Smart sensors are set to reshape the future of food freshness. In an exclusive interview with BlakBear and Solidus, we explore how wireless sensors embedded in fibre-based packaging can track real-time spoilage, deliver dynamic shelf-life forecasts, and cut unnecessary food waste across the supply chain. By pairing recyclable materials with precision freshness data, this early-stage R&D points to a future where fixed expiry dates become obsolete — and food truly tells us how fresh it is.
- Could you take us behind the scenes and explain how your wireless sensors actually work inside fibre-based packaging to monitor food freshness in real time?
BlakBear places tiny sensors in packages of food. The sensors detect freshness by measuring gas inside the package. The sensors send out data wirelessly every second, by Bluetooth and RFID, and we show the data in a web dashboard or API. BlakBear sensors measure two things, spoilage gas and temperature. BlakBear detects a wide range of spoilage gases released as food spoils —volatile compounds like ammonia. Spoilage gases correlates highly with the total number of bacteria on the food, and the odor from the food, which are two industry standard metrics for quality. BlakBear AI uses sensor data to give real-time microbiology, odor and shelf-life forecasts.
The sensor is based on a core technological insight we published academically in 2019 Reference: https://blakbear.com/research/
- Your technology measures specific indicators of spoilage. How does this move us away from static expiry dates and towards a more accurate picture of a product’s true shelf life?
Expiry dates are chosen to cover a worst-case scenario, based on simulated storage conditions. Once expiry dates are chosen (typically during annual validation tests) they do not change. We track actual biochemical change, not time. That means a product’s shelf life becomes dynamic, based on reality, not assumptions.
- In practical terms, how do you see this smart packaging reducing food waste across the supply chain — from producers right through to retailers and consumers?
The status quo is 5-10% of fresh food wasted every day in grocery retail stores, and even more in homes. Consumers and businesses all rely on fixed dates, which are chosen to cover a worst-case scenario. That means most food wasted at the expiry date is still good to eat or to cook. Instead of a fixed date, food should tell you how fresh it is. There are often many days extra shelf-life than printed on the pack. A single day of extra shelf-life can reduce fresh food waste by 40% in retail stores. But to unlock that, we need to know which packs are good and which are bad.
In the future we will not need printed dates on food, but the change starts with a hybrid model, printed dates plus dynamic shelf-life from sensors. This enables dates to be printed longer (reducing waste), secured by sensors catching outlier packs that will spoil early. BlakBear uniquely generates real-time freshness data and forecasts the remaining days of freshness with AI. It can tell you when food will spoil, weeks before it happens.
- Solidus is already known for its recyclable fibre-based solutions. What environmental advantages come from pairing these materials with freshness-tracking sensors?
Fibre-based packaging has recycling levels across Europe that are significant higher than any other material. About 85% is collected for recycling that is at least twice as much as plastic. Another benefit of fibre based packaging is that, especially when based on recycled fibres, the recycled content is typically well over 90%. Minimum recycled content is another requirement mandated by the PPWR which will become active across the EU for the middle of 2025. Finally, fibres are a natural renewable resource which are traceable and certified whereas most plastics today are still fossil based. The latter also shows up in carbon footprint comparisons which is important as packaging can contribute up to 20% of the scope 3 emissions.
- Real-time freshness insights could transform logistics. How might producers and retailers use this data to optimise distribution, reduce unnecessary testing, or even reroute shipments?
very pack of food is intrinsically different and spoils at a different rate. Even two packs produced on the same manufacturing line on the same shift can spoil differently. Furthermore, temperatures are unpredictable and exacerbate the intrinsic variation between products. The exact impact has so far been difficult to ascertain. In a supply-chain disruption, for example in a truck stopped in the sun due to an accident ahead, the food may be exposed to heat for a long period of time. This could limit the effectiveness of refrigeration, warming the products on the upper layer. This might be acceptable for most products in the vehicle, but cause unacceptable spoilage on the worst 20% of products. You can measure the temperature but it won't tell you the impact on freshness. The result is that businesses hold the food while waiting a week for a lab test result. On a product with a 20 day shelf-life, this can result in significant mark-downs or waste. BlakBear tells you temperature's impact on freshness, so our customers can adapt and make decisions in real-time based on data streaming in.
Every summer, entire manufacturing sites are blacklisted due to poor quality products causing customer complaints. With BlakBear, manufacturers and retailers now get early warning if products are not going to meet shelf-life. They use these data trends to improve product shelf-life and cold-chain before that happens.
- Fibre-based packaging already helps cut plastic and extend product life. How does adding digital freshness data take this one step further towards meeting global sustainability targets?
Food waste is a massive contributor to greenhouse gases. An accurate understanding if food can still be consumed will reduce unnecessary disposal. Today the “fresh until” date is a conservative estimate that guides consumers in their choice to eat or dispose. A digital sensor monitors food quality in realtime resulting in additional shelf-life: less food will be discarded and, consequently, less food will need to be produced which saves precious resources such as water and reduces CO2 emissions.
- This project is still in the R&D phase. Why do you believe early-stage experiments like this are so vital for pushing the food industry towards a more sustainable future?
Fundamentally this is about changing industry standards. That means we need many parties to give input to come to the right solution that not only is technically feasible, but also meets the requirements set by regulators and must be economically attractive to the various participants along the value chain. This requires learning together, sharing insights and being willing to address potential shortcomings. Fortunately, we have partners who share the same vision for a more sustainable future and are enthusiastically participating in the developments.
- Every breakthrough comes with challenges. What hurdles do you expect when it comes to scaling this technology for real-world adoption?
We are changing the world’s most crucial and complex supply-chain and, for most businesses, food safety comes before food waste. This means reducing waste is not enough. We also have to demonstrate we have a positive impact on food safety, rather than adding risk, and build trust in a rightly careful industry.
- Solidus has invested heavily in sustainable packaging innovation — from MAP and skin packaging to advanced prototyping. How does this culture of innovation support partnerships like the one with BlakBear?
Solidus is committed to contributing to a cleaner world with less waste, both packaging wate and food waste. We see many opportunities in these areas which are both supported by advancing regulation and consumer preferences. However, this requires technology which Solidus does not develop and therefore for many years now we have actively build a network of technology partners and build a culture of open innovation. We see this as the only way to accelerate developments and be recognised in the industry as a leader of packaging solutions that create value for our customers.
- If you had to imagine the food industry ten years from now, how do you see the combination of smart sensors and recyclable packaging changing the way we shop, eat, and waste less?
Ten years from now we expect that smart packaging which is now less than 3% will become the standard.
In the future we won’t need fixed printed dates on food.
Food will tell you how fresh it is, and in doing so we will end the $billions of unnecessary food waste.