By Matt Hale, Global Key Account Manager, HRS Heat Exchangers

The recent news that there are now more than 300 biogas systems in the U.S. converting food waste into renewable energy¹ is great news, not only in terms of reducing emissions, but also for waste management, sustainable agriculture and soil health.

As the American Biogas Council (ABC) points out, ‘While prevention remains the best strategy to reduce wasted food, biogas systems help ensure the food that still gets discarded is used productively.’ Unlike other forms of renewable energy, biogas is extremely flexible and ‘can be used to power and heat homes, fuel vehicles, or generate electricity through engines and fuel cells.’

Overall anaerobic digestion (AD) systems in the U.S. currently ‘recycle 12.8 million tons of food scraps and other organic waste into over 35 billion cubic feet (Bcf) of biogas a year, enough to cover the year-long energy use of 283,000 U.S. households.’ However, ‘if three-quarters of the discarded food from homes, grocers, restaurants, and food processors were recycled in biogas systems, we could turn that wasted material into 115 billion cubic feet (Bcf) of biogas per year, equivalent to the energy needs of nearly one million U.S. households.’

But increasing capacity is only part of the challenge. Maximizing AD plant efficiency and ensuring that the valuable digestate produced has the greatest value, are key to delivering a thriving and successful biogas industry.

Of particular benefit for plants treating food waste is the HRS Digestate Pasteurization System (DPS), which has been installed in biogas plants across the globe. The HRS DPS is capable of pasteurizing digestate, feedstocks, and similar materials pre-or post-digestion, allowing operators to maximize the efficiency of their overall process while meeting regulatory (Class A biosolids) and customer requirements so that digestate from food treatment plants can be used as fertilizer. Its continuous process is simpler than single tank options and provides up to 70% heat regeneration, making it extremely energy efficient.

For more information on the HRS DPS, and our other systems to improve the efficiency and operational life of anaerobic digestion plants, please contact us today.

¹https://americanbiogascouncil.org/as-thanksgiving-approaches-abc-releases-new-data-on-biogas-energy-from-food-waste/

With fast approaching, Jenny Stanley, Managing Director of Appetite Creative, author of Connected Packaging: The Game-Changing Marketing Tool, shares why brands can no longer afford to ignore the evolution of packaging from static billboard to dynamic digital channel.

Connected packaging has long promised an exciting new kind of brand-consumer relationship, but 2025 has seen that potential start to truly take form. From Tesco's GS1-powered trial launch in the UK to rising adoption of AI, the past year has turned hype into action. It has given brand owners a lot to think about.

"When we spoke back in February, there was still a sense that this was an emerging opportunity. Now, it's here," Jenny says. "The GS1 Tesco test is huge because it brings something substantial to the UK market. We've talked about pilots and potential impacts, but this is real. And brands are finally asking, 'What does this mean for us?'"

For years, connected packaging has proved clever and creative, but often limited in scale. That changed when UK retailer Tesco became the first major player to trial GS1-powered on-pack QR codes at scale.

Unlike generic QR links, GS1 digital links connect to a globally recognised standard, unlocking everything from product data and marketing content to traceability and digital product passports. “It’s a major shift,” Jenny explains. “This is not a gimmick, it’s infrastructure.” As more retailers explore GS1 adoption, the conversation is moving fast.

A channel that’s already in your customers' hands

According to Jenny, brands are waking up to the idea that connected packaging is not a novelty; it's an important media channel. "It’s becoming better understood that the purchase isn't the end of the journey; it's the beginning. The product in your customer's hand is the most direct line you have.

Executed well, it's a win-win. Brands unlock first-party data, consumer insights and campaign ROI, while customers get access to tailored content, education, and brand storytelling. Recent campaigns tell the story: Etika hit 218,000 unique visitors with 120% goal achievement. Suntop delivered over 1 million visitors with a 1% bounce rate. KDD achieved 100,000 scans across two markets. These results are leagues ahead of digital ad click-through averages and, on average, deliver a 20% increase in sales.

"But if you do it badly, it's worse than not doing it at all," Jenny warns. "If you just link to your homepage with no value for the user and nothing distinct to offer, don't bother. You're training people to be disappointed. Every scan should be an opportunity to surprise, inform, or delight."

Education, trust and transparency

Jenny points to areas like product authentication, digital product passports, and sustainability messaging as key growth areas for 2026 and beyond. As regulation continues to evolve around EPR, PPWR, and transparency mandates, brands will need to provide proof points and traceability. And consumers, she says, are ready.

