Food and Drink. Food and Drink. The Centre for Process Innovation. From innovation to commercialisation

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1 Food and Drink Food and Drink The Centre for Process Innovation From innovation to commercialisation

2 The Centre for Process Innovation From innovation to commercialisation The Centre for Process Innovation is the UK s national technology and innovation centre to serve and support the process manufacturing industries. We are chosen by key industry leaders and SMEs to develop, prove, prototype and scale up the next generation of products and processes. We work across a range of technology platforms, each of which have the potential to generate a substantial impact on the future of manufacturing. We provide product and process development facilities and expertise in industrial biotechnology and biorefining, formulation and flexible manufacturing, printable electronics and biologics with the overall aim of creating less waste, cleaner, more efficient and more economic products and processes. Our open innovation model enables our clients to develop products and prove processes with minimal risk. We provide assets and expertise so our customers can demonstrate the process and prove it is feasible before investing substantial amounts of money in capital equipment and training. New products and processes can be proven; on paper, in the lab and at pilot scale before being manufactured at an industrial scale. By utilising our proven assets and expertise companies can take their products and processes to market faster. There is no down time in production as all of the process development is completed off-line. Better Products, Faster We help our clients to produce better products with increased quality and performance. We can create processes with higher yields and reduced manufacturing time with faster conversion of raw materials or feedstock to product. Low Cost, Low Waste Manufacturing We enable companies to decrease capital and manufacturing costs by facilitating batch to continuous processes, increased automation and reduced manufacturing time. We help reduce and reuse wastes, utilise natural materials and decrease reliance on fossil fuels. Introduction The food and drink industry is the largest in the world, yet it faces challenges and opportunities of equally significant proportion; a rapidly expanding global population, increased wealth precipitating Western appetites in emerging economies, diminishing natural resources, as well as widespread obesity and famine. To address these issues the industry must become more efficient and deliver new solutions for production growth, whilst delivering increased nutrition from reduced foodstocks. How can these challenges be addressed? Cross sector technological innovation provides the best opportunity to bridge the gap between current challenges and longer term opportunities. CPI can work collaboratively with food and drink sector companies to help them develop and commercialise innovative technologies. We work across a range of technology platforms which have the potential to impact upon ingredient formulation, how foods are made, global distribution, and the repurposing of waste streams into a more efficient manufacturing supply chain. From smart packaging solutions to the development of biofuels from food waste, CPI provides organisations across all levels of the supply chain with world class open access facilities, allowing them to carry out proof of concept scale up activities and proving that their new ideas are commercially viable before taking on financial risk.

3 Manufacturing Sensors in manufacturing Novel materials Batch-to-continuous production Sensors in Manufacturing Innovations in sensing technology are enabling improved real-time performance monitoring of manufacturing equipment and the quality of the foods and drinks produced. Multifunctional sensors monitor production line performance, relaying and assessing process parameters such as pressure, volume, temperature, moisture content, oxygen content and acidity. Accessing our capability in printed and graphene based sensors, a distributed network can be permanently bonded either onto surfaces of existing machinery, or integrated into the core structure of new manufacturing components. The flexible nature of the sensors means that they are suitable to meet even the most challenging design constraints, and can be cost effectively mass produced. Real-time process monitoring can not only enhance food quality and consistency, but also significantly reduce the need for human involvement, meaning minimal downtime, faster manufacturing, less repair work, less waste and higher yields.

4 Novel Materials Utilising our expertise in formulation and graphene, we can help companies develop and optimise functional coatings and composite materials for the food manufacturing sector. Companies can partner with CPI to test new processing technology for the pilot production of materials that are lighter, hard wearing, with enhanced robustness and longevity, or provide excellent functional properties such as nonstick surfaces, thermal stability and self cleaning performance. In addition, CPI also has significant experience in the processing of bio-plastic materials derived from a number of waste sources in the food manufacturing supply chain. Batch-to-Continuous Production CPI has a track record of developing continuous processing technologies at pilot scale for the production of chemical and biological materials. Clients can engage with CPI to test, improve or refine their existing batch processes, or run systems based computer models, in order to identify better performing and more resource efficient continuous manufacturing methods. Biomaterial Production from Waste Root Crops CPI helped to advance Cellucomp beyond early stage science and towards financing the construction of their own facilities for the production of Curran, a novel fibre technology derived from waste root crop product. Cellucomp first approached CPI to test feasibility for the scale-up production of Curran. This translated lab scale development towards commercial scale manufacture, achieving final product specification and meeting the requirements of the end-user. Process development included investigating downstream processing techniques for extracting and purifying the product from the reaction mixture.

