The
Demand for healthy, functional beverages is making probiotics popular PG. 20
Mike McCann. Application Specialist. Packaging Expert.
“I’m
2022 • VOL. 82, I002
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Photos courtesy Evive,
Dare Foods Limited, Adobe Stock
The disruptive potential of cellular agriculture foods
Food and beverage companies are looking to meet increasing consumer demands for healthy, affordable, clean label products manufactured using sustainable practices. From cell-based to upcycled food products, the food industry is constantly evolving and innovating. Therefore, Food in Canada launched a three-part webinar series this spring to deconstruct the emerging trends in the food and beverage processing industries.
The first of the webinar series was on “From Lab to Plate: Innovating with Cellular Agriculture,” held April 6. Panelists Elaine Corbett, PhD, director, Sector Innovation and Programs at Ontario Genomics; Dana McCauley, chief experience officer, Canadian Food Innovation Network (CFIN); Jennifer Côté, CEO and co-founder, Opalia; and Mark Juhasz, PhD, principal and founder, Harvest Insights, took a deep dive into the world of cellular agriculture, and its potential to disrupt the food industry. Catch the whole session at www. foodincanada.com/webinars/free-webinarinnovating-with-cellular-agriculture.
Canada’s $12.5B opportunity
Corbett began her presentation by defining cellular agriculture. She highlighted the processes of precision fermentation and tissue engineering and cell culture. In the former, cells are grown in microbrewery-like tanks to produce large quantities of a desired product without using animals. In the latter, “cells from livestock, seafood or fish are grown outside the body in specialized
media to produce muscle tissue, fat or other tissue types,” she explained. The end goal of both methods is to create a product that is biologically equivalent or nearly equivalent to the conventional plant or animal protein/product.
Future Fields, Harvest Moon, Noblegen, Because Animals, Aux Labs, Whiteboard Foods, Biofect Innovations, Appleton Meats, Mara, Liven, Myo Palate, Opalia, Ardra, and Caro Meats are some of the Canadian companies in the cultured food space.
Corbett also highlighted a 2021 Ontario Genomics study that found the Canadian cellular agriculture is worth around $12.5 billion and can create 142,000 jobs. She said it is important to “develop a national vision and strategy for a Canadian cellular agriculture industry in the near term, establish a clear and transparent regulatory framework for cell-ag products in Canada and provide supporting mechanisms for research and commercial development.”
Cegan food innovation
McCauley then took the floor to explain why CFIN has partnered with Ontario Genomics to launch the “Accellerate-On: Food Innovation with Cellular Agriculture” competition, Canada’s first regional food innovation with cellular agriculture contest. According to McCauley, Canada can become a go-to place for cell-ag product development.
McCauley highlighted Biomilq, a food tech startup in Durham, North Carolina, that is producing mammary
Nithya Caleb
cell-cultured breast milk to provide an alternative to infant formulas.
Opalia
Côté then introduced the participants to her company Opalia that produces whole milk with mammary cells. Using enhanced mammary epithelial cells that grow and lactate inside a bioreactor that replicates the in-vivo environment of the cow udder, Opalia is able to manufacture all of the functional components of traditional dairy without involving any animals in the process. The replacement substrate used in Opalia’s proprietary process is FDA-approved. Further, Opalia’s milk contains all of the functional components of traditional cow milk.
A consumer perspective
Lastly, Juhasz presented the results of a survey conducted by Agri-food Analytics Lab at Dalhousie University in partnership with Caddle, Inc., in fall 2021 to determine Canadians’ protein preferences. More than 30 per cent of the respondents agreed that cultured food products would be less impactful on the environment and be more ethical. More than 100 readers attended the webinar. In May, we will be looking into the upcycling phenomenon. To register, visit https://us02web. zoom.us/webinar/register/WN_ vR72vErRQ1eeblD6KWFalA.
Nithya Caleb ncaleb@annexbusinessmedia.com
Kraft Heinz and The Not Company partner to accelerate AI-driven plant-based innovation
The Kraft Heinz Company and The Not Company (NotCo) announce a joint venture. The Kraft Heinz Not Company will leverage the inherent strengths of both companies. NotCo will bring its patented, first-of-its-kind technology and proven artificial intelligence solutions, while Kraft Heinz will offer its iconic brand portfolio and scale to develop plant-based versions of co-branded products.
News> file
Calgary-based startup
Secret Foods expands across Western Canada
Secret Foods, maker of premium tahini finishing sauces, secures retailer partnership with Save-On-Foods. This means its products will be on Save-On-Foods shelves across Alberta, Saskatchewan British Columbia, and Manitoba. After launching just a year ago, Secret Foods has experienced tremendous growth as an alternative
PEOPLE
condiment in the traditional grocery space. Following this deal, it will be in over 300 stores across Western Canada.
Canada’s food manufacturers grow sales, despite challenges: Farm Credit Canada report Buoyed by pent-up demand and higher prices, Canada’s food manufacturing industry performed well in 2021, according to the latest Farm Credit Canada Annual Food Report. Food manufacturing sales increased 14.8 per cent to more than $125 billion in 2021 and are projected to increase 7.4 per cent in 2022. Last year was the strongest year-over-year sales growth recorded since 1992.
IGA launches an accelerator for Quebec companies
IGA launches Local Accelerator, an initiative aimed at supporting Que-
bec agri-food companies that are developing products with the potential to shake up the industry.
To stimulate innovation and help Quebec entrepreneurs get their products onto store shelves, IGA will inject $1 million into this project annually. From merchandising to marketing, logistics and finance, each acceleree will receive customized support and exclusive access to IGA resources to maximize the chances of successfully bringing their product to market.
Congebec leasing a $70M industrial freezer in Montreal
Congebec signs a long-term lease at a development in Montreal’s North
> Eat & Beyond Global Holdings appoints Justin Osborne to the newly created role of vice-president of sales. With over 10 years of CPG sales and marketing experience, Osborne will work closely with select Eat & Beyond portfolio companies to accelerate their commercial success in the market.
> The Saskatchewan Food Industry Development Centre appoints Dr. Mehmet Tulbek as the Food Centre’s new president. Dr. Tulbek brings over 20 years of agricultural business and leadership experience to the Food Centre.
> Mondelez International appoints Karla Schlieper as president, Mondelez Canada. Schlieper comes to this leadership role in Canada following her success leading the Mondelez business in Latin America’s Southern Cone region (Argentina, Uruguay and Paraguay).
> Handtmann Canada appoints Jason Medeiros as key account manager and Kevin Hankins as territory sales manager in a new Western Ontario region.
> Certified Group and Food Safety Net Services appoint Justin Malvick as president, Food and Beverage, where he will be responsible for the formulation and execution of the division’s growth and long-term strategic plans.
> Sokol Custom Food Ingredients recently introduced a new leadership team as John Novak retires as president. Tim Novak will take on company leadership as president. Michael Novak has been promoted as chief operating officer. Paul Noble has been promoted as chief commercial officer and Fiore De Simone has been promoted as director of procurement & logistics.
> Barentz names Mike Brennan as director of supply chain and logistics for North America. Brennan has over 25 years of experience in global supply chain and logistics management across a variety of industries.
Justin Osborne
Karla Schlieper
Justin Malvick Mehmet Tulbek
Kevin Hankins
Tim Novak
NEW PRODUCTS
INGREDIENTS
> Conagen scales up production of two new high-intensity sweeteners, thaumatin I and thaumatin II . The development will expand commercial partner Sweegen’s sugar reduction solutions of zero-sugar natural sweeteners.
