ITALIAN FOOD TECHNOLOGY 74/2013

n. 74 - November 2013 ISSN 1590-6515

food

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DEPARTMENTS

November 2013 numero 74

contents   5 - BIOFILM

Listeria monocytogenes:

biofilms in food processing

P. Di Ciccio - M. Conter

E. Zanardi - S. Ghidini - A. Vergara

D. Paludi - A.R. Festino - A. Ianieri 18 - SAUSAGE

Listeria monocytogenes in traditional fermented sausages produced in Sardinia (Italy)

D. Meloni - F. Piras

A. Mureddu - R. Mazza

D. Nucera - R. Mazzette

30 - RESEARCH The effect of food structure on satiety - Broader scope may enhance UV screening of navel oranges - Impact of the shape on sensory properties of chocolate pieces Olive-oil milling leftovers scrutinized in new ARS studies - What effect of polydextrose on satiety and energy intake? - Functional foods based on fruit and vegetable residue flour - French fries oil content: lower with infrared heat 36 - FOOD PROCESSING Radio frequency applications for the food industry: defrosting - Multifunction vacuum plant with rotating coil - Vertical mixers - Cooking ovens with counterpressure - Food processing equipment 40 - MEAT PROCESSING Innovative raw ham production technology - Horizontal slicers - Plates and knives set for sausage production - Automatic press for ham and bacon - Clippers 44 - BAKERY AND CONFECTIONERY Rice and cereal processing - Melters for blocks of fat and butter 46 - PACKAGING EQUIPMENT Process control and efficiency boosts European packaging machinery market Coffee capsule production - Integrated wrapping systems - Automated handling systems for products and packaging 50 - PACKAGING MATERIALS Are your food labels legal?

52 - ANCILLARY EQUIPMENT Flexible conveyor - Sorting machines - Automatic bag emptying machine with belt - Check-weigher 56 - CONSUMER TRENDS Consumers go nuts for healthy snacks - Alternative bases & upmarket toppings help pizza hold ground - Even more launches of new food and drink containing vitamin K2 - Fruity flavours favoured in new yogurt formulations - Worldly Snacks: Culinary Trend Mapping Report - Why profit margins are trending in the dairy industry? GMO-free moving forward in new products 66 - MARKETING REPORTS World cocoa market will be in deficit for next two years - China’s dairy industry: review and outlook 70 - PACKAGING TRENDS US demand for meat, poultry and seafood packaging to reach in 2017 72 - NEWS AND TECHNOLOGY New UN food safety and nutrition standards will benefit consumers - Can a vegetarian diet reduce mortality? - Resistant bacteria remain an important issue - Olive oil assays may help assure authenticity - The new App for iPhone developed by Pavan - Private label conference and exhibition in Bologna - UCIMA chooses Cibus Tec to shape Food Pack - Intenational events in Italy 80 - ADVERTISER INDEX 80 - COMPANY INDEX

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biofilm P. Di Ciccio1* - M. Conter1 - E. Zanardi1 - S. Ghidini1 - A. Vergara2 - D. Paludi2 - A.R. Festino2 - A. Ianieri1 University of Parma - Dept. of Animal Production, Veterinary Biotechnologies, Food Quality and Safety - Parma - Italy University of Teramo, Dept. of Food Science - Teramo - Italy *email: pierluigialdo.diciccio@nemo.unipr.it

1 2

Listeria monocytogenes: biofilms in food processing

Key words biofilm, food industry, food safety, Listeria monocytogenes

INTRODUCTION Listeria monocytogenes is a ubiquitous facultative intracellular bacterium that is potentially pathogenic to humans (Farber and Peterkin, 1991). This pathogen is frequently isolated from a variety of food products and also from soil, vegetation, fecal matter, sewage, water, and animal feed (Donnely, 2001; Moltz and Martin, 2005; Tompkin, 2002).

Meat, poultry, dairy, vegetables, and ready to eat (RTE) products

have all been implicated as vehicles of listeriosis (Conter et al., 2009a; Efsa, 2007; Teixeira et al., 2007).

In fact, ingestion of food contaminated with L.m is the primary route of transmission to humans (Dussurget, 2008).

Although the incidence of listeriosis is low, it remains a public health concern because of its high mortality rate (20-30%) (Sutherland et al., 2004). L.m strains show heterogeneous levels of virulence (Liu et al., 2007) that are regulated by the pres-

Abstract Contamination of food by Listeria monocytogenes (L.m) frequently occurs in food processing environments, where cells persist due to their ability to attach to surfaces. L.m is able to attach and colonize environmental surfaces by producing a three-dimensional matrix of extracellular polymeric substances (EPS) called biofilm; such structures are dynamic systems. Once established, biofilms can serve as a source of product contamination.

Moreover, L.m in the biofilm state shows a reduced susceptibility to antimicrobial agents. The present review focuses on L.m biofilms in food processing environments. In addition, some aspects of biofilm control and eradication are highlighted.

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ence of pathogen-specific genetic factors, which affect the outcome of human and animal infection (Conter et al., 2009a; Thevenot et al., 2006). Additional factors, however, may contribute to the pathogenesis potential (Chatterjee et al., 2006).

L.m is able to colonize surfaces, and particular subtypes may persist in food production plants for several years (Piette and Idziak, 1991). One reason for this persistence may be the ability of L.m to form biofilms (Schlech et al., 1983). Biofilms are assemblages of microorganisms that adhere to each other and/or to a surface and are embedded in a matrix of exopolymers (Morris and Monier, 2003). Particularly, biofilms allow microorganisms to persist in the environment and resist desiccation, UV light, and treatment with antimicrobial and sanitizing agents (Di Bonaventura et al., 2008).

BIOFILM FORMATION The term “biofilm� was created to describe the sessile form of microbial life, characterized by adhesion of microorganisms to biotic or abiotic surfaces, with consequent extracellular production of polymeric substances (Musk et al., 2005). It is now generally accepted that bacteria grow preferentially as biofilms (Hall-Stoodley and Stoodley, 2005).

In fact, in nature and food systems, microorganisms are attracted to solid surfaces. Initially, microorganisms are simply deposited; later, they get attached, grow, and actively multiply to form a colony of cells (Allison and Sutherland, 1987). This mass of cells then becomes large enough to entrap organic and inor-

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ganic debris and other microorganisms, leading to the formation of a microbial biofilm. In food processing environments, these biofilms may be a few micrometers or several millimeters thick and contain 9097% water (Stoodley et al., 2002).

Biofilm development can occur on almost any surface in any environment in which viable microorganisms are present. Biofilm formation is a dynamic process and involves a series of steps. Initial attachment is via weak electrostatic and van der Waals’ forces and occurs rapidly; but, within a short time, film growth begins with physical attachment of the cells to the surface by complex polysaccharides (Oliveira et al., 2010). In particular, the first step of biofilm formation is conditioning of the surfaces (Hood and Zottola, 1997). This conditioning film favors biofilm formation and alters the physicochemical properties of the surface (e.g., changes in hydrophobicity and electrostatic charges) (Dickson and Koomaraie, 1989). The second step of biofilm formation is the attachment of microorganisms to the conditioned surface. During this stage, bacteria can easily be removed. The irreversible attachment of cells happens in the third step, and the removal of cells requires much stronger forces.

During this period, the attached cells also produce additional extracellular polymeric substances (EPS) that help anchor the cells to the surface (Costerton et al., 1995). Multilayers of bacterial cells entrapped within the EPS-containing matrices develop within the biofilm. Besides EPS and microbial cells, biofilms are composed of proteins, nucleic acids, and lipids, which provide

mechanical stability, surface adhesion, and scaffold formation for the three-dimensional architecture that interconnects and immobilizes biofilm cells (Flemming and Wingende, 2010). However, diverse polymers are used by different species or strains of the same species.

The identification of these matrix components may provide clues for the identification and application of matrix-degrading enzymes that prevent formation and/or activate biofilm dispersion (Karatan and Watnick, 2009; Landini, 2009).

Microorganisms within the biofilm grow in the matrix-enclosed microcolonies interspersed within highly permeable water channels (Costerton et al., 1994). At some point after film formation, the attached bacteria or pieces of film are released in order to allow the cells to survive and colonize new niches. This release leads to contamination of the product stream. The vegetative cells may reattach in downstream parts of the plant and initiate biofilm formation, completing the cycle.

When planktonic cells attach to a surface, there may be a lag before growth commences as they adapt to the sessile state. The cells released from the film may behave like biofilm cells when they reattach, showing no lag and growing more rapidly than primary cells (Rasmussen et al., 2005). The drivers for biofilm formation are the following: defence against harmful conditions; colonization of a favorable niche; utilization of potential benefits of the community; protection from the bulk phase environment, where there may be toxins, antibiotics, detergents, or sanitizers; the possibility of organization through

biofilm

inter-cell signalling; and transfer of genetic information, including resistance genes (Jefferson, 2004).

BIOFILMS IN THE FOOD ENVIRONMENT Microbial adhesion and biofilms are of great importance for the food industry and occur on a variety of food contact surfaces (Oliveira et al., 2007). Biofilms continue to pose concerns to food manufacturers as they are one of the major reasons for limiting the shelf life and favoring pathogen contamination of food products. Moreover, biofilms form a reservoir of contamination that persists where manufacturing plant cleaning is ineffective (Senczek et al., 2000). Depending on the specific systems investigated and the nature of the microorganism, biofilms can display a wide range of phenotypes. L.m biofilms, grown under static conditions, generally consist of a homogeneous layer of cells and/or microcolonies, with biofilm cells displaying morphology similar to that of planktonic cells. In contrast, L.m biofilms grown under continuous flow conditions consist of spherically shaped microcolonies that are surrounded by a network of knitted chains composed of elongated cells (Rieu et al., 2008).

Studies have shown the capacity of L.m to persist in the environment for years. Biofilms form not only on processing environment surfaces but also on food itself, which offers the potential for cross-contamination and post-process contamination (Kumar and Anand, 1998).

Moreover, environmental surfaces such as floors and walls may also be

indirect sources of contamination, e.g., transference to food products by vectors such as air, people, and cleaning systems (Gibson et al., 1999). In food systems, improperly cleaned and sanitized equipment and air-borne microbiota are usually considered important niches of contamination (Fig. 1) (Simões and Vieira, 2009). Other common sources involved in biofilm accumulation include floors, waste water pipes, bends in pipes, rubber seals, conveyor belts, stainless steel surfaces, glasses, etc. Buna-N and Teflon seals have also been implicated as important sites for biofilm formation (Frank and Koffi, 1990; Rodas-Suarez et al., 2006). Herald and Zottola (1988) observed that L.m can attach to stainless steel via produced attachment fibrils. In meat and dairy processing industries, the presence of L.m has been found on equipment and utensil surfaces (López et al., 2008).

Importantly, bacterial biofilms have

been consistently described as being more resistant to biocides than planktonic cells (Gilbert et al., 2002; Scenhir, 2009). The reasons for this decrease in susceptibility or “tolerance” is a biofilm-associated phenotype (Ashby et al., 1994; Brown and Gilbert, 1993; Das et al., 1998), which includes decreased metabolism, quiescence, reduced penetration due to the extracellular polymeric matrix (Pan et al., 2006), and enzymatic biocide inactivation (Scenhir, 2009).

In nature, biofilms may be composed of a single species or represent a consortium of numerous species. Several types of microorganisms (spoilage or pathogenic) are capable of participating in adhesion processes and biofilm formation. Mixed species biofilm formation of several Staphylococcus aureus strains with L.m has been demonstrated (Rieu et al., 2008).

In addition, some researchers have found that L.m grows preferably

Fig. 1 - Example of possible niches of L. monocytogenes in a battering and breading machine.

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as a biofilm as part of a consortium of bacterial species (Jeong and Frank, 1994a-b; Kalmokoff et al., 2001). Other reports examining longer-term biofilm formation have noticed that L.m is a poor organism for cell attachment and biofilm formation, and this has led to suggestions that L.m may use a primary colonizing bacterium of a different bacterial species to form a biofilm consortium on a surface (Moltz and Martin, 2005).

Carpentier and Chassaing (2004) and Tompkin (2002) showed that the ‘‘house flora’’ of food processing premises has a strong effect on the likelihood of finding L.m on inert surfaces. A study on mixed biofilm formation of L.m in combination with various secondary species showed that mixed species biofilms were established, and depending on the specific combination, they showed increased, reduced, or no effect on the number of L.m cells in the biofilm (Carpentier and Chassaing, 2004).

Furthermore, an elaborate study on the formation of mixed species biofilms of L.m and Lactobacillus plantarum showed that mixed species biofilms have the capacity to be more resistant against disinfectant treatments than a single species biofilm or planktonic cells (Van Der Veen and Abee, 2010). Another interesting study on the adherence of L.m to preformed Lactococcus lactis biofilms with different architectures, matrices, and cell surface properties showed that L.m biofilm formation can be influenced by resident biofilms (Habimana et al., 2009). The impact of secondary species on L.m settlement, biofilm formation, and persistence in food

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processing environments remains to be characterized.

Bacterial attachment to surfaces is influenced by the physicochemical properties of both the surface and microorganism, such as temperature and hydrophobicity (Gorsky et al., 2003; Hood and Zottola, 1997). It has been suggested that flagellation and motility play a role at the cell level in several stages of biofilm formation (Moens and Vanderleyden, 1996). Motility has been shown to facilitate attachment to both biotic and abiotic surfaces (Butler et al., 1979), since flagella, in addition to being the locomotive organelles of bacterial motility, have also been reported to serve as adhesive structures (Moens and Vanderleyden, 1996). With regard to food surfaces, many studies have shown the attachment of L.m to meat and poultry surfaces (Chung et al., 1989; Dickson and Koohmaraie, 1989; Thenevot et al., 2006).

However, these studies did not clearly reflect the formation of biofilms with regard to these surfaces.

LISTERIA MONOCYTOGENES AND BIOFILM L.m can adhere rapidly and firmly to inert surfaces commonly found in the food processing industry. This bacterium has been found to form biofilms on surfaces such as plastic, polypropylene, rubber, stainless steel, and glass and on the interface between two different materials (e.g., plastic and stainless steel) (Chae et al., 2006; Hood and Zottola, 1997; Moltz and Martin, 2005; Simões et al., 2010). Listeria sources

in processing plants include conveyor belts, cutters, slicers, bringing and packaging machines, coolers, freezers, floors, and drains (D’orio et al., 2007; Eklund et al., 1995; Miettinen et al., 2001).

The mechanisms by which L.m survives under harsh physical and chemical stress conditions are, at least in part, due to its ability to form biofilms on surfaces within the food processing environment (Chae et al., 2006; Holah et al., 2004).

Several researchers have reported that L.m is not capable of forming thick biofilms made up of several layers (9 to 12 Log CFU/cm2), but rather it adheres to surfaces at levels ranging from 4 to 6 Log CFU/cm2 (Gram et al., 2007).

The ability of L.m to produce biofilm significantly differs according to the growth temperature and growth surface. For example, L.m has the capacity to adhere rapidly to stainless steel surfaces, and this risk is aggravated considering that this bacterium is able to reach an irreversible stage in a few hours (Oh and Marshall, 1996). The ability to form biofilms at 4°, 12° and 22°C is significantly more pronounced on glass than on polystyrene and stainless steel. Furthermore, at 37°C, both stainless steel and glass allow comparable amounts of biofilm formation, significantly higher than on polystyrene (Figs. 2 and 3) (Di Bonaventura et al., 2008). The ability of L.m to colonize a surface at low temperatures, used in the food industry to process and store a significant amount of foodstuffs, added to the recent finding that L.m cells in biofilms can survive storage at 4° or 10°C for at least 5 days (Smith et al., 2004), increases the

biofilm

Fig. 2 - Scanning Electron Microscopy (SEM) images of biofilm formed by L. monocytogenes on stainless steel at different temperatures.

Fig. 3 - Scanning Electron Microscopy (SEM) images of biofilm formed by L. monocytogenes on polystyrene at different temperatures.

propensity for cross-contamination to foodstuffs.

Recent studies have shown significant differences in biofilm formation on polyvinyl chloride (PVC) (Borucky et al., 2003; Djordjevic et al., 2002) or stainless steel (Folsom and Frank, 2006) between different lineages, although the findings were contradictory (CHAE et al., 2006; Djordjevic et al., 2002). Di Bonaventura et al. (2008) did not find any relationship between phylogeny and the ability to form a biofilm on different surfaces at different temperatures. Furthermore, no differences among environmental and food strains were observed in the experiment. At the same time, differences in biofilm production have been shown (Kalmokoff et al., 2001; Palmer et al., 2007): serotype 1/2c forms a higher average amount of biofilm than serotype 1/2a on stainless steel and serotypes 1/2a and 4b on glass, at 37째C. Food contact surfaces have different physicochemical characteristics: hydrophilic (glass, stainless steel) and hydrophobic (polystyrene).

Some studies have failed to find a correlation between hydrophobicity and surface attachment. Particularly, Chae et al. (2006) recently found that attachment on glass is independent of hydrophobicity level.

Other authors (Di Bonaventura et al., 2008) suggested that the hydrophobicity level is correlated with biofilm formation on glass. These conflicting results are probably due to the fact that hydrophobicity can differ between serotypes or strains, and it can change with variation in growth conditions (Giovannacci et al., 2000).

The cell surface is generally con-

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sidered a significant factor in bacterial attachment to surfaces. Many studies suggest that microbial cell surface charge and hydrophobicity play an important role in the initial steps of microbial adhesion. Chae et al. (2006) demonstrated that high levels of extracellular carbohydrates produced by L.m increase their ability to form biofilms, indicating the importance of this characteristic for the biofilm forming ability of a given strain.

Bacterial attachment to surfaces is influenced not only by cell surface and hydrophobicity but also by the presence of particular surface appendages such as flagella and fimbriae. Very little is known about the relationship between motility and biofilm formation and, in any case, only swimming motility has been considered. Recent findings suggest that Gram-positive organisms, including L.m, have evolved multiple molecular strategies for the formation of pili on microbial surfaces (Hung and Schneewind, 2004).

