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.

The migration to 2D codes – also known as GS1 Sunrise 2027 – is set to transform the world of packaging and product marking. But what does it mean for manufacturers, packagers and brand owners? What opportunities and challenges come with this migration? And how can you make sure your company is fully prepared?

Everyone’s been talking about 2D codes in general terms. We make it specific.

Yes – LEIBINGER printers can handle 2D codes. 

And yes – there are clear, proven reasons why we do it better than others.

We have prepared a technical article that reports on the true facts about 2D migration and provides important information on implementation for manufacturers.

Please find the article report attached below

Attachments:

LEIBINGER 2D code migration.doc

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By: Oscar Infanzon, Design Engineer & Manager,

Amerikooler Cold-storage rooms may look like simple metal boxes, but their performance is governed by what lies between the inner and outer walls. Insulation determines how efficient the refrigeration is, how much energy is consumed, how long it resists moisture and corrosion, and, ultimately, how reliably it protects food or pharmaceuticals. As energy codes tighten and operating margins shrink, cold storage manufacturers are rethinking everything from the materials they use to the systems that shape them. The industry is moving toward three central priorities: higher performing insulation, precision driven automation, and more sustainable manufacturing practices.

Why Traditional Foam Falls Short

For roughly fifteen years the industry standard has been foamed-in-place (FIP) polyurethane. The chemistry delivers a respectable R-value on day one, yet its micro-cell structure is vulnerable to two forms of degradation. First, the blowing agents that create the foam’s closed cells migrate out over time, a phenomenon known as thermal drift. The result is a steady drop in resistance to heat flow. Second, the open edges and microscopic voids readily absorb water. Operators who disassemble aging walk-ins often discover rust bands and soft, spongy spots where moisture accumulated over time, causing the foam to collapse.

Service technicians see the effects in the field: compressors cycle more often, evaporators struggle to defrost, and energy bills inch upward year after year.

Compounding the risk, most FIP panels ship with no meaningful long-term thermal warranty, leaving owners to absorb repair or replacement costs sooner than expected.

How Extruded Polystyrene Keeps its Chill

Extruded polystyrene (XPS) addresses those weak points at the molecular level. Formed as dense, closed cell boards, XPS locks in its blowing agent early in the manufacturing process, so the R-value stabilizes and remains essentially unchanged for decades. Independent lab tests show water absorption of less than one percent by volume, considerably lower than FIP or expanded polystyrene.

The durability translates directly into operating savings. Panels that resist moisture do not lose R-value to trapped water, and surfaces stay structurally sound instead of degrading near the floor line. When owners run lifecycle analyses, insulation that holds its R-value delivers a clear, long-term drop in refrigeration energy use—often a noticeable share of the walk-in’s annual consumption—compared with panels whose performance drifts as they absorb moisture or lose blowing agents.

No Foam, No Voids: How Automation Supports Material Integrity

Even the highest-performing insulation fails to deliver if installed improperly or manufactured inconsistently. Gaps at joints or thresholds compromise thermal performance and cause long-term energy loss. As a result, the move toward XPS has coincided with advances in panel fabrication, ensuring tighter fits and more reliable energy efficiency.

Some manufacturers have moved away from traditional foaming and toward digitally integrated production lines tailored to board-based insulation. In these facilities, CNC routers cut each XPS panel to a unique digital blueprint, ensuring a precise, gap-free fit. Robotic press brakes form the metal skins to exact dimensions, while barcode tracking and in-line scanning verify each step and improve traceability in real time. This level of precision reduces variability, minimizes errors, and helps maintain the performance potential of high-quality insulation.

These advancements aren’t just about thermal performance; they also improve production timelines. Orders that once took six to eight weeks to fulfill can now ship in as little as two, even for custom walk-ins. As a result, manufacturers are able to meet tighter construction schedules without compromising quality or energy efficiency.

Amerikooler, a leader in commercial refrigeration solutions, was one of the first major walk-in manufacturers to fully adopt XPS as a standard, not just as an option, across all of their custom and quick-ship products. What sets them apart, however, is how their highly automated manufacturing process supports the full performance potential of XPS.

The company’s Miami-based facility has evolved significantly over time, replacing older,

manual practices like jigs, tape measures, and handwritten labels with an almost fully

automated panel production line. Automated systems precisely shape each panel’s insulation board and form metal skins to exact specifications, with quality assurance checks integrated at every stage of production. Advanced barcode tracking and in-line scanners capture detailed data points in real time, providing complete visibility into each job’s progress. This end-to-end automation not only guarantees exceptional quality and tracking, but also enables us to efficiently produce custom boxes to order, which eliminates the need for warehousing preset

panel sizes. Rigorously minimizing variability and safeguarding product integrity allows

Amerikooler to deliver systems that provide exceptional benefits far beyond mere speed.

Building for Efficiency and Responsibility

In cold storage design, energy efficiency is a long-term performance metric. When

insulation maintains its integrity over time, walk-ins require less energy to keep temperature stable. Panels that resist moisture and thermal drift help reduce compressor runtime, limit system strain, and support lower utility costs across the equipment’s lifespan.

Energy use is just one part of the sustainability equation. Forward-thinking manufacturers are also reexamining how panels are built and what happens to the materials that don’t make it into the finished product. Some facilities now bale XPS insulation off-cuts for return to the supplier, where they’re reprocessed into new board stock. Metal scraps are diverted to recycling streams rather than waste bins, and digital fabrication techniques are reducing the number of miscuts or reworks on the production floor.

Precision driven systems also help reduce overfill and chemical waste often associated with foamed-in-place insulation. By adopting recyclable board-based insulation and refining manufacturing to eliminate unnecessary material use, producers are helping end users reduce both operational emissions and embodied carbon. For facilities navigating stricter energy codes and ESG reporting requirements, these improvements in material selection and production control can offer meaningful, measurable benefits across the product’s full lifecycle.

Adapting to new regulations, such as state-level restrictions on certain finishes, updated refrigerant standards, and evolving sanitation codes, has also driven manufacturers to select more durable, corrosion-resistant materials like Acrylume and 304 stainless steel for panels and hardware. These choices not only ensure long-term product integrity but also help cold storage systems meet the highest standards for safety, durability, and compliance. Additionally, our internal R&D engineering department works closely with sales and customer service teams to continuously drive improvements in design, quality, and manufacturing processes.

A New Blueprint for Cold Storage

As the cold storage industry evolves to meet today’s demands, insulation can no longer be treated as a static commodity. The transition away from foamed-in-place polyurethane toward more durable, board-based alternatives like XPS marks a meaningful shift in how cold rooms are designed and built. Yet, material choice is only part of the equation. The rise of precision automation and closed-loop manufacturing is ensuring that insulation performs as promised—not just on day one, but for decades to come.

The next frontier is intelligent cold storage: manufacturers are now investing in smart systems for inventory tracking, humidity and temperature control, automated alerts, and remote monitoring. These innovations promise to further enhance reliability, efficiency, and traceability across the cold chain. At Amerikooler, ongoing R&D is focused on integrating these intelligent features into future product lines, reflecting a broader industry commitment to continuous innovation. By refining processes and embracing new technologies, companies like Amerikooler are helping to set new benchmarks for performance, sustainability, and long-term value as the industry moves toward a smarter, more resilient future.