> Renaissance BioScience Corp. has received new patent allowances and grants for its non-GMO acrylamide-reducing yeast (ARY) from regulatory authorities in China, Russia, India, Australia and Vietnam. These five new ARY patent grants and allowances join previously issued patents from the US, Japan, Indonesia, Chile and Colombia.
> EverGrain Ingredients’ entire portfolio of upcycled barley protein and fibre ingredients has received the Upcycled Food Association’s (UFA’s) certification . The first-of-its kind mark, which was launched last year, will enable food and beverage manufacturers that use the ingredients to place the upcycled claim on its packaging.
> Givaudan and Fiberstar enter into an agreement allowing Givaudan to commercialize and use Fiberstar’s natural, plantbased texturizing ingredient, Citri-Fi. The collaboration will support the expansion of Givaudan’s Taste and Well-being portfolio while extending Fiberstar’s geographic footprint and research & development opportunities.
Shore. This $70-million development will include a new 219,000-sf cold storage facility that will enable food producers in the region to store inventories closer to their operations, thereby creating efficiencies within the supply chain. Construction of the building is expected to be completed in 2023.
Oat Canada and Roquette partner to develop novel oat ingredients
Protein Industries Canada invests in a project between Oat Canada and Roquette. This $4.1-million project will see the development of novel oat ingredients and nutritionally superior oat-based food and beverage products. Roquette will develop Canada’s first oat-protein ingredient through the project. Oat Canada will test the ingredient in its current line of products as well as in several new ones.
$29M project seeks to create a better plant-protein ingredient
Protein Industries Canada, More Than Protein Ingredients, Quantum Mechanical Technology, and Hamman Ag Research have announced a $29-million project to create one of the most functional plant protein ingredients available on the market. Project partners will first focus on the breeding and agronomic level to improve the protein quantity and quality of yellow peas and lupin. The next step is pre-treatment to help prepare the crops for ingredient processing. The final step is scaling up innovative processing technologies to produce functional protein ingredients for plant-based consumer food manufacturers.
Alfa Laval designs new pulse seat clean for drain valves
The new Alfa Laval ThinkTop pulse seat clean reduces cleaning-in-place (CIP) liquid for mixproof valves by up to 90 per cent, the pulse seat clean cuts drain valve CIP liquid consumption by up to 95 per cent.
Short bursts, or pulses, drive the valve cleaning process, activating the valve when shear forces peak. Each position-based pulse takes less than a second, preventing pressure shocks in the system. The pulse creates high turbulent flow as the liquid passes through the narrow gap between the valve house and valve seat, effectively removing all residuals for spotless drain valves.
Intended for use with single-seat valves or butterfly valves used as drain valves, pulse seat clean is a standard feature of ThinkTop V50 and V70 sensing and control units with one solenoid valve. Regardless of actuator mode, the drain valve may be configured as a normally open or normally closed shutoff or changeover valve.
www.alfalaval.com/thinktop
Luxme develops an automated food-grade bag slitter
Addressing the vegan and plantbased food industry’s need for a hygienic, high-volume bag opening solution that eliminates dust and removes the associated H&S and cross-contamination risks, Luxme International has developed the MiniLux, an automated food-grade bag slitter constructed to FDA standards with self-contained dust collection and recovery.
Capable of opening up to six 25-kg bags per minute, the MiniLux is an all-in-one conveying, slitting, emptying, integral dust filtering, and empty bag compaction solution. It features multiple clean-out access points for easy cleanability to ensure allergens and pathogens do not enter the food chain. www.luxme.com
Hemco launches UniFlow SE FM
floor-mounted walk-in
hoods for large processes
UniFlow SE FM Fume Hoods are designed for synthesis, distillation and other rack type operations where tall apparatus is used, or equipment is rolled into the work area. Fume hood features a double wall construction with an angled picture frame opening with either double vertical side sashes or horizontal sliding glass doors. A removable upper front panel allows access to ducting connections and electrical services. The varaflow baffle system maintains a uniform airflow to the bell-shaped exhaust collar. www.hemcocorp.com/fmfh.html
TAre you ready for the
upcoming changes to traceability?
Amy Proulx
he United States is updating Section 204(d), which relates to traceability. In Canada, we should be paying close attention because any time the US makes a change, we see the impacts here whether the regulations reflect it or not.
I work with a lot of small businesses, and traceability seems daunting. The foundations of a traceability program focus on the following items:
1. Having good receiving and storage documentation practice, cataloging and inventorying incoming materials, purchase orders and bills of lading for lot numbers, and documenting receipt, storage and transfer to production.
2. Development of proper production and batch records indicating the lot numbers of specific ingredients and other inputs.
3. Application of a system for batch or lot coding (from CFIA’s durable life date coding, when appropriate), so that finished goods can be traced back to a production record. Some companies, if they have the ability in their lot coding printer, are even including production line and time of manufacture to their lot codes.
4. Registration with GS1 for a UPC or GTIN set for your goods packaging, case pack and pallet.
5. Developing a means of keeping sales records, showing who received what product, lot number or serialization block, and UPC or GTIN code.
6. Retaining records, noting that they should be kept for two years from the date of receiving product, and two years from the date of sale, and not necessarily the best before or manufactured dates.
Buy GS1
A lot of small businesses are getting into trouble for a couple things. First, it’s tempting to think you can save money buying a UPC or GTIN number from an independent wholesaler. You have to consider that for a single product, you’ll require two codes—one each for package, case and pallet. If you’ve got two to three unique products, a small business package at GS1 makes sense. Now if you have different-sized packages for the same product, each with three labels, you’ll need dozens of UPC codes.
keep paper copies of receiving, production and shipping details. These paper copies must be organized properly so information regarding trace forward or traceback recalls can be retrieved rapidly. Electronic records are good, but ensure users are trained on best data entry practices, and keep a master code document. If you are doing electronic data management in spreadsheets, make sure to save unmodifiable versions (“marked as final” or “read only”) to prevent unauthorized users from changing records.
Serialization allows traceability back to discrete events in manufacturing, and not just lot by lot blocks
The CFIA and other global food inspection groups are using GS1 codes as part of recall systems, making it essential to have authenticated codes. Retailers also need authentic codes from GS1. Independent retailers may not be verifying GS1 codes, but when a business scales to regional or national level, these codes are needed. I have often heard of small businesses redoing their packaging because their GS1 UPC codes were not unique to their products.
Keep records
Documentation and record keeping is another issue. Small businesses typically
Before investing in a traceability enterprise resource planning software (ERP), carefully determine current and future company goals. Many small businesses will invest in an ERP only to find out that the software is not compatible with large retailers or distributors.
Potential changes
The US is likely to modify traceability based on risk profile of products. Watch for changes in the Canadian system too. For now, we’re seeing serialization on certain commodities like lettuce. This serialization allows traceability back to discrete events in manufacturing, and not just lot by lot blocks. Secondly, traceability will need to link back to critical tracking elements, such as growing, receiving, transforming, creating, and shipping. Key data elements, such as bills of lading, production records, UPC or GS1 codes, will also become essential for traceability and recall.
Amy Proulx is professor and academic program co-ordinator for the Culinary Innovation and Food Technology programs at Niagara College, Ont. She can be reached via email at aproulx@niagaracollege.ca.
Photo
TSupply chain constraints versus compliance
Gary Gnirss
he current supply chain and inflationary challenges will remain with us for some time.
During the early part of the pandemic, the Canadian Food Inspection Agency (CFIA) introduced measures to provide manufacturers compliance flexibility in managing supply challenges.