Furthermore, Dons et al. (2004) showed that motility by swarming is critical in host-cell invasion and virulence of L.m. In an attempt to individuate a relationship between L.m flagellum-mediated motility (swimming) and biofilm formation, it has been shown that temperature strongly influences flagellum production in Listeria spp. (Djordjevic et al., 2002). On the contrary, motility did not show a positive correlation with biofilm-forming ability, regardless of the substratum (Djordjevic et al., 2002). On the whole, functionally active flagella (motility) are probably not required for biofilm formation in L.m, and changes in surface structures other

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than flagella contribute to bacterial attachment to a solid surface.

At both 4째 and 12째C, L.m produces a rudimentary biofilm consisting only of sparse clusters of cells and minimal amounts of EPS, regardless of the substratum. On the contrary, at 22째 and 37째C, the biofilm formed is more complex in terms of cell number and EPS produced.

Although only on glass it appeared as a complex three-dimensional architecture, consisting of dense cell aggregates held together by extracellular matrix and surrounded by void areas, probably representing water channels for nutrient circulation and facilitation of waste removal in the biofilm (Costerton et al., 1995). The relevant amount of EPS that can be observed in biofilms formed on glass raises a relevant hygienic/sanitary issue, since the chlorine resistance of L.m strains may be closely associated with the amount of EPS produced by the biofilm cells (Folsom et al., 2006).

The time available for biofilm formation depends on the frequency of cleaning regimes. Product contact surfaces are typically cleaned several times per day, while environmental surfaces such as walls are cleaned once per week. Therefore, there is more time for biofilm formation on environmental surfaces.

Gibson et al. (1999) found that although attachment to a variety of surfaces in the food processing environment readily occurred, extensive surface colonization and biofilm formation only occurred on environmental surfaces. Finally, routine cleaning in place (CIP) cycles in food plants may not remove all cells, and the remaining biofilm

cells may allow more rapid plant recolonization by a seeding process or by providing a surface to which new cells may readily adhere (Mashall, 1994). The situation is exacerbated if fouling has occurred, and it is not removed during CIP (Hinton et al., 2002).

BIOFILM AND SANITIZING AGENTS The elimination of biofilms is a very difficult task because many factors affect detachment. Sanitation, i.e., cleaning and disinfection, is carried out in food processing plants in order to produce safe products with an acceptable shelf life and quality. An effective sanitation program is the major method to control surface contamination.

When L.m is in the biofilm state, it exhibits an increased tolerance to disinfectants than their free living counterparts; and thick complex biofilms are more difficult to remove than adhered single bacterial cells (Klaeboe et al., 2006). The recalcitrance of biofilms towards biocide treatment is not in dispute, and the existence of resistance phenotypes induced by various nutrient limitations has been postulated to explain this observation (Brown and Gilbert, 1993).

Sinde and Cerballo (2000) found that sanitizers alter the surface properties of materials, and this alteration is directly related to the degree of attachment. Thus, sanitizers have different effects on bacterial adhesion depending on food contact materials. In particular, quaternary ammonium compounds were more effective against L.m

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attachment on stainless steel and rubber than on polytetrafluorethylene (PTFE), for which the effect was very similar. In some studies, it has been reported that L.m attached to food contact surfaces exhibited a reduced susceptibility to conventional sanitizers like acid anionic sanitizers and quarternary ammonium compounds (Frank and Koffi, 1990). A reasonable explanation for the reduced efficacy of such agents against biofilms is incomplete biofilm penetration by such reactive biocides (Huang et al., 1995) and the wide variation of environmental conditions that exist on food contact surfaces.

Antimicrobial agents are far more effective against actively growing cells, i.e., the best disinfectants for planktonic cells are not necessarily the most suitable ones for biofilm cells (Holah et al., 1990). Caustic chlorine washes can be very effective in removing well-established biofilms by breaking down the polysaccharide matrix, rather than inactivating the microorganisms, probably because high pH favors ion-promoted detachment (Costerton et al., 1995). Pan et al.

(2010) demonstrated that biofilm cells show a reduced susceptibility to a sanitizer. This resistance to a sanitizer was greater on a Teflon substrate than on a stainless steel substrate. Similar results were observed by Krysinski et al. (1992), who found that the resistance of L.m biofilms on stainless steel was lower than that on polyester or polyester/ polyurethane. In addition, Bremer et al. (2002) reported that there was a significant difference in the effectiveness of sanitizers against cells attached to stainless steel surfaces

than to conveyer belt surfaces (PVC/ polyester).

The hydrodynamic conditions under which biofilms grow also have a significant effect on structure (Steward and Costerton, 2001).

Thus, Liu and Tay (2001) found that at relatively high shear stress, as might be found in a food production plant, the biofilm was denser than at lower shear. Therefore, shear stress during biofilm development may profoundly affect the results of disinfection trials and the success of cleaning procedures.

Physical surface phenomena such as increased nutrient concentration at the surface are also often quoted as improving the tolerance to antimicrobial stress of biofilm bacteria.

A recent work showed that microand nano-emulsions may be effective anti-biofilm agents, although L.m films appeared to be resistant (Takeuchi et al., 2000). The widespread use of antimicrobial agents such as sanitizers or disinfectants in food processing or equipment cleaning and their effect on antimicrobial resistance is being investigated (Conter et al., 2009b; Splendiani et al., 2006).

Genetic factors such as the mobility of antibiotic resistance genes found on plasmids and transposons can increase the transfer of antibiotic resistance between bacteria (Somers and Wong, 2004). The ability of bacteria to adapt to adverse environmental conditions is an important factor in the development of resistance. This is because exposure of the organism to a sublethal level of an antimicrobial agent can lead to adaptation and development of resistance to higher levels of the antimicrobial agent or even cross-

resistance to other agents. Although several authors report interactions between the bacterial biofilm physiological state and resistance to antibiotics or biocides, very little information is available on the cross resistance of sessile bacteria to antibiotics and biocides (Scenhir, 2009). The emergence of resistant bacteria to conventional antimicrobial agents clearly shows that new biofilm control strategies are required (Sim천es and Vieira, 2009).

SOLUTIONS: CONTROL AND REMOVAL OF BIOFILMS The evaluation of biofilm sanitation procedures should be part of the Hazard Analysis and Critical Control Points (HACCP) development plan in order to control those biofilms prevalent in processing areas (Senczeck et al., 2000). There are several steps in normal cleaning/sanitation procedures, including cleaning, rinsing, and sanitizing, in that order (Gibson et al., 1999). The purpose of cleaning is to remove residual materials that may interfere with the sanitation procedure, because the presence of organic material on the biofilms significantly reduces the log kill.

This reinforces the importance of adequate cleaning before the use of sanitizers (Krysinsky et al., 1992).

Biofilms in the food industry can be eliminated by adopting different strategies such as physical, chemical, and biological methods. The use of enzyme-based detergents as bio-cleaners can serve as a viable option to overcome biofilm problems in the food industry. Due

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to EPS heterogeneity, a mixture of enzymes may be necessary for sufficient biofilm degradation. However, the use of enzymes in biofilm control is still limited due to the low prices of chemicals used today compared to the costs of enzymes.

As a matter of fact, the technology and production of these enzymes and enzyme-based detergents are mostly patent-protected. Moreover, the low commercial accessibility of different enzyme activities limits their current usage. Enzymes and detergents have also been used as synergists to improve disinfectant efficacy (Johansen et al., 1997).

An interesting study on the control of L.m in a biofilm by competitive exclusive microorganisms indicated that L.m in biofilms can be strongly inhibited (> 5 Log CFU of L.m/cm2) by metabolites of Enterococcus durans and Lactococcus lactis subsp. lactis. These two strains were isolated and screened from biofilms obtained from the floor drains of food processing plants that were free of L.m according to records. Enterococcus durans and Lactococcus lactis, subsp. lactis are beneficial organisms and can be used as starter cultures for food fermentation, and they have great potential for controlling L.m biofilms in food processing environments (Zhang et al., 2007).

Studies have shown that some detergents are bactericidal, and some disinfectants may even depolymerize EPS, thus enabling biofilm detachment from surfaces, e.g., oxidants such as chlorine and hydrogen peroxide (Juven and Pierson, 1996). Monolaurin (glycerol monolaurate) was also found to be lethal to L.m at low concentrations.

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In addition, a synergistic interaction between monolaurin and organic acids like acetic acid also caused a pronounced inhibition of L.m (Nikolaev and Plakunov, 2007).

More recently, several authors (Guerrieri et al., 2009; Sorum and L’Abee-Lund, 2002) demonstrated that bacteriocin producers showed the best antilisterial potential.

Microbial molecules, commonly used as biopreservatives, such as nisin, lauricidin, reuterin, and pediocin, have been well documented for their biofilm control potential against microorganisms commonly found in dairy processing facilities, including L.m (Mahdavi et al., 2007; Zhang et al., 2007). Bacteriocin application has also been tested on food packaging materials for the biocontrol of L.m on meats (Ming et al., 1997). The antagonistic effect was made more effective by decreasing the pH due to lactic acid production in the Lb. plantarum biofilm; the outcome was confirmed by the considerable activity in the Lb. plantarum biofilm and suspension. Comparing the antilisterial activity of lactic acid bacteria (LAB) biofilms against both planktonic and adherent cells, the L.m adherent cells showed a higher resistance. This finding can be explained by the greater resistances that microorganisms display to exogenous agents in biofilms (Safdar and Armstrong, 2003).

The use of bacteriophages to control biofilms may provide a natural, highly specific, nontoxic, and feasible approach for controlling several microorganisms involved in biofilm formation (Kudva et al., 1999). A bacteriophage (L.m phage ATCC 23074-B1) was used successfully in

L.m biofilm inactivation (Hibma et al., 1997). Lu and Collins (2007) engineered a bacteriophage to express a biofilm-degrading enzyme. This enzymatic phage had the ability to attack bacterial cells in the biofilm and the biofilm matrix, substantially reducing the biofilm cell counts (more than 99.9% removal). The technology for this process has not yet been successfully developed, and relatively little information is available regarding the action of bacteriophages on biofilms (Stoodley et al., 2002).

More recently, the use of chlorine dioxide (CD) as a decontamination agent has demonstrated its high effectiveness against a wide variety of microorganisms. It is a strong oxidizing agent with several advantages, such as the formation of low toxic disinfection by-products, effectiveness at low concentrations, low reaction time, ease of generation, and effectiveness over a broad range of pH values (Chang et al., 2000). The efficacy of CD gas to disinfect biofilms has not been studied in detail. A recent study demonstrated that low levels of gaseous CD (0.3 mg/L) and aqueous CD (7 mg/L) have equivalent inactivation of L.m cells in a biofilm matrix compared to conventional sodium hypochlorite treatment (50 mg/L). Additional research is needed to establish the CD levels and treatment times required for complete inactivation of biofilm cells. The potential use of CD to inactivate biofilms from food processing equipment surfaces should be further explored.

The discovery that many bacteria use quorum sensing to form biofilms makes it an attractive target for their control (Poyart-Salmeron

biofilm

et al., 1990). It is conceivable that quorum sensing inhibition may represent a natural, widespread, antimicrobial strategy with significant impact on biofilm formation. A good understanding of the cell-cell signaling phenomena of bacteria such as L.m can be used to control the biofilm formation process by the identification of products that can act as quorum sensing antagonists (Sharma and Anand, 2002; Sinde and Cerballo, 2000). This property can lead to the development of new and efficient natural products for biofilm control.

The literature demonstrates that there is no unique strategy with absolute biofilm control efficiency.

Nevertheless, the importance of adequate cleaning and disinfection procedures, in order to avoid L.m becoming established in processing environments and thus posing a product contamination threat, is widely accepted. Furthermore, continuous environmental monitoring schemes for L.m are of major importance to identify potential contamination sources and as an early warning system for food business operators, especially in food processing plants with low L.m prevalence in their food products.

CONCLUSIONS AND FUTURE DIRECTIONS Pathogenic microorganisms in biofilms are the major source of food contaminations and clinical infections. Preferably, preventing biofilm formation would be a more logical option than treating it. Nutrient and water limitation, equipment design, and temperature control are impor-

tant in biofilm control. In addition, the choice of material herein is crucial in terms of biofilm formation. The hygienic properties of the material can be altered by specific modifications to render it intrinsically antibacterial and/or less susceptible to attachment (Van Houdt and Michiels, 2010). The deposition of antifouling layers on stainless steel can influence their hygienic status, as demonstrated by the 8196% decrease in L.m attachment and biofilm formation on polyethylene glycol-modified stainless steel.

The modified surface properties were obtained by plasma-enhanced cross-linking of polyethylene glycol on stainless steel (Dong and Zhang, 2005).

Biofilm detectors have been developed to monitor surface colonization by bacteria and allow the control of biofilms in the early stages of development (Pereira et al., 2008).

Many authors have suggested that L.m may be inhibited by some bacteriocin-producing LAB (Sabia et al., 2002; Tyopponen et al., 2003).

Newer strategies devised for the bio-control of Listeria in planktonic form or in biofilms could include the adsorption of bioactive compounds, such as bacteriocins, onto food-contact surfaces (Guerrieri et al., 2009). Several attempts have been made to avoid biofilm formation by incorporating antimicrobial products into surface materials, coating surfaces with antimicrobials (Gottenbos et al., 2001), and/ or modifying the surface physicochemical properties (Rodriguez et al., 2007).

Biosurfactants are compounds with surface-active properties, which are produced by microorganisms. Their

use has been suggested as an alternative to synthetic products. Their major advantages over synthetic detergents are their low toxicity and highly biodegradable nature.

Biosurfactants may also show antimicrobial and anti-adhesive activities. Biosurfactants have been mentioned as promising multipurpose ingredients, which simultaneously exhibit emulsifier, anti-adhesive, and antimicrobial activities, and they are consequently suitable for many food applications (Nitschke and Pastore et al., 2002; Nitschke and Costa, 2007). Therefore, these compounds of microbial origin could be used as detergent formulations to clean surfaces that come in contact with food and prevent food contamination (Freire et al., 2009). Thus, biosurfactants could be utilized in the development of new strategies to retard L.m surface colonization and biofilm formation (Nitschke et al., 2009; Araujo et al., 2011).

Plant-derived compounds have gained widespread interest in the search to identify alternatives for microbial control (Essawi and Srour, 2000). It has been postulated that surface pre-treatment with plant extracts produces an unfavorable film that promotes microorganism detachment (Sandasi et al., 2010).

To date, rational equipment design that minimizes laminar product flow, reduces static product, and facilitates cleaning and CIP processes can result in reduced bacterial attachment to processing equipment.

The next step is the choice of materials modified by a set of coatings and surface modifications in order to reduce surface adhesion and biofilm formation (Sze, 1981; Man-

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dracci and Ricciardi, 2007). The increased biofilm resistance to conventional treatments enhances the need to develop new control strategies (Sharma and Anand, 2002).

Research on microbial biofilms is proceeding on many fronts, with particular emphasis on elucidation of the genes specifically expressed by biofilm-associated organisms, evaluation of various control strategies (including medical devices treated with antimicrobial agents and antimicrobial locks) for either preventing or remediating biofilm colonization of medical devices, and development of new methods for assessing the efficacy of these treatments.

The majority of bacteria are able to form biofilms displaying a large diversity in architecture, phenotypes, and matrix components. Novel insights include factors contributing to phenotypic heterogeneity within biofilms, such as the identification and characterization of a range of matrix building blocks.

To date, the prevention and control of L.m biofilms in food processing environments should be based on integrated efforts. The food industry should develop cleaning plans and disinfection programs and monitor their efficacy. In addition, the process equipment should be designed with high standards of hygiene in mind. Finally, a better understanding of how L.m attaches, grows, and detaches is urgently needed, and much effort should be invested in research on novel biofilm prevention and control strategies. da Italian Journal of Food Science No. 3, 2012

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SAUSAGE D. Meloni* - F. Piras - A. Mureddu - R. Mazza - D. Nucera1 - R. Mazzette Dipartimento di Medicina Veterinaria - UniversitĂ di Sassari - Via Vienna 2 - 07100 Sassari - Italy 1 Dipartimento di Patologia Animale - UniversitĂ di Torino - Via L. Da Vinci 44 - 10095 Grugliasco - TO - Italy *dmeloni@uniss.it

Listeria monocytogenes in TRADITIONAL FERMENTED sausageS PRODUCED IN SARDINIA (ITALY)

INTRODUCTION Listeria monocytogenes is a ubiquitous organism, widely distributed in the environment. The principal reservoirs are soil, forage and water (EFSA,2011). Other reservoirs include healthy humans and animals(ILSI, 2005) or infected domestic and wild animals (EFSA, 2011). L. monocytogenes has been isolated throughout the pork processing industry (Nesbakken et al., 1996), with an increase of contam-

ination along the production line (Chasseignaux et al., 2002). One of the most recent listeriosis outbreaks (Canada 2008) was linked to the consumption of ready to eat (RTE) pork meat products, causing 22 deaths and 57 confirmed cases (PHAC, 2009). Fermented RTE pork meat products, such as dry and semi-dry sausages, have rarely been implicated in food poisoning.

Nevertheless, in the manufacturing of traditional fermented products, an empirical application of hur-

Key words biofilm, fermented sausages, Listeria monocytogenes, polymerase chain reaction, pulsed-field gel electrophoresis

Abstract Environmental samples, raw materials and fermented sausages produced in Sardinia (Italy) were analysed in order to investigate the prevalence and enumeration of L. monocytogenes. Isolates were identified by single PCR and characterised by multiplex PCR-based serogrouping. The contamination routes of L. monocytogenes in the plants were traced using PFGE. In addition, a quantitative assessment of the in vitro biofilm formation was carried out. Fermented sausages seem to be regularly contaminated with L. monocytogenes: results showed the ability of the pathogen to overcome the hurdles of the manufacturing process and adapt to the processing plant environments, forming biofilms.

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dletechnologies often occurs and these products are regularly contaminated with L. monocytogenes.

