The three dimensions of Industry 5.0 transforming food production today

TNA Solutions has long been at the forefront of technological innovation within the food industry. Since our inception, we have pioneered advancements that redefine the market. It all began in the 1980s with the development of the world’s first rotary vertical form fill and seal packaging system, which revolutionised food packaging by increasing speed and efficiency. Today, TNA continues this proud tradition by introducing cutting-edge solutions aligned with the Industry 5.0 approach. 

What is Industry 5.0?

Defined by the European Union as a vision of industry that extends beyond efficiency and productivity, Industry 5.0 reinforces the role and contribution of industry to society. It places the wellbeing of the worker at the centre of the production process and leverages new technologies to achieve prosperity that prioritises human welfare and respects the planet’s boundaries. The core dimensions of Industry 5.0—human-centric, resilient, and sustainable—emphasise creating a balance where industrial growth aligns with the wellbeing of employees and sustainability. 

1. Human-Centric

According to Deloitte, 62% of European manufacturers face ongoing challenges with talent recruitment and retention, with this shortage predicted to continue well into 2030. Similarly, a Deloitte and the Manufacturing Institute report suggests that US manufacturers may need as many as 3.8 million new workers by 2033, with approximately 1.9 million roles potentially remaining unfilled if current labour gaps persist. The report also highlights a 75% rise in demand for simulation and simulation software skills, which benefit from connected devices and integrated systems. 

With talent acquisition and retention challenges increasingly pronounced across manufacturing sectors, including food manufacturing, Industry 5.0 offers a transformative approach by prioritising employee welfare. Industry 5.0 positions workers as key contributors rather than mere cogs in an automated system, supporting skills development, inclusivity and engagement. This framework seamlessly integrates human creativity and expertise with advanced technology. 

For example, TNA recently launched the tna intelli-assist platform—a cutting-edge initiative that unites humans and technology in a hyper-customised, collaborative environment. The immersive digital twin setup leverages spatial technology to facilitate the validation and integration of equipment into both new and existing food production lines. By harnessing XR and simulation technologies, teams can virtually create exact replicas of their manufacturing sites to simulate optimal integration with minimal disruption. The platform delivers 95% planning accuracy and reduces reworks to zero. 

To further enhance collaboration, tna intelli-assist enables remote meetings within the virtual environment via VR headsets, allowing multiple stakeholders to join the plant simulation, preview the project and interact directly with the digital twin. This approach streamlines stakeholder buy-in and troubleshooting, enhancing the human element of manufacturing by fostering creativity, productivity and problem-solving without physical barriers. 

This not only improves project planning but also empowers employees to contribute meaningfully, gaining hands-on familiarity with advanced systems before physical implementation. Industry 5.0 is paving the way for a more human-centric future in manufacturing, addressing critical workforce challenges while driving efficiency and innovation. 

2. Resilient

In response to challenges like COVID-19, global supply chain disruptions and the war in Ukraine, food manufacturers worldwide are prioritising more resilient systems and processes. This second dimension of Industry 5.0 promotes robust operations that can adapt to and withstand external disturbances while maintaining efficiency and minimising downtime. Additionally, resilience in Industry 5.0 involves the ability to anticipate and respond to challenges promptly.  

This is particularly important for food producers integrating new processing or packaging equipment into existing or new lines. Industry 5.0 solutions, such as tna intelli-assist, combine digital twins with VR capabilities, enabling virtual simulations to validate plant design and test systems in a low-risk, cost-effective manner. Potential clashes can be identified and resolved before physical installation, significantly reducing downtime.  

The tna intelli-assist allows manufacturers to visualise plant layouts, virtually replace systems and validate designs in a simulated environment, ensuring seamless integration. By reducing project planning time and improving accuracy, this tool helps teams achieve optimal outcomes the first time. Key benefits include: 

• Enhanced decision-making: Faster, more confident decisions through virtual issue visualisation. 
• Efficient onboarding: Smooth integration of external stakeholders with detailed project insights. 
• Cost control: Clear project specifics reduce unexpected costs and variations. 
• Installation planning: Ensures equipment fits seamlessly into existing structures. 

Once operational, real-time production optimisation and virtual training further improve efficiency. Advanced tools like Generative AI enhance predictive maintenance, enabling proactive responses to potential issues and ensuring consistency and reliability. In a world of persistent supply chain uncertainties, these innovations bolster resilience and operational success. 

3. Sustainable

Sustainability, the third dimension of Industry 5.0, emphasises environmentally conscious practices, including minimising resources required for brownfield or greenfield projects. For instance, the tna intelli-assist platform reduces production’s environmental impact by limiting the need for physical travel and on-site interventions. Teams can collaborate remotely to review production lines using VR headsets or computers, saving time and resources while reducing emissions. This approach supports sustainability goals and aligns with global efforts to combat climate change. 

The future of Industry 5.0 in food manufacturing

The future of Industry 5.0 in food manufacturing is promising. Soon, operators could receive training and support virtually, interacting with an exact digital replica of their production line. For instance, teams could conduct training sessions—live or pre-recorded—in a VR environment, where trainers and operators work with the digital twin for a realistic, hands-on learning experience. This immersive training deepens understanding of equipment and processes, ensuring a smoother transition during system upgrades. 

Additionally, aftermarket support will be transformed with VR functionality, enabling operators to share live views with remote technicians and receive real-time guidance. This approach will reduce the need for costly, time-consuming on-site visits, ensuring faster response times and minimal production interruptions, enhancing resilience and adaptability. 

Our commitment 

TNA’s commitment to innovation and excellence is reflected in our embrace of Industry 5.0 principles. By integrating human-centric solutions, we empower food manufacturers to boost productivity, reduce environmental impact and adapt smoothly to future challenges. Through technologies like tna intelli-assist, we aim to redefine possibilities in food production, making processes more collaborative, efficient and sustainable than ever.