Manufacturing today and into the future is dependent on new innovations like 3D printing to reinforce stronger supply chains, improve production line efficiency, and transform industries, including the food and beverage industry. Matthew Hunter from Konica Minolta, looks at how.
The food and beverage industry is one of the most vital industries in Australia for employment and economic output. However, environmental disasters, lack of produce, import and export challenges, and labour shortages have put undue pressure on the industry.
Subsequently, business leaders must consider implementing new technology that can meet current demands while ensuring their organisation can navigate future challenges, especially as the need to respond more quickly to consumer demands and trends increases.
The food and beverage industry has already seen vast improvements through the adoption of technologies such as tablets, dark kitchens, and back-end management software.
3D printing, a subset of additive manufacturing, has the potential to propel the industry even further.
Already, advancements in 3D printing have evolved to create 3D metal printers capable of printing in various metal composites including stainless steel, nylon, copper, carbon fibre, fibreglass, Kevlar, and many more. As a result, manufacturers can produce end use parts for production lines, which are just as high quality as the original part itself, faster, and more efficient.
It’s predicted that the additive manufacturing market will grow at a compounded annual growth rate (CAGR) of 29.89 per cent worldwide and will reach more than US$65 million by 2027. Despite the industry disruption caused by the COVID-19 pandemic, demand for 3D printing has only heightened as the organisational and operational benefits are realised.
There are three key ways that 3D printing is transforming the food and beverage industry:
1. Operational efficiency
Manufacturing in the food and beverage industry typically requires processing plants and equipment capable of being used for high-volume, intensive processing. However, some parts, such as rollers, gears, spray nozzles, and robot’s end effector pick heads, tend to have more strain put on them which can cause wear and breakages that halt the production line.
Part failure can result in the machine being nonoperational for weeks or even months while a replacement part is sourced, causing losses in productivity and expensive downtime.
This can be exacerbated by difficulties caused by international shipping delays, including increased shipping costs, geopolitical tensions, environmental challenges, and employee shortages.
However, 3D printing offers a solution that both improves machine maintenance and increases operational efficiency, as manufacturers can print required parts on demand using appropriate materials.
By printing parts in the same metal or a higher quality composite, organisations can reduce downtime and eliminate the need to wait for spare parts to be delivered. This can also improve the overall quality and effectiveness of the machine and its individual parts, as well as reduce the amount of part inventory manufacturers store onsite which in turn provides cost benefits.
The Australian Meat Processor Corporation (AMPC), the research and development corporation for the red meat processing industry in Australia, recently participated in a world-first 3D printing service model trial which will help revolutionise equipment maintenance and printing parts for meat processing plants nationwide.
The trial involves the operation of two mobile carbon fibre industrial 3D printers in eight-week trials before rotating to the next processing plant.
Staff receive training and guidance to use the printers to create pre-metal prototypes and produce non-metal parts for end use.
To date, end-use 3D printed parts have been a more cost effective, faster produced alternative, which improves flexibility and in-house capabilities to manufacture parts and increase the control and productivity of operations.
2. Enhanced innovation
Additive manufacturing has the potential to enhance innovation within organisations and the broader industry because it provides tools that encourage new improvements, creative thinking, and the means to conduct research and develop prototypes more cost-effectively.
Within the food and beverage industry, there are two specific areas where 3D printing is helping organisations to explore new innovations: part manufacturing, and product design and development.
Part manufacturing
3D printing provides manufacturers and engineers the tools to apply design thinking to parts. They can experiment with different composites and find stronger, more resilient materials to print machine parts that lead to less breakages and increased machine productivity.
The capacity to 3D print also lets engineers rapidly create prototype designs that will improve or add further value for production lines and organisations.
Product design and development
The innovation 3D printing provides the food and beverage industry does not end with keeping the production line operational, it can also play a critical role in bringing new products to market.
By combining durable end use materials with the speed to manufacture using 3D printers, companies have the ability to pivot quickly to consumer demand.
For example, customer research might suggest the perfect chip packet size and weight is different to the traditional product; however, the cost and speed of traditional manufacturing makes it almost impossible for the manufacturer to react quickly and cost effectively.
By using 3D printing to design and construct the bagging shoot the manufacturer can create custom bag sizes fast, providing the company with an effective and efficient solution for its products while pivoting quickly to address customer demand and ensure a competitive advantage in the market.
3. Improved sustainability
3D printing also lets the food and beverage industry reduce and tackle the issue of waste, for example using 3D printing to repurpose food waste into biodegradable plastics.
The process of 3D printing can also be a more sustainable method of manufacturing.
In combination with manufacturing only what is needed, 3D printing onsite can help to reduce the carbon footprint of manufacturers by minimising the need and frequency of using transport and logistics services. This in turn contributes to the overall reduction of carbon emissions involved in the food and beverage industry.
Incorporating 3D printing into the food and beverage industry has many benefits ranging from production to consumption.
It lets the industry create stronger, more resilient operations with improved efficiency, enhances the possibilities for companies to think creatively, and addresses the global concern around sustainability.
