26 n FOOD AND BEVERAGE March 2025 www.drivesncontrols.com A sober look at automation According to data from IWSR Drinks Market Analysis, global sales of non-alcoholic and lowalcohol beverages are expected to grow with a CAGR of 6% between 2023 and 2027, with alcohol-free beer being the main driving force. In the UK, the revamp of the alcohol duty is likely to encourage growth in low-alcohol products – drinks below 3.5% ABV now qualify for a new lower rate of duty which, per litre, is typically less than half of that on drinks over that level. Further evidence comes from the Dry January movement, which has witnessed a dramatic increase in participation. In 2013 around 4,000 people took part. Skip ahead to 2023, and more than nine million people planned to give up alcohol for the month. These figures highlight a clear pivot towards health-conscious choices and the desire for alcohol-free options. The shift to low/no-alcohol drinks presents both an opportunity and a challenge for manufacturers. Producing alcohol-free drinks isn’t as simple as removing alcohol from a recipe – it involves balancing taste, quality and production efficiency. Traditional production methods for alcoholic beverages rely on fermentation, which inherently produces alcohol. Removing it while maintaining the beverage's flavour profile often requires complex processes such as vacuum distillation or reverse osmosis. Heineken and Guinness are examples of companies using innovation to thrive in the alcohol-free space. Heineken 0.0, for example, uses a proprietary process to brew and remove alcohol while preserving the beer's traditional taste. Similarly, Guinness gently removes the alcohol through a cold filtration method that preserves the beer’s taste and character. These brands illustrate the potential for combining innovative production methods with consumer-centric product design to achieve success. However, they also demonstrate some of the key challenges that manufacturers must overcome to make the most of this move towards low- and noalcohol alternatives. Adapting to changes Traditional production lines are often designed with specific products in mind. Adapting these lines to produce alcoholfree alternatives requires equipment capable of quick changeovers and multifunctionality. Automated systems equipped with modular hardware and software can be reconfigured easily to handle different production processes. For instance, a single production line could switch seamlessly between producing non-alcoholic beers, spirits and soft drinks, enhancing efficiency. Manufacturers must also consider the impact that switching to low- and noalcohol beverages will have on their product range. Technologies such as advanced motion controls and real-time data analytics ensure precision in mixing, bottling and packaging. Maintaining consistent quality is critical for alcohol-free beverages, as even minor deviations can alter taste or shelf life. By using digital twins – virtual models of production lines – manufacturers can go one step further and simulate processes, test recipes and troubleshoot issues without disrupting their operations. This accelerates the development of new alcohol-free products and optimises production efficiency. Finally, alcohol-free drinks must adhere to strict labelling and production guidelines, which often differ across countries. This necessitates adaptable systems for tracking and ensuring compliance. The alcohol-free trend is more than a passing fad – it reflects a profound change in consumer preferences. Beyond Dry January, demand for low- and no-alcohol drinks is likely to grow year-round as more people prioritise health and wellness. Food and beverage manufacturers must invest in technologies that allow for flexible, efficient and high-quality production. For manufacturers ready to adapt, the opportunities are immense. The era of zeroalcohol innovation has arrived, and those who embrace it will shape the future of food and beverage production. n The growing popularity of alcohol-free beverages means that manufacturers to need to rethink their production strategies. Stephen Hayes, managing director of Beckho UK, explains how automation can help food and beverage manufacturers to cater to the low- and no-alcohol market. The growing popularity of non- and low-alcoholic drinks poses challenges for manufacturers
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