This fact may present a major public health concern if the pathogen is able to multiply and reach high levels of contamination (Thevenot et al., 20061). Previous surveys carried out on traditional fermented products at the end of ripening showed a prevalence of 10% in France (Thevenot et al., 2005), 10.6% in Chile (Cordano and Rocourt, 2001) and 15.2% in Italy (De Cesare et al., 2007). In a former study, L. monocytogenes was found in 40% of “Salsiccia Sarda” at the end of ripening (Meloni et al., 2009) with contamination levels always lower than 100 CFU/g. “Salsiccia Sarda” is the primary meat product (37% of consumption) of the meat supply chain in the Sardinia region (Italy) and is included on the national list of traditional food products. It is one of the typical Italian semi-dry sausages (aw ranging from 0.90 to 0.95), naturally fermented (Greco et al., 2005) and marketed locally and regionally in Italy (Comi et al., 2005). The physico-chemical and microbiological profile of “Salsiccia Sarda” is not homogeneous and is influenced by the technological process. The presence of spoilage and poor hygiene indicators in the ripened sausages is directly related to the duration of the ripening period (Mazzette et al., 1994) and sometimes, to an inappropriate process of acidification and dehydration (Mazzette et al., 1998). L. monocytogenes may survive during the processing of the fermented meat products due to its high tolerance to low pH conditions and high salt concentrations (Farber and Peterkin, 1991) and if

the standard hurdle technologies are ineffective. The main hurdles used during the processing of dry fermented products are nitrite and salt content, the decrease in redox potential and water activity (aw) that inhibit many aerobic bacteria in the early stages of production (Pseudomonas spp. and other Gram-negative bacteria), and selecting the lactic acid bacteria (LAB) which cause the pH to decrease (Barbuti and Parolari, 2002). These hurdles, with the coagulase negative Staphylococci development and the length of the ripening period, are essential for the microbial safety and stability of quick-ripened fermented sausages, which are not greatly dried. Pork meat used for the manufacturing of sausages may be contaminated from a wide variety of sources and L. monocytogenes once introduced in the processing plants can persist over time in the environment, contaminating food processing machines (Lopez et al., 2008). L. monocytogenes forms assemblages of surface-associated microbial cells that are enclosed in hydrated extracellular polymeric substances and grow in biofilms on surfaces in contact or not with the food (Gandhi and Chikindas, 2007), such as floor drains, storage tanks, hand trucks, conveyor belts and other foodcontact materials (Mafu et al., 1990). The presence of the pathogen on surfaces in contact and without contact with food increases the food safety risk (Kim and Frank, 1995). Thus, L. monocytogenes may become an important source of secondary contamination of food products, and without suitable sanitisation procedures, crosscontamination of the meat products

may occur (Samelis and Metaxopoulos, 1999). The main objective of the present study was to evaluate the occurrence of L. monocytogenes in the fermented sausage production of the Sardinia region (Italy). Isolates were identified by single PCR and further characterised by multiplex PCR-based serogrouping. The contamination routes of L. monocytogenes in the plants were traced using PFGE. In addition, a quantitative assessment of the in vitro biofilm formation was carried out in order to investigate the potential for persistence.

MATERIALS AND METHODS Survey on the production of traditional fermented sausages in Sardinia The survey has been conducted at four processing plants (plants A-BC-D) located in different provinces of Sardinia (Italy) and representative of the regional fermented sausage production. Preliminarily, check lists for the acquisition of the main characteristics of plants and products were prepared: 1. Main characteristics of the plants - General features of the plant: eg. year of construction; year of starting production; total area of the plant; general structural requirements; condition of the plant; scheduled adjustment or maintenance operations.

- Regulatory framework: health marking, sanitary authorization or other reference standards.

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- Management issues: conduction (public/private), human resources (number of employees, training activities), certifications (system and product certification, environmental certification).

2. Main characteristics of the production - Amount and type of production.

- Main activity of the plant: production, storage, packaging.

- Destination of the products: distribution, marketing strategy, presence of a plant store.

- Description of the plant environments: equipment and other facilities.

- Characteristics of raw materials and ingredients: origin and storage conditions.

- Description of the technological process: identification of the phases and indication of the process parameters.

- Packaging and labelling of the products.

- Storage of the products.

The check lists were compiled at the plants interviewing the owner and/or the staff responsible for the production. The acquisition of information was completed by an inspection of the plant and an audit of the production stages where the product characteristics and process parameters were checked and verified.

Sampling A total of 170 samples from environments, raw materials and final products from two large (A and D) and two small (B and C) process-

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ing plants were sampled in order to investigate the prevalence, ecology and genetic profile of L. monocytogenes. Three of the processing plants (A, B, D) were only sampled once (S1). In order to evaluate the role of swine carcasses as a possible source of plant contamination and the persistence of L. monocytogenes-adapted strains, in plant C (randomly chosen) sampling was repeated within three months (S2).

Details on samples collected from each plant are provided in Table 2.

A total of 132 environmental samples were collected: 96 swabbed surfaces without contact with meat (SWCM) and 36 surfaces in contact with meat (SCM). SWCM and SCM were sampled during the production stages by swabbing with 10 by 10 cm sterile gauze pads rehydrated with 10 mL of neutralising buffer (Solar-cult sampling kit, Biogenetics, Padova, Italy) and using a sterile template to delineate the swabbed area of 100 cm2. Sampling locations were chosen in order to represent those most likely to present L. monocytogenes contamination. Sampling sites for SWCM included walls and floor drains of the ground meat store rooms, drying and ripening rooms, processing and packaging/shipment rooms.

Regarding SCM, the sampling sites included work tables, sausage trolleys, hooks, mincing, mixing, and stuffing machines. A total of 16 samples from ground meat and 10 from fermented sausages at the end of ripening were collected. Only during the repeat sampling (S2) in plant C12 samples from swine carcasses were collected: 6 of raw pork meat with and without rind and 6 swab samples of vertebral canal

between the first thoracic vertebra and the seventh lumbar vertebra, in correspondence with the bone saw surface of the swine carcasses. The carcasses were stored at +4째C and were sampled before their entry in the processing line. Samples were collected by swabbing as previously described. All of the items were aseptically sampled, placed in sterile bags (kept in ice boxes at +3째C) during transport and were immediately analysed upon arrival at the laboratory.

Physico-chemical analysis For all the samples of ground meat and sausages at the end of ripening the pH and water activity (aw) were determined. The measurement of pH was carried out by inserting the pin electrode of a pH-meter Forlab 710 (Carlo Erba, Italia) directly into each sample. Water activity (aw) was determined using a water activity meter Acqualab CX-3, (Decagon, Pullman, WA, USA). Two pH and aw measurements were performed and the final value was averaged.

Detection and enumeration of L. monocytogenes Detection and enumeration of L. monocytogenes was carried out using the ISO 11290-1:1996 and 11290-2:1998 protocols, respectively. Samples of raw pork meat, ground meat, fermented sausages and swabbed samples were homogenised 1/10 with Fraser broth base (Biolife, Milan, Italy) in a Stomacher LabBlender 400 (Seward Medical, London, UK) for 2 min. The homogenates were incubated at +20째C for 1 h, in order to resuscitate stressed

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microorganisms. For the enumeration of L. monocytogenes, 1 mL of each inoculum was distributed over the surface of three Aloa (Biolife) 90mm plates using a sterile spreader.

The plates were incubated at +37°C for 48 h. For detection of L. monocytogenes, the homogenates were supplemented by Fraser half-selective supplement (Biolife) and incubated at +30°C for 24 h. Afterwards, 0.1 mL of the primary enrichment was inoculated in 10 mL of Fraser broth supplemented (Biolife) by Fraser selective supplement (Biolife) and incubated at +37°C for 48 h. Cultures were streaked onto Oxford (Oxoid, Milan, Italy) and Aloa (Biolife) plates and incubated at +30° and +37°C for 48 h, respectively.

From each plate of the primary and secondary enrichment, five colonies presumed to be Listeria spp. were streaked on Tsyea plates (Biolife) and incubated at +37°C for 24 h.

Colonies were selected for typical appearance on Tsyea and submitted to Gram staining, catalase and oxidase tests. Haemolytic activity and CAMP tests on sheep blood agar were performed for confirmation of L. monocytogenes. Biochemical characterisation of all the isolates was performed using the API Listeria identification system (bioMérieux, Marcy l’Etoile, France).

Molecular identification and characterisation Single PCR-based identification The phenotypic identification of L. monocytogenes isolates was confirmed by a single PCR-based method (sPCR) aimed at prfA gene fragment detection. L. monocytogenes

isolates were grown on BHI (Oxoid) at +37°C for 16-18 h. The cells were pelleted by centrifugation of 1 mL at 12,000 rpm for 5 min at +4°C and washed twice in phosphatebuffered saline (PBS). DNA was extracted by suspending the pellet in 1 mL of PBS, which was boiled for 5 min and centrifuged at 10,000 rpm.

The supernatant was quantified with a UV-1700 PharmaSpec spectrophotometer (Shimadzu, Kyoto, Japan) at OD260 and then stored at -20°C until use. Heterologous DNA of S. xylosus ATCC 29971 was used as a negative control and DNA of L. monocytogenes reference strain ATCC 19115 was used as a positive control. The sPCR was carried out with the primer set Lip1 and Lip2 (D’Agostino et al., 2004; Jofrè et al., 2005) which produces a fragment of 274bp (Simon et al., 1996).

All amplification reactions were performed in a final volume of 50 µL containing 5 μL of DNA, 5 μL of 10X PCR buffer (Invitrogen, Carlsbad, USA), 2.5 mM of MgCl2, 0.3 mM each of dNTP, 0.3 mM each of primer and 1U of Platinum Taq DNA polymerase (Invitrogen). All amplification reactions were performed in a GeneAmp 2700 Thermal Cycler (Applied Biosystems, Foster City, CA, USA) programmed as follows: denaturation at +94°C for 2 min., annealing at +55°C for 30 sec and elongation at +74°C for 1 min, followed by a final extension period at +74°C for 5 min. The amplified fragments were separated by 1.5% agarose gel electrophoresis (Roche diagnostics, Milan, Italy) in 1X Tris-acetate EDTA (TAE, Invitrogen) and stained with ethidium bromide (0.1 mg/mL) for 20 min. The gels were observed and digitalised

by the Gel-Doc UV trans-illuminator (Bio-Rad, Hercules, CA, USA).

Multiplex PCR-based serogrouping Multiplex PCR-based serogrouping was carried out using the target genes lmo0737, lmo1118, ORF2819, ORF2110 and prs (Doumith et al., 2004). The multiplex PCR products were resolved by electrophoresis on 1.5% agarose gel in 1X TAE (Invitrogen) and stained with ethidium bromide (0.1 mg/mL) for 20 min. The gel images were visualised and captured using the GelDoc UV trans-illuminator (Bio-Rad).

DNA macrorestriction and pulsed-field gel electrophoresis (PFGE) Isolates were submitted to DNA macrorestriction with ApaI and AscI (New England Biolabs, Beverly, MA, USA). The separation of the restriction fragments was carried out by PFGE in a CHEF Mapper XA system (Bio-Rad) using the PFGE-PulseNet protocol (Graves and Swaminathan, 2001). Gel images were visualised and captured using the Gel-Doc UV trans-illuminator (Bio-Rad). The banding patterns for each enzyme were assigned through visual analysis of the restriction profiles. Isolates were designated genetically indistinguishable (same pulsotype) when their restriction patterns had the same number of bands and the corresponding bands were the same apparent size (Tenover et al., 1995; Graves et al., 2005). AscI and ApaI macrorestriction patterns were analysed using BioNumerics software (Applied Maths, Sint-Mar-

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tens-Platen, Belgium). The similarity between restriction patterns, based on bands position, was expressed as a Dice coefficient correlation.

The position tolerance was optimal when set at 1.0 and 2.0% for AscI and ApaI, respectively. Clustering and construction of dendrograms were performed by the Unweighted Pair Group Method using arithmetic averages (UPGMA) combining both AscI and ApaI macrorestriction patterns into one unique PFGE profile.

Quantitative assessment of in vitro biofilm formation Isolates were tested for their ability to attach to abiotic surfaces forming biofilm. The quantitative assessment of the in vitro biofilm formation was carried out on sterile 96-well polystyrene microtiter plates using the method described by Stepanovic et al. (2004), with some modifications. Isolates were grown for 24 h in 2 mL of BHI broth. All the wells of a polystyrene microtiter plate were filled with 230 μL of BHI broth. Afterwards, 21 wells per strain were filled with 20 μL of culture. Each plate included 12 wells of BHI broth without inoculum, as a negative control. Microtiter plates were incubated at +30° for 24 h. At the end of the incubation the content of the wells was removed and the microtiter plate washed three times with 300 mL of sterile, distilled water in order to remove loosely attached bacteria. The remaining attached bacteria were fixed with 250 μL of methanol per well, and after 15 min. the wells were emptied and air dried. Each well was stained with 250 μL of crystal violet for 5 min. After staining, the micro-

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titer plates were washed under running tap water, then air-dried and the dye bound to the adherent cells was solubilised with 250 μL of 33% (v/v) glacial acetic acid per well. The microtiter plates were read spectrophotometrically (OD620) using a Sunrise RC absorbance reader (Tecan, Maennedorf, Switzerland). The strains were dividedinto four categories: no biofilm producers (NP, OD=<0.5), weak producers (WP, OD= ≥0.5<1.0), moderate producers (MP, OD= ≥1.0<1.5) and strong producers (SP, OD= ≥1.5).

RESULTS Survey on the production of traditional fermented sausages in Sardinia 1. Main characteristics of the plants The four processing plants included in the survey (A, B, C, D) were representative of the regional fermented sausage production. Two of them were large (A and D > 300 tons of “Salsiccia Sarda” per year) and two were small (B and C from 50 to 100 tons of “Salsiccia Sarda” per year) processing plants.They were privately-owned and located in different provinces of Sardinia: Cagliari (plant A), Nuoro (plants B and D), and Sassari (plant C). In general, the structural requirements were conformed to the EU hygienic standards (EC Reg. 853/2004). Taking into account the date of construction (between 1991 and 1996), three plants (A, B, and D) could be defined as “new conception plants.” The plant C derived from an existing building (since 1971) adapted to the new EU

food safety requirements (in 199496).The production was organized so that the entire process was carried out on the same level in plants A and B and on two different floors in plant C and D.The total area of the plants ranged from the 600 square meters of the plant C to the 30,000 square meters of the plant D. In all the plants separate areas for receiving and cold storage of raw materials were distinctlydifferentiated (two cold rooms in plant A, six in plant B, two in plant C and five in plant E). A processing room proportionate to the amount of production was present in each plant. Only plant D was equipped with store rooms specifically designed for each technological step: two store rooms for the dripping step; ten for drying, fifteen for ripening and one room for the smoking process. Plants A, B and C were equipped with “dynamic” store rooms: through the modification of the process parameters (time / T° / ventilation / RH), different production stages were carried out in the same store room: for dripping and drying, seven store rooms were present in plant A, two in plant B and one in plant C. For ripening and smoking, three store rooms were present in plant A, two in plant B and one in plant C. All the plants were equipped with store rooms for finished products; separate areas for packaging / labelling, dispatching and a plant store.

All the plants were equipped with the main facilities for the production of meat products: work tables, trolleys, mincing, mixing and stuffing machines. In terms of processing line complexity, plants A and D showed larger and more complex equipment.

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2. Main characteristics of the production The origin of ground meat was mostly regional and national. Only in plant D, was processed ground meat of North-European origin.In general, ground meat was obtained from fresh pigs carcasses cut in half (all the plants) or from fresh commercial meat cuts (plants A, B, D). In all the plants were produced several different pork meat products (dry-cured ham, salami, fermented sausages, bacon, cured neck, loin). Other minor pork meat products (cured cheek, lard, cured salami made from leftover meat and cooked ham) were produced only in plant A and D. The “Salsiccia Sarda”, a typical semi-dry sausage (aw ranging from 0.90 to 0.95), naturally fermented and obtained from fresh pork meat of pigs aged 10/12 months and of 140/180 kg of weight, was theprimary product in all the plants, produced in the classical and smoked typology. A small amount of thin and cylindrical sausages was produced only in plant A and D. The main composition and characteristics of “Salsiccia Sarda” included: minced lean pork (87%) finely chopped in 1 cm pieces; pork back fat (8%) cut into 1 cm cubes; salt (3%); a mixture of sugars and additives (0.8%); garlic (0.15%); ground

pepper (0.25%); and a mixture of whole pepper, nutmeg, cloves,seeds of anise, fennel and pimento (0.8%).

The mixture, refrigerated overnight, was stuffed into artificial (plant D) or natural pork casings (plants A, B and C). After they were first warmed up at 20°-22° C and 55-60% RH for 4-6 h, the products were dried for six days.On the first day of drying, the products were stored at 20°22° C and 60% RH. Over the next five days of drying the temperature was gradually reduced to 15°C and RH was gradually increased to 70%.

Ripening was then carried out for a period ranging from 7 to 15 days in store rooms at 15°C and 70-75% RH. The final products were cylindrical (about 30 mm Ø), about 40-45 cm long, shaped like horseshoes, and about half a kg each in weight. In general, the consistency was hardelastic and the casing showed the typical moulds bloom. The internal dough was composed of a proper balance of fat and lean meat, coloured in dark red with the back fat cubesin evidence. Some characteristics of the plants and of the production are summarised in Table 1.

Physico-chemical analysis The mean values of pH and aw in fermented sausages at the end of

ripening were 5.32 ± 0.90 and 0.88 ± 0.03, respectively. These values were in accordance with the normal pH and aw of “Salsiccia Sarda” at the end of ripening reported by Greco et al. (2005).

Detection and enumeration of L. monocytogenes The results (Table 2) showed the presence of L. monocytogenes in all of the fermented sausage processing plants (overall prevalence in the environments: 15%). None of the samples from pork carcasses was positive for L. monocytogenes. The occurrence was 37% in ground meat and 80% in the fermented sausages. These products did show detectable levels always below 10 CFU/g, complying with the food safety criteria provided for RTE foods able to support the growth of L. monocytogenes (EFSA, 2005). According to Thenovet et al. (20062), several factors, such as the manufacturing process, the use of spices with antioxidative or antimicrobial properties, and the growth of the natural competitive microflora should significantly reduce the count of L. monocytogenes in fermented sausages. Altogether, 170 strains of Listeria spp. were isolated:

Table 1 - Some characteristics of the four Sardinian processing plants.

