Food manufacturing innovation is increasingly focused on solutions which contribute to sustainability targets, such as CO2 reduction and eliminating single-use plastic.
Our latest Freshline® Sustainability Whitepaper can bring value to the industry by quantifying the impact on emissions in specific food categories from food waste reduction, plastic elimination and transport, storage and production initiatives.
As noted in the paper, around 21% of emissions generated by the food industry relate to energy used in transport, packaging and processing1.
To solve this issue, the food industry will require additional innovative solutions and need to fully understand the environmental benefits of these innovations. To do so, our researchers examined three examples of where food gas technology has led to reduced emissions: cryogenic food freezing, Modified Atmosphere Packaging (MAP) and non-carbonated drinks bottling.
Read on to learn more about the findings…
Cryogenic Food freezing
While food manufacturing accounts for only 10% of energy related emissions in the food chain – according to estimates by the Food and Drink Federation and the Carbon Trust – around 60% of these emissions are linked to refrigeration and freezing by large frozen food manufacturers2.
Traditional mechanical freezers use a recirculating refrigerant with an air cooler that exchanges heat from air circulating within the freezer to reduce the temperature of the food. In contrast, cryogenic freezers use liquid nitrogen, which improves the freezing rate and results in lower levels of product dehydration and therefore higher quality product and less waste.
Our researchers reviewed published data on the environmental impacts of meat production and plant-based protein products across their life cycle. Based on this data, we carried out a study and concluded that in the case of burgers, while the carbon footprint of cryogenic freezing is greater than mechanical freezing, the impact of food waste resulting from, for instance dehydration, can be three times greater for other technologies compared with cryogenic freezing. The equivalent of 3% of the total product is wasted with other technologies, versus 1% with cryogenic freezing.
Modified Atmosphere Packaging (MAP)
MAP is a proven and natural method of extending the shelf life and quality of food products. It uses a specific single gas or a mixture of gases to create a protective atmosphere around the food, replacing conventional air packaging. This protective atmosphere, combined with appropriate packaging material and lowered temperatures, can preserve the taste, safety and appearance of food for longer. In turn, this reduces food waste and avoids carbon emissions.
Using this technique, the shelf life of fresh food products can be safely extended by between 50% and 500%, depending on the product - enabling retailers to optimise their supply chain and reduce food waste.
The Food Packaging Calculator was developed through our own studies and in collaboration with key industry partners. It calculates the avoided emissions according to different food products and packaging types. Using the calculator, our studies found that avoided emissions range from 3.11 kg CO2e/kg for beef to 0.018 kg CO2e/kg for nuts.
Non-carbonated drinks bottling
When it comes to non-carbonated beverages, nitrogen better provides the right level of pressure in the package to allow the use of thinner bottles – while still maintaining the rigidity needed for stacking during and after transportation. The liquid nitrogen also protects against spoiling and waste. Carbon emissions are avoided through the use of thinner bottles with lower weight PET (Polyethylene terephthalate) polymers.
The future of food freezing technologies
Ultimately, working towards generating a cleaner future is good business practice, not just environmentally but also economically. As the food and drink manufacturing industry seeks to improve its processes, increase efficiency and reduce its environmental impact, new technologies are emerging.
Air Products Freshline® Smart Technology for cryogenic freezer solutions uses wireless sensors and cloud technology to continually monitor process parameters taking data from the production system and the liquid nitrogen tank, suggesting improvements, and optimising efficiency, ensuring every drop of liquid nitrogen is used effectively.
Adopters of this technology receive automated daily email summaries of their daily nitrogen usage and how tank levels change throughout production. Furthermore, “recipes” can be created and saved to each freezer line to ensure the optimal operational parameters are maintained for each of your products.
What is the future?
Air Products will continue to innovate and challenge what it is our customers need from their freezing solutions, in order to support them in meeting consumer demands while being a successful business.
As the sector increasingly focuses on digitisation, it's critical that companies not only collate data but use it effectively. This is where a process of collaboration is key. Our expert team can work with our customers to understand the data and analyse it to implement change.
Further improvements and additions will continue to be implemented and brought to our customers as part of our Freshline® Smart Technology continuous development.
The fact is consumer demand for frozen food isn’t showing signs of declining. Our customers need to continue to meet this demand, while maintaining a competitive advantage and innovating their offering.
- To read the full Freshline® Sustainability Whitepaper, click here.
- To discover the carbon impact of your food packaging, click here.
- For more information on our Freshline® Food Solutions, click here.
1 Carbon 4 Finance, Report on the food and beverage sector, 2020
2 Cold feat: choosing the right freezing technology for your production line, Dr Chris Kennedy, 2009
