factory outside Copenhagen where the company’s products are crafted, is covered by power from Danish windmills. In 2019, the business is believed to have become the first confectionery company in the world to switch to 100 per cent recycled and recyclable (R-PET) plastic jar packaging. Another example of a business engaging with B-Corp is Spanish firm Alvinesa Natural Ingredients, specialising in a broad base of plant-based product ranges.

As the company noted, signing up to the major global environmental initiative involves addressing the entirety of a business’ operations and covers five key impact areas of governance, workers, community, environment and customers.

Moreover, it noted that the B Corp process is rigorous, with applicants required to reach a benchmark score of over 80 while providing evidence of socially and environmentally responsible practices relating to energy supplies, waste and water use, worker compensation, diversity and corporate transparency.

To complete the certification, the company will legally embed a commitment to purpose beyond profit in its company articles. For its part, robotics business Omron has celebrated achieving platinum rating from EcoVadis, placing it in the top one per cent of all businesses assessed for sustainability performance. This is the third time that the company has attained the recognition, which includes the business observing codes laid down under the Science Based Targets initiative, which recommends establishing medium and long-term greenhouse gas reduction goals based upon tangible scientific evidence demonstrating achievements.

Advanced factory facilities

As Belcolade advances in its journey toward sustainability, the Belcolade carbon-neutral chocolate factory remains at the forefront of environmental responsibility. The facility is currently in full production mode, showcasing Belcolade’s steadfast dedication to providing professional customers with the highest quality chocolate and services.

“With our carbon-neutral factory at Belcolade, we are certainly leading the way in the sector as we do not need to use any fossil fuels and work with 100% renewable energy coming from our innovative heat pump technology, combined with energy from our solar panels and wind sources,” shares Youri Dumont, Director of the Chocolate Business Unit at Puratos.

“In addition to our operational achievements, we’re proud to announce that our factory has successfully attained third-party certifications, including the BREEAM Very Good Certification and the CO2 Neutral Certification provided by CO2logic, highlighting our commitment to sustainable practices,” continues Youri Dumont. From operating on 100% renewable electricity to implementing innovative water-sourcing methods, the Belcolade factory stands as a testament to ongoing efforts to minimize the environmental footprint.

In addition to the sustainability focus, Belcolade actively contributes to Belgian economic growth. With plans to create 100 jobs across various functions in the coming years, Artur Nowak, Site Manager, emphasises Belcolade’s commitment to nurturing a diverse workforce and investing in the well-being of the team. “Belcolade is more than a producer of exceptional chocolate; it is an active participant in fostering a sustainable and thriving community.”

Furthermore, his colleague,Francesca Angiulli, Sustainability Director at Puratos explained that the company’s broader policies on sustainability were especially significant to the business in its overall outlook.

She said: “Sustainability has become non-negotiable across the food industry, driven by concerns about climate change and the desire to reduce energy and water use, waste and our collective carbon footprint. In fact, according to global insights from Puratos’s proprietary Taste Tomorrow research program, 64% of consumers worldwide now look for products that are produced sustainably. And within this context, for confectionery and baked goods specifically, discerning shoppers list sustainable packaging as their highest priority (31%), closely followed by fair prices for farmers (28%), minimising waste and responsible sourcing of ingredients (28%).

The demand for brands to become more sustainable has only increased in recent years. However, to continue making sustainable choices every day, shoppers need brands’ help to be clearer and more transparent. So, how does this translate to the food industry?

Making changes
Angiulli continued: “With talk across Europe about a potential ban on ‘misleading’ environmental claims, like ‘planet-friendly or ‘100% green,’ only sustainability labels using approved certification schemes will be allowed. This crackdown on so-called ‘greenwashing’ will place more pressure on brands to provide better transparency, and accountability, by making real changes and improvements. It will become essential to be more open about the positive steps they are taking to reduce their carbon footprint along the supply chain. To make a real impact, brands should be prioritizing working with sustainably-minded suppliers, reducing emissions, from scope 1 to scope 3 and exploring ways to make their own operations and products with lower environmental footprint.

“Formulating with plant-based ingredients is one way to help reduce a product’s environmental impact. For example, according to life cycle analysis, Puratos’s Mimetic plant-based butter alternative is up to three times more sustainable than traditional butter, while its Sunset Glaze ingredient has a 59% lower environmental impact than pasteurised egg. However, it will be collective action that drives positive change, not just one sustainable action, factory or product.”

“Consumers are also increasingly looking at the bigger picture before they make their choices, with interest growing in brands that go the extra mile to ensure a sustainable social future for all. It is leading some suppliers to go beyond standard industry practices to maintain supply chain sustainability and visibility – especially when it comes to ensuring the ethical provenance of cocoa. Puratos’s Cacao-Trace™ program, for example, uniquely prioritizes quality over quantity in cocoa production. This sustainable cocoa sourcing initiative supports farmers in the adoption of efficient and climate-smart farming techniques, resulting in superior cocoa beans and increased farmer income. Farmers receive a Quality Premium and a Chocolate Bonus for every kilo of Cacao-Trace™ chocolate sold, which is equivalent to two to five months of income.”

She added that with the focus on sustainability showing no signs of slowing, the time is now for confectionery brands to take steps to do better for the planet, particularly in light of consumers’ climate change concerns. In the long term, choosing suppliers that are committed to a sustainable future for all will be key to brand resilience and long-term adaption of the food chain.

Beyond certification
As Confectionery Production has covered in recent years, there is no shortage of companies coming forward that are committed to developing ever-more sustainable machinery and packaging designs which is continuing to greatly benefit the wider industry. But beyond that, there are a number of small and medium-sized enterprises which are making their mark with business models and concepts with sustainability right at their heart. One such business is British-based ecofriendly snacks producer Nim’s Fruit Crisps. This is being made possible through its achieving zero food waste in its innovative manufacturing operations. As our publication has previously reported, the company, based in Sittingbourne, Kent, has used specialist air-dried production methods that helped the firm gain a coveted Queen’s Award for Industry, which brought the business national media attention.

Its continued development, which has seen it grow to utilise more than 600 tonnes of fresh fruit and veg a year, has resulted in a turnover boost nearing 20 per cent due to its drive to make full use of produce that may otherwise have gone to waste. As the business, which now employs 18 people noted, with the assistance of a £30,000 investment in an additional processing line, it has extended its base of core ranges out from snacks, moving into garnishes, baking decorations, as well as edible teas that have seen it gain a string of listings with major national supermarket chains.

Its fruit options include apples, pineapples, pears, watermelons, and all citrus fruits and can be used to flavour alcoholic and non-alcoholic drinks at the point of manufacture, as well as being used in bars, pubs, and hotels at the point of making/serving cocktails. Speaking on the company’s continued fortunes, founder Nimisha Raja MBE, explained that she had forged the business on the basis of wanting to be as responsible as possible with her production methods, which has been enabled further as her enterprise has grown. She said: “0.03 per cent is unfit for human consumption, but we even have an answer for that with it being successfully sent to an anaerobic waste treatment plant and returned to us in the form of energy,” enthused the entrepreneur.

“This isn’t marketing rhetoric either. Our commitment to transparency and compliance has meant scrutiny through rigorous auditing bodies, such as BRCG, Sedex and SMETA, as well as customers such as Pret A Manger, The Azzurri Group, Marks & Spencer and Holland & Barrett all holding us to account. We did this for sustainable reasons. However, we quickly found that with the right machine we could create smaller ingredients that we are now selling online or direct to trade.”

Related content