Four macro trends impacting food manufacturing today: Are you prepared?
trends | 8 mins read
enero 15, 2025
By Thiago Roriz, Chief Operations Officer, TNA Solutions
In today’s volatile economic and geopolitical landscape, staying ahead of market trends is essential for food manufacturers. As we step into 2025, the start of the year shaped by geopolitical crises, cost-of-living pressures, supply chain disruptions, and political shifts, several trends are poised to define the future of food production.
As a complete technology solutions partner to food manufacturers—spanning every aspect of the production line, including project management and aftermarket support—TNA Solutions is committed to helping customers navigate these trends, enhance resilience and drive growth in an increasingly competitive market.
Here is a closer look into what food manufacturers can expect over the next year and how technological innovations could help them thrive.
Persistent supply chain disruptions
Global supply chains remain fragile due to geopolitical tensions and climate change. The Russian invasion of Ukraine disrupted global supplies of key commodities, with Ukraine previously accounting for 46% of sunflower oil exports and 9% of the global wheat market, according to the USDA’s Foreign Agricultural Service. Conflicts in the Middle East, including attacks on shipping vessels, have affected trade routes. Simultaneously, extreme weather events like droughts and floods, exacerbated by El Niño, have strained agricultural productivity, leading to increased raw material costs.
According to Food Engineering’s 45th State of Food Manufacturing report, producers are focusing on efficiency to combat rising costs, which have increased by an average of 12% per product. Automation is a top priority, with 48% of capital expenditure allocated to such projects, according to the CRB Group’s Horizons: Digital Age of Food Manufacturing report.
At TNA Solutions, we innovate continuously to provide manufacturers with holistic automation solutions designed to improve efficiency, reduce waste and simplify processes. By partnering with a complete solutions provider like TNA, food producers benefit from a single-point responsibility, pillared on performance, responsibility, and customer-centricity. With over 40 years of experience, our expert team support customers from concept to full-scale production, ensuring long-term success.
TNA has introduced a range of innovative technologies designed to improve efficiency and help food producers face modern challenges. For example, the tna conti-cut® hydro cutting system has redefined standards in french fries processing. Featuring advanced ‘switcher’ technology, this system achieves industry-leading output capacities of approximately 30 metric tonnes per hour.
In confectionery production, the tna moguls offer a next-generation solution for flexible and efficient operations with reduced losses. Equipped with precision printing tables featuring high-frequency vibration, they support intricate mould designs, while enhanced starch containment systems minimise material waste. Capable of producing up to 5,500 kg per hour depending on the model and product, the tna moguls address the needs of manufacturers looking for high-output capacity and precision.
In addition, the tna auto-splice® 3 pairs seamlessly with the tna robag® 3e—VFFS system—offering automated film splicing without the downtime associated with manual splicing.
Cost of living crisis
Economic pressures continue to shape consumer behaviour. In October 2024, 53% of UK households reported higher living costs, according to Statista. Similarly, McKinsey & Company’s ConsumerWise Q3 report revealed that 53% of US respondents cited rising prices as a key concern despite declining inflation.
Consumers are increasingly seeking products that balance indulgence and affordability. GlobalData identified «restrained hedonism» as a leading snacking trend in 2024[1]. For manufacturers, this translates into growing demand for affordable treats that consumers love, whether in smaller pack sizes or economical bulk formats, while ensuring production lines remain efficient and cost-effective.
At the same time, health and wellness trends are driving demand for less-processed, low-sugar, and plant-based snacks, as well as confectionery with added nutritional benefits like high-fibre and high-protein ingredients. Consumers are increasingly prioritising organic and natural options, encouraging manufacturers to innovate while balancing costs. For instance, the rise of veganism is expected to increase manufacturing costs, leading to higher pricing for authentic plant-based items[2].
TNA is dedicated to helping food manufacturers navigate these challenges with innovative technology and complete solutions designed to enhance production efficiency. One way food producers can adapt to economic pressures is by rethinking the use of materials, typically considered waste. For instance, rejects from a french fries line—perfectly suitable in quality but not in shape—are often discarded. TNA works closely with its partners to explore transforming these rejects, as well as slivers and nubbins, into value-added products like hash browns, formed potato items or potato flakes. This approach not only reduces waste but also creates opportunities for new revenue streams, aligning with a commitment to responsible practices.