"People want to know where their product came from. Was it ethically sourced? Is the packaging sustainable? Can I reuse it or recycle it? Brands don't need to shout these things; they need to show them, clearly, simply, and honestly."

She adds that while some sectors like food and drink are less affected by DPP right now, others such as textiles, pharma, and luxury, are moving fast. "It’s a case of asking: what does this mean for me, specifically? There’s no magic bullet or one-size-fits-all." Appetite Creative’s consultancy arm supports clients with exactly that kind of tailored strategy.

A modern marketing superpower

The opportunity to use connected packaging goes way beyond regulatory compliance, it’s deeply creative. Jenny champions connected packaging to inject the spark of humanity into the digital journey: "Behind every scan is the opportunity for personalisation. Whether it's a gamified experience, storytelling, heritage, or usage tips, these are unmissable chances to create emotional connection."

And while some see digital and crafted packaging as opposites, Jenny sees alignment. "It’s not about replacing creativity with code; it’s about enhancing what’s already there. For example, a hand-illustrated label can trigger a scan that shares the story of the illustrator. A cardboard toy can link to an AR build guide. It’s retro and futuristic in one."

A rare moment of focus

Most digital interactions today vanish faster than a blink, a fleeting flick of the thumb, a scroll, or a skip. But connected packaging breaks that rhythm.

“The time needed to grab attention used to be seven seconds,” says Stanley. “Now we’re down to just two.” That’s the average time a consumer might pause before swiping past your message. In that high-pressure, high-speed environment, the two-minute average interaction time connected packaging can deliver is nothing short of extraordinary.

“This is an uninterrupted channel,” Jenny explains. “No ads competing for space and attention, no distractions, just a direct, intentional engagement.” It gives brands a chance to educate, inspire, or entertain. Whether it’s sustainability stories, how-to guides, or personalised rewards, those two minutes become a meaningful exchange a way most marketing channels can only dream of.

The data speaks volumes

For Appetite Creative, the ROI case is clear. Brands see up to 20% sales uplift through connected packaging campaigns, plus gold-dust first-party data. "You're not just getting a click. You're getting the time, location, engagement, repeat scans. It’s marketing that listens as much as it speaks."

That feedback loop feeds everything from flavour launches to marketing messaging. "We’ve had clients completely reposition a product after listening to what consumers told them through connected packaging. At the heart, it’s a consumer intelligence platform."

What's next?

As we look ahead to , Jenny predicts key themes will include:

• Greater uptake of GS1 codes
• Dual QR code strategies for DPP and marketing
• Growth in authentication tools for anti-counterfeit and consumer trust
• Expansion of accessible packaging initiatives like NaviLens

"I think we’ll definitely see more maturity," she says. "Not just 'should we do it?' but 'how do we do it well?' That’s when things really get exciting."

Packaging Innovations & Empack 2026 this February offers brands a roadmap to navigate the fast-evolving world of connected packaging, regulation, and data-led creativity. For brands looking to get ahead, the time to scan in is now.  and be ready for what comes next.

Inline blending is reshaping how hybrid proteins are best produced, says KROHNE’s Ryan Kromhout, with real-time precision process control helping scale with consistency, control, and consumer trust.

In the protein space, ‘blending’ no longer means compromise – it means most efficient control. A quiet revolution is happening in the pipes, not the headlines, and Ryan Kromhout is at the heart of it. As Global Industry Manager for Food at KROHNE, Kromhout isn’t just tweaking gauges and flow rates – he’s laying the groundwork for a hybrid food future built on precision, repeatability, and trust.

“Don’t be intimidated by the complexity,” he says. “With the right partners and the right technology, hybrid products can be made with the least tolerance possible, and both reliable and scalable.” That confidence comes from a simple but profound shift: replacing batch-based guesswork with real-time, in-line measurement. In a sector where even minor inconsistencies can make or break consumer trust, the ability to engineer every gram with surgical accuracy is no longer a luxury – it’s fast becoming the baseline.

From chipotle sausages to seaweed-infused chicken, the next generation of hybrid products is emerging. And behind the scenes, it’s instruments such as KROHNE’s Coriolis mass flow meters that ensure every bite tastes (and behaves) exactly the same, every time.

The physics of repeatability

Kromhout’s job isn’t to design the next viral vegan burger. His job is to make sure that, when it gets scaled to industrial production, it still tastes like the first bite consumers loved. Because in this field, quality isn’t a one-off achievement – it’s a standard that must be replicated endlessly.

