The digitisation of food manufacturing to reduce waste - Case study of a ready meal factory.

Generation of food waste (FW) continues to be a global challenge and high on the political agenda. One of the main reasons for its generation is the absence of detailed data on the amount, timing and reasons for created waste. This paper discusses the design, the application and investigates the Internet of Things (IoT) based FW monitoring system to capture waste data during manufacturing in real-time and make it available to all the stakeholders in a food supply chain (FSC). A case study of ready-meal factory comprises of design and architecture for tracking FW including both hardware and software, its implementation in the factory and the positive data-driven results achieved. The case study demonstrates the benefits of digital FW tracking system including the FW reduction of 60.7%, better real-time visibility of the FW hotspots, reasons for waste generations, reliable data, operational improvements and employee behavioural transformation. Although the system replaced the paper-based manual system of tracking FW in the factory, it still needed human input to confirm the waste and was prone to human errors. Overall, the implementation of an IoT-based FW tracking system resulted in a reduction of FW and created a positive environmental and financial impact.

Analytical methods for waste minimisation in the convenience food industry.

Waste creation in some sectors of the food industry is substantial, and while much of the used material is non-hazardous and biodegradable, it is often poorly dealt with and simply sent to landfill mixed with other types of waste. In this context, overproduction wastes were found in a number of cases to account for 20-40% of the material wastes generated by convenience food manufacturers (such as ready-meals and sandwiches), often simply just to meet the challenging demands placed on the manufacturer due to the short order reaction time provided by the supermarkets. Identifying specific classes of waste helps to minimise their creation, through consideration of what the materials constitute and why they were generated. This paper aims to provide means by which food industry wastes can be identified, and demonstrate these mechanisms through a practical example. The research reported in this paper investigated the various categories of waste and generated three analytical methods for the support of waste minimisation activities by food manufacturers. The waste classifications and analyses are intended to complement existing waste minimisation approaches and are described through consideration of a case study convenience food manufacturer that realised significant financial savings through waste measurement, analysis and reduction.