Baking & Snack - March 2023 - 86

SLICED BREAD PACKAGING
The packaging
department is primed
for labor-saving
automation.
Rexfab Inc.
translates in cost savings over the long run, " he said.
Bakers can promote sustainability by using less energy
and labor as well, which can be achieved via energyefficient
machinery and the automation of labor-intensive
tasks, noted Angela McDaniel, marketing and sales
coordinator, Formost Fuji.
" The bagging machines and flowwrappers we offer
have a lot of sustainable features that cut down on energy
and reduce carbon footprint, " she said. " It's easy to
look at the material side because that's what the consumer
sees, and they don't necessarily consider the sustainability
of the packaging equipment itself. "
Making sustainable attainable
The push for eco-friendly packaging is gaining, but
obstacles remain before these materials truly break
through and become commonplace. For example, regulations
promoting or requiring the use of these materials
are lacking in the United States, and the country's poor
recycling infrastructure means many recyclable products
are still thrown away. But the biggest obstacle for
bakers in using these materials is cost.
" It is difficult for the baker to spend the extra money
it costs to get recyclable bags because they have to pass
that on to the customer, and sometimes that's a make or
break for the customer on whether or not they're going
to pay more for that loaf of bread, " Ms. McDaniel said.
Because PCR bags are more expensive, Ms. Ataya recommended
bakers start by using them with premium
breads where consumers are willing to pay more.
Consumer knowledge around recyclable materials is
another challenge.
" You can't tell a consumer it has PCR. You just need to
say recycled content, " Ms. Ataya said. " The message has to
be clear. You have to educate the consumer, so they know
if they have to pay more, why they have to pay more. "
It's critical bakers ensure sustainable bags can still
hold up on the packaging line. Just because a bag looks
the same doesn't mean it will run the same.
Mr. Gunnell shared an example of a customer who re86
Baking & Snack March 2023 / www.bakingbusiness.com
placed their bag with a more sustainable alternative but
didn't test the product beforehand. It wasn't until after
they purchased and began running the bags that they
discovered 20% of them would split open on the line.
" You just defeated your purpose and slowed your line
down and caused all sorts of problems, " he emphasized.
" Communication and getting it tested thoroughly is
key to making sure it'll function throughout the supply
chain. We offer free testing in our lab for this reason. "
Thankfully, with testing, bakers can make the adjustments
necessary to ensure sustainable bags run similarly
to conventional ones.
For closures, Mr. Hughes said, Burford's Servo Tyer
may require a relatively inexpensive kit when shifting to
plastic twist tie material.
" However, once added, no adjustment is needed
to run either standard or plastic twist material when
switching between the two types, and new equipment
can be fitted for this option when ordered so that it arrives
ready to accept either type of material, " he said.
Sustainability was the word in the industry a few years
ago, Mr. Gunnell said, but it took a bit of a backseat as
supply chain and labor disruptions took hold. But he
sees the pendulum swinging back to the topic.
" As we get to the second half of 2023 and beginning of
2024, you're going to see sustainability climb in importance
again, " he said.
Automate the right way
Automation remains a top trend in the baking industry
as manufacturers look to maximize throughput with a
limited workforce. And the packaging department, often
one of the most labor-heavy areas of the production
room floor, is primed for it.
" We're always going to have a labor shortage, because
frankly, it's not a highly sought-after position, " Mr.
Gunnell said. " So if you can eliminate or semi-automate
some of those manual labor jobs, you're way ahead. "
But the decision to automate presents its own challenges
and consideration for bakers.
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