At the core of KROHNE’s offering is the Coriolis mass flow meter – a deceptively simple device that reads like a physics textbook but works like a chef’s most exacting tool. Picture a guitar string vibrating. When fluid flows through it – anything from soy isolate to algae slurry – it alters the frequency of the vibration. That disturbance is directly proportional to mass flow and the process density of the measured goods.

“What you get is two critical measurements,” explains Kromhout. “Mass flow, which is pressure- and temperature-independent. And density, which tells you how much mass is in a given volume. Both are essential for consistent product formulation.”

The margin of error? Just ±0.1% on mass flow and ±0.2g/cm³ on density. “If you’re blending at 200 tons per hour, that’s a tolerance of just 200kg. That’s how tight we’re talking,” he says. This kind of precision becomes especially important with viscous, unpredictable inputs – think fermented soy, sourdough, or anything laden with air pockets. “Even in difficult conditions, we can still measure with 0.5% accuracy, and then help customers fine-tune from there,” he adds.

Why hybrid products need inline tech

Kromhout is bullish on hybrids. Not because they’re a shortcut to a plant-based future, but because they’re a realistic, scalable, consumer-friendly solution – and one that respects the diverse motivations of modern eaters. “What Lidl has done in the Netherlands is a brilliant example,” he says. “They introduced a 50:50 meat and plant blend, priced it lower than meat, and matched the taste. Consumers are cutting CO₂ emissions in half – without even noticing the difference.”

But to make that kind of blend work, repeatability is essential. If one batch tastes great and the next is dry or chewy, trust evaporates. Inline blending ensures that both plant and animal inputs are added in perfect proportion – continuously and in real time – before entering a static or dynamic mixer.

“It’s not just about quantity,” Kromhout emphasizes. “It’s about behavior. Plant-based inputs and animal fats behave differently under stress. That’s where understanding shear, rheology, and flow profiles becomes vital.”

KROHNE’s instrumentation captures exactly that – feeding back real-time data on how materials interact inside the pipe. “You can tweak flow velocity, mixing intensity, even adjust for temperature-based fat behavior,” he explains. “It’s like having eyes and ears inside the pipe.”

Inline systems also address some of the most pressing concerns in food tech – namely, label transparency and nutritional compliance. Many producers hedge against variation by overdosing expensive ingredients.

“I’ve seen it everywhere,” says Kromhout. “Facilities aiming for 32g of protein per serving will actually target 34g, just to avoid falling short. That drives up cost – and it’s unnecessary if your process is under control.”

With inline measurement, that safety buffer can be narrowed. Processors hit their targets without overcompensating, hence cleaner label, less ingredient waste, and better nutritional consistency across batches.

Raising the bar on repeatability

KROHNE’s systems are widely validated in the pharmaceutical sector – where standards for accuracy are often stricter than food. “These sensors don’t drift,” says Kromhout. “The reading you get on day one is the same you get on day 1,000. That kind of repeatability is how you build consumer trust.”

And in the competitive world of consumer-packaged goods, that trust can be everything. A single discrepancy – whether in nutritional value or sensory performance – can trigger reformulation, recalls, or reputational damage.

Hybrid formulations aren’t just about merging two ingredients. They’re about merging behaviors. Animal fat solidifies at different rates than coconut oil. Soy isolate thickens differently than whey. And when emulsifiers are removed – either for cost or label clarity – there’s no margin for error.

“Our systems detect phase separation in real-time,” says Kromhout. “If your emulsion is breaking, we see it in the sine wave of the sensor. You can correct it immediately.”

This early warning system doesn’t just catch faults – it prevents them. “Better control upstream means fewer problems downstream,” he adds. “That applies to foaming agents, stabilizers, even suppliers.
If we detect too much air in your spinach blend, maybe it’s a sourcing issue – not just a blending one.”

It’s a reminder that precision doesn’t just save money – it prevents crises. And when time, ingredients, and consumer attention are all finite, that’s a powerful form of risk management.

Scaling without losing soul

In Kromhout’s view, the biggest hurdle for many new players isn’t formulation – it’s scale. “Too often, startups work with engineering firms that offer legacy solutions – tank, scale, whisk. That’s not how modern food production should operate.”

KROHNE is taking a more collaborative approach, offering sensors on a trial basis and working side by side with teams developing new hybrid ideas. “These companies are experts in taste and texture. They don’t need to become experts in process control – that’s our role.”