Plants Tons/year

A B C D

300-500 50-100 50-100 >500

Processing line complexity

Origin of the ground meat

Characteristics of the ground meat

Ripening period (fermented sausages)

+++ ++ ++ ++++

Domestic Domestic Domestic Domestic /European

Fresh Fresh Fresh Fresh

15 days 15 days 15 days 7-15 days

Processing line complexity: ++(simple equipment); +++(more equipment, more complex); ++++ (a lot of equipment, with a complex design).

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Table 2 - Listeria monocytogenes in environments, raw materials and final products of four fermented sausage processing plants.

Plants

SCM***

SWCM****

Pork carcasses

Ground meat

Fermented sausages

Positive/Total % Positive/Total % Positive/Total % Positive/Total % Positive/Total %

A S1 0/6 - 2/18 11.11 - - 2/4 50 2/2 100 B S1 2/6 33.33 4/18 22.22 - - 2/4 50 0/2 C S1* 0/10 - 6/18 33.33 - - 2/4 50 2/2 100

S2** 0/8 - 2/20 10 0/12 - - - - D S1 2/6 33 2/22 9 - - 0/4 - 4/4 100 Grand total

4/36 11.11 16/96 16.66 0/12

-

6/16 37.50 8/10 80

*S1: first sampling; **S2: repeated sampling; ***SCM: Surfaces in contact with meat; ****SWCM: Surfaces without contact with meat.

39% were L. welshimeri, 23% L. monocytogenes, 21% L. innocua, 10% L. grayi, 4% L. ivanovii, and 3% L. seeligeri. A subset of 20 L. monocytogenes isolates was selected and primarily identified by

single PCR. From each processing plant, L. monocytogenes strains were selected in order to include almost 50% of each category of positive samples. Isolates were further characterised by multiplex

PCR-based serogrouping, PFGE and in vitro biofilm formation. A summary of the phenotypic and genotypic characteristics of the 20 L. monocytogenes isolates is reported in Table 3.

Table 3 - Distribution of 20 Listeria monocytogenes isolates in the four processing plants, in relation to serotype, pulsotype, PFGE profile and in vitro biofilm production.

Plant and source of contamination

Strain code

Serotype

Pulsotypes

PFGE profile

Biofilm production

AscI ApaI A Ground meat store room: floor drains Ground meat Fermented Sausage

A1 A2 A3

4b 4b 1/2b

I II III

I II III

9 11 13

NP MP NP

B

Ground meat store room: floor drains Ground meat store room: floor drains Ground meat Drying room: floor drains Drying room: floor drains Ripening room: hooks Ripening room: hooks

B1 B2 B3 B4 B5 B6 B7

1/2b 1/2b 1/2b 1/2b 1/2b 1/2b 1/2b

IV IV V V VI VII VII

IV IV V V VI VII VII

4 4 2 2 7 1 1

MP NP WP WP NP WP WP

C

Drying room: floor drains Ground meat Fermented sausage Shipment room: floor drains Ripening room: floor drains Ripening room: floor drains

C1 C2 C3 C4 C5 C5bis

1/2b 1/2b 1/2b 1/2b 1/2b 1/2b

VIII IX IX X X X

VIII IX IX X X X

12 5 5 8 8 8

NP WP NP WP NP MP

D

Fermented sausage Fermented sausage Processing room: work tables Processing room: floor drains

D1 D2 D3 D4

1/2a 1/2a 1/2a 1/2a

XI XII XIII XIV

XI XII XIII n.t.*

6 3 10 n.t.*

WP WP WP NP

*n.t.:not typeable; NP: no biofilm producers; WP: weak producers; MP: moderate producer.

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Molecular identification and characterisation Single PCR-based identification The amplification product of 274bp was found in all the strains phenotypically identified as L. monocytogenes.

The amplification products always exhibited the same electrophoretic pattern. These results confirm that the prfAgene is a reliable target gene for identification of the pathogen (Vazquez-Boland et al., 2001).

Multiplex PCR-based serogrouping The prevalent serotype was 1/2b (70%), followed by 1/2a (20%) and 4b (10%). No specific serotype was recovered during the processing and ripening of the sausages (Thenovet et al., 2005).

DNA macrorestriction and pulsedfield gel electrophoresis (PFGE) A high heterogeneity of pulsotypes (14 with AscI and 13 with ApaI) oc-

curred within the plants (Table 3).

Restriction patterns were combined in 13 PFGE profiles appearing to be plant-specific. One strain from plant D was typeable only with AscI (pulsotype XIV) and consequently was not assigned to any PFGE profile. Within each processing plant, particularly in the two large ones (A and D), a high heterogeneity distribution of PFGE profiles was observed. The presence of PFGE profile five both in ground meat and in the fermented sausages, may evidence the ability of specific strains of L. monocytogenes to survive during “Salsiccia Sarda” fermentation.

Furthermore, the recovery of PFGE profile eight in floor drains from different rooms in both samplings (S1 and S2) showed the ability of the pathogen to adapt and persist in the different processing environments of plant C. The PFGE profiles were allotted into three major PFGE clusters (similarity ≥ 70%) labelled A-B-C (Table 4 and Fig. 1).Cluster A included 9 isolates of serotype 1/2b (8) and 1/2a (1) from three process-

Fig. 1 - UPGMA clustering of the19 Listeria monocytogenes PFGE profiles.

Table 4 - Clustering of 18 Listeria monocytogenes strains.

Cluster

Overall similarity

PFGE profile

No. of isolates

Serotype

Source of contamination in the plants

A 73.3%

1 2 3 4 5

2 2 1 2 2

1/2b 1/2b 1/2a 1/2b 1/2b

Hooks in the ripening room Ground meat and floor drains in the drying room Fermented sausage Floor drains in the store room Ground meat and Fermented sausage

B 77.3%

6 7 8 9 10 11

1 1 3 1 1 1

1/2a 1/2b 1/2b 4b 1/2a 4b

Fermented sausage Floor drains in the drying room Floor drains in the shipping room (1) and ripening room (2) Floor drains in the store room Work tables in the processing room Ground meat

C

12

1

1/2b

Floor drains in the drying room

74.4%

Italian Food & Beverage Technoloy - LXXIV (2013) november -

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SAUSAGE

ing plants (B-C-D). Cluster B included 6 isolates belonging to different serotypes: 1/2a (1), 1/2b (4) and 4b (1) from all of the processing plants (A-B-C-D). Cluster C included three isolates of serotype 1/2a, 1/2b, and 4b from plants A-C-D. One strain (A3) of serotype 1/2b isolated from fermented sausage was an outlier, showing low similarity (47%) with the other clusters.

Quantitative assessment of in vitro biofilm formation More than half (60%) of the strains previously identified and characterised by molecular methods were able to attach to abiotic surfaces forming biofilm. The results of this experiment are shown in Table 3 and Fig. 2. Serotypes 1/2a and 1/2b showed weak OD (OD=≥0.5<1.0) or moderate OD (OD=≥1.0<1.5) ability in biofilm formation. The microtiter plate assay is a useful method to assess the ability of L. monocytogenes strains to attach to abiotic surfaces (Stepanovic et al., 2004).

DISCUSSION AND CONCLUSION In this study, the contamination of four “Salsiccia Sarda” processing plants representative of Sardinian fermented sausage production was investigated on samples from surfaces (with and without contact with meat), ground meat and fermented sausages. Our results show the overall presence of L. monocytogenes in environmental niches, raw materials and final products. L. monocytogenes was not detected in the pork carcasses

26 - Italian Food & Beverage Technoloy - LXXIV (2013) november

prior to processing: contamination of the final products appears to be due to strains already present in the processing environments (Lopez et al., 2005), with all of the facilities serving as the source of product contamination (Chasseignaux et al., 2002). In the Sardinian processing plants and their products, L. monocytogenes serotype 1/2b predominated, followed by serotypes 1/2a and 4b. Previous studies have also reported the presence of these serotypes in meat processing environments (Chasseignaux et al., 2001; Thenovet et al., 20061). The recovery of serotypes frequently associated with epidemic or sporadic cases of listeriosi (McLauchlin et al., 2004) is an interesting result in terms of public health protection.

Previous surveys have shown that lineage I strains of serotype 4b belonging to a clonal group (DUP-ID 1038) linked to several listeriosis outbreaks (De Cesare et al., 2001) were recently recovered in the same meat products (Meloni et al., 2009). It must be emphasised that the presence of such strains in the processing plants, and as a consequence in fermented sausages, mayrepresent a hazard if the pathogen is able to multiply during the ripening of the product and reach levels higher than 1,000 CFU/g (Ross et al., 2002; Thenovet et al., 2006 1). Thirteen different PFGE profiles were obtained indicating a great level of diversity among the strains collected from the Sardinian processing plants and their products. The high number of PFGE profiles and their heterogeneous distribution within the plants is in agreement with the results of previous surveys carried out in meat

processing plants (Thenovet et al., 20061). Such subtypes appear to be unique to each processing plant (Fugett et al., 2007). These results may be due to the limited number of isolates included in this study or to the great diversity of the L. monocytogenes strains collected from ground meat, but also to the quantities used by each plant. The large plants exhibited the highest PFGE profile heterogeneity, since these plants also used the greatest amount of raw meat from several different sources (domestic and Eu-

Fig. 2 - Biofilm production of the Listeria monocytogenes strains.

SAUSAGE

ropean). Numerical analysis of the PFGE profiles showed that the isolates included in the study could be allotted into three major PFGE clusters labelled A-B-C. Contrary to all expectations, these three genomic divisions were not linked with the flagellar antigen type, in spite of what was described by several authors (Chasseignaux et al., 2001; Autio et al., 2003; Thenovet et al., 20061). In this study, L. monocytogenes strains were thought to be persistent when the same PFGE profile occurred in samples collected from the same plant equipment C after an interval of three months: such strains were found in several floor drains. The persistence of the same PFGE profile (eight) is probably due to two interacting factors.

First of all, the nature of the strains themselves, which have a moderate ability to form biofilms and have adapted to environments where meat is processed. Several authors have shown that certain L. monocytogenes strains were more capable of causing persistent contamination of meat processing plants than others (Autio et al., 2003; Thenovet et al., 20061) probably due to their ability to form biofilms. The second factor affecting persistence may be the presence of ineffective cleaning and disinfection measures. Treatments need to reach the contamination site in sufficient quantities and duration in order to be effective (Thenovet et al., 20061). This may not always occur with routine cleaning procedures because of the complexity of the processing line structure and because environmental niches, such as floor drains can be a site critical for controlling contamination of the processing plant

environment and food products (Tompkin, 2002). Decontaminating floor drains is especially challenging because, when entrapped in a biofilm, L. monocytogenes is afforded unusual protection against available disinfectants and treatments (Zhao et al., 2004). L. monocytogenes strains can become well established in the floor drains and persist as resident microbial flora for up to several years. This study has shown the presence of adapted L. monocytogenes strains able to survive during sausage fermentation, overcoming the current hurdles of the “Salsiccia Sarda” manufacturing process. Our results highlighted that L. monocytogenes is able to survive in meat processing plants by forming biofilms on abiotic surfaces. The surface used for the in vitro experiment (polystyrene) approximately mimics the plastic material used in the plants (e.g., conveyor belts). Further testing with appropriate steel specimens of each plant is needed in order to understand better the mechanism of biofilm formation in vivo. To decrease the presence of L. monocytogenes in the traditional fermented sausages at the end of ripening, food business operators should adhere to accurate application of hurdle technologies. Products can also become contaminated through contact with work surfaces and equipment, even after routine cleaning and disinfecting operations (Thenovet et al., 20061). More attention should be focused on respectinggood manufacturing practices and the application of HACCP principles. da Italian Journal of Food Science No. 3, 2012

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The effect of food structure on satiety

A study by Mackie et al. (published in the American Journal of Physiology: Gastrointestinal and Liver Physiology) has investigated the effect food structure has on satiety, examining the role of gastric retention and nutrient sensing as indicated

by CCK, a hormone excreted in the gastrointestinal (GI) tract.

The scientists prepared two meals. The first meal, a homogeneous liquid meal, was the control and comprised an emulsion of 27.5 g sunflower oil, 243 g of 1.2% sodium caseinate solution blend-

ed together and added to a 200 g solution containing 1.24% sodium caseinate and 10% whey protein isolate, 6.1 g of sugar and vanilla flavouring.

The second meal, referred to as the â&#x20AC;&#x153;Active mealâ&#x20AC;? (a mixture of solid/liquid food), was prepared by mixing 88 g of grated Gouda cheese with 73 g of low fat yogurt, served with 339 mL of bottled water. The sodium content of the Active meal was 64 mM whereas the control meal was 20 mM; however the meals contained the same number of cal-

30 - Italian Food & Beverage Technology - LXXIV (2013) november

ories (67% from fat, 27% from protein, and 6% from carbohydrates).

The meals were fed to 10 healthy male volunteers aged between 20 and 50 with a BMI between 19 and 30, on separate days in a crossover study.

The researchers assessed subjective appetite ratings, gastric contents using an MRI scanner and plasma CCK over a period of three hours.

The Active meal reduced hunger, eliciting a higher fullness score compared to the control meal. Up to about 50 minutes after ingestion, emptying rates of the control meal were more than twice of that for the Active meal and plasma CCK levels were higher. However after this hour both gastric emptying and plasma CCK levels were found to be similar.

Mackie et al. report that the Active meal was constructed to provide a sed-

imenting system, where the food in the stomach separates into two layers.

The upper layer is the energy-poor liquid and the other one being viscous energy-rich sediment.

The sediment enters the small intestine first, keeping the energy-poor layer on top. This increases the satiating effect as the volume of the stomach stays larger for a longer period of time, and the small intestine signals an influx of high-energy food. The detection of fat in the duodenum can significantly reduce hunger, increase fullness and delay gastric emptying.

The scientists conclude that appetite was correlated with volume of the gastric contents rather than gastric emptying rates or plasma CCK; they state that this indicates that gastric retention is a key factor in reducing appetite.

Rssl.com

Broader scope may enhance UV screening of navel oranges Sweet, juicy navel oranges owe much of their high quality to the behind-thescenes work of growers, packers, shippers, retailers, and researchers.

The scientists Obenland and Smilanick by U.S. Department of Agriculture (USDA) develop and conduct research at Parlier laboratories in order to determine how to better protect the freshness, flavor, and other qualities of citrus, table grapes, and other highly perishable fruits throughout packing, shipping, and storage.

In one study, published in 2010 in the journal HortTechnology, Obenland, Smilanick and their colleagues investigated UV (ultraviolet) screening and sorting of oranges. According to Obenland, California packinghouses have used UV screening for more than 50 years to detect spots - about the size of a quarter, or larger - that glow a bright fluorescent yellow when navel oranges are viewed under UV light.

Packinghouse workers know to promptly cull any oranges that have this distinctive “fluorescence signature” on the peel. That’s because the spots, more likely than not, are telltale

indicators of the presence of Penicillium microbes that cause blue mold or green mold.

But other, less-studied patterns of fluorescence on navel orange peels may warrant more attention.

Fluorescence in the form of specks, smears, smudges or blotches, for instance, may indicate the presence of cuts, punctures or other peel wounds that may pave the way to attack by decay microbes.

To learn more about these less familiar patterns, the researchers sampled about 5,000 navel oranges over a 2-year period. Oranges were sorted by fluores-

cence level-zero, sparse, moderate or high-noted during UV screening; in addition, the oranges were evaluated under normal light - not UV - within 24 hours after UV screening and after the fruit had been stored at 59 degrees Fahrenheit for three weeks. As expected, fruit with high fluorescence developed further decay and peel-quality problems during storage, but so did many of the oranges that had only moderate fluorescence.

Taken as a whole, the findings suggest that packers who are not already doing so might want to expand

UV screening to take several fluorescence levels and patterns into account when sorting navel oranges.

The idea of expanding UV use to include more than detection of the classic decay signature is not new.

But the Parlier study, though preliminary, is likely the first to present as detailed a look at this approach. www.ars.org

Impact of the shape on sensory properties of chocolate pieces The sensory characteristics of dark chocolate have been studied for many years and to date; its oral perception has been modulated only by playing on conventional factors (e.g. processing, particles size, ingredients or recipe).

Researchers from Nestle Research Center of Lausanne (Switzerland) carried

out a study aims at enhancing the in-mouth perception of chocolate based on the shape of the chocolate piece introduced in the mouth. The results were published on LWT – Food Science and Technology.

Ten chocolate shapes with the same recipe were moulded into designs based on the palate

geometry of young adult women. Sensory test conditions were restricted so that trained subjects did not bite into the chocolate shapes during the evaluation. Texture and flavour properties of the different shapes were measured through monadic profiling. Further, time–intensity was used to characterise

Italian Food & Beverage Technology - LXXIV (2013) november -

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the potential link between cocoa perception and the perceived melting.

Sensory profiling highlighted significant differences among the shapes on the characteristics of melting, smoothness and smaller but significant differences on cocoa, caramel and aftertaste. Melting perception was not correlated with flavour intensity.

The time–intensity measurements performed on cocoa intensity confirmed the differences observed with monadic profiling. Thus,

the shape of dark chocolate pieces does impact texture and flavour perceptions. In addition, contra-

ry to the initial hypothesis, in-mouth melting is not the sole factor influencing the cocoa flavour intensity.

Olive-oil milling leftovers scrutinized in new ARS studies For every gallon of olive oil that’s pressed from the ripe fruit, about 38 pounds of olive skins, pulp and pits are left behind. Known as pomace, these leftovers typically have low-value uses. But Rebecca R. Milczarek, U.S. Department of Agriculture (USDA) agricultural engineer, and her colleagues are working with olive growers and olive-oil processors in California, where most of the nation’s commercial olives are grown, in order to find new, environmentally friendly, and profitable uses for pomace.

According to ­ Milczarek,

pomace from California mills is usually a wet, heavy goulash that ranges in colour from green to brown to black to purple, and has an aroma somewhat like that of olive tapenade, a flavourful spread made of finely chopped or puréed olives, anchovies, capers, garlic, and olive oil.

Milczarek notes that one key to creating higher-value uses for pomace is to develop techniques that millers can use to quickly and affordably dry it onsite. That would make the pomace lighter, and easier and less expensive to

32 - Italian Food & Beverage Technology - LXXIV (2013) november

ship to, for example, a centralized processing plant.

There, specialized equipment could be used to extract additional oil or perhaps compounds for use in new foods, pharmaceuticals, cosmetics or other products.

