A consortium of companies, technology providers, and aid organisations has trialled an AI-based solution in the UK to reduce food waste. Participants included Zest, Nestlé, FareShare, and the Company Shop Group. The project demonstrates how losses in food production – including in conjunction with packaging processes – can be better recorded and reduced, and surplus quantities can be specifically redistributed.
Within the 16-month pilot project, production data was analysed using artificial intelligence to visualise the locations and timings of food losses in real-time. This also brings interfaces with packaging into focus, for example, when products cannot enter regular distribution due to packaging errors, labelling problems, or process deviations.
AI connects data across production and packaging
A key outcome of the project is improved transparency along the production processes. The AI technology used links previously isolated data points, thereby enabling more accurate analysis of waste and surplus – even at the interfaces between production and packaging.
Losses often occur at these interfaces in highly automated lines, for example, due to faulty seals, damaged packaging or incorrect labels. AI-supported analysis can identify such causes faster than manual procedures. In one application, the analysis speed could be halved while simultaneously quadrupling the amount of identified food waste.
Packaging determines recyclability
In addition to analysis, redistribution was also a focus. Zest's platform directly links available food surpluses with demand from organisations such as FareShare. However, in many cases, intact and compliant packaging, ensuring transport, storage, and food safety, is a prerequisite for onward distribution.
Over the course of the project, around 201.9 tonnes of food were redistributed, which corresponds to approximately 480,000 meals. According to project figures, a total of around 94,000 people were supported through hundreds of organisations. Additionally, 4.8 tonnes of edible surplus food were identified that had not previously been used and were now available for human consumption.
Meaning for packaging processes and design
The results also reveal potential for the packaging industry. Data-based analyses can be used to specifically identify and reduce weaknesses in packaging processes. At the same time, it is clear that packaging plays a central role in avoiding food waste and making surplus products available for alternative utilisation pathways.
Against the backdrop of increasing regulatory requirements and growing sustainability goals, this combination is gaining additional importance. Packaging must not only consider material usage and recyclability but also contribute to minimising product losses along the value chain.
Scaling as the next step
The organisations involved see scaling the technology as the next step. This requires closer collaboration along the value chain – including the integration of packaging processes into data-based control systems – as well as the use of shared platforms to coordinate supply and demand.
The project is considered an example of how digital technologies can contribute to increasing efficiency and reducing food loss. At the same time, it shows that packaging, as part of the overall system, is increasingly being integrated into data-driven optimisation approaches.
Source: Nestlé UK