And the beauty of inline systems is that they don’t require producers to lock themselves into rigid infrastructure. “If you’re switching from soy isolate to ground beef to single-cell protein, no recalibration is needed. You just keep flowing.” Such flexibility is especially crucial for smaller companies operating in pilot environments, where batch size is limited and speed of iteration is key. “The goal,” he continues, “is to give innovators the tools they need to scale without losing what made their product great in the first place.”

Looking ahead

For those still wondering where hybrid applications shine brightest, Kromhout has a clear answer: meat and cheese. “Meat is the obvious one,” he says. “It’s where the biggest impact lies – in sustainability, cost, and taste. Cheese is more complex – but also more exciting. It’s notoriously difficult to replicate with plants alone. Hybrids might be the bridge.”

But more broadly, Kromhout sees a transformation coming – not just in the products we eat, but in how we make them. “Process control isn’t just about machines,” he says. “It’s about making better decisions, earlier. If we want consumers to trust new protein formats, we have to deliver consistency, nutritional integrity, and a great sensory experience every single time.”

That requires data, precision and a willingness to move beyond legacy methods – to embrace real-time insights, advanced instrumentation, and a mindset focused on continuous improvement and future-ready processes. “There’s a future of advanced methodologies out there,” Kromhout concludes. “Let’s not rely too heavily on the past.”

Walk down the fresh meat or prepared foods aisle, and you’ll see more than dinner—you’ll see change. Today’s consumers want packaging that reflects their values: freshness, sustainability, ease of use, and visual appeal.

A recent survey of 883 U.S. grocery shoppers conducted by Supermarket Perimeter made it clear: shelf life and freshness top the list. Sustainability and convenience are fast climbers — especially among Millennials and Gen Z, and nearly half of all shoppers, are even willing to pay more for eco-friendly packaging.

MINDFULNESS CREATES PRODUCTION PRESSURE

That neat, grab-and-go tray may look simple, but behind the scenes, it’s a different story.

Labor and material costs are rising. Retailers expect shelf-ready presentation and extended freshness. Shoppers want clean-label sustainability without added cost. Producers must meet these demands—not by packing more, but by packing smarter.

This is where advanced tray seal packaging solutions step in.

TRAY SEAL TAKES READY-MEAL CHALLENGES HEAD ON

Tray sealing meets the ready-meal moment with innovation. Features like Modified Atmosphere Packaging (MAP) help extend shelf life—without freezing. Lightweight, recyclable mono-material trays cut plastic use and protect product integrity at high speed.

Modern tray seal is more than function. It’s form, sustainability, and savings—all in one format that looks good on shelf and checks the boxes for producers, retailers, and consumers alike.

REIMAGINING THE FLOW OF PACKAGING

Few technologies demonstrate this shift better than the Sinfonia.

As traditional lines struggle with labor shortages, waste, and downtime, Sinfonia takes a different path—literally. It replaces linear conveyor systems with high-speed magnetic shuttles that move trays independently across custom tracks and through dedicated lines.

This autonomous, non-linear flow lets producers package up to 450 trays per minute—without stopping the line. No more bottlenecks. No oversized layouts. Just faster, leaner production with maximum control.

START WITH PRECISION, NOT JUST SPEED

High-speed tray sealing may be the last step, but the real efficiencies start upstream—with precision portioning via multihead weighers.

Manual portioning leads to overfill and labor strain. In fixed-weight markets, it creates costly giveaway—often 5–6%. Multihead weighers change that.

By using real-time load cell data, these systems portion with remarkable precision. Giveaway drops below 2%. Labor drops by as much as 70%.

For a $100 million operation, that’s up to $4 million in recovered product each year.

Better still, these weighers integrate seamlessly with Sinfonia and other high-speed tray sealing lines, creating a fully automated line from weigh-in to final seal.

FROM PACKAGING TO PROFIT CENTER

Innovative tray sealing isn’t just closing a package. It’s unlocking new efficiency, yield, and margin as part of a larger, long-term growth strategy. One that helps producers stay ahead in a market defined by rising costs, thinner margins, and high consumer expectations.

POWERING PROFIT IN THE READY-MEAL PACKAGING SHIFT

Shoppers expect more from ready meal packaging. Producers must deliver—and fast. Tray sealing, paired with precision weighing, offers a future-forward solution: reducing labor, eliminating waste, extending shelf life, and supporting sustainability.

With innovations like Sinfonia for tray seal, packaging becomes a strategic advantage. Producers who act now will be best positioned to meet tomorrow’s retail demands.