In her research, Milczarek is investigating the dynamics of drying pomace. The goal of these studies is to determine precisely how long it would take for water to diffuse from the pomace under specific conditions.

In preliminary experiments, Milczarek’s team dried small batches of fresh pomace, using a combi-

nation of microwave and convection (hot forced air) heating; the drying rates for the 4 internal temperatures studied (104, 122, 140, and 158 degrees Fahrenheit) averaged about 28% lower than those reported in some studies conducted by other scientists.

The bottom line? Lower drying rates mean more drying time is needed in order for the pomace to dry sufficiently.

What can olive mills do about that? For commercial drying, pomace would be carried on a conveyor belt through a “drying tunnel.”

With the drying rates in mind, the tunnel could be lengthened, or the conveyor belt could be slowed, to ensure that pomace emerging from the tunnel isn’t damp and prone to mold.

Of course, drying adds to

mill energy costs. However, the combination of microwave and convection drying that Milczarek tested is inherently more energy-efficient than drying options that are based solely

on convection, she points out.

The two features of Milczarek’s study, keeping the pomace’s internal temperature steady when testing each temperature regimen

and taking pomace shrinkage into account, likely made the research unique among olive-pomace-drying experiments and contributed to the accuracy of her results.

What effect of polydextrose on satiety and energy intake?

Studies have reported that polydextrose can reduce food intake but the optimal dose required to achieve this effect is currently unknown.

Nerys Astbury et al., from the University of Nottingham (UK), investigated the effects of consuming a range of doses of polydex-

trose on appetite and energy intake (EI) using a randomised within-subject, cross-over design and today publish their findings

in the British Journal of Nutrition.

Twenty-one participants (12 men, 9 women) consumed an 837 kJ liquid preload containing 0 g (control), 6·3, 12·5 or 25 g polydextrose; subjective appetite ratings were collected using visual ana-

Italian Food & Beverage Technology - LXXIV (2013) november -

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logue scales and an ad libitum test meal was served 90 min later. Participants recorded EI for the remainder of the day in a food diary.

Test meal EI following the control preload (5756 (sem 423) kJ) was significantly higher than following the 6·3 g (5048 (sem 384) kJ), 12·5 g (4722 (sem 384) kJ) and 25 g (4362 (sem 316) kJ) preloads (P< 0·05),

and EI following the 6·3 g preload was significantly higher than following the 25 g preload (P< 0·01).

There were no differences in self-reported EI during the remainder of the day between the preloads containing the varying doses of polydextrose; total EI (breakfast+preload+ad libitum test meal+remainder of the day) was significantly higher when the con-

trol preload was consumed (12051 (sem 805) kJ) compared with either the 12·5 g (10854 (sem 589) kJ) or 25 g (10658 (sem 506) kJ) preload (P< 0·05). These differences in EI were not accompanied by corresponding differences in subjective appetite ratings.

In conclusion, polydextrose effectively reduces subsequent EI in a dose-dependent manner.

Functional foods based on fruit and vegetable residue flour Fruits and vegetables are extensively processed and the residues are often discarded; however, due to their rich composition, they could be used to minimize food waste.

Mariana S.L. Ferreira et al. from the Federal University of Rio de Janeiro (Brazil) have published a study in Journal of Food Science Technology aimed to develop food products based on the solid residue gener-

ated from the manufacture of an isotonic beverage.

This beverage was produced based on integral exploitation of several fruits and vegetables: orange, passion fruit, watermelon, lettuce, courgette, carrot, spinach, mint, taro, cucumber, and rocket. The remaining residue was processed into flour and its functional properties were evaluated. The fruit and vegetable residue (FVR) flour was incorporated with different levels (20 to 35%) into biscuits and cereal bars. The proximate composition, microbiological stability until 90 days and consumer acceptance were analyzed. The FVR flour presented a higher water holding capacity

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than oil holding capacity, respectively 7.43 and 1.91 g g−1 of flour, probably associated with its high levels of carbohydrates (53%) and fibres (21.5%). Bis-

cuits enriched with 35% of FVR flour presented significantly higher fibre, ranging from 57 to 118% and mineral contents, from 25 to 37% than when only 20% was added. Cereal bars presented about 75% of fibres and variable mineral contents between 14 and 37%. The incorporation of FVR did not change the fat content.

The microbiological examinations are within acceptable limits according to international regulation. The incorporation of FVR flour did not impair consumer acceptance, the sensory attributes averaged around 6. The chemical, microbiological and sensorial results of the designed products attested for an alternative towards applying and reducing agro-industrial wastes.

French fries oil content: lower with infrared heat French fries typically soak up a lot of oil while they’re in the deep-fat fryer. But U.S. Department of Agriculture (USDA) scientist Zhongli Pan and his colleagues have shown that prepping the raw fries for three minutes with infrared (IR) heat, before the fries are dunked in the fryer, can

reduce oil uptake by about one-third, as compared to raw fries not treated with IR. Pan’s team made hundreds of fries – about 20 pounds in all – to determine the combination of IR heating times and intensities, and deep-frying times and temperatures, that would yield

appetizing fries with less oil.

Of the 77 volunteer taste-testers who sampled the fries, more than half said they found the taste and color of the IRprepped fries to be no different from that of conventionally prepared fries.

More than half of the panelists said they preferred the IR fries’ crunchier texture, according to Pan. The IR unit that his group

experimented with heated just the top and the bottom of the fries. Pan noted that an IR unit that heats all surfaces of the fries might lower the fries’ fat content even further than the 37.1% reduction that the team achieved.

Pan also noted that although the group’s published data was based on experiments with fresh fries, IR prep is also suitable for fries that are partial-

ly processed at potato processing plants. After partial processing, the fries are frozen and then shipped for later “finish frying” at restaurants, cafeterias or other eateries.

The idea of prepping fries to help reduce oil uptake isn’t new, but the experiments that Pan led are apparently the first to extensively explore IR as a prepping option for fresh or partially processed French fries.

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food PROCESSING Radio frequency applications for the food industry: defrosting

The traditional defrosting methods introduce a number of difficulties directly related to the heat transfer mechanisms such as slow process (hours, sometimes days), bacteria growth in the product, high drip loss (economic loss), deterioration of the product surface, and batch processing (high handling costs, risk of breakage, bruising and other damage to the product due to such handling).

But now the product surface deterioration and other drawbacks attributed to conventional defrosting methods can be avoided, thanks to the ability of radio frequency (RF) defrosting to rapidly generate heat volumetrically within the product.

Established in 1978, Stalam is a world leader in the development of radio frequency (RF) equipment with different applications. In the last decade, many innovative applica-

tions of radio frequency technology in the food industry were introduced for the first time on a truly industrial scale, such as the quick defrosting of frozen fish, meat and other raw or processed food products.

The heating process is uniform and controlled, thus resulting in a significant reduction of drip losses. It also offers great flexibility in the production schedules and is the ideal solution for many tempering, softening and thawing processes.

The product is placed on the conveyor belt and is transferred by means of the RF unit (tunnel) passing between upper and lower metallic plates (electrodes).

When the RF generator applies high frequency alternating voltage between these plates, the dipolar water molecules of the frozen product will vibrate and rotate in the attempt to align themselves accord-

36 - Italian Food & Beverage Technology - LXXIV (2013) november

ing to the fast changing opposite plate polarities.

This phenomenon causes intermolecular friction, which will in turn generate heat rapidly and uniformly within the whole product mass regardless of its size, weight, shape, and thermal conductivity.

The amount of heat generated inside the product and the defrosting time are accurately controlled through the voltage applied on the electrode plates and the speed of the conveyor belt.

The RF defrosting offers sev-

RF defrosting tunnel (Stalam).

eral advantages. First, time saving. In fact, defrosting is achieved in minutes rather than hours or days, even for large product blocks and, if necessary, directly inside packaging used for storage (carton boxes, polyethylene bags, etc.). The processing speed and uniformity minimise product degradation. Neither drip loss nor any deterioration of the physical and organoleptic properties occur, and the growth of bacteria is reduced, thus preserving the best quality of the product.

Radio frequency defrosting can be carried out continuously, with significant logistical advantages in product handling and production scheduling. The production can be organised according to “just-intime” criteria and this is a great advantage in case of sudden orders, last-minute changes in the order under processing, etc.

Finally, the radio frequency equipment requires much less floor space compared to traditional ones such as large defrosting rooms or equipment. Overall processing costs can also be reduced drastically compared to conventional techniques.

The RF machine works a at a radio frequency of 27,12 MHz and production capacities can vary depending on the type of product to be defrosted and the final temperature required. Made of Aisi 304 and 316 stainless steel submitted to anti-corrosion treatments (passivation, pickling) and shot-peening finish, it is characterized by a modular construction; Stalam RF defrosters are available in module sizes from 3 to 105 kW and multiple modules can be combined to increase the production capacity.

The external protection boxes of the RF generator are made of insulating sandwich-type panels with sheeting and bearing frame

in Aisi 304 stainless steel, thus ensuring IP65 protection level. The wide conveyor belt (up to 180 cm) is made of certified foodgrade rigid polyethylene modules or solid-surface reinforced polyester, depending on the product to be processed. A builtin conveyor belt, tunnel washing facilities and full

internal access for cleaning through the multiple side panel doors, and a PLC control system for multiple product recipes complete the list of the specific features of the RF machine.

(Stalam - Via dell’Olmo 7 Z.I. 36055 Nove - VI - Italy - Tel. + 39 0424 597400 - Fax +39 0424 590722 email: stalam@stalam.com)

Multifunction vacuum plant with rotating coil Established in 1998, today Labs is present worldwide and especially in Europe, Africa, Eastern Countries, the Middle East and South America. The company develops plants and complete lines for the receiving, washing, processing and transformation, pasteurization and preservation of fruit, tomatoes and vegetables. After 10 years of investment and diversification, Labs proposes a range of plants and complete lines (also turn-key) for fruit, tomato and vegetable processing for the production of preserved food.

It supplies machines and complete plants for products processed from fresh or semi-finished product such as jams and marmalades, fruit juices and nectars, and soft drinks, fruit pulps, purees and concentrates, hot-

break and cold-break tomato paste, tomato pulps and passata, baby food and homogenized, red pepper paste, special products, and preserves in general.

In addition, Labs also develops pasteurization, cooling and conveying lines for different kinds of packaged products such as tinplate and aluminium cans, glass and plastic jars, glass, PET and HOPE bottles, “gable-top” carton briks, and pouches, bags, and doypacks.

Thanks to its efficient technical and engineering department which works with 3D engineering technology, Labs can offer highly customized machines and plants following specific customer requirements.

The company presents the multifunction vacuum plant with rotating coil

mod. Revolution. These types of installations are conceived for the production of jams, marmalades, sauces, tomato sauces and preserved products according to recipes in which fruit, tomatoes and vegetables are the main ingredients. The particular and delicate heating and mixing system of the product with rotating serpentine makes the installation particularly suitable for processing products in pieces and whole fruit.

The installation can carry out the different functions of low temperature evaporation, cooking, mixing, recipe preparation and formulation, and finally defrosting.

The keywords which characterize the Revolution systems despite the traditional ones are efficiency, quality, integrity, and flexibility.

The heating system with rotating coil has higher efficiency and a larger exchange surface than the external traditional double jacket. This makes it possible to increase the evaporation capacity and decrease the work cycles and batch time.

The high-vacuum system and the efficiency of the rotating coil avoid product burning and grant an homogenous mixing and low temperature evaporation.

The particular configura-

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tion and delicacy of the rotating coil system make it possible to produce jams or semi-finished products in pieces or with whole fruit granting the entirety of the final product.

Regard flexibility, the Revolution system is installed

on a “mono-skid” structure reducing the overall dimensions for easier installation and connection.

(Labs - Via Follerau 12 43122 Parma - Italy - Tel. +39 0521 775191 - Fax +39 0521 778205 - email: info@labs-srl.it)

Vertical mixers The Gimat vertical mixers are characterized by a conical body with a unique vertical axis mixing helicoid. The rotation of the helicoid creates four cross flows, three forced and one created by gravity. An upward forced flow of product on the peripheral portion of the mixing chamber and a descending one by gravity in the center. An upward forced flow of product in the center of the mixing

Gimat vertical mixer.

chamber, from the bottom valve to the middle height of the mixer, and a descending forced flow of product, still in the center of the mixing chamber, from the top to the middle height. With these technical solutions, the mixing occurs in a faster and more homogenous way compared to common vertical mixers, in particular in the center of the mixing chamber.

The mixing is gentle and without overheating the mixed product. Furthermore, the low speed peripherals make these mixers particularly suitable for applications in hazardous areas in accordance with ATEX regulations. The rotation of the mixing shaft is carried out by means of a gearmotor with right-angled axles that ensure a high output of the entire kinematic chain and quiet operating.

Compared to common vertical mixers, vertical mixers developed by Gimat have the support of the mixing

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shaft which is separated by the gearmotor allowing to change the latter without disassembling the mixing shaft, thus reducing maintenance time and costs.

The mixing shaft is supported and centred only on the top of the mixer thanks to a ribbed die-cast food grade aluminium frame that comprises two conveniently separate large ball bearings. This solution cre-

ates an effective joint for the mixing shaft.

The particular shape of the conical mixer body allows a high quality of interior finish and an ease of cleaning through its wide hatch.

(Gimat - Via dell’Artigianato 1 - 17 loc. Ponte Rizzoli - 40064 Ozzano dell’Emilia - BO - Italy - Tel. +39 051 799573 - Fax +39 051 798260 - email: info@ gimat.bo.it)

Cooking ovens with counterpressure Verinox presents the new J/ HP UN series oven generation, suitable for dry cooking, drying and roasting, for standard steam cooking, steam cooking with counterpressure up to 0.5 bar, and finally for high temperature pasteurization with counterpressure up to 108°C.

The exceptional rapidity and uniformity of heating up to 180°C is guaranteed thanks to particular high thermal efficiency impellers made of stainless steel Aisi 304 and special electrical resistors.

The possibility to perform phases with a room in counter pressure, with or

J/HP UN series cooking ovens (Verinox).

without forced ventilation, also allows to obtain very high cooking and pasteurization levels that cannot be reached with traditional ovens, and also an increase in thermal efficiency, a reduction of losses and energy consumption and cooking time, maximum uniformity and efficiency of the heat treatment.

The control of the working cycles is performed by VISIO, an innovative type touch-control.

(Verinox - Via Fricca 37 - 38049 Vigolo Vattaro TN - Italy - Tel. +39 0461 845500 - Fax +39 0461 845555 - email: info@ verinox.it)

Food processing equipment For 40 years, Firex has been a leading company in the development of machines for the food industry and catering equipment. The company presents highly automated innovative cooking systems that allows savings in terms of energy and resources.

Automatic features, ease of use and a wide range of versions are the characterizing features of the Firex offer. The company selects the best raw materials and constantly checks all phases of production through a certified quality system.

For example, High-P is a vacuum cooker with knife and mixer, designed to rapidly transform raw materials at low temperatures; it

The High-P vacuum cooker by Firex.

is suitable for producing jams, sauces, jellies, ice creams, and custards.

(Firex - Z.I. Gresal 28 32036 Sedico - BL - Italy - Tel. +39 0437 852700 - Fax +39 0437 852858 email: firex@firex.it)

MEAT PROCESSING Innovative raw ham production technology Inox Meccanica presents the exclusive technology “Fiore Crudo” which is developed for the production of a good foreign raw ham salted in the traditional way with a cost saving of production of approximately 1 – 1.5 euro per kg.

This remarkable saving can be reached with a method/ system developed by Inox Meccanica R&D that allows an easy production process to be obtained. In this way it is possible to shorten the seasoning time from 6/8 months for the traditional salted ham to 90/100 days for the “Fiore Crudo”.

The fresh gammon is deboned with a particular method and also during this phase a saving in labour is evident compared to the deboning of seasoned ham and it is also possible to recover fat, pigskin, shin-bone, and mince.

Deboned gammons are put into a special tumbler by Inox Meccanica that carries out a quick and homogeneous salting phase of the product and allows to decrease the water presence

inside the product just after the first 48 hours from the very beginning of the salting cycle, thanks to a particular massaging step and to the patented system of Osmotic Extraction developed by the company. In this way a virtuous process will start and will allow the product to be processed in a better microbe stability during the next phase of drying and seasoning. This water will be automatically discharged thanks to another patented system from Inox Meccanica.

After this step, every single gammon is formed and stuffed firstly into a casing and then into an elas-

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tic netting thanks to a special Inox Meccanica machine for forming and stuffing thus guaranteeing a well compact and formed product.

Then products are put into a special grate that will press every single ham for approx. 8 weeks. After the drying and seasoning steps, 3 months have passed from deboning with a total loss of weight of approx. 34/38% compared

to fresh gammon. Finally, thanks to an easy and appropriate press it is possible to form the two heads of every single ham and “Fiore Crudo” ham will have the final “tile” shape ready to be sliced.

(Inox Meccanica - Strada Solarolo 20/B-C-D 46040 Solarolo di Goito - Mantova - Italy - Tel. +39 0376 608282 - Fax +39 0376 608180 - email: info@inoxmeccanica.it)

Horizontal slicers Grasselli presents the KSL horizontal slicer which cuts parallel slices perfectly using the Grasselli multi-blade cutting system.

The KSL has a cutting capacity of over 2,000 kg/hour for

fresh meat or cooked boneless meat and an adjustable operating speed of ±40%.

The cutting speed, cutting chamber height and product control pressure are all adjustable. The control system of the product during the cut is fully adjustable even for delicate products, including the option “through slicing” for the return of 100%. A variety of blade profiles are available for a wide range of applications and multiple feed belt surface texture options enable the KSL to be customized to specific products.

All major mechanical components are made of ex-

tra high-grade heat-treated steel and the modern design with seamless welding and radius edges allow an efficient sanitation.

The Dual Lane version with two independently adjustable cutting lanes is available upon request with 6 mm minimum slicing pitch and also a â&#x20AC;&#x153;butterflyâ&#x20AC;? cutting option.

