Food is one of the most traded commodities in the world. With the globalization of markets and an increasing global population, the food supply chain will continue to grow in scale and complexity. This has a significant impact on the production as well as the distribution of food products. Compliance with food production quality standards is more essential than ever. Every year, one in ten people suffers from food-borne illness or injury, according to the World Health Organization. An estimated 420’000 people die each year as a result of poor food hygiene. The packaging industry has an important role to play in extending the shelf life of food products and making them less susceptible to interruptions in logistics chains, such as those caused by the COVID-19 pandemic.

In 2022, the global food market generated sales of almost EUR 7.75 trillion, with a strong upward trend. The EUR 10 trillion mark is expected to be exceeded in just five years. The food production and processing is booming, but according to the Food Index Report 2021 of the United Nations (UN), more than 900 million tonnes of food go to waste every year. The production and transport of food still puts a strain on resources such as energy and water, as well as land, where fertilizers and pesticides are used.

Food manufacturers and producers, together with the packaging industry, are developing new technologies and smarter food packaging solutions that make food last longer or make it less susceptible to disruptions in logistics chains. GF Machining Solutions works closely with customers in the packaging industry. Packaging, together with Food and Beverage, is one of the division's five key segments, and GF estimates the global market size for machine tools for packaging production at approximately USD 1.5 billion.

For its customers in this market, GF Machining Solutions develops solutions in the areas of laser texturing, milling, EDM and additive manufacturing, as well as automation and software. GF Machining Solutions thus provides the technology to produce ultra-precise cutting dies and molds for plastic, aluminum, paper and combinations of multiple materials. The GF division enables packaging manufacturers to break new ground in an energy-efficient way. 

Berhalter has been successful in the packaging industry for decades. The Swiss company, based in the Rhine valley in Widnau (Switzerland), uses a total of five GF wire-cutting EDM to process punches and dies for cutting out materials like plastic lids for food packaging.

GF's wire-cutting EDM technology enables Berhalter to machine composite materials, which make food and beverages last longer. Composite materials generally have a high strength-to-weight ratio, and can therefore be used to manufacture strong and efficient packaging. In addition, composites provide a high barrier to moisture, oxygen, microbes and light.

Several trends are emerging in the packaging industry. First, the sector wants to help tackle food waste through shelf-life-extending packaging. It is also promoting a shift toward recycled packaging and expanding the production of biodegradable or compostable alternatives to plastics. Reducing plastic and increasing the effectiveness of packaging requires high precision and accuracy in the manufacturing process, which should consume as little energy as possible. Together with Berhalter and other customers, GF Machining Solutions will continue to develop innovative solutions in this field.

New composite materials can be used to manufacture strong and efficient packaging that makes food and beverages last longer. When cutting or punching a yogurt lid, for example, precision is essential. The tighter the tolerances in a lid's closure, the better the content of the cup is protected. Wire-cutting EDM technology is ideal for filigree cuts. It uses a metallic wire (electrode) to cut a programmed contour in a workpiece. This infographic shows how it works.