CFIA’s philosophy of compliance historically distances itself from publicly expressing “enforcement discretion,” but never in the context of disregarding written rules. For instance, recently CFIA extended the transition period for new nutrition and ingredient labelling rules. The transition period formally ended on December 14, 2021. The extension means new rules are in full force, but with a caveat.
“For the first year following the transition period, CFIA will focus its efforts on education and compliance promotion (until December 14, 2022). After that date, CFIA will verify compliance and apply enforcement discretion in cases of non-compliance when regulated parties have a detailed plan that shows how they intend to comply at the earliest possible time, and no later than December 14, 2023,” said CFIA.
In examining this wording, it’s obvious CFIA is not saying it’s ok for foods to not be labelled as required. Those foods would not be compliant. CFIA is simply expressing its likely action in such cases.
Omissions and substitutions
The considerations noted in the above paragraph might sound trivial, but they are important in the context of compliance. Operating in a space created and defined by CFIA as “enforcement discretion” does not mean the food is compliant. It simply means it might
be “untouchable” for the moment. It also comes with conditions.
In the November 2021 “Notice to industry – Flexibility in the declaration of a list of ingredients” letter, CFIA shared insights into its operational considerations. This is not new or a turn by CFIA away from its prudent approach to compliance. CFIA does not have the authority to be indifferent to rules. The note is also not a guidance. It doesn’t recommend the industry to not follow applicable rules. However, it points out that Canadian ingredient labelling rules under CFIA’s authority has provisions to omit or substitute ingredients under certain circumstances. For prepackaged foods, this is expressed in B.01.011 of Food and Drug Regulations (FDR). In the case of certain edible meat products, this provision is found in Section 284 of the Safe Food for Canadian Regulations (SFCR). There are also provisions in FDR and SFCR to vary the proportion of ingredients. In all scenarios, there are conditions. Firstly, it must be an “acceptable manufacturing practice”. While this is not explicitly defined, it should be obvious that a key ingredient may not be substituted or omitted. Another consideration is that the omission or substitution must be stated in the ingredient list, so that all ingredients that may be present in the food are declared. The need for substitutions or omissions must be anticipated in any 12-month period. A classic example is substitution of vegetable oils like “soybean oil and/or canola oil”. CFIA’s note goes on to remind the industry that if this can be planned in advance, they would expect that label to meet applicable rules.
Enforcement discretion
One shortcoming of the formal rules
on omissions and substitutions is that this must be anticipated. In life, there are unforeseen circumstances. Thankfully, CFIA’s note speaks to this. It explains they would likely not engage in enforcement control measures (i.e. seizure, withdrawal or recall), as long as the conditions do not warrant. This would mean noncompliance is a low risk. However, there should not be health or safety concerns (undeclared food allergen, use of non-permitted food additives, etc.) or any major economic factor or misbranding (fraud such as value-engineering ingredients or including preservatives when claims are made for their absence).
CFIA notes that “current CFIA inspection framework allows for flexibility”. For clarity, CFIA is not saying it is ok with the noncompliance. They just may not use enforcement control measures. If CFIA becomes aware of such scenarios, it would like to see documentation establishing a supply issue, the length of the problem, and a plan to remedy the omission or substitution if it is occurring for an extended period.
Manufacturers caught in supply chain issues that may necessitate their labels not complying with requirements for a short period of time are not asked to alert CFIA. However, they would be expected to explain to CFIA label deficiencies, if asked. CFIA’s note provides a reasonable means of predicting its enforcement actions in the case of omissions and substitutions.
Gary Gnirss is a partner and president of Legal Suites Inc., specializing in regulatory software and services. Contact him at president@legalsuites.com.
NUTRITION
in a wheel
Known for its smoothies, Evive has launched a line of RTE lunch bowls
— BY MARK CARDWELL —
When Claudia Poulin and Dominic Dubé first started making and selling frozen smoothie cubes as university students in Sherbrooke, Que., six years ago, their goal was to break even. After racking up $27 million in sales in 2021—a figure they think could reach $38 million this year—the entrepreneurial couple continues to work hard to develop new products, open new markets and transform their company, Evive Nutrition, into an international food brand.
“Every year it feels like we’re on the starting line, but we’re not taking our feet off the accelerator,” Dubé told Food in Canada recently from Texas, where he and Poulin were in the midst of a three-month road trip with their first child, a sixmonth-old boy named Louam, to showcase their wares at food stores across several southwestern American states, including California.
The couple’s trip is a follow up to their entry into the US food store market in 2021, a foray that was launched online and targeted all consumers. Dubé said the company got most traction in and around the large population centres on both the East and West Coasts with the most smoothie-hip demographics.
In addition to online sales, Evive Nutrition products are now being carried in eight distribution centres and sold at more than 500 natural and organic health food stores in the US, including both independent and chain stores, as well as online.
The company successfully used the same game plan here in Canada, where it sold product online from the get go, as well as to independent natural health food stores in Quebec before expanding nationwide through major grocery store chains, such as Loblaws, Sobeys and Save-On-Foods.
“We’re trying to recreate the same strategy here in the US, which is to create brand awareness,” said Dubé. “We’re doing it region by region, state by state, store by store. It’s just that the scale here is so much bigger.”
THE WOW FACTOR
According to Dubé, the blender-free ease of Evive Nutrition’s three lines of frozen smoothie and meal cubes, as well as a newly launched line of ready-made frozen
Photos courtesy Evive
Evive manufactures frozen, ready-to-drink smoothies.
California Raisins - A Natural Sugar Substitute and Much More
By Chef Nelita Silva
Whenyou’re scaling recipes up to meet the demands of your high-volume business, things can get complicated quickly. That’s why it’s vital to choose quality ingredients that create consistency, great taste, and versatility in your product line. California raisins check all these boxes, and more.
At the recent Bakery Showcase Tradeshow in Toronto, award-winning Chef Nelita Silva demonstrated the versatility of naturally sun-dried California raisins to industry experts, bakers, and food manufacturers alike. Silva, a professor at Centennial College in Scarborough, previously owned the Ancaster Bakery, a busy operation present in farmers’ markets throughout the Golden Horseshoe, and stores in Hamilton. She was delighted to create recipes showcasing the incredible potential and a myriad of uses of this simple dried fruit. Her first demonstration was a twist on the classic chocolate brownie. Raisin Fudge Brownies are just as delicious as they sound –moist chewy California raisins buried in a rich chocolate brownie, topped with peanuts.
A Binding Agent with Flavour Depth
One of the most useful aspects of California raisins is their ability to function as a substitute for refined sugar in a multitude of recipes. They’re ready for use as is, however in this application, they can be processed into a paste which creates a pleasant chewiness for cookies, cakes and assorted treats. This increases the nutritional profile of any ingredient list, while simultaneously adding depth to the flavour profile, a winning combination. California raisins are also an effective binder, creating the ideal texture for cakes, cookies, and savoury dishes. And speaking of texture, the unique skin that California raisins possess translates to no migration of moisture from raisin to recipe, eliminating the concern of unneeded moisture.
About Chef Nelita Silva:
Cost-effective and Versatile
Food cost is a constant concern for medium and large-scale producers. California raisins are an economical choice and will contribute to a reasonable cost per portion across many product lines. Their incredible versatility means that they’re a multi-purpose SKU, adaptable to a multitude of recipes. They’re also a meaningful addition to fatfree offerings, adding much-needed flavour and texture to recipes in this category
For manufacturers catering to the increased interest in plant-based foods, California raisins are a great choice With their rich mouthfeel and deep flavour profile, California raisins effectively counter the notion plant-based foods sacrifice taste or texture. They’re a great addition to an environmental product line, and their nutritional profile shows well on labelling.
