How to reduce food waste in the industry
Reducing food waste is not just about throwing away less food. It goes much further: it means working more efficiently, making better use of raw materials, cutting costs, and extending the shelf life of every batch that leaves the factory. On a packaging line, even a small failure can lead to significant losses, whether due to waste, rework, or product returns.
At Ezquerra Group, we are highly aware of these challenges because we see them every day in the plants we work with. We know that when filling is precise and the can seam is properly airtight, food is better preserved, reaches the consumer safely, and unnecessary rejections are reduced. In this way, reducing food waste ceases to be a difficult goal to achieve and becomes a real outcome, with benefits for both the company and the environment.
Why is it important to reduce food waste?
Reducing food waste in the industry is not only an ethical issue; it is also a strategic decision. Every kilo of food that does not reach the consumer represents raw materials, energy, and money that are lost. Globally, this waste generates around 10% of greenhouse gas emissions, more than air transport or plastic production. In Spain alone, more than 1.2 million tonnes of food were thrown away in 2023.
For companies, minimizing these losses means saving costs, improving sustainability, complying with regulations, and strengthening consumer trust. Packaging plays a key role in this process: an airtight seam prevents leaks and contamination. At Ezquerra Group, we develop seamers and fillers that ensure safe, long-lasting seams, helping extend food shelf life and reduce waste at the source.
Main causes of waste in the food industry
Food waste in the industry is often caused by small failures that, when compounded, result in significant losses. Some of the most common causes are:
Production errors
Inaccurate dosing, overfilling, or a poorly made seam can leave entire batches out of specification.
Preservation problems
Packaging that does not provide sufficient protection or has defective seams reduces the product’s shelf life.
Inefficient inventory management
Excess stock, poor rotation, or unrealistic forecasts lead to products expiring in storage.
Unexpected line stoppages
When machinery stops, part of the product may be lost because it no longer meets quality parameters.
Confusion over consumption dates
Removing food that is still suitable for consumption due to confusion between “use by” and “best before” dates.
At Ezquerra Group, we know that many of these problems can be avoided with more stable processes, airtight seams, and a good preventive maintenance plan.
Effective strategies for reducing waste
Reduce food waste requires action at several key points. The most effective strategies focus on preventing waste at source, improving inventory management, and optimizing production processes.
Prevention at source
The best way to reduce waste is to prevent it from occurring in the first place. Three factors are essential here: choosing the right packaging, ensuring an airtight seam, and maintaining a preventive maintenance plan.
Metal packaging, for example, offers an excellent barrier and is easy to recycle. When combined with a properly adjusted seamer, it helps prevent leaks or contamination that would otherwise result in product losses. At Ezquerra Group, we design seamers and fillers with this goal in mind: extending product shelf life and ensuring process repeatability.
Improving inventory management
A large part of the waste is generated outside the machine. Adjusting production to actual demand, coordinating expiry dates, and maintaining a FIFO (first in, first out) system significantly reduce the risk of products expiring in storage.
When forecasting is realistic, production peaks are avoided, along with the surplus stock that never reaches the market.
Optimising production processes
This is where technology plays a key role. Filling with the exact required quantity and seaming in a stable, consistent way ensures that every container meets quality standards.
At Ezquerra Group, we offer both new equipment and rebuilt seamers remanufactured/rebuilt to as new condition, always with the same objective: maintaining precision, traceability, and line continuity.
Preventive maintenance is once again essential. Replacing a roll or seaming tool on time can prevent an entire batch from being lost due to a deviation.
The role of food engineering in reducing waste
Engineering brings method and reliability. Validating filling and seaming parameters for each product reduces uncertainty and, with it, waste.
Automation also helps anticipate problems. Sensors that verify seams, weighing systems, and software that records data make it possible to detect deviations before a batch is lost. At Ezquerra, this is precisely what we work on: integrating systems so that information flows and fast, data-based decisions can be made.
Metal packaging is another great ally: it protects food, extends its shelf life, and can be recycled infinitely, which fits perfectly with the circular economy.
Waste management in the food industry
Even when all the above measures are applied, some waste will inevitably be generated. The difference lies in how it is managed. Some options include:
- Internal reuse: reintroducing suitable product — in accordance with regulations and HACCP — into processes where viable.
- Valuable by-products: peels, bones, production losses, and trimmings can be transformed into broths, flours, or secondary ingredients.
- Animal feed and other uses: provided that safety requirements are met.
- Composting and anaerobic digestion: converting organic waste into compost or biogas.
- Packaging recycling: choosing materials with well-established recycling channels, such as metal, reduces impact and improves sustainability indicators.
With these practices, waste management in the food industry stops being a problem and becomes an opportunity to create value.
Reducing waste starts with a good seam
Many of the causes of food waste in the industry can be avoided with more stable processes and reliable packaging. At Ezquerra Group, we put our experience in seamers and fillers at the service of companies that want to improve efficiency, reduce losses, and meet the most demanding quality standards. Our goal is for every container to leave the line perfectly seamed and reach the consumer in the best possible condition.
If your company wants to move towards safer, more profitable, and more sustainable production, contact our team. We will advise you on the solution that best fits your needs, whether through new equipment, rebuilt machinery, or maintenance plans that extend the service life of your line. Because reducing waste is not just a goal; it is a better way of working every day.reduce food waste