Additionally, reducing material consumption remains a key focus for TNA. As such, single-serration jaws on VFFS systems help minimise the use of biaxially oriented polypropylene (BOPP), a recyclable but non-biodegradable material. By enabling a 5-millimetre material saving per seal, a system producing 150 bags per minute can save 2.26 million bags monthly. In a facility operating 10 packaging lines for 12 hours a day, this equates to nearly 390 kilometres of film saved per month. By reducing waste and material use, manufacturers can navigate economic challenges more effectively and continue delivering value to consumers.
Labour shortages
The food manufacturing sector faces a significant labour shortage. A report by Deloitte and the Manufacturing Institute suggests that US manufacturers will need 3.8 million new workers by 2033, with nearly half of those roles potentially remaining unfilled if current labour gaps persist. Similarly, Deloitte reports that 62% of European manufacturers struggle with recruitment and retention, with this shortage expected to continue well into 2030.
This issue is compounded by an ageing workforce. According to a study by the Food and Drink Federation, nearly a third of the UK workforce is projected to reach retirement age by 2033–2035, leading to the loss of valuable skills and knowledge from the industry.
To address these challenges, the industry has accelerated its adoption of automation and prioritised user-friendly technologies. TNA recently introduced the tna ropac® 5—the world’s fastest case packing system. Case packing often represents a bottleneck in many manufacturing sites, and some manufacturers are just beginning to automate this function. Australian snack manufacturer Majans achieved a 140% increase in throughput within 12 months after implementing the tna ropac® 5. Andrew McManus, Manufacturing Manager at Majans, highlighted its impact: “Just five years ago, we regularly had between 28 and 35 people on a single shift, bagging, mixing and case packing. Today, with the help of TNA Solutions, that same factory operates with just 10-11 people per shift at outputs up to 6.9 times greater than before the automation process began. Casual jobs have been transformed into stable, full-time employment contracts, and technicians and maintenance crews have also been upskilled to effectively service and support these systems at a higher technology level.”
TNA engineered the tna ropac® 5 to operate at up to 95% efficiency, even at elevated speeds. Its patented rotary shelves gently catch bags in rows before collectively loading them into cases, avoiding high accelerations that could damage products or disrupt throughput.
Another TNA innovation is the tna auto-splice® 3, which complements the tna robag® 3e VFFS machine. The tna auto-splice® 3 automates film splicing without downtime, eliminating the need for manual operator intervention and ensuring uninterrupted packaging. Together, tna robag® 3 and tna auto-splice® 3 can deliver significant productivity gains. For a typical 7-hour shift across three shifts per day, running at 140 bags per minute, this technology can produce an additional 3.5 million bags annually and reduce downtime by 385 hours per year, achieving a 5.1% overall equipment efficiency improvement.
Digitalisation
While fully integrated smart manufacturing systems may still be a long-term goal for many food producers, elements of digitalisation are already transforming the industry. Increased demand for flexibility and speed in responding to market shifts has driven interest in technologies such as augmented reality (AR), virtual reality (VR) and remote assist platforms.
AI is rapidly transforming the manufacturing sector, offering significant advancements in operational efficiency and reliability. One of the most impactful applications is in predictive maintenance, where advanced tools such as Generative AI allow manufacturers to anticipate potential issues before they occur. By analysing data in real-time, these systems enable proactive responses, minimising downtime and ensuring consistent, reliable production processes. This technology not only reduces costs associated with unexpected failures but also supports manufacturers in maintaining optimal performance across their operations. According to Deloitte, 70% of public companies that outperform competitors on key financial metrics will be data and analytics-centric by 2025.
TNA has embraced this trend with the launch of the tna intelli-assist™ platform. The tna intelli-assist harnesses XR and simulation technologies to enable food manufacturers to virtually create and integrate new equipment and technology into production lines. Delivering 95% planning accuracy and reducing reworks down to zero, the platform leverages a digital twin environment using spatial technology. These immersive replicas of manufacturing sites allow food producers to visualise plant layout, detect and prevent clashes, virtually replace systems, commission equipment, and validate plant design and installations—all within a low-risk, simulated environment.
The platform brings together multiple stakeholders across various locations into one collaborative space, streamlining teamwork and saving our customers time, effort and money. Guided by TIATM, the platform’s virtual assistant and mascot, food manufacturers benefit from simplified onboarding, with support for tasks such as data compilation and call scheduling, ensuring seamless navigation and enhanced efficiency.
Our commitment At TNA, we are committed to empowering food manufacturers with the tools they need to navigate today’s challenges and prepare for future opportunities. By delivering innovative, efficient and sustainable solutions, we enable our customers to thrive in an ever-changing market. Together, we aim to redefine what’s possible in food production, ensuring success at every stage of the journey.