At the Bakery Showcase Tradeshow, Chef Silva also demonstrated how well California raisins adapt to another favourite – the donut. Oatmeal Raisin Donuts are a baked treat that scale easily to industrial levels. With both dark and golden California raisins, this recipe presents beautifully. Because California raisins hold up so well under high temperatures and multiple cooking methods, they’re a superior choice for large-scale, commercial recipes.
California raisins are a practical, multipurpose ingredient. Rediscover them today
Chef Nelita Silva currently teaches Commercial Operations at Centennial College in Toronto and is an award-winning chef who has worked in the culinary arts since 2008. A graduate of the Certified Chef de Cuisine Program at Liaison College in Hamilton, Ontario, Nelita has enjoyed a variety of work in food service and recipe formulation development where her creativity and attention to detail have contributed to her success in the culinary world.
muffin cubes, is the wow factor that continues to set his company apart from the competition and help convince both retailers and consumers to give their healthy food products a try.
“We always get a great reaction from store owners or broker partners when they see our products for the first time or try some of our new ones,” said Dubé. “There’s nothing like them anywhere. It’s an
In January, for example, he said a major food store retailer who he and Poulin pitched to in Texas told them she would place an order immediately if they promised to make the words ‘Blender Free’ bigger on their packaging. “We said yes, and she bought it
Enthusiasm for Evive products has never been in short supply. It’s been that way since 2015 when Poulin, a budding vegan who was taking psycho-educational courses at the Université de Sherbrooke, started making smoothies every morning for her and Dubé, who was studying to be a mechanical engineer.
To save time, they started making trays of frozen smoothies that they cut up into cubes by hand and put in the freezer in plastic bags.
In the morning they would put a handful of the cubes into a Mason jar or bottle and add enough water, milk or other liquid of choice to cover the cubes. The cubes were then left to melt for about 15 minutes, shaken and, viola! a fresh smoothie without the use of a blender.
Eager to share their idea and wholesome recipes with the world, and make a buck doing so if they could, the couple started making and selling their cubes, first on Facebook and to friends and fellow students, then through local natural food stores.
TIMELY BREAK
As sales and distribution increased, they moved production into a small pilot plant with a commercial kitchen at Agriculture and Agri-Food Canada’s research facility in Saint-Hyacinthe, an hour’s drive away.
There, Dubé hit on a key innovation that literally and figuratively changed the company’s fortunes: a round plastic wheel that holds the eight cubes
needed to make a single smoothie.
“We were still cutting cubes by hand,” recalled Dubé about the production process, which was done in two shifts. “It was brutal work. Both of my wrists were injured from doing it and we couldn’t figure out how to scale up without having to buy a machine we couldn’t afford. I was ready to quit.”
In a timely eureka moment, Dubé hit on the idea of pouring smoothies into moulds on a plastic wheel while working on the notion of using a circular tray to freeze smoothies instead of the bulkier rectangular trays they were using. “It was the best idea I’ve ever had,” he said.
In addition to eliminating the need to cut, handle and bag frozen smoothie cubes, the sealed moulds on the plastic wheels meant that the product could be shipped, thawed and refrozen after mailed delivery to online customers.
The company’s now-patented wheel also helped Evive Nutrition stand out in the highly competitive smoothie category, which has grown exponentially in recent years. “That’s where consumers are going,” said Dubé. “Smoothies combine convenience, nutrition and great taste in foods that are family friendly.”
NEW PRODUCTS
Initially, the company made a few flavours of smoothies using bags of mostly locally procured and
Dominic Dubé and Claudia Poulin
to make a single smoothie changed the company’s fortunes.
sometimes locally produced fruits, vegetables and other plantbased, organic and gluten-free foods and ingredients.
It now produces three smoothie lines—Energizing, Extra Protein and the latest, Super Functional, which was launched online only in November 2021—as well as a line of lunch bowl and soup options.
The company has enjoyed 300 per cent year-over-year growth and has sold more than 10 million smoothies, which make up half of its 22 product SKUs, both online and through some 2,500 retail locations across North America.
Company sales notably skyrocketed following the couple’s appearance on CBC’s Dragon’s Den in 2019, when they were doing just over $1 million in sales and were seeking a $100,000 investment for a 10 per cent stake in the company.
They got offers from all five dragons, including a winning offer of $150,000 for a 10 per cent stake from Manjit Minhas. Minhas ended up not investing in the company, much to the delight of two private funds, Quebec’s CSN union-backed Fondaction and Vancouver’s Renewal Funds, which did.
This winter, Evive added to its product line ready-made
Evive has grown 300 per cent year-over-year, and has sold more than 10 million smoothies.
Evive is an innovative nutrition brand with delicious and healthy blender-free smoothies that have raised the standards for budget-friendly, ready-to-go meals.
— Dominic Dubé
Choco-Spice muffin bites. Made with superfoods like hemp seeds and baobab, the frozen vegan- and gluten-free snacks, which come in a six-portion wheel and can be made in an easy four-step, 35-minute baking process, the muffins are a perfect addition, Dubé says, to a food company with a mission to make and provide healthy foods that are convenient and good for people from all walks of life.
“They’re great because they save people from having to make a mess in the kitchen,” Dubé said about the muffins, which were formulated and produced—like their other products—by he, Poulin, and food scientists at their production partner’s facility in Montreal’s South Shore region.
The muffins were also notably taste-tested by thousands of online subscribers, some 70 per cent of whom provided written feedback on the new product. “We learned a lot of things,” said Dubé. “We increased fibre, for example, and did some minor tweeks to check all the consumer need boxes.”
He added that allowing working moms and other Evive product users the opportunity to taste-test, comment on and/ or order through the company’s eye-catching website or social media platforms is another major competitive advantage.
“It’s great because we want to develop and bring new products and food ideas to the marketplace,” Dubé said about Evive, which now has 55 employees who work mostly remotely to handle marketing, customer support and R&D. “Evive is an innovative nutrition brand with delicious and healthy blender-free
2022 FCC Food Industry Report: Growth amid inflationary pressures
The annual FCC Food Report reviews last year’s economic environment and highlights opportunities and risks for Canadian food manufacturers for 2022. This includes an annual sales forecast, grocery sales performance, and a new gross margin index.
Industries featured in the report are:
• Grain and oilseed milling
• Sugar and confectionery products
• Fruit, vegetable and specialty food
• Dairy products
• Meat products
• Seafood preparation
• Bakery and tortilla products
Beverage manufacturers, we didn’t forget about you. We will be releasing a separate beverage report later this year.
Takeaways
Several external factors impacted Canadian food industries in 2021, which have resulted in higher input costs, amplified labour shortages and upended food consumption patterns. In early 2021, there was hope that the pandemic could soon be behind us; however, new variants provoked more disruptions, restrictions and uncertainty. Despite these challenges, food manufacturers’ performance proved to be strong.
Here are three key observations from this year’s report:
Gross margins as a percent of sales in food manufacturing increased in 2021 YoY but remain below historical levels and below 2019 (Figure 1). Manufacturers have struggled to fully pass on higher labour and material costs for almost a decade. But margins improved slightly in 2021. At the individual industry level, results widely differ, which we dive into in the report.
Food manufacturing sales increased 14.8% YoY to $125 billion in 2021 (Table 1). This is the strongest YoY sales growth in recorded history (starting in 1992). Increased foodservice volumes and higher selling prices offset volume declines at grocery stores.