5 Smarter Packaging Intelligence in packaging Greener packaging Intelligence in Packaging The integration of advanced printed sensors into packaging opens up a range of market opportunities for the food and drink industry. CPI has expertise in smart packaging: the incorporation of sensors into packaging to monitor and communicate the freshness of contents. The sensors measure changes in critical indicators such as microbial activity, temperature, ph, oxygen and CO 2 levels. Adoption of this technology will reduce reliance on inaccurate best before dates, thereby minimising food waste. This technology can also be harnessed to prevent counterfeiting and product tampering. CPI is working with several partners to embed smart packaging with near field communication, radio frequency identification and other wireless based applications. This easily incorporated technology has the ability to monitor and detect food quality or contamination online. A product can be tracked throughout the entire supply chain, providing the opportunity to improve logistics. Smart packaging offers a multitude of creative marketing opportunities, as well as the chance to communicate valuable point of sale messages to consumers. Greener Packaging CPI is working across a range of technologies to develop greener, more environmentally sustainable food packaging, such as bio-plastics derived from food waste streams. Companies can partner with CPI to develop processes for recycling used packaging into valuable materials, for example, we are working with an industrial partner to help convert plastic packaging into construction materials. Utilising our expertise in atomic layer deposition coating techniques, which yield excellent moisture and gas barriers, CPI can reduce the level of aluminium compounds and polymer materials used in food packaging films while providing excellent protective atmospheres.

6 Resource Efficiency Management Distribution Resource efficiency management Intelligent logistics A rapidly increasing world population, competition for natural resources, increasing consumer demand for locally sourced products and transparency as to the origins of their food. Factors such as these mean that resource efficiency management and supply chain tracking are crucial in the food and drink industry. CPI can help businesses to make their supply chains more flexible and profitable by piloting or demonstrating innovative processes or products for producers and distributors. We work with companies to help them identify and select the most efficient technologies, systems and processes and sustainably sourced resilient raw materials. In this way, we help our clients maximise the resource efficiency and overall effectiveness and sustainability of their products. We have expertise in the implementation of big data information systems, which we apply to our clients individual supply chain. This enables them to confidently establish where they fit into the overall flow of materials, and realise opportunities for greater operational efficiency and cost reduction. Working with CPI, companies can capitalise on the industry shift towards localised manufacturing and understand how improvements in factory design can improve their own manufacturing processes. Intelligent Logistics It is estimated that 30 percent of the world s food production is wasted due to spoilage occurring from incorrect packaging and transit issues. Food companies face a number of supply chain challenges for achieving transparency and traceability of their products and systems. There is a need throughout industry for companies to secure more effective monitoring and control of their foodstuffs, in order to enhance quality, increase shelf life, and reduce waste. CPI has expertise in printed sensing and communication technologies with the potential to improve distribution, efficiency, validation and quality-control of food products. The nature of these sensors permits autonomous operation and real-time monitoring of the processing of raw materials, not only in the factory and the warehouse, but through all stages of the supply chain. The technology can also be used for product validation against anti tampering in transportation, providing distributors and retailers with a cost effective solution that accurately determines whether a product has experienced abusive conditions. By offering such speed, precision and clarity, this form of intelligent sensing will significantly increase quality assurance within in the food and drink sector.

7 Waste to Worth Reduce or re-use food waste Second generation biofuels Reduce or Re-use Food Waste It is universally acknowledged that food waste is a significant global concern which must be redressed if production levels are to satisfy the growing population. An estimated one third of global food produced for human consumption is lost or wasted. This amounts to 1.3bn tonnes per year - an area roughly eight times the size of the United Kingdom would be required to re-grow this obsolete stock. Companies can work with CPI to improve their production lines and waste streams at every stage of supply, from selecting raw materials and manufacturing techniques to reusing industrial and consumer waste streams. CPI has significant experience in assisting companies from every level of the supply chain with creating high value commodities from food waste streams. These streams can be from sources as diverse as municipal waste, supermarket food, industrial waste, animal byproducts and sewage sludge. Using our industrial biotechnology expertise and world class facilities, CPI has the capability to help our clients turn food waste into valuable bio-products such as fuels, plastics, chemicals and materials. Second Generation Biofuels CPI is facilitating the development of energy efficient, second generation biofuels which can be grown or produced without negatively affecting food supplies, or using fresh water and arable land resources. These sustainable biochemical or biosynthetic alternative fuels can be integrated into the existing supply chain by blending with current fuels, without the need for large scale infrastructure reform. Adopting these fuels offers food and drink companies the opportunity to lead the way in reducing their carbon footprint and natural resource consumption, minimising the commercial risks associated with oil price volatility and security of supply.

8 CPI Study is a Game Changer for EnviroSystems CPI helped double sales through a study comparing lime ash, gypsum, straw, sawdust and Envirobed. CPI s scientists carried out a six-week laboratory scale study that included a series of bench scale anaerobic digestion assays. CPI designed a rigorous scientific protocol, comparing lime ash, gypsum, straw, sawdust and Envirobed. These bedding materials were blended with dairy manure, to provide ample nutrients, as well as a seed inoculum, to establish a microbial culture.

9 To find out more about our full range of services visit: call: +44 (0) Industrial Biotechnology and Biorefining Printable Electronics Formulation Biologics Centre for Process Innovation Wilton Centre, Wilton, Redcar, Cleveland, United Kingdom, TS10 4RF T: +44 (0) E: W: Copyright 2016 Centre for Process Innovation Limited. All rights reserved.