Embracing Industry 5.0 in Food Processing and Packaging

The tna intelli-assistTM leverages XR technology to deliver 95% planning accuracy, enabling food manufacturers to streamline equipment integration and eliminate reworks. Image courtesy of TNA Solutions

How human creativity and advanced technologies are combining to shape the future of the food manufacturing industry.

By Natasha Avelange, Global Extended Reality Manager, TNA Solutions

In the wake of Industry 4.0 and the digital revolution it has ushered in, the food manufacturing sector is now on the precipice of a transformative new era: Industry 5.0. This paradigm shift goes beyond simply automating processes and accumulating data to bolster efficiencies; rather, it focuses on seamlessly integrating advanced technologies with human ingenuity. This close collaboration between humans and advanced technologies allows manufacturers to enhance sustainability, resilience, and efficiency across production processes like never before.

Although some food manufacturers may argue that they are still mastering Industry 4.0, the reality is that Industry 5.0 is closer than most think. In fact, the foundations of this new technological phase are perfectly aligned with the goals and priorities of many food manufacturers.

Industry 5.0 is built on three core principles: human-centricity, resilience, and sustainability. Unlike its predecessor, which is centered on connectivity and the automation of machines, Industry 5.0 places people at the heart of production. By empowering employees with technologies such as Extended Reality (XR), digital twins, and AI-driven analytics, companies are now able to solve complex challenges with creativity and precision.

One of the main drivers for this change is the rapid adoption of XR technologies. XR — which encompasses virtual, augmented, and mixed reality technologies — is revolutionizing how food manufacturers visualize plant layout, detect and prevent clashes, commission equipment, and validate plant design and installations. For example, XR-powered digital twins are now being used to create virtual replicas of physical facilities, allowing engineers and operators to simulate production environments. This capability not only allows for 95% planning accuracy but also reduces reworks down to zero, allowing for more efficient integration of equipment into both new and existing lines.

This adoption is showing no signs of slowing down, either. According to Market Research Future, the augmented and virtual reality market in manufacturing is expected to grow from $4.38bn USD in 2023 to approximately $42.2bn USD by 2032. This steep projected growth is a testament to the accelerating pace of technology adoption across industries.

Packaging, Reimagined

While market analysis gives only a limited view of how Industry 5.0 technologies are being adopted across industry verticals, the value to the food production market is clear. Modern processing and packaging lines must be agile and robust, capable of adapting to evolving consumer preferences while maintaining strict quality standards.

Technologies such as XR-powered digital twins are now being utilized to visualize and monitor installation projects from initial planning through finalization. Having real-time visibility into the latest design adjustments helps streamline both new installations and integrations into existing lines.

Building further on this sense of greater collaboration, new solutions are emerging that enable various teams and stakeholders to collaborate in virtual replicas of the plant environment. Teams that can meet remotely in real time to troubleshoot and verify designs far faster, reducing project lead times and errors.

Beyond process optimization, Industry 5.0 is redefining the role of human operators on the production floor. Whereas increased use of automated systems in the past decade has been rife with concerns about workers being replaced, this new era is focused on augmenting human skills with technology. Virtual assistants and AI-powered analytics are now supporting real-time decision-making, providing actionable insights that help operators maintain high standards of quality control and operational efficiency. This collaboration of humans and machines drives continuous improvement and fosters a culture of innovation where every employee is empowered to contribute to the company’s success.

Further, virtual environments are the perfect setting for providing operators with comprehensive and practical system training. The realistic environment simulated by a digital twin offers new operators an immersive learning experience and helps all team members get up to speed on new systems quickly, safely, and efficiently.

Immersive digital twins allow manufacturers to visualise plant layouts, prevent clashes and optimise installations. Image courtesy of TNA Solutions

Extended Adaptability

The impact of Industry 5.0 extends beyond food production premises and into the wider food supply chain, giving food manufacturers the adaptability in their processes to meet ever-evolving market requirements. By streamlining collaboration and allowing teams to act more efficiently on collected data, companies can innovate and respond faster than ever before.

Packaging and processing, in particular, stand to benefit enormously from these advancements. Modern consumers demand packaging that is not only functional and visually appealing but also sustainable and eco-friendly. Industry 5.0 technologies facilitate rapid prototyping and testing of new packaging materials and designs, accelerating the development of solutions that reduce environmental impact. This is crucial in supporting circular economy initiatives and meeting the growing regulatory and consumer demands for sustainability.

Similarly, these technologies still offer the benefits that have come from Industry 4.0, such as the ability to meet fluctuating demand — though now with greater levels of resiliency. Digital twin technology, coupled with real-time data analytics, allows manufacturers to predict and mitigate potential disruptions before they escalate. This proactive approach enhances overall operational resilience, ensuring that the industry can continue to meet consumer demands even in the face of unexpected challenges.

It may still be early days, but it’s clear that Industry 5.0 is set to revolutionize the food manufacturing industry. From XR-powered digital twins that optimize production processes to AI-driven analytics that enhance real-time decision-making, the benefits of this new paradigm are both extensive and transformative. Embracing Industry 5.0 is not a distant future but a tangible, actionable strategy that can drive significant improvements in efficiency, safety, and sustainability across the food manufacturing sector. For companies determined to remain competitive in an ever-evolving market, integrating these technologies offers a promising roadmap to long-term success and innovation.

About the Author

As Global Extended Reality (XR) Manager at TNA Solutions, Natasha Avelange leads the development of the tna intelli-assist™ platform, which harnesses XR and simulation technologies to enable manufacturers to virtually create and integrate new equipment and technology into both new and existing production lines. With a bachelor’s degree in architecture, Natasha was an early adopter of digital design, completing the first computer-generated project at her university. She applied her expertise to major TNA infrastructure projects, designing and managing the construction of TNA Melbourne’s manufacturing facility and TNA’s European and North American headquarters. Beyond her architectural contributions, Natasha played a key role in business operations and expansion, leading the setup of TNA’s Middle East and Asian offices as Operations Manager. Visit www.tnasolutions.com or contact tnateam@tnasolutions.com to learn more.