Food manufacturing sales are projected to increase 7.4% in 2022, driven by:
• Historically strong disposable income and accumulated savings in 2021
• Food prices remaining elevated
• Robust export markets with food exports representing an estimated 36.8% of overall sales
Figure 1: Gross margins grew in 2021 but remain below historical levels
Source: Statistics Canada, FCC Economics
Table 1: Manufacturing sales and exports grew in 2021
Source: Statistics Canada
The bottom line
Economic conditions are evolving rapidly. The labour market continues to be a challenge, and inflationary pressures continue to climb. War in Eastern Europe and economic sanctions also pose a risk to global economic growth, creating food shortages in many countries that depend on commodities from this region, potentially causing a food crisis for millions.
Stronger disposable income and higher savings in 2021 will support 2022 domestic food consumption growth, although inflation is diminishing many households’ purchasing power. Margin growth will depend on several factors, the biggest being the COVID pandemic’s evolution and how businesses adapt to interest rates increases and input costs.
Read the full report at fcc.ca/foodreport
Kyle Burak, FCC Senior Economist
The excitement of exotic flavours
Candy companies are delivering travel-like experiences with new taste profiles
— BY JANE DUMMER —
Consumers are looking for fun and excitement with their food and beverage choices after spending two years at home due to rotating lockdowns designed to curb the spread COVID19. Exploring exotic flavours from around the globe offers consumers a travel-like encounter without the actual excursion. Confectionery is a great option for this type of flavour exploration. It provides convenient, bite-size formats to sample new flavours that may not be available in their original form locally, and for people who are typically not adventurous with their food choices.
Lisa Jackson, director of marketing, FlavorSum, agrees, “Exotic flavours bring taste excitement to confectionery. The relatively small size and assortment structure of confections make trying a new flavour a low-risk.”
Stefanie McCreary, research and development specialist, La Presserie, concurs, “People are looking for a change. They want to try flavours that they may not normally buy fresh at the grocery store or may not be available locally.”
Some early adopters are craving new and interesting. However, the trend of an exotic fruit-forward flavour along with a more traditional counterpart is appealing to a wider market. “Front-of-pack imagery can reassure consumers that the taste adventure may have familiar elements,” points out Jackson.
The demand for fun food experiences is inspiring confectionery brands to launch new, exotic flavours.
Popular flavours
What are the popular exotic flavours showing up in confectionery? Jackson explains, “Citrus fruits remain popular, but blood orange offers a complexity that attracts consumers’ attention. The taste carries a subtly sweet orange base combined with notes of tangy red grapefruit, tart cherries, and sweet raspberries. We use Mintel’s Global New Products Database (GNPD) to support our innovation efforts. Data from North America, Latin America, and Europe show that confectionery launches in retail featuring blood orange flavour doubled in the last year (off a small base).”
Dragon fruit, yuzu and lychee are fruit-forward options powered by global cuisine. Candy makers are experimenting with these exotic flavours as they go well with traditional sweet and sour confections.
Tracy Brenner, manager, candy innovation and product development, Dare Foods Limited, describes, “At a high level, I am seeing some confectionery brands use exotic fruit flavours like dragon fruit and starfruit either individually or paired with more mainstream fruits. Many of the exotic fruit flavours pair well with sweet and/or sour profiles, so candy is the perfect space to try them out. Further, flavourists can specially design fruit flavours that contain only the desired flavour notes. For
example, if an exotic flavour has too many ripe or pungent notes, these notes can be reduced in favour of fruitier and/or fresh notes, as this will likely appeal more to consumers.”
The space offers several ways to defining a flavour signature and enhancing visual appeal. Jackson explains, “Dragon fruit is an exotic taste of interest to our customers. The mildly sweet flavour with notes of kiwi and pear has both taste and visual appeal for consumers. The novelty of a bright pink outer layer with clean white fruit and black seeds creates interest and excitement about the flavour. Conversations about dragon fruit candy are trending, up 30 per cent vs. last year in the United States. Another exotic flavour of interest is yuzu. This tart, lemon-like flavour is emerging in confections, especially in Europe. While the name is fun to say, the flavour of yuzu is the draw, pulling in tastes of grapefruit and mandarin orange. Retail launches across North America and Europe are stable, according to Mintel GNPD. In addition to monitoring launch data to support innovation, we also examine social chatter through the Tastewise platform to identify the flavours consumers are researching, preparing, or discussing. Social conversations about yuzu increased 17 per cent in the last year among Americans. Lastly, lychee has gained interest. It is a taste profile that’s challenging to describe. Some liken it to sweet citrus, while others pick up notes of watermelon or pear. People like the sweet-tart combination, however it emerges. Retail confection launches featuring lychee flavour increased 67 per cent across Europe and North America off a small base in the last year.”
A ‘healthy’ perspective
Consumers continue to take their health seriously because of the pandemic. Flavours, such as these exotic fruits, support this health and wellness trend. While flavour components are not a primary way to deliver functional health benefits, Jackson suggests, “Some exotic fruit flavours carry a ‘health halo’ that aligns with consumers’ growing concern about their well-being. The association would fit with consumer perceptions of confections infused with vitamins.”
Sour confections are a long-time favourite. This is a chance to bring both exotic and nostalgia together. Jackson describes, “Sour is a versatile framework that fits with many flavours. FlavorSum has seen exotic flavours like passionfruit, dragon fruit, and blood orange emerge in sour formats in the last year.” McCreary agrees with the interest in sour flavours. “La Presserie is getting numerous requests for blood orange, along with cranberry and kiwi,” she says. Brenner describes, “Dare recently launched two RealFruit Sours innovations with more mainstream flavours including cherry, peach, watermelon, orange, lemon/lime, and pink grapefruit. Other popular sour flavours include blue raspberry and green apple. Also, combinations of two flavours in one piece are of interest to the consumer.”
Consumers’ priorities to make fun food experiences are creating innovation opportunities for confectionery brands. Most importantly, the convenience of confectionery is key to trying new, exotic flavours. Exotic flavour exploration is expanding in confectionery to keep consumers interested and engaged.
Flavourists are able to design fruit flavours that contain only the desired taste notes.
Sour confections continue to be favoured by consumers.
BEvolution of beverage packaging
Carol Zweep
everage packaging has evolved over the years. In the 1970s, 2L polyethylene terephthalate (PET) and glass bottles were the predominant package formats for carbonated soft drinks. Since then, the beverage industry has expanded to other categories with different processing techniques. This trend has resulted in various packaging formats and materials to accommodate processing techniques and levels of product protection.
Processing constraints and barrier technology
PET and glass bottles can withstand and retain the internal pressure of carbonated soft drinks. Pasteurization and hot filling for shelf-stable acidic beverages require packaging materials and design considerations for high-temperature filling and vacuum integrity. Retort exposes packages to even higher temperatures, so in addition to choosing appropriate materials, proper package handling systems during processing is critical. Aseptic processing allows for less rigorous packaging constraints for cold filling in paper-based cartons and rigid plastic formats. High-pressure processing is relatively new to the beverage industry, and packages must accommodate high hydrostatic external pressure without compromising package integrity.
Unlike glass and metal, plastics are permeable to gases. Building barrier properties into packaging (bottles, pouches, cartons) can extend product shelf life by preventing product oxidation, which can result in discolouration and off-taste. For bottles, techniques such as inserting a barrier layer within the structure, using an oxygen scavenger in the material, or applying a thin interior or exterior barrier coating are used to mitigate oxidation.
Sustainability and circular economy
The 3Rs (reuse, reduce, recycle) have been the mainstay of sustainability with much effort placed on the reduction or light-weighting of packaging. For example, a 500-ml PET water bottle has decreased from 17 g to as low as 6.5 g (38 per cent of its original weight).
