Innovations Driving Sustainability in Frozen Food Manufacturing

Sustainability has become immensely important in the manufacturing sector. Though the world depends on manufacturing for both the products and jobs it creates, it’s also suffering because of it. From the beginning of the Industrial Age, factories have been polluting the planet and creating excessive amounts of waste. These days, the race is on to continue creating the products we all rely on while also minimizing their negative effects on our world.

Looking at the Importance of Sustainability in Food Production

Although achieving greater sustainability is essential in every industry, it’s particularly crucial in frozen food production. Reports show that the global demand for frozen foods surpassed $284 billion last year, and it’s expected to reach nearly $364 billion within the next few years. At the same time, Earth’s food supplies, viable soil, water, and other related resources are reportedly running low. As such, reducing waste, conserving resources, and decreasing the industry’s environmental impact are a must.

No doubt, the frozen food industry boosts sustainability in its own right by making foods last far longer than they would otherwise. For example, IQF burger manufacturing minimizes the risk of contamination and preserves the quality of frozen burgers. That prevents millions of tons of meat from being thrown away because of contamination or spoilage each year. Still, that’s only the beginning. Numerous new innovations have come into play to drive sustainability in frozen food manufacturing. 

Exploring the Latest Frozen Food Manufacturing Innovations

When it comes to sustainability, the frozen food industry has a few key focal points. One is keeping waste at a minimum. Another is using fewer resources in food production processes. Reducing harmful emissions is also a major factor. Many recent innovations revolve around those aspects either directly or indirectly. Take a look at some of the most important rising developments in the industry. 

Automation

Automation is one of the most significant and effective innovations in frozen food manufacturing. Some people may say it’s old news at this point; after all, it has been around to an extend for quite some time. According to some historical accounts, it began back in the 1600s but didn’t fully take off until the late 1800s and early 1900s. Regardless, automation has made unprecedented strides just over the last few years. Today’s level of automation in frozen food production fosters sustainability in many ways.

• Minimizing Human Contact – For one, automation reduces the amount of human contact required to process and package foods. That further reduces the risk of contamination as well as the possibility of human error. In doing so, it prevents large batches of foods from having to be thrown away due to exposure to pathogens, incorrectly measured ingredients, improper mixing, and many other issues. 
• Temperature Monitoring – Automated frozen food production equipment can also provide precise temperature monitoring. That ensures foods constantly remain at the right temperatures for quality and safety throughout the production process. In turn, it prevents bacteria growth, texture and consistency variations, and an array of other problems that could stem from temperature fluctuations. Again, that can reduce the amounts of foods manufacturers ultimately have to throw away rather than sending them on to consumers. 
• Packaging Precision – Automated production systems can also guarantee more precise packaging than manual processes. They don’t overfill or underfill packages, so less product goes to waste from those types of problems. If a measurement or calibration issue does arise, automated machines are designed to detect the problem immediately and shut down production, which further reduces waste. 

Automation can improve frozen food safety and reduce safety risks for production companies’ employees. It can cut production costs without compromising on quality as well. Beyond that, it can streamline the manufacturing process to help companies be more productive. Those are only a few of the ways automation is having a positive influence on frozen food production and its sustainability. 

Reduced Resource Consumption

Efforts are also underway to consume fewer resources in frozen food manufacturing. For one, companies are finding ways to use less water in their manufacturing processes. In the frozen food industry, massive volumes of water are used for food production, equipment cleaning, and other purposes. With Earth’s supply of clean drinking water dwindling and the planet’s population consuming more water than ever, these companies are trying to conserve. 

They’re making the switch to equipment that uses less water overall, and that’s making a significant difference. New strategies have also been developed to reclaim and repurpose the water they’re using. Those include advanced filtration systems, automated water use monitoring, and collection and storage systems to name a few. Frozen food manufacturers are certainly facing challenges when it comes to reusing water because safety is a major concern. Still, the latest innovations in this sector are making it possible. 

Energy consumption is also a significant factor. Though processing foods uses a certain amount of electricity, the majority of the industry’s energy consumption comes from refrigeration. It filters down from food production facilities to supermarkets, restaurants, and other distributors. Several advancements have come into play in this regard as well. More efficient refrigeration systems have been developed. New heat recovery systems are also being used now. Some pipe heat generated by refrigeration systems into other areas to reduce heating costs and energy consumption. 

Eco-Friendly Packaging

While food waste and energy consumption are major factors to contend with in frozen food manufacturing, packaging is also a problem. Until recently, frozen food packaging almost always consisted of cardboard, styrofoam, and plastic. Those materials rarely get recycled. Instead, they end up in landfills and oceans or strewn everywhere. 

With that being the case, the industry is leaning toward more eco-friendly packaging solutions. This, too, presents a challenge for frozen food manufacturers. Packaging needs to protect the product within from outside forces. It needs to be sturdy enough to hold in leaks if the product thaws and protect people from contaminants that might come from the product as well. While reusable packaging isn’t always an option in the frozen food sector, biodegradable materials can improve sustainability. 

Carrying Frozen Foods Into the Future

Since its beginning in the 1930s, the frozen food industry has prevented countless tons of food waste. It keeps food from spoiling and prevents contamination among other benefits. It has caused a few problems as well, though, including wasted product, excessive water and energy consumption, and waste from packaging. Automation, more energy-efficient refrigeration systems, water recycling, and biodegradable packaging are a few of the recent innovations that are ramping up sustainability in the industry. They, along with many other advancements, will carry frozen food manufacturing into the future. 

Isa Emaa