KSL ZERO-T improves to its best the KSL standards in terms of performance and efficiency. The best performance of cutting regardless to a set of cut and installed on the type of product being processed is highlighted by its system of downward pressure based on the number of slices required without any waste. By means of a touch-screen, it is possible to easily adjust the speed of the tapes, the cutting parameters and all other mechanical and electronic set-

KSL horizontal slicer (Grasselli).

tings in a completely automatic way.

KSL ZERO-T means the fastest ROI for such a kind of machine according to the average of the recovered trims and the market price of the product. Payback is guaranteed in a few months, no later than one year when working, on average, shifts of 8 hours per day.

(Grasselli - Via S. Dâ&#x20AC;&#x2122;Acquisto 2/c - 42020 Albinea - RE Italy - Tel. +39 0522 599745 - Fax +39 0522 598147 email: info@grasselli.com)

Plates and knives set for sausage production Velati presents a real innovation to optimize costs and to ensure the quality and safety of meat for the producers of mortadella, salami, and sausage. The innovation is called Evocut and it is a set of plates and knives, covered worldwide by various patents, already experienced, and able to revolu-

tionize the food industry for its important characteristics.

Every sausage manufacturer knows the importance of the replacement of plates and knives to assure an efficient processing of the meat. The importance of their maintenance is not limited to efficiency, but it is also extended to the

quality of the grinding and of the final product, due to a lesser wear.

Today manufacturers, in addition to the cost of the plates and knives, which must often be replaced according to the type of processing, also incur the ordinary maintenance costs and the consequent down time of the machine.

Therefore in recent years, knowing about the importance of this operation, but also the waste of resources and hours of maintenance, Velati Research and Development team started looking for materials able to guarantee longer durability and lower maintenance of plates and knives, in order to reduce ordinary operations costs substantially. From this research Evocut was born.

Evocut is an unbeatable kit in terms of performance, because it has a currently tested durability of up to 6 years and it is composed of a maximum of 5 plates and 5 knives in the case of mortadella production, or of a knife and a plate, in the

case of salami production.

It is made of an innovative steel material for the food industry with a high level of hardness and strength, a very low coefficient of friction and a high resistance to wear and corrosion.

Thanks to these features, Evocut is employed in industrial production (10/12 ton/h) extending its performance in a time not to be compared with any other product currently on the market, revolutionizing the technology of grinding in the industrial process.

Evocut is a patented system that every producer should have in order to guarantee productivity and the quality of the final product in full compliance with the current regulations.

(Velati - Via Trento 2 20067 Tribiano - MI - Italy - Tel. 02 9064717 - Fax 02 90630808)

Evocut set of plates and knives for mortadella, salami, and sausage production (Velati).

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Automatic press for ham and bacon Menozzi presents the automatic press suitable for Parma ham or speck and bacon in a rectangular or traditional shape.

The same machine allows the production both of rectangular hams to be sliced and traditional hams to be sold whole because the same machine can be equipped with two or more independent pressing stations, both with a rectangular or traditional shape.

As regards the rectangular shaped mould, height

and width of the product, these are given by the customer when ordering. The height and width of the form are fixed so as to always get the same slice, while the length is given by the weight of the product to be pressed. The product can be discharged directly in the envelopes for freezing or free, according to specific production requirements.

(Menozzi Luigi & C. - Via Roma 24/A - 42020 Albinea - RE - Italy - Tel. 052235471 - Fax 0522599743)

Clippers The IC 18/15 is the new clipper developed by International Clip. It has been created for working the 18 and 15 series clip, maintaining the maximum reliability and simplicity in usage of the DKU 18/15 with several new features.

In particular, a new design and frame in stainless steel, a display in stainless steel certified FDA(IP69K), electric board isolated in an extractable stainless steel box and finally a new modular conveyor belt (certified

FDA) with pneumatic or electric motor.

The IC 18/15 clipper can be equipped with many additional accessories such as the loop inserter, string dispenser, pneumatic casing brake, cutting tube (for cooked hams), airless slagfill (for products in moulds) and many more in order to meet any requirements for application and also for personalization.

The conveyor belt presents a new modular belt, with a pneumatic or electric mo-

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Automatic press for seasoned ham or bacon (Menozzi).

tor which is FDA certified.

The string dispenser is made of stainless steel thus guaranteeing a constant length of string in the ring sausage production. The pneumatic casing brake allows to stuff very hard and calibre stable delicate casings. The casing end switch stops the Clipper automatically at the end of casing.

The machine has a length portioning system with photocell in order to assure a constant length for the sliced sausages.

The label printer, ID-Print and the inserter, ID-Dispenser, guarantee a 100% traceability of the products printing such as logo, production date, expiry date, lot number, bar code, weight and QR-code on the label ID 6020.

(International Clip - Via

Roma 13 - 20080 Vermezzo - MI - Italy - Tel. +39 02 94941002 - Fax +39 02 94941016 - info@internationalclip.it)

IC 18/15 clipper (International Clip).

dal 1909

dal 1909

BAKERY AND CONFECTIONERY Rice and cereal processing

Three generations and 80 years of history, artisan tradition and great satisfaction in the field of rice and other grains processing.

This year Re Pietro celebrates its eightieth anniversary.

Re Pietro offers its cus-

RP Series rice cake machine (Re Pietro).

tomers complete production lines for rice cakes, from processing machines up to packaging lines, providing qualified consulting in the design phase which allows complete customization of machines and plant according to the specific needs of the customer as well as a qualified after-sales service.

In the last 15 years, the core business of the company has been the RP Series rice cake machines for the production of cakes with different cereals (rice, spelt, wheat, etc. and/or mix of grains) as well as for the production of non-fried snacks from pellets.

The RP Series rice cake machines are available in three different versions: basic model with painted chassis, basic model with food chemical nickel coated chassis, and the latest version in food chemical nickel coated chassis with side control panel for a

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more easy management of the production operations.

Re Pietro is focused on customer needs and, therefore, is always very attentive to improvements in the RP. In fact, the new versions of the RP Series rice cake machine have been equipped with a new Siemens control panel with colour touch-screen allowing the operator to interface seamlessly with the machine and the operations. The most important functions integrated in this new touch-screen control panel are the storage of recipe parameters in order to recall them immediately avoiding always having to set them manually by production changes, and diagnostic integration enabling a full control of the machine. In case of errors and/or serious malfunctioning, alarms are generated and production stops automatically.

Always with the aim to en-

sure customers the highest quality and safety standards in the manufacturing of the RP Series machines, the company announces the achievement of the Conformity Mark released by TIFQ Institute, third party body for the Hygienic Qualification of Food Technologies. TIFQ is an independent Institute for the verification and the implementation of laws and for the Hygienic Qualification for technologies and production processes. The certification activity regards the materials intended for contact with food-stuffs, drinking water, and cosmetics.

The aim of TIFQ is to safeguard the end consumer through the verification of the manufacturing traceability of the process and of the correct importation and/or distribution of objects intended for contact with food stuffs.

The visualization of TIFQ

Mark on the finished product shows the compliance with the regulations and with the hygienic rules.

This certification is subject to verification steps carried out by TIFQ. First, verification of materials and components which have to fulfill the compulsory International and CE requirements; then hygienic and manufacturing verification (“Hygienic Design”) included the indications and instructions of the final customer in order to assure the hygienic maintenance of the products; finally verification of the manufacturing processes, definition of the type-approval of the different product range and drawing up of the technical dossier (collection of the documentation indispensable to demonstrate the performed verification activities and the lab analysis if provided).

Obtaining the Hygienic Quality Mark allows Re Pietro to grant customers the certainty of a qualified supplier in the position to ensure and demonstrate the compliance and suitability of its products and the demonstrability of “excellence” as regards hygiene with the addition of compliance to the regulations.

(Re Pietro - Via G. Galilei 55 - 20083 Gaggiano - MI Italy - Tel. +39 02 9085025 - Fax +39 02 90842014 email: info@repietro.com)

Melters for blocks of fat and butter Tecno 3 introduces the new FC range of continuous melters for blocks of fat, with a melting capacity of 1,000, 2,000 and 3,000 kg/h. Developed for confectionery, dairy and food industries in general, the plant features a particularly innovative system that guarantees high productivity, reduced energy costs, and labour savings.

The thermal exchange is highly efficient thanks to the mechanical work performed by hot rotors, which carry out a scraping action on the surface of the blocks. The melting cycle is considerably faster compared to traditional static systems, without a need for excessively high temperatures, thus allowing a preservation of the properties of the raw material. It is easy to introduce the blocks, with no need to lift them, as the loading hopper is located at operator height. The melted fat is filtered and continuously sent to the storage tanks or production lines.

Entirely made of Aisi 304 stainless steel and perfectly insulated, the FC series continuous melters are fitted with a dual temperature control circuit in order to keep the operating

FC series continuous melter for blocks of fat (Tecno 3).

temperature constant and under control. The melters are managed by a comprehensive electrical system on board the machine.

The overall dimensions are reduced and, as a result, they can also be installed in confined spaces.

Tecno 3 continuous melters can be equipped with

CIP cleaning systems and automatic devices for complete emptying in the event that the product needs to be replaced.

(Tecno 3 - Via Mastri Cestai 2 - 12040 Corneliano D’Alba - CN - Italy - Tel. +39 0173 610564 - Fax +39 0173 619494 - tecno3@ tecno-3.it)

Inner view of FC melter (Tecno 3).

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packaging EQUIPMENT Process control and efficiency boosts European packaging machinery market

The high standard of living in Europe has popularised packaged goods, including packaged food, beverages, toiletries and cosmetics, thereby spurring demand for packaging machinery in the region. The need for packaging solutions for products of different shapes and sizes, along with manufacturer focus on automation to enhance process efficiency across industries, will sustain investments in the market.

New study from Frost & Sullivan’s “Analysis of the European Packaging Machinery Market” finds that the market earned revenues of more than $12.62 billion in 2012 and estimates this to reach $14.63 billion in 2016. The research covers filling, closing, and filling and closing (FCFC) machinery, form-fill-seal (FFS) machinery, wrapping machinery, group packaging machinery, and palletising machinery; end-user segments include chemicals

and petrochemicals, food, beverage, pharmaceuticals, confectionery and tobacco, and toiletries and cosmetics.

Demographic changes such as an aging population and the increasing number of small households in Europe drive the need for single-portion packaging, leading end-user sectors to turn to specialised packaging lines and machinery.

“Intense competition and the economic downturn have forced industries across Europe to optimise their production processes and decrease operational costs,” said Frost & Sullivan Industrial Automation and Process Control Research Manager Sivakumar Narayanaswamy. “Automation packaging machinery that eliminates labour, generates less waste, and enhances productivity is, therefore, becoming widely accepted.”

Sale volumes have gone up further with the advent of multi-functional packag-

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ing equipment that reduce costs and provide better space management. Integrated systems also have greater operational flexibility and can adjust to new production specifications.

However, mature markets such as Germany, France and Italy are already wellequipped, and likely to generate limited orders for these advanced packaging machines. High taxation and labour costs in these Countries also dissuade foreign investors and limit green field projects, curbing new equipment uptake.

In Southern Europe, the

downturn has affected process and discrete industries. End users are looking to trim operating and maintenance costs, and are unwilling to invest in non-crucial automation processes.

“Machine suppliers need to concentrate on regions that have not been affected by the economic downturn,” concluded Narayanaswamy.

“The markets in Scandinavia, Central and Eastern Europe, and the United Kingdom will offer the highest scope for adoption due to their stable economy and end-user growth.” www.frost.com

Coffee capsule production Acma is a universally renowned leader in developing cutting-edge technological solutions for the wrapping industry, for which it designs, builds and sells innovative and highly performing machines.

The company has recently reorganised itself within the Coesia group and has chosen to tackle the Fast Moving Consumer Goods market by preparing to be competent in technological platforms, capable of offering the market a wide range of solutions in the primary packaging sector.

Proof of its commitment toward this substantial target is also the recent acquisition of Tecnomeccanica, a key player in the tea packaging sector.

To meet the productive and marketing needs of major coffee roasting enterprises, Acma recently invested important resources to offer a range of applications that satisfy the new requirements of coffee producers and that cover all the primary and secondary packaging phases for capsules, in the most popular shapes and sizes requested by the market.

These capsules – in sizes from 5 to 14 grams – are designed to be completely recycled in view of the ease with which their com-

ponents can be separated. The capsule also guarantees an excellent price/ quality ratio thanks to the extrusion and modelling technologies with which it is created.

The machine developed by the R&D department is called “QI”; its layout is compact and it can therefore be installed in small production areas.

QI – sold under the Acma brand – is designed to fill rigid and semi-rigid capsules. It guarantees a high production rate (the line speed may be 140, 350 or 500 pieces per minute).

The Acma capsule processing machine, thanks to the design of the batchers on the independent stations, guarantees maximum precision in controlling the

weight during the filling phase (the precision tolerance is less than 0.1 g per capsule). It is also pre-arranged for vacuum directly inside (in the configurations from 350 and 500 ppm), required to extend the product shelf life. Ergonomic access to the packaging stations – for maintenance or cleaning operations – is made easier by the fact that whole machine units can be pulled out comfortably to work on them. During the design phases, special attention was paid to reducing the consumption of the capsule assembly materials; for example, initial tests on the material used to seal the upper part of the capsule (or insert the filter paper inside it) indicate a reduction in waste paper and savings of 48% (depending on the diameters) as op-

QI station for coffee capsule production (AcmaVolpack).

posed to the conventional machines.

The central core of the system is its transfer unit, which develops horizontally. By exploiting the full perimeter of the machine, the overall spaces are minimised and the production flow can be set clockwise or anti-clockwise according to the layout requirements of the production area. This also means that it is possible to employ just a few operators on several machines who can supervise one or more lines. The extensive experience in the primary and secondary packaging sector has enabled the company to offer its partners innovative solutions to package single or multiple capsules.

In the first case, packages that cut right back on wrapping material compared with conventional solutions have been created. Flexible packaging on the other hand (bags) guarantees new consumption management and communication possibilities.

One of the most important coffee roasting enterprises that have placed their trust in the company from Bologna and that will exploit the new range of QI machines, is the famous Illy; an Italian giant of the coffee industry.

(AcmaVolpack – Via Colombo 1 – 40131 Bologna – Italy – www.acmavolpak.com)

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Integrated wrapping systems Cavanna develops highly technological integrated wrapping systems that are flexible, efficient and performing. The complete wrapping lines take care of the products coming from the processing line down to the primary and secondary packaging unit.

The company offers custom-made and innovative solutions for all the specific customer requirements. In detail, accumulating and buffering systems, distributing and feeding devices, automatic horizontal and vertical loaders, horizontal flow-pack wrapping machines, and finally multiple axis manipulators used both in primary and secondary wrapping.

Zero 5 is the electronic wrapping machine with semi-automatic or automatic infeed for high production speeds.

It is a continuous motion horizontal packaging machine for wrapping products by using thermo-sealable and/or cold-sealable materials taken from reel.

Designed to meet the growing demand for quick changeovers, Zero 5 combines easy use and maintenance, low-cost operation and high performance. Depending on the characteristics of the product to be

wrapped and of the wrapping material, the machine has a speed of over 1,000 packs per minute.

Zero 5 NKZ is a horizontal continuous-motion wrapping machine for slug products with automatic or manual feed. It is conceived to appropriately meet the growing needs of fast format changes.

Zero 5 electronic wrapping machine (Cavanna).

(Cavanna - Via Matteotti 104 - 28077 Prato Sesia NO - Italy - Tel. +39 0163 829111 - Fax +39 0163 829237 - email: cavanna@ cavannagroup.com)

Automated handling systems for products and packaging A new project by Ilpra arises from its join-venture with Abrigo, a company boasting 30 years experience in automated handling systems for products and packaging. Two companies working together on tailored end-line robotic automation systems for packaging lines.

Ilpra presents its new range of innovative solutions such as robotized loading systems for products to be packaged, endline with robot, secondary packaging, and palletizing. Each solution has been studied by Ilpra with the intention of integrating all systems within a single constructive con-

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cept as regards materials, compactness and reduction of encumbrance and components used whether they are mechanical, electrical or electronic.

The I-Load island is the automatic loading system for various types of products that come in bulk on a belt by means of a robotic system coupled with a sophis-

ticated vision system that can detect the location, the size of products and also able to throw away possible defects.

Unlike other systems currently on the market, this system loads from a belt placed above (and not laterally) on the packaging line, thus significantly reducing the space required for its installation.

Besides I-Load, it is also possible to create different customized solutions for automatic loading for the specific needs of a product, whether the product is coming in single row, in step sequence or random.

(Ilpra - Corso Pavia 30 27029 Vigevano - PV - Italy - Tel. +39 03819071 - Fax +39 0381 88245)

I-Load island automatic loading system (Ilpra).

PACKAGING MATERIALS Are your food labels legal?

Survival in the food industry comes down to more than price competitiveness: failure to comply with legislation positions the label printer not only as an ‘also ran’ but as a complete non-starter in the end-user’s qualification process.

UPM Raflatac strive to promote and educate converters and brand owners alike regarding recent changes in European legislation with regards food packaging materials, of which labels are an integral part.

FINAT, in a collaborative effort with its member UPM Raflatac EMEA, reports on the new EU 10/2011 Regulation. This regulation on plastic materials and articles intended to come into contact with food came into legal force on 1 January 2013. It replaces Commission Directive 2002/72/

EC and national legislation based on that directive. Its purpose is to support brand owners’ and retailers’ duty of care to their customers, and represents an important additional measure in ongoing endeavours to ensure the quality and safety of food. Label printers who

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supply to the EU food industry have a key role to play.

Direct and indirect food contact The new regulation applies the same principles as EC No 1935/2004 for

materials and articles intended to come into contact with food. Such materials are required to be sufficiently inert to not transfer their constituents to food in quantities large enough to endanger human health, and to prevent unwanted changes to the composition of the food and how it looks, tastes or smells. While EC No 1935/2004 applies to food packaging in general, the new EU 10/2011 specifically concerns all plastic materials and articles intended to come into contact with foodstuff, with labels considered an integral part of such packaging. EU10/2011 consolidates 2002/72/EC and seven amendments (these were previous regulations for plastics).The idea of the regulation is to harmo-

nise the different legislation that has existed previously within individual member states; this should make it easier for different countries to deal with each other in terms of the shipping of goods.