Paper, metal and glass are identified as highly recyclable. Innovation has led to the use of renewable paper-based beverage packaging. Coca-Cola has created a recyclable paper bottle prototype with a paper shell, plastic closure and recycled plastic liner. Boxed Water’s carton and cap are plant-based from well-managed forests. Pulpoloco Sangria from Spain is packaged in a recyclable 250-ml aseptic paper can (CartoCan). The entire can is made from a four-layer paper-based barrier structure except for the pull tab.
Reusable, recyclable or compostable plastic help ensure the material stays within the circular economy. Companies such as Ice River Springs, Evian from Danone and Keurig Dr. Pepper use 100 per cent recycled PET for their beverage bottles. Designing collapsible PET water bottles enables more efficient recycling.
Bacardi has invested in a biodegradable bioplastic technology that uses
polyhydroxyalkanoates (PHAs). Unlike conventional plastics made from fossil fuels, micro-organisms produce these polyesters through bacterial fermentation of sugars or lipids.
Several global brands have partnered with Carbios to produce food-grade PET bottles using a novel enzymatic technique. A naturally occurring enzyme found in compost heaps has been optimized to break down any kind of PET into building blocks. This material can be used to make virgin-quality PET. Unlike conventional recycling, enzymatic recycling overcomes degradation issues.
Consumers have shifted their beverage preferences from carbonated soft drinks and fruit juices to energy drinks and functional beverages. Behavioural changes in consumption, advances in processing, technology, and focus on sustainability are all contributing to a shift in beverage packaging. Innovation in materials, packaging design and technologies are paving the way to meeting consumer demands and challenges in the beverage industry.
Carol Zweep is consulting and technical service manager for NSF Canada. Contact her at czweep@nsf.org.
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THE RISE OF PROBIOTIC DRINKS
Trends in gut health and probiotics in beverage processing —
The pandemic has inspired consumers to focus on functional, nutritional foods. The promotion of gut health, improved immunity and general well-being are driving awareness of and the demand for probiotic beverages as a convenient food source. Koirala and Anal, writing in Future Foods in 2021, note that probiotics are leading innovation in the next generation of beverages.
The connections between digestive health, the microbiome, gut health, and cognitive function, energy and mood are better understood now. The potential of probiotics to serve a positive influence on immunity is leading new research. According to the International Scientific Association on Probiotics and Prebiotics (ISAPP), the widely accepted scientific definition of probiotics are ‘live micro-organisms that, when administered in adequate amounts, confer a health benefit on the host’.
Probiotics are said to enrich the gut microbiome with healthy bacteria by digesting different types of prebiotic fibres and producing beneficial compounds as a byproduct. Foods (e.g. kefir and kombucha) have been fermented for thousands of years to produce natural probiotics.
Current interest in, and demand for functional beverages such as probiotics, may come from the perception that overly processed foods can lack the nutritional value and elements required for a healthy gut environment. GetNews, in February 2022, added that consumers are realizing probiotics in a regular diet
BY MARK JUHASZ —
offers health benefits including improved digestion, boosted calcium absorption and general energy improvement. A 2017 assessment by GanedenBC, notes that 76 per cent of U.S. consumers are aware of probiotics, and 93 per cent of those consumers believe probiotics can support their digestive health.
Fortune Business Insights has argued that greater demand for healthy, functional foods and beverages will be a positive driver for probiotics, and that given the global rate of obesity has tripled in the past half century, the impact of lifestyle diseases will drive demand for immunity- and vitality-boosting products. In 2021, Food Beverage Insider referenced a Grand View Research assessment of the global probiotic drink market with an estimated CAGR of six per cent between 2020-2027, while Data Bridge Market Research expects probiotic beverages to reach $69 billion by 2027, with an eight per cent growth rate from 2020-2027, led by the Asia-Pacific region, with strong performance of both dairy- and fruit-based probiotic beverages.
Probiotics also fit into active lifestyles by claiming to boost immunity and help with irritable bowel syndrome or strenuous fitness routines. Writing for Shape magazine, Kelly and Mackenzie mention that while health authorities have not officially approved the health claims of probiotics, they can be an important part of a nutritional diet. Further, probiotics are best consumed after prebiotics (fibrous food such as fruits and vegetables, whole grains, etc.) that then ‘feed’ the functioning of probiotics.
ABOVE: The increasing demand for healthy, functional foods and beverages will increase the sales of probiotic drinks.
BELOW: Tepache is a fermented, slightly alcoholic drink that is popular in Mexico and central America.
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Amidst the exuberance of recent years, experts seem to suggest more clinical trials are required to better understand the myriad ways in which probiotics interact in different human biochemistries, with different food pairings. The surge in probiotic drinks also provides a reminder of the important role of safety evaluation, consumer information and practical regulation.
Types of probiotic beverages
Several market research organizations expect the market for probiotic beverages to remain strong as consumers seek to match greater health with convenience. In February 2022, iMarc Services mention the growing incidence of gastrointestinal issues as a major factor driving ready-todrink probiotic beverage market growth. Probiotic drinks have many forms and manifestations. Some traditional drinks, such as kefir, (a fermented dairy product), are an excellent source of protein, calcium and vitamins. Kombucha has emerged particularly in North America over the past decade as a plant-based alternative (and with a history all its own). Probiotic drinks are generally manufactured by adding dairy, water, fruits or herbal extracts, and sugar to a probiotic culture of bacteria and yeast in a process using bio-fermentation. Additional probiotic traditional beverages include tepache (a fermented, often slightly alcoholic drink popular in Mexico and central America), apple cider vinegar, and kvass (a fermented beet juice, low in sugar, and often filled with wild probiotics).
Whether or not probiotic drinks will grow in greater popularity via dairy- or plant- and fruit- based sources remains to be seen. The natural richness of human cultural traditions in fermented beverages is extensive, and often location specific, such as hardaliye, a unique fermented beverage made from red grapes in Turkey. Whichever the case, Mordor Intelligence said in 2021 that many beverage companies are extending their product lines by adding a probiotic beverage to meet the worldwide demand for functional foods.
Nazhand et al, writing in 2020, note that fermented yogurt is worth an estimated EUR46 billion worldwide, adding the human consumption of fermented beverages forms the fastest-growing segment of the U.S. food market. As a lowcost technology, fermentation plays a key role in enhancing the nutritional value and sensory property of beverages.
Leading brands
A space of particular attention among some of the leading global food and beverage brands has been meeting the demand for probiotics from either dairy or plantbased sources. Some of the most established brands in this space include France’s Danone, Canada’s Lallemand, Pepsi and Post from the USA, Japan’s Yakult Honsha, Switzerland’s Nestle, and Hanssen from Denmark.
In particular, for a younger demographic, plant-based probiotics may have a greater consumer preference. Harfmann, writing in Beverage Insider in February 2022, mentions that on TikTok, the hashtag probiotics touts over 107 million views alone, not including views of varied hashtags, and that there has been a 30 per cent increase in #probiotics on Instagram between August 2020 and January 2022. Leading brands are also introducing innovative new probiotic drinks that are shelf-stable, do not require refrigeration
and are targeted at fitness, energy and performance communities.
Legacy probiotic dairy-based drink companies, such as Yakult and Bio-K, are facing intense competition from emerging firms. Each brand is responding to their market segments with tailored products, such as for aging populations (and their needs in preventative health and cognitive function). Mordor Intelligence added that in July 2020, Chobani launched a new plantbased probiotic drink with fermented fruit juice and oats.
