In step with needs of food producers

Food quality is one of the most important factors in a healthy, happy lifestyle today, and forms the basis for wellness worldwide. Wherever one looks in the world today, those involved in food production aim to increase the safety of their products at every stage along the processing chain. Furthermore, there is growing knowledge about each of the raw materials used and continual expansion of the technology employed in production.

The ongoing discussion concerning bird flu is a good example of why the safety and wholesome nature of food is so important. Consumers need to be informed and convinced of a food’s quality, and producers are aware that there is demand for ever more detailed information about the origin of and production processes involved in the food that they buy.

Revolution with RFID technology
The handling of raw materials is an extremely important factor in the quality of a finished product, and it is exactly this production stage that Icelandic company Sæplast serves. For over 20 years, it has gained a reputation worldwide as a manufacturer of high-quality plastic tubs for the food industry.

The ongoing development of Sæplast plastic tubs has from the start focused on preserving the freshness of its raw-materials as much as possible before being further processed. Part of this product development involves the company’s latest technology – radio frequency identification (RFID). Computer chips, which are embedded into the tub walls, record detailed information regarding the tub’s contents, ensuring traceability and increasing productivity.

This solution has been in development for several years now in cooperation with a major food producer in Iceland, as well as with research institutes. The result is an advanced system that has significant benefits for food producers. The solution has been displayed at exhibitions in which Sæplast has recently participated, and was chosen as the most interesting innovation at the Icelandic Fisheries Exhibition in 2005. The system, however, was not specially developed for the fisheries industry, but rather for all food producers utilising Sæplast tubs.

R&D work was the foundation
Sæplast was founded about 20 years ago and has since developed and grown in line with rapid advances in Iceland’s fisheries industry. It is undisputed that Icelandic marine products are known worldwide for quality – quality that Icelandic producers would not have attained without enforcing strict raw material and handling requirements at every stage of production. Initially, Sæplast emphasised manufacturing tubs insulated with polyurethane (PUR), which proved very successful since good insulation is key in product handling. The company then developed a tub insulated with polyethylene (MPC) that is even stronger and has significant insulation properties.

Sæplast tubs quickly became predominant in land fish processing and later on board vessels. After the tubs became common in Iceland’s fishing industry, the company developed an RFID traceability system, a natural continuation of its ongoing R&D programme for tubs. This system is based on information first recorded on a tub’s embedded computer chip as soon as raw material is placed into the tub. Further information is then recorded as appropriate.

Why traceability?
Food producers in the US and Europe must today abide by more extensive laws than previously regarding the traceability of raw materials throughout the production process. However, it is not only laws that motivate producers to tighten security, but the customer as well. Consumers are increasingly demanding more information and in a highly competitive environment producers must not only be able to answer for their processing, but also for the origin and handling of raw materials. A producer that cannot answer such questions is likely to lose customers to a competitor.

RFID in new and used tubs
Sæplast embeds RFID chips into rotational-moulded tubs during production, and also embeds them into used tubs if a customer requests. An example of how the new technology works in the fisheries provides an insight into how well it improves the flow of quality information. When the catch is brought on board and placed into tubs, all information is uploaded into the vessel’s computer system. When the catch is landed for processing, sensors read the data stored in each RFID tub, such as contents, size category, catch date, etc., which then enable production managers to efficiently and economically coordinate individual raw material supply with product demand. This maximises both processing efficiency on land, and raw material quality. This is only one example of how RFID can be utilised, an example which is identical for other food industries such as meat.

Providing for the food industry
In recent years, Sæplast has developed its tub production with a focus on cross-industry utilisation, and has marketed its tubs for use in food production in general. The tub’s characteristics – including high insulation properties and long durability – are as valued in the meat industry as in the fisheries. These are desirable characteristics for processing industries regardless of whether temperatures are freezing or hot. The company is placing increasing emphasis on introducing these plastic tubs to various food-processing industries, and as part of this programme participates in many of the best-known food exhibitions in the world.

Production around the world
Tubs from Sæplast are available in sizes ranging from 50-1500 litres. As mentioned above, the tubs are rotational moulded and double-walled. Buyers can choose between two types of insulation depending on need: polyurethane or polyethylene.

Over the past 20 years, Sæplast has built-up a network of manufacturing companies in the plastics industry that, in addition to making traditional containers, produce a broad range of products used in food production, transportation, fish farming, agriculture, etc. The company was originally built up around the manufacture of containers, which remains a principal part of operations.

Today, the company’s production facilities are located in numerous countries, as are its sales operations. This helps the company to realise one of its primary goals – to provide customers with services as close as possible to their locations. This also creates greater possibilities for developing innovations, such as the RFID system, since Sæplast has always worked on R&D in close cooperation with customers in order to understand specific operational needs.

For further information, please contact Sæplast Dalvik ehf on Tel: +354 460
or visit www.saeplast.com

Traceability has been defined in many ways, but it can be worded as “the ability to trace and follow a food, feed, food-producing animal or substance intended to be, or expected to be incorporated into a food or feed, through all stages of production, processing and distribution.”