Both direct food contact labels furnished with a plastic layer, as well as plastic labels applied to food packaging, now require Declarations of Conformity (DoCs) stating which controlled but authorised substances are present in their make-up.

Only when the packaging material or any layer provides a functional barrier that prevents migration of substances from behind that barrier into food, are labels and other packaging components exempt from EU 10/2011. Material compositions that are purely combinations of paper and board continue to be covered by national legislation or recommendations such as those of the German BfR.

and as DoCs move downstream within the supply/ manufacturing chain, such substances must be clearly identified and documented so that compliance can be optimally tested.

fore required to provide DoCs for their labels to enable tests for restricted substance levels and migration behaviour in specific environmental conditions to be carried out.

Final responsibility for conformance lies with the end user

Label printers: responsibilities and risks

It is the end user – packager or brand owner – who has final responsibility for checking that the packaging as a whole conforms to EU 10/2011 (in addition to any extant national legislation for papers, as well as to EC 1935/2004, the Framework regulation for all packaging materials), taking into account the nature of the packaged food, its defined shelf life, and ambient conditions.

Label printers are there-

Food label printers supplying into the EU therefore need to be provided with DoCs both from their labelstock and ink suppliers to be able to compile their own DoCs, which must, of course, also incorporate conformance information about any curing processes used during label production.

It should be noted that the enactment of these regulations means that printers unable to supply DoCs cannot now be accepted as

Plastics in food packaging A checklist for label printers

Restricted and unrestricted substances All authorised substances – both restricted and unrestricted – which may be used in packaging containing plastic in its layers, are stipulated on the ‘Union List’ within EU 10/2011.

Only restricted substances need to be declared;

The scope of the EU 10/2011 Regulation on plastic materials and articles intended to come into contact with food: (a) Materials and articles and parts thereof consisting exclusively of plastics; (b) Plastic multi-layer materials and articles held together by adhesives or by other means; (c) Materials and articles referred to in points a) or b) which are printed and/or covered by a coating; (d) Plastic layers or plastic coatings, forming gaskets in caps and closures that, together with those caps and closures, compose a set of two or more layers of different types of materials; (e) Plastic layers in multi-material multi-layer materials and articles.

part of the end user’s supply chain, and may also leave themselves open to the financial repercussions of a product recall. It is therefore essential for label printers to be proactive in obtaining and supplying the necessary documentation if they are to retain their place as responsible and viable links in the broader professional packaging chain.

The benefits of a secure supply chain Finally, all the above points underline the value of DoCs as a form of insurance for a label printer’s business, as a means of retaining existing customer contracts, and as an entry ticket to end users qualification processes for new business – with the ultimate aim of protecting the consumer. Producing DoCs to a satisfactory standard creates a level playing field for all operations – however large or small. www.finat.com

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ancillary EQUIPMENT Flexible conveyor

Marpatech presents the Sortech, an extremely flexible conveyor belt that meets the multiple requirements of different sectors regarding the flow management. This system allows a wide variety of actions with excellent control. Furthermore it can dynamically connect various infeed and outfeed config-

urations. Sortech can slow down, speed up, rotate, sort, transfer, align while running, selecting transfer times and speeds and even diversifying actions for each product. The reduced pitch of the rollers and the quality of raw materials used for development allow the machine to operate even with relative

Sortech flexible conveyor belt (Marpatech).

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small-sized products and heavy loads (700 kg/sq m), maintaining performance level over the long term.

Sortech represents the first system to be based on a modular polyacetal chain, mod. 2253RT System Plast, that integrates rollers which, when set into motion, allow for simultaneous forward movement of the chain and

intelligent product transfer.

Given its relative manufacturing simplicity, the Sortech conveyor is solid, convenient and guarantees complete operator safety without the use of external guards.

The real innovation of Sortech is the combination of functions that would otherwise require the use of more than one system, thus reducing not only the space requirements but also the difficulties tied to the software communication between multiple machines.

The first creation by Marpatech was the combination of two sorters with two infeeds and three outfeeds (available on the company website). It was installed in February last year and has been running 24 hours around the clock non-stop since then.

(Marpatech - Via dellâ&#x20AC;&#x2122;Orzo 2 - Santarcangelo di Romagna - RN - Tel. +39 0541 629005 - Fax +39 0541 688370 - email: marpatech@marpatech.it)

Sorting machines Thirty years of experience in the field of optical-electronic sorters has allowed ASM (which stands for Advanced Sorting Machines) to launch a cutting-edge and technologically advanced product.

The new Vision sorters series represents the last frontier in the field of optical electronic sorters. With years of experi-

ence in CCD digital vision technology, this new series uses the revolutionary Blob Analysis system, the latest frontier in acquiring and processing images. The main goal of this effort in technological research is to maximize the performance in production sorting.

The software interface guarantees the greatest ease of

use thanks to different functions of self-checking, auto-level adjustment, and remote management.

The LED lighting system guarantees the possibility to find any kind of defect. Furthermore, it guarantees a steady lighting strength in every season and the stable and constant level adjustment of the sorter.

The product-feeding chutes are unique in the Vision series. Their dimensions allow for maximum production capacity and their

technical features allow to sort more products on the same machine. The ejection system has passed the toughest speed and resilience stress tests.

The Vision series is reliable and precise in sorting like no other sorter on the market today. It is available in 5 models to meet all production needs.

(ASM - Via del Lavoro 10/12 - 40050 - Argelato - BO - Italy - Tel. +39 051 6630419 - Fax +39 051 897386 - email: info@ sortingasm.com)

Automatic bag emptying machine with belt

Vision electronic sorter (ASM).

Comav presents the SVR model, an automatic bag emptying machine with belt. This machine is designed to empty bags of products in powder or granules, available in different materials and in various versions. For a potential capacity of up to 600 bags/hour, it may be fed by a conveyor belt on which an operator or an automated robot positions one bag after another. Two contrast rollers or cutting blades crush or cut open the bags, and then a rotating drum completely separates the bag from the product. The vibrating hopper or the screw feed-

er transfers the product to the process or to another collection system. The bags are conveyed to the collection chamber that may be accessorised with a screw-press designed in order to reduce the volume of the empty bags.

The SVR automatic bag emptying system with automatic depalletizer is designed to empty bags of various types of pallets available on the market. The system fits pallets of bags, turning them 90째 to gradually feed the cutting unit with rotating blades, cuts the bags open cleanly and lets them fall into a rotating drum which separates

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the cut bags from their contents. The emptied bags remain inside the drum, and drum rotation causes them to fall through the drum and into the screw press, where they are compacted. The content of the bags falls through the mesh of the drum and off the machine through a collection hopper.

The machine is available in different sizes and configurations. It is made of different materials (Fe, AISI 304, AISI 316L) and in various versions (Atex II 2D/3D, with and without dedusting filter).

To run the machine in a continuous cycle and pre-

vent down time between pallets, the SVR with automatic depalletizer may be accessorised with a series of slat conveyors on which the operator may place 3 or 5 full pallets in a row, automatically feeding the depalletizer.

At the end of each emptying cycle the empty pallet is automatically expelled by the depalletizer and stacked in a storage unit.

The presence of an operator at the machine is reduced to a minimum.

(Comav - Via Statale 337 44047 Dosso - FE - Italy Tel. +39 0532 848348 - Fax +39 0532 848390 - email: info@comav-srl.com)

Check-weigher Idecon develops systems for online quality control, combining check-weighers and metal detectors with complete handling lines (stackers, rotary tables, tilting units, and conveyors).

Its highly qualified staff works in order to meet all requirements from customers operating in a variety of different manufacturing sectors, while assuring reliability, competence, and on-time deliveries.

By building its machines in-house, Idecon can offer close assistance to customers in the different stages of

design, installation and after-sales, always ensuring a careful support by its technical staff. All the systems are developed in compliance with the current HACCP regulations.

The WPM check-weigher series combining weight control with the detection of contaminant metals of a wide range of packed or loose products, always ensuring high level performances. The software has also been conceived to make the operatorâ&#x20AC;&#x2122;s work easier by integrating the check-weigher interface

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Automatic bag emptying system mod. SVR (Comav).

with metal detector remote control, in order to reduce the recipe change time.

The WP unit offers a number of variations and customizations aimed at increasing Customersâ&#x20AC;&#x2122; satisfaction, cost saving and volume reduction, but with a view to maintain the pe-

WPM check-weigher (Idecon).

culiar easiness-of-use that has always been a distinguishing features of all Idecon equipment.

(Idecon - Via dellâ&#x20AC;&#x2122;Industria 242 - 48014 - Castel Bolognese - RA - Italy Tel. +39 0546 50083 - Fax +39 0546 655328 - email: info@idecon.it)

ADVERTORIAL

WONDERBATCH THE TOTAL SOLUTION FOR YOUR BULK MATERIAL HANDLING AND INTELLIGENT BATCHING SYSTEMS Nol-Tec Group is present in three continents and through the years has built a well-know reputation for Bulk Handling and Air Pollution Control. Nol-Tec Europe is an international firm dealing with pneumatic conveying system for granular and friable products. In addition to Pneumatic Conveying and blending, Nol-Tec has gained proficiency in Mechanical Conveying, Weighing, Dosing and Automation systems, as well as in Air Cleaning and Emission Mitigation systems.

Nol-Tec offers several solutions for raw materials storage and recovery, from silo to battery of storage silos, big and bulk bag unloaders, with innovative and customized options as electronic weighing and dosing, bulk bags automatic closure and integrated pneumatic conveying.

WONDERBATCH® The Wonderbatch® concept is the result of NolTec’s engineering knowledge, and truly listening to our customers’ specific requirements. The revolutionary in-line formulation concept is realized through the combination of using intermediate bulk

the products when opening the big bags, so that this procedure can be completed outside of the batching housing.

• Inventory: all the big bags are weighted and traced when loaded into the discharging stations.

• Time Saving: fast change of big bags on the discharge station and reduced cleaning time.

• Cost Saving: totally automated process. Only one qualified operator needed in the batching area, responsible for monitoring and emergency activities.

The tests carried out at the Nol-Tec Europe and SIAD Research Centre showed a time saving of 40% compared to traditional systems.

Typical Applications: Bakery - Ice Cream / Cakes Colorants - Additives Formulation - Food - Thè, caffe ', cocoa - Dairy products - Aromas and flavors - Feed - Spices - Health Food Typical Wonderbatch® System The Wonderbatch® system uses the technology of M510 and M513 Stations for the storage and distribution of products.

The M513 and IBC are positioned on the unloading and dosing station with cone valve M510, to flexibly compose any kind of batch.

Typical Advantages are: • No contamination • Short cleaning times • Accuracy of dosage directly from Bulk Bags • Control and traceability

containers (IBC), flexible bulk containers (FBC), minor and micro innovative feeders, and different mixing and packing equipment in an extremely simple and fast way.

As a result of this new approach to design, Nol-Tec has made executing industrial recipes easier, safely reducing or eliminating cross–contamination and allergens, and has developed a system that can handle the Halal-Kosher process as well. Indeed, thanks to its smart technology, the Wonderbatch® concept guarantees the correct composition of recipes through the entire production process.

The main advantages of Wonderbatch® are: • Flexibility in Storage and Formulation: Wonderbatch® is designed for day bins, IBC-FBC, 25kg bags.

• Modularity: easy expansion of the system with reasonable investments.

• Innovation: a new concept with patented and proven solutions.

• Safety: no chain hoists, no operator contact with

DOSING AND MIXING Through years of experience, Nol-Tec Europe developed a particular and unique dosing control system: each ingredient is dosed with a double control, slow/fast, with an automatic dosing system of the value of the dosing set-up. The mixing is realized with a last generation mixer, BLENDER M244 (in ATEX, DAIRY, GMP version), that, without mechanical parts, uses the air force to obtain product mixings with different bulk density and particle size.

During the blending cycle, compressed air pulses gently lift the materials upward and outward in a continuous circular motion until the blending target is achieved.

Key benefits of Nol-Tec Blender: • Quick, gentle blending • Ultimate control of blend cycle • Clean operation • Low maintenance

www.nol-teceurope.com

• Uses standard plant compressed air • Available USDA Dairy 3A approved unit • Temperature and Oxygen Control Concentration Control System DENSE PHASE SYSTEM AND BULK BAGS FILLING/BAGGING Nol-Tec Dense Phase Pneumatic Conveying uses a reduced quantity of compressed air to transport big quantity of product, trough the use of the AIR ASSIST™, strategically positioned along the convey pipeline, in which the air is injected creating short and regular sludges of product.

Furthermore, Nol-Tec Europe has patented an evolution of the EconoMizer or Air Mizer technology, that makes the system extremely flexible and secure against clogging, allowing low speed convey for fragile, abrasive and/or blended products, and energy savings of up to 30%.

Peculiarities: • Low speed convey • Decrease of pipes and components abrasion • Reduced degradation of conveyed product • Conveying of premix with reduced segregation of components • Restart of convey with pipe full of product (nonpurging concept) • Reduced air consumption The Dense Phase system is particularly effective for the conveying of product in Bulk Bags filling or Bagging machine, preserving the bulk density stable and/or the blending degree and/or the integrity of the product. The Bulk Bag loader M502 is suitable in this regards as it is equipped with a weighing system that allows a semi-automatic work cycle and precision of the Bulk Bag loading.

Ugo Vivone, Corporate Technical Emanuele Fratto, Sales Coordinator Specialist - Wonderbatch sales@nol-teceurope.com

consumer trends Consumers go nuts for healthy snacks

Given that 20% of all meal occasions are snacks, accounting for 25% of all calories consumed, itâ&#x20AC;&#x2122;s no surprise that more healthful snacking will be a major focus area for many food companies and food service operators this year.

Among other weight management trends causing Americans to rethink eating habits, there is growing recognition of the nutritional benefits of nuts.

Market research indicates that this nutritional trend will continue to propel consumer use of nuts and other natural foods as leading snack products. Food producers and retailers are

responding by offering a greater range of tasty and convenient products, including nut and fruit bars and trail mix.

Nutritional benefits of nuts drives sales The recent data at Packaged Facts indicates that almonds in particular are finding wide application in healthier snacks; this development is in part associated with research findings that the actual caloric content of whole almonds is 20% less than the Nutrition Facts Panel indicates.

Consumers can expect to

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see nut snacks with nutritional benefits based on inherent nutritional composition, along with added nutrients or components such as caffeine for an energy boost; some of the new offerings expected to enter the market this year also feature bolder, adult-oriented flavors. Retailers are responding to consumer demand for healthy food and wellness-oriented development in snacks: portion-controlled, single-serve snacks of all types.

Another healthy snackfood item that is truly exploding is ready-to-eat air popped popcorn. The recent discovery that it is a better source of antioxidants than fruits or vegetables has contributed to popcornâ&#x20AC;&#x2122;s appeal in 2013. The popularity of airpopped, whole grain popcorn is likely to spur interest in and development of other popped whole grains, such as sorghum.

All things fruit and all things vegetable will be fair game for snacking in 2013. Vegetables and fruits are being dehydrated and freeze dried from their fresh forms to create shelf-stable munchable chips. Research indicates that the vegetable chips showing the greatest appeal will be those based on healthy natural ingredients, including beans and other legumes, kale, sweet potato, and seaweed.

More consumers go nuts for fruit, too Another shelf-stable format for fruit will continue to be various forms of squeezable fruit, with some items some developed to appeal to kids, others targeted toward adults.

Retailers are also offering more varieties of precut fresh fruit and vegetables, especially those in single serve and por-

tion-controlled packages. Research indicates that growing numbers of consumers crave single-serve, easy to use healthy snacks contained in packaging that also includes seasoning (often in separate packaging) for added flavour.

This emerging category is becoming increasingly popular and it also factors in mini-sized vegetables just right for snacking,

including cucumbers, peppers, tomatoes, and carrots.

And finally, there is another healthy snack contender waiting in the wings: cheese.

This is partly due to recent findings that kids who snack on cheese and fresh vegetables eat fewer calories, and thus require less food to feel full than kids who eat regular

potato chips. Also driving the growth of snack-able cheese in 2013 are introductions of more varieties of string cheese. Producers and marketers are targeting adults with bolder, more sophisticated flavours, and also gearing more cheese products toward kids using visual appeal such as multiple colors and fun shapes. www.marketresearch.com

Alternative bases & upmarket toppings help pizza hold ground According to Innova Market Insights research, over the past few years new product activity levels in the pizza market have remained relatively consistent, despite ongoing consolidation in the industry, particularly in the US and in the frozen pizza sector.

As might be expected, the most developed convenience foods markets of North America and Europe dominated launch activity, accounting for over 80% of the total pizza launches recorded globally by Innova Market Insights in the 12 months to the end of June 2013. Western Europe alone accounted for over 40% of the total, reflecting the large number of Countries and companies

involved, while the highly developed US market took over a quarter.

According to Lu Ann Williams, Director of Innovation at Innova Market Insights, recent new product activity is focusing on areas such as authentic and traditional-style pizzas, gourmet ingredients, and toppings and healthier alternatives. She reports that a new style product receiving particular attention in the US in the first half of 2013 was flatbread pizza. “New products are particularly using upscale flavors. These include Palermo’s Creamy Spinach & Goat Cheese and Italian Sausage with Mushroom & Fire-Roasted Onions flatbreads, Phillips Chesa-

peake Crab and Bourbon BBQ Shrimp flatbreads and Trader Joe’s Mushroom & Black Truffle flatbread,” Williams says.

The US market has also seen considerable activity in gluten-free options,

with 10% of pizza launches in the year to the end of June 2013 featuring “gluten-free” claims, compared with a much more modest 4% globally.

The other key US trend towards more complex, upmarket and often increasingly spicy toppings is also strongly in evidence in Europe, where branded and own-label new product activity is continuing apace.

In the UK, the retailers play a significant role in the market, particularly in chilled pizza and recent launches have included Asda’s Kickin’ Piri Piri Chicken, Smokin’ Sensation, Pep-Me-Up and Veggie Chilli Cheezilla thin and crispy stonebaked pizzas, as well as Tesco’s Italian Stonebaked Pepperoni & Tomato Chilli Crumb and Italian Black Pepper Chicken and Parmesan variants.