Creativity is being delivered by companies like So Good For You with their line of probiotic juice shots, containing, for example, apple cider and ginger, with up to 1 billion CFUs (colony forming units), or Siggi’s plant-based probiotic drink made with coconuts and pea protein. Out of Australia is the notable, Remedy, producing over 90 million cans and bottles per year shelf-stable kombuchas and Scoby (a symbiotic culture of bacteria and yeast). The possibilities for probiotic innovation in beverages continue as well with Portland-based (Oregon) Good Wolf beverage company and their probiotic tonic, a sparkling water kefir benefiting from its function as both a prebiotic and probiotic. Amid the important and current factors of convenience and strong concern for proactively managing personal health, probiotic beverages seem to have a positive outlook.
Fermentation helps to enhance the nutritional value and sensory property of beverages.
Exploring the growth of plant-based milk
Processing tips to enhance the nutritional value of alt-milks — BY MATT HALE —
Plant-based milk is the largest plant-based category in North America. It grew five per cent last year, with sales of plant-based dairy products approaching $2 billion. In fact, the plant-based milk market now accounts for around 10 per cent of the global milk market. The most popular plant-based milk in North America is almond milk, followed by oat milk, and soy milk. Plantbased milk alternatives are being made from more raw ingredients than ever before, with pea- and barley-based drinks being among the recent newcomers to the market.
There are many reasons for the popularity of plant-based milks. A rise in the adoption of vegan and plant-based diets due to health and moral grounds and environmental concerns are driving this uptake. Proponents claim plant milk has a lower greenhouse gas (GHG) footprint than dairy production, although the overall picture is highly complex, and the figures are disputed by the dairy industry. An apparent increase in the level of lactose intolerance in developed countries is also helping to increase demand.
The range of plant-based milks also allows for consumers to express their tastes and identities as cafes and restaurants open-up after lockdown. As one industry analyst said earlier this year, “To choose your specific type of plant-based milk in Starbucks seems to be a way of identifying yourself.”
Dairy milk is typically seen as a drink or a meal accompaniment. For example, it is used as an ingredient or with cereal. There are increasing signs that plant-based
drinks, particularly those with a thicker more yogurt-like texture or those sold in individual portions, are seen as a healthy snack. Research by the Brisan Group suggests that up to a third of these products are viewed as a snack, and 61 per cent are viewed as ‘a treat.’1
Globally, soy milk products remain the most popular, and they accounted for 29.5 per cent of revenue globally in 2019. Coconut-based beverages are one of the fastest growing segments, predicted to increase 8.6 per cent between 2020 and 2027.
Production of plant-based milk
Contrary to public perception, the idea of plant-based milks is not new. ‘Milk’ made from soybeans has a long history in China (where recorded production dates to 1365), while almond milk was recorded in the Middle East in the 13th century. A commercial soy milk factory was established near Paris in 1910 and demand for soy milk rose through the 1970s and 80s due to increasing awareness of lactose intolerance.
These days there is a wide range of plantbased milks made from nuts, grains, and legumes, as well as other seeds (such as sunflower and hemp) or coconut.
There are two main methods for processing plant-based milk: wet or dry. The wet process involves soaking and grinding the raw material in large volumes of water for up to 12 hours. In some cases, enzymes are added to hydrolyze starches (for example, in oat milk production). The dry process involves milling the raw material into a flour or powder, which is then processed to sepa-
rate the starch, protein, and fibre as desired, before being hydrated. As a result, dry production processes can result in a higher protein content in the finished product.
The production method means that, if the soaked product is not ground to sufficiently fine a size, the number of particles removed when the mixture is strained creates high levels of waste. It is also important to mix products well, particularly those containing oils or thickening or stabilizing agents. Therefore, maintaining product consistency is a key goal for the manufacturing process, and will determine the choice of processing equipment including pumps, heat exchangers, etc.
Disadvantages of alt-milk
Plant-based milks cannot match the natural nutrition profile of dairy milk in terms of protein levels and essential amino acids. However, as well as being free of lactose, they are lower in saturated fat and cholesterol than non-skimmed milk.
Plant-based milks are not immune from
Plant-based milk products, such as oat milk, are increasing in popularity.
Photo © Sea Wave / Adobe Stock
criticism, and in some countries and regions, including the European Union, such products cannot be sold or marketed as ‘milk’ or ‘yogurt.’ Additionally, supporters of dairy milk say plant-based drinks are highly processed and full of additives, while diary milk is simply homogenized and pasteurized.
Despite this, such is the interest in the sector that many of the world’s largest dairy companies, such as Lactalis, Nestlé and Danone, are investing in dairy-alternatives, through product development or company acquisition. Several market analysts believe the market is ready for rationalization, with many brands falling by the wayside or being acquired by larger food producers.
Maintaining quality and demand
The quality of the product is very important, and monitoring of key parameters includes viscosity, particle size, protein content, digestibility, nutrient content, and flavour analysis. Maintaining these important quality characteristics requires the minimal amount of processing. Making sure that processes such as pasteurization cause as little disruption to the product as possible can help alleviate criticisms about the highly processed nature of plant milks.
Where possible, combining processes such as dilution and sterilization can provide benefits and reduce overall processing of the product. The benefit of sterilizing using direct steam injection is the speed of the process, with sterilization temperatures of 212 to 293 F being reached in around a second. For products such as plant milks, this rapid heating prevents cooking of the product and formation of caramel-type compounds, which can darken the product or produce unwanted flavours.
It is also useful for grain-based products, such as oat milk that benefit from the additional dilution with water, which the food-grade steam provides, but the type and model of heat exchanger chosen will depend on different factors, such as the nature of the process to be carried out (pasteurization, sterilization, dehydration, etc.) and the viscosity of the drink being processed. Whatever plant-based milk product you are producing, it is important to remember
that the beverage has the same requirements for pasteurization, sterilization, cooking or cooling as other drinks. It is therefore crucial to invest in the most effective and efficient processing technology available for all stages of production.
Note 1 Visit https://brisangroup.com/food-industry-thoughts-articles/the-future-of-plantbased-beverages.
Matt Hale works for HRS Heat Exchangers.
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Improve cold chain inside storage facilities
Vertical-storing levellers, vehicle restraints and high-speed roll-up doors can help maintain temperatures — BY
WALT SWIETLIK —
Acold chain can break at many different contacts from point-of-origin to the consumer. Inconsistent temperature control during shipment, poor temperature control inside the warehouse, and product sitting on an open dock (or in an open trailer) for long periods of time are common scenarios for cold chain disruption. Considering the value of a standard OTR food shipment is between $50,000 and $100,000, any flaw in a cold chain’s integrity can become an expensive mistake.
Within this supply chain, facility managers must examine how the cold chain is maintained. There are both immediate and incremental ways to improve cold chain, enhance security and improve operational efficiencies with the right system of equipment and high-speed doors.
Drive-through setup is ideal
From both an energy and operations standpoint, loading docks, which use a ‘drivethrough’ design are the industry benchmark for cold chain integrity. This set-up, in which truck trailer doors are opened into the facility, creates a true extension to a facility. Potentially harmful outside air is prevented from infiltrating temperature-controlled operations inside the loading dock.
A drive-through loading dock requires a system of equipment that works together, including a vertical storing leveller and an automatic vehicle restraint interlocked into a smart control system, as well as a dock shelter compatible with vertical levellers.
Vertical-storing levellers
Creating a smooth bridge from the trailer to inside the facility is a matter of operational safety and efficiency. While traditional levellers perform this function admirably, not all types allow for drive-through capabilities.
Levellers that store vertically—inside the facility—help maintain cold chain integrity, environmental control and security. This is because security seals can be broken and trailer doors can be opened and closed inside the loading dock instead of on the drive approach, which improves cold chain integrity and enhances the security of products and processes.
