Public Funding for Insignia Technologies Limited

Like many sectors, the food industry has been impacted by the COVID-19 pandemic. However, Insignia Technologies, experts in smart label technology, are developing innovative smart labels which can add real benefit during these challenging times. This project aims to develop intelligent labels to help ensure food deliveries occur quickly, safely and at the correct temperatures, providing reassurance regarding the quality and safety of the food being delivered. COVID-19 has significantly changed consumer behaviour regarding how food is purchased and consumed, with more consumers now using online delivery services rather than shopping in-store or dining out. Supermarket deliveries have boomed in 2020, as consumers avoid safety challenges associated with in-person shopping. The trends show many households who previously shopped in-store are now committed online shoppers. Hot food delivery companies have also seen a surge in demand recently as consumers swap dining out for takeaway deliveries. Growth of the food delivery sector as a result of COVID-19 brings new challenges. It is essential that controls/procedures are in place to ensure deliveries are quick, safe and at the correct temperature. Delays and poor temperature controls during grocery deliveries result in poor food quality and perishable items spoiling prematurely, ultimately leading to food being wasted. With hot food, customers expect their food delivered hot and fresh every time and failure to fulfil orders quickly and efficiently leads to customers receiving unsatisfactory food, again leading to food being wasted. Food waste is one of the top sustainability challenges globally and the UN states that if food waste were a country it would be the third largest greenhouse gas emitter, with the resources consumed producing food that is then wasted having a CO2 footprint of ~3.3bn tonnes. Therefore, it is important that consumers know their food has been stored and transported correctly, and hot food orders have been fulfilled quickly and efficiently, to avoid unnecessary waste. This project will address this challenge by developing innovative labels for use as a tool to indicate food has been maintained at correct temperatures and delivery has occurred within a set timeframe. Using Insignia's patented sensing technology, labels will be designed to change colour over pre-set timeframes at specified temperatures and, if these temperatures are exceeded, the label will change colour faster. When receiving deliveries, if the label has not fully changed colour then customers know the expected temperatures and delivery times have been met and their food is still at optimum quality. Different label constructions will be tested to achieve a series of time/temperature profiles and the labels will be tested under different conditions to optimise them for use in various delivery settings.

Insignia Technologies have been developing time-temperature indicators to improve upon the management and effective use of personal protective equipment (PPE). It is estimated that 129bn face masks are being used during the COVID-19 response each month. This dramatic increase in demand is understandable, but shortages remain of medical supplies like gloves, surgical masks, N95 respirators, face shields, gowns and aprons. Over the coming months, the supply chains will increase manufacturing to meet the rising global demand, however it is necessary to implement rational and good management systems to ensure effective and practical use of PPE supplies. Insignia has developed an innovative solution which would assist in managing the rotation of PPE and help prevent overuse. It has developed an indicator that changes colour over a pre-set time period which will visually indicate when the product is required to be changed. This project intends to develop a range of new label constructions to provide a series of necessary timings along with performing essential verification work. In addition to the technical aspects of this project, work will be carried out to assess the potential market size, and expansion of customer base. Time will be invested to understanding the key timings necessary to fit within the recommended guidelines for different equipment types, which can be discovered through conducting research and speaking to customers. This implementation of this innovation will result in a monitoring system that helps with the management of PPE and aid staff in using it effectively.

This project addresses the theme "Enhancing the Benefits and Value of our Natural Resources" in the government's Clean Growth Strategy, targeting the reduction of food waste and associated carbon emissions and greenhouses gases. Unnecessary food waste is a significant problem which has substantial cost and environmental impact associated with it. One challenge the industry faces in the fight against waste is ensuring food doesn't spoil in the supply chain before the end of the shelf life. Modified atmosphere packaging (MAP) is used widely throughout the food industry to help extend shelf life by preventing the growth of aerobic spoilage microbes. It involves replacing air within the pack with a carbon dioxide (CO2) rich/oxygen deficient gas mixture which keeps the food fresher for longer by inhibiting the growth of spoilage microbes. However, a major problem with MAP is the presence of leaks within the packaging, which results in the CO2 rich protective atmosphere being disturbed. This results in premature food spoilage as the growth of the aerobic spoilage microbes is no longer inhibited, which ultimately leads to food being wasted. This project aims to develop a cost effective, colour-changing indicator that can be on every pack to quickly identify if a leak is present. Such a technology will allow the manufacturer/packer to continually monitor the packaging process and identify problem packs which can then be reworked rather than being wasted. The economic and environmental benefits of this technology for the food industry are significant, as wastage will be reduced, and costs associated with current expensive and unreliable testing methods can be cut. As with many sectors, COVID-19 has impacted the food industry and is changing the way in which it operates. Due to restrictions posed by COVID-19, such as social distancing measures, food production facilities are having to adapt to operating with less staff and enhanced safety/hygiene protocols. To account for this, there is a move towards using more automated processes to increase operating efficiency and reduce the resource required to perform the necessary quality checks etc. As a result, time and cost savings will become ever more important and an innovation like this, which can improve efficiency, save cost and address food waste reduction, will help the industry with a sustainable economic recovery from the COVID-19 pandemic.

"Insignia Technologies have been working with a leading UK supermarket on a project to help improve food safety and quality and help consumers reduce food waste at home. It is estimated that over 2 million slices of ham go in the bin every day in the UK alone. Insignia came up with an innovative solution to this problem in the form of an after opening timing label. The timer changes colour once the package has been opened to show how long a product has been open. Consumer research proved that the technology helped to reduce food waste and improve food safety and quality. However in its current form it is too expensive to be considered for use long term. Most film widths for modern packing machines are too wide for standard label applicators to handle, therefore specialist equipment has been required. This equipment is expensive to run and has limited availability, therefore a roll out of the label technology for food categories such as raw meat, poultry, cooked and cured meats, cheese is not sustainable beyond one or two SKUs (stock keeping units). This project aims to revolutionise the technology to create an after opening timer that is printed as part of the packaging material, negating the need for an additional label. This would reduce the price point dramatically encouraging mass uptake of the system. The project will develop an innovative colour changing ink that can be printed into a recyclable mono-polymer construction of the lidding material, replacing the normal multi-polymer material used, which is currently not recycled. The printed indicator will change colour automatically when the consumer opens a product to show how long it has been opened. Insignia have partnered with Antonine Inks, who are specialists in printing inks for this type of packaging, to move the intelligent pigment from its current plastic film format into an ink system. The ink will need to be food contact approved and compatible with wide web flexo / gravure printing processes. The timing of the ink will need to be tuneable to the various manufacturers consume within guidelines."

Modified atmosphere packaging (MAP) is widely used throughout the food packaging industry. It involves replacing air within the pack with a CO2 rich/O2 deficient gas mixture which keeps the food fresher for longer by inhibiting spoilage by microorganisms. However if an accidental leak is present in the packaging, the preservation mechanism is disrupted and food spoils quicker. The presence of a leak is not always obvious, or its significance realised by consumers. This project will develop a simple colour-changing label which quickly provides information about the integrity of food packaging. Such inexpensive indicators will increase food safety, reduce waste and will vastly improve the quality assurance procedures currently used throughout the food packaging industry.