A vertical leveller (when in the stored position) allows the loading dock door to close directly on the pit floor instead of on the leveller. This difference means that there are fewer gaps for outside air to get inside temperature-controlled operations. It also reduces energy lost by minimizing outside air infiltration.
Additionally, the vertical design makes it easy to clean or wash down the pit floor when the leveller is in the upright and stored position. Since ease of cleaning is a major component to sanitary transport rules, this type of leveller is recognized as a major upgrade in the Safe Food for Canadians Regulations (SFCR).
The role of vehicle restraints
Automatic vehicle restraints have become more common at loading docks and with their role in a drive-through setup, it’s easy to see why. They automatically engage a trailer’s rear-impact guard (RIG) or rear wheels to secure the trailer to the loading dock when it backs into position. They provide safety for workers at the loading dock by keeping boots off the ground and can prevent poten-
Vertical-storing levellers help maintain cold chain integrity, environmental control and security in a processing plants and storage facilities.
Photos courtesy Rite-Hite
tial tampering that might occur if a trailer was able to pull away from the facility.
Some automatic restraints feature a control panel that can be integrated into building management or security systems, providing another level of security. The most advanced restraints will actually re-fire if there is tampering or the trailer attempts to pull away when in locked position. Some models can even help secure intermodal overseas container chassis, which have become increasingly common across the food industry supply chain.
Maintaining the cold chain inside a facility
Facilities that process, manufacture and store temperature-sensitive products create a host of challenges for workers and facility managers. Finding the right door in cold environments can be critical in improving operational and energy efficiency, as well as safety. Facility managers can depend on high-speed, high-performance doors with quick cycle times to improve temperature separation inside the plant. They must find doors that meet the regulations required in critical environments, as well.
High-speed roll-up doors trending up
When compared to traditional slow-moving, high R-value doors, the biggest advantage high-speed doors offer in cold operations is in their name—high speed. While doors with high R-values offer better temperature separation when closed, their slower operating speeds are detrimental in facilities that maintain regular traffic between spaces.
Many cold operations require frequent material handling operations, so doors with slightly lower R-values that reduce air infiltration with fast cycle times are more practical. Not to mention, faster doors mean less opportunity for material-handling operators to run into the doors.
In the rare event that a high-speed door is struck, the doors can break from their tracks and then re-align when rolled back up. In contrast, traditional rigid doors are susceptible to forklift damage, which can lead to
improper sealing and becoming ineffective. Additionally, many high-speed doors come with LED countdown systems that reduces the likelihood of an impact.
Food operations
A new generation of roll-up doors has come on the market in recent years featuring wash-down capabilities and anti-microbial materials, making them ideal for use in the food industry.
High-speed doors play an essential role in maintaining clean operations and food product integrity. They are designed to address food facility needs for environmental control, productivity and safety (as well as cleanliness). In cleanroom applications, they are used not only to prevent cross-contamination, but also to help maintain correct room pressures, air circulation rates and optimal operating efficiency.
Completing the cold chain
The cold chain can be broken in many different places before it reaches the consumer. It’s important for facility managers to control the one link that they have ultimate authority over: their own facility.
In order to deliver safe food to consumers, it’s vital the best loading dock equipment and practices are used. Completing the seal with dock shelters and implementing a drivethrough loading dock are the best ways to ensure cold chain integrity. When evaluating what type of door to implement in an operation requiring low temperatures, it’s important to understand if the doors will be used frequently. If they are, using the most advanced high-speed doors inside the processing plant can help facility managers improve operational efficiency, decrease energy use and also make their plant safer for both employees and customers.
LOne giant leap
Cher Mereweather
oblaws’ commitment to be net zero by 2050 reminds me of a proverb: “The awakening of a giant shakes the world”. While we are blessed in Canada to have a rich and diverse landscape of food and beverage retail, comprising over 15,000 individual stores, Loblaws represents more than $50 billion in annual sales, more than twice that of its nearest grocery competitor and nearly a third of the total market.
So, when this retail giant commits to achieving net-zero carbon emissions for their operational footprint by 2040, and net-zero for Scope 3 emissions including those generated by suppliers by 2050, it does feel like our world is being shaken.
The scale of the challenge facing the industry is significant. There are 7,800 food and beverage processing/manufacturing companies in Canada, and only one (Agropur) has set a net-zero target under the Science Based Targets Initiative launched last year.
“For many SMEs, it can seem daunting when considering how they’re going to get to net zero,” says Tobias Parker, North American lead on Climate and Net Zero solutions at Anthesis Group. “But, the time to start the journey is now and many businesses will find some low-hanging fruit they can focus on in the short term.”
Almost daily an SME will reach out because they’ve been asked by a major customer for sustainability data, or to complete a reporting standard or scorecard. Most of the time, they are panicking.
We all know that running a F&B business means you are focused on the immediate and urgent priorities like getting the product out of the door, which leaves little time for things like building a plan to meet sustainability reporting requirements. However, the problem with this approach is that when your customer
asks for data you don’t have (as they inevitably will), you find yourself having to make significant investments, in both time and money, to build sustainability frameworks in a hurry. It’s a backward way of doing things, while also missing out on the value that sustainability can drive for your business.
are working to develop net-zero strategies for small businesses. Agri-food is one of the sectors that will deliver impact fastest. As the fifth largest exporter of agricultural and agri-food products in the world the importance of Canada’s agri-food sector cannot be understated.”
Loblaws’ goal to achieve net-zero for emissions generated by suppliers is significant because retailers achieve their goals through their supply chain.
Net-zero operations
Loblaws’ goal to achieve net-zero for emissions generated by suppliers is significant because retailers achieve their goals through their supply chain. The inclusion of Scope 3 emissions, which the GHG Protocol Corporate Standard defines as “all indirect emissions that occur in the value chain of the reporting company, including both upstream and downstream…”, means Loblaws is going to lean heavily on all its suppliers, both large and small, to achieve this impact.
At Anthesis Group we’ve set a goal to reduce emissions by 3 gigatons through our client work by the end of the decade. The only way to achieve that is by creating ways for SMEs to first understand what net zero means, and then to build and implement their own net-zero plans.
As Paul Crewe, chief sustainability officer at Anthesis Group, explains, “We
Ninety-seven per cent of the Canadian food industry is composed of SMEs and we need to work together to ensure that every single one is properly trained and supported if we are to achieve the ambitious and necessary goals in this decade and beyond.
Future Food Leaders Academy
This is why we have launched the Future Food Leaders Academy, a new virtual community and training space to support food leaders in their path to net zero. Over a hundred companies are participating already, accessing resources and collaborating to become more sustainable, more circular and to create pathways toward net zero.
As the largest food retailer in the country, Loblaws has thrown down the gauntlet for the industry. It cannot achieve net zero without its supply chain.
This means sustainability reporting requirements for SMEs are going to accelerate. It also means the leaders of food and beverage companies of all sizes are going to need to make their own sustainability journey a priority.
There is a lot of help out there, including the Future Food Leaders Academy, to provide support. The giant has also awoken and the call from your customer is inevitable. Whether it shakes your world or not when it does happen, is up to you.
Cher Mereweather, CEO of Anthesis Provision, is a Canadian-based food industry sustainability expert.
On March 22nd, Annex Business Media’s Manufacturing Group teamed up to host ADVANCE: Women in Manufacturing, a one-day virtual summit that brought together industry experts and thought leaders to promote gender equity, diversity and inclusion in Canadian manufacturing. Visit womenincanadianmanufacturing.com to view on-demand content, including videos and podcasts.
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