Interest in thin-based prod-

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ucts was also in evidence in Europe. Activity in France includes chilled foods specialist Sodebo’s extension of its range to include five Pizza Style products with thin oval bases and large

toppings. On the other hand, there was also activity in deep pan pizza, with UK frozen pizza market leader Dr. Oetker launching into the category for the first time with its Panebello range, already available in some other countries.

Notable activity in organic and sustainable products has also been reported in Europe, with Lea Nature extending its Jardin Bio organic foods range in France into chilled foods for the first time. In Germany, Fish & More extended its Followfish sus-

tainable fish brand with what it claimed was the country’s first MSC (Marine Stewardship Council) certified tuna fish pizza.

“The retail pizza market has benefited more than most from the financial downturn,” Williams concludes, “offering an attractive option in times of increased financial pressure, with consumers able to buy in advance for social nights in, as a cheaper alternative to home- delivery, takeaways and eat-in restaurants.” www.innovadatabase.com

Even more launches of new food and drink containing vitamin K2 The global functional food market has been steadily increasing in recent years and manufacturers have become more and more innovative with the ingredients they include to bring benefit to the consumer.

But it seems there may be a new ingredient that brands are realising the opportunity of. Indeed, new research from Mintel reveals new product launches* containing vitamin K2 have almost doubled (+183%) globally over the past five years (2008-2012).

Comparatively, the bet-

ter known form of vitamin K, vitamin K1, posted a healthy, but slower growth (+90% ) over the same reviewed period. Furthermore, looking at all food, drink, vitamin and supplements launches globally containing either vitamin K1 or K2, vitamin K1 was used in the overwhelming 96% of products, with the remaining 4% containing vitamin K2.

Laura Jones, Global Food Science Analyst at Mintel, said: “Vitamin K1 has a relatively short half-life and is rapidly cleared from the

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blood and is cleared by the liver within eight hours. In comparison vitamin K2 has a longer half-life of up to 72 hours, meaning it remains biologically active in the body for longer. Vitamin K2 is also absorbed better by the body compared with vitamin K1. These factors, along with the additional health benefits linked to vitamin K2, should encourage the use of vitamin K2 over K1 when trying to correct vitamin K deficiency.”

Within recent food and drink launches containing vitamin K2, the most

active categories are vitamins and dietary supplements, which account for the majority (76%) of new product launches globally in 2012, followed by baby formula (6%), beverage mixes (6%), flavoured milk (6%), and soy based drinks (6%) in 2012.

This year (January to August 2013), while vitamins and dietary supplements are still the most popular launches with K2 (58%), Mintel research has recorded a higher penetration of soy based drinks (25%), drinking yogurts and cultured milk (8% respectively).

“Vitamins and supplements continue to be the largest category in which vitamin K2 is used. However, on going research and ingredient companies promotion of vitamin K2 as a health ingredient will likely to assist its uptake in more food and beverages.

And while vitamin K2’s has been traditionally associated to cardiovascular and bone health, its role could extend beyond these features with its growing list of health benefits such as a role in sports nutrition and possibly in the prevention of cancer.” Laura adds.

And it seems the various health benefits of vitamin K could appeal to a considerable number of consumers.

Indeed, over a third (35%) of UK consumers buy func-

Via Mecenate, 78/b 20138 Milano - ITALY Tel. +39 02 504095 +39 02 504195 Fax +39 02 5062646 info@danioni.com

GRINDING MILLS AND PLANTS ITALO DANIONI manufactures grinding mills, mixers and crushers since 1918.

The Company also produces closed circuit, refrigerated and conditioned and explosion proof plants for products in powder.

Customers have at their disposal a test room with industrial machines for verification of functioning and capacity

Upgrading to existing installations

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tional food and drink products to maintain a healthy heart and almost a quarter (24%) to lower blood pressure or cholesterol.

Overall, the use of cardiovascular and bone health claims is growing globally, with food and drink products holding bone health claims almost tripling in

the past five years (+330%) and cardiovascular claims posting a healthy 66% growth over the past five years (2009/2012).

“This demonstrates recent interest in products targeting a global aging population. Increasing incidence of cardiovascular and osteoporosis issues, will mean

bone and cardiovascular claims will continue to be a key focus for functional foods and supplements, with women in particular being the main target for bone health products, due their higher incidence of osteoporosis.

The main bone health ingredients will continue to be calcium and vitamin D, but as consumers’ awareness of vitamin K2 increases, its prevalence in food and supplements making a bone health claim will increase. Effective cardiovascular ingredients will be sought after too and vitamin K2’s potential in cardiovascular health should be highlighted.” Laura concludes. www.mintel.com/

Fruity flavours favoured in new yogurt formulations Fruit flavours dominate the yogurt market, featuring in over two-thirds of global launches recorded by Innova Market Insights in the 12 months to the end of March 2013, rising to three-quarters of the US total and nearly 70% in Latin America.

This encompasses a wide range of different types of fruit, from more tradition-

al strawberry and peach to more unusual such as papaya, damson and coconut.

Lu Ann Williams, Director of Innovation at Innova Market Insights, reports “The yogurt market is generally showing good growth, and this is reflected in terms of new product activity, where levels are continuing to rise

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ket, such as desserts, bakery and confectionery.”

Companies are trying to ring in the changes with increasing numbers of limited edition and seasonal options.

Meanwhile, flavour trends in the yogurt market in 2013 seem to be following a similar path to recent years, with the exotic, unusual and more complex

globally. With an increasingly competitive marketplace, the need for product differentiation has led to developments in flavours over recent years, most notably into more upmarket and complex options, often featuring a number of different ingredients, sometimes with formulations taken from other sectors of the mar-

featuring strongly across a range of countries. In the UK, Collective Dairy has even added value to a new natural yogurt variant sweetened with honey, by giving it its own identity under the Plain Jane name. Other range extensions featured the more exotic and upmarket, including Banoffi and White Peach & Raspberry, while a limited edition Papaya & Coconut variant replaced the previous Mighty Mango line. www.innovadatabase.com

Worldly Snacks: Culinary Trend Mapping Report Product developers have been taking inspiration from international – cuisines for decades, and with good reason – consumers like them. For snack food developers, it’s an exciting time to be exploring new options influenced by forms, flavours and traditions coming from abroad. Market Research team knows snacks are increasingly in demand and consumers are increasingly demanding about their snacks.

Since snacks are replacing meals, they need to be both satisfying and nutritious. They also need to be portable some of the time and sharable at others. And snacks must match a variety of moods and cravings, cravings which, by the way, increasingly revolve around the tasty, global foods consumers have discovered from exuberant restaurant going and travel. Snacks additionally need to speak several languages to meet the needs of multi-cultural consumers, such as the Latino and Asian communities.

Take a tour around the world with CCD Innovation and Packaged Facts in their joint report, Worldly Snacks, and discover for

yourself some of the influential snacks consumers are embracing that can offer innovative inspiration for new alluring menu items and exciting packaged foods. CCD Innovation’s signature Trend Mapping technique tracks significant developments in worldly snacks across several stages:

ing holes of the working class are catching on in the United States as a popular new dining trend. The willingness of young, flavour-loving consumers to line up for both classic and fusion Japanese and Korean bar food bodes well for cross-over appeal in several foodservice categories, especially trend-forward fast-casual restaurants.

Brazilian Brigadeiros Crunchy Ancient Grains As a sweet snack brigadeiros have a lot going for them. This iconic recipe has few ingredients and has grown in popularity on recipe websites since they are so easy to make.

This familiarity with home cooks will assist marketers who choose to introduce them, whether in grocery store dessert cases, on the shelf or on a menu, especially for coffeehouses.

There’s growing interest in heirloom foods, and adapting ancient grains for snacks reflects that trend. It also dovetails with the increasing population of eat-

ers who have food allergies or gluten intolerance, and who are searching for alternatives to wheat. Adding ancient grains to cookies, savoury snacks such as crackers or chips, and bars offer product manufacturers a chance to stand out with unique textures and flavour profiles in familiar snack places.

Indian-Inspired Munchies Many popular global snack items get their start on the street, served by mobile food vendors peddling tasty morsels on the go for just the right price. India may be snack central for street-inspired small bites, and there has long been an India-to-Rest of World snack route, including to hungry American consum-

Asian Bar Snacking What’s the next big thing in Asian cuisine? Asian bar snack spots: Informal Japanese and Korean joints selling small portions and strong drinks. A part of Japanese and Korean culture for centuries, these water-

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ers, whether via the frozen food case for filled and fried favourites like samosas, or through the windows of colourful street food trucks and carts. Around the U.S., food trucks, pop-up restaurants and brick-and-mortar joints have all been serving traditional Indian foods as well as some re-imagined with a modern American spin.

Sicilian Arancini Being such fun-loving cousins to fried cheese sticks, croquettes and other styles of fried appetizers, it is surprising arancini haven’t spread farther and faster into mainstream grocery and foodservice. Their Italian heritage and familiar base ingredients, including beloved gooey, melted cheese, make them a sure win with kids, teenagers and indulgence-prone snackers of any age. The inclusion of toothsome rice, in addition to fried breading and cheese fillings, make this snack a bit more meal-like than other styles of fried starters.

The built-in variability allows both restaurants and frozen food manufacturers to change up fillings for a line of traditional Italian flavours (think fontina, gorgonzola or ricotta) or more adventurous, cross-cultural mash-ups.

Mexican Takis These crunchy packaged Mexican snacks-a fried, rolled corn tortilla chip that comes in five flavours—have found a following among city-dwelling tweens and teens who crave the snack’s spicy-salty taste and satisfying crunch.

At $2 a pop for a large bag, Takis are just within the financial reach of kids, and they’re sold at corner convenience stores that they tend to frequent. On a grander scale, Takis are playing in the mainstream snack arena, already in-

spiring intensely flavoured imitations from Frito-Lay and private label producers. Clearly, bold, globally flavoured snacks will be taking up more shelf space in the snack aisles in years to come.

Old World Pistachios It’s clear that the pistachio, now available domestically in greater quantities and with an impressive nutrient profile, is a bright new star in snacks of all types, both sweet and savoury. Yet pistachios also have a unique

ability among less glamorous nuts to stand out as a global ingredient. They are increasingly showing up in recipes and food products with their native Mediterranean, Middle Eastern and even Indian roots re-vivified. As American consumers continue delving into global culinary traditions in search of new flavours and cultural experiences, pistachios represent a unique opportunity to introduce savvy eaters to new food adventures with Old World colours. www.marketresearch.com

Why profit margins are trending in the dairy industry As Americans become increasingly concerned about the negative health effects of certain foods or food ingredients, manufacturers are introducing a greater variety of healthier products, lower-sugar flavoured milks and reduced-fat cultured products for instance.

This move has expanded profit margins throughout the food industry because health-conscious consumers are generally willing to pay more for food that they believe is healthy for them.

In particular, large companies that have been providing Americans with foods

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for years have established brand loyalty, so when they introduce healthier, more-expensive products, they typically do not experience significant declines in demand for their products because people view them as high-quality brands, according to a recent industry report. As such, these companies can realize higher profit margins than companies that do not have well-established brands.

Food processors must purchase a variety of commodities, such as feed, corn, milk, wheat and sugar, to

produce their goods. The prices of these commodities help determine how processors in a variety of food industries price their goods.

So when the price of a com-

modity fluctuates rapidly from year to year, the cost of manufacturing products becomes volatile.

Volatility, in turn, leaves processors less able to anticipate cost increases.

They will often pass these costs on to consumers in the form of higher product prices, or, as in the case of ice cream, by reducing package size. Although this move does not bode well for consumers, many will still pay the higher prices, or accept the smaller package, especially for foods that are staples in their di-

ets. Processors end up benefiting because the higher input prices arenâ&#x20AC;&#x2122;t eating into their profit margins, while demand from consumers stays steady.

And there is some good news on commodity prices.

They are expected to be less volatile during the next five years, which presents even more opportunity for processors to expand their profit margins. Most notable is the price of corn, which is an input in all 10 of the most profitable food industries, one of which is ice cream.

Food processors aim to

strike a balance between providing Americans with the food that they love at a reasonable price and maximizing company profitability. During the next five years, profit margins in these already-profitable food product industries are expected to expand as commodity prices become less volatile and operators cut costs associated with production. In addition, if prices do rise, they will be better able to pass off cost increases in the form of higher product prices to consumers because disposable

incomes are improving in line with the economy.

In particular, larger and well-established companies produce brands that millions of Americans are familiar with and loyal to.

Still, Americans will look to their favourite brands to introduce healthier food products as they strive to live healthier lives. Processors that introduce and advertise healthier products are likely to be rewarded with greater sales, thus benefiting margins further. www.marketresearch.com

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GMO-free moving forward in new products In recent years, interest in natural products has grown markedly; this has been reflected in a number of ways in new product activity, such as the use of all natural colors, flavors and other raw materials. The popularity of organic products and the promotion of milk and dairy products from grass-fed livestock is also on trend, as is the growing use of GMO-free labelling.

In terms of product activity, launches featuring GMO-free claims and labelling remain relatively limited on a global scale. While nearly 13% of launches recorded by Innova Market Insights in the 12 months to March

2013 were marketed on an “additive-free” or “preservative-free” platform, nearly 7% were marketed as “natural” and 6% as “organic,” just 1.1% used GMO-free labelling. This figure rises slightly higher in certain Countries and regions, notably Europe and Australasia, falling to less than 1% in North America and Asia. In terms of products carrying GMO-free claims, snacks, dairy and bakery have the largest number of launches, reflecting the significance of GM ingredients in sectors using high levels of cereals for food or feed.

They accounted for 14.1, 13.3 and 12.5% respec-

tively, of global GMO-free launches recorded, ahead of baby foods, meat, fish and eggs, confectionery and ready meals.

Lu Ann Williams, Director of Innovation at Innova Market Insights reports “In addition to the compulsory labelling regulations in place in the EU since the 1990s, there has also been a more recent move to verify and more easily identify GMO-free food and drinks.” She notes particular interest in using GMOfree labelling for dairy products, with Germany and Austria tending to lead developments. Austria’s ongoing interest in marketing the purity of its dairy prod-

ucts resulted in it increasingly combining the use of pasture milk (Heumilch) with GMO-free labelling and this trend spread to Germany, as illustrated by Arla’s late-2012 introduction of its Bergbauern Emmentaler and Bergkäse cheeses marketed as being made with pure pasture milk (Heumilch) and carrying a GMO-free logo.

Innova Market Insights has also recorded a wide range of US launches marketed as GMO-free over the past 12 months, including mainstream lines, such as Breakfast Smoothies and drinks from Bolthouse Farms, Silk soy milk lines and Plum Kids organic baby food products. More specialist products include Amy’s Bowl Meals range and Garden of Eatin tortilla chips; and new organic milks from retailer ownbrands, particularly Fresh & Easy, owned by the UK retailer Tesco.

“The demand for GMOfree labelling seems set to continue to grow as a marketing tool globally,” Williams concludes “as even where GMO foods have to be labelled, such as in the EU, there is still apparently demand for easy recognition of GMO-free lines as the use of logos and certification schemes continues to grow.”

Innovadatabase.com

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+ NEWS = + INFORMATION IF YOU WANT TO KEEP UP TO DATE ON FOOD WORLD NEWS, LOOK AT THE NEW PORTAL

www.foodexecutive.com

marketing REPORTS World cocoa market will be in deficit for next two years

The cocoa market will be in deficit both this season and next, as rises in production fail to keep up with grindings.

The Public Ledger’s Cocoa S&D Poll of 43 industry experts showed that world production will total 3.965m tonnes in the current 2012/13 season ver-

sus grindings of 4.039m tonnes, resulting in a deficit of 74,000 tonnes. In 2013/14, the deficit will increase to 178,000 tonnes with output at 4.036m tonnes and grindings at 4.214m tonnes.

The cocoa sector has seen a surplus for the last two seasons, which has helped

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prices on the terminal market cool from a 33-year high of over £2,700 ($4,080) a tonne reached in 2010. But a recovery in demand as Europe and the US emerge from recession will help keep futures – which have traded at around £1,400 to £1,600 over the last year – supported over the coming two seasons.

“I expect the global price of cocoa to increase compared to 2012/13 levels.

Demand in Europe and the US is expected to increase due to an anticipated recovery of their economies,” said one poll respondent, an analyst based in Ghana.

The poll revealed that one of the biggest concerns in the cocoa market currently is falling prices, which could affect the crop next season as growers in some producing nations neglect trees. However, strong demand growth in emerging

markets in Asia and South America will present the greatest opportunities for the sector in the coming years.

Demand On the demand side, a rise in world grindings in 2012/13 will be driven by growth in Indonesia, Ghana, and the US; global growth is forecast at 2.9% this year.

The second European trader was more bearish, however. “For global demand growth a lot of people had been suggesting over 3%. I would tend to say that it’s going to be anything between 1.5 and 2.5%,” he noted.

The EU Biggest grinder the EU is expected to process few-

er beans this year (1.332m tonnes versus 1.359m tonnes last year). However, grindings are likely to recover next year to 1.406m tonnes.

“I wouldn’t be surprised to see demand in Europe coming off again this year,” said the first European trader. “The demand for butter and powder combined is nothing to write home about. I wouldn’t be surprised to see some capacity not being used in the second quarter again as well.”

Europe’s first-quarter cocoa grind fell 3.9% from the same period last year to 339,377 tonnes, in line with trade forecasts.

North America Expectations for grindings in the US are slightly more optimistic. This year 400,000 tonnes of beans will be processed versus 387,000 tonnes last year, while next year the figure should rise again to 410,000 tonnes, according to the poll.

US butter ratios have been strong in recent months due to renewed demand in the region. Grindings in North America were higher than expected in the first quarter of this year, up nearly 6% versus the same period of 2012. While traders had expected relative-

ly stagnant data, it turned out to be the biggest yearon-year rise in two years.

Many traders are expecting another slight rise in North American grindings in the second quarter as chocolate makers build up stocks.

Asia Cocoa grindings in Malaysia and Singapore will be more or less flat this year (295,000 and 83,000 tonnes respectively), although overall Asian grind will be boosted by growth in Indonesia, which is expected to process 315,000 tonnes from 265,000 tonnes last year.

Indonesia, Malaysia and Singapore are all expected to see growth in 2013/14 to 338,000, 305,000 and

85,000 tonnes respectively, due to strong consumption growth for cocoa in most of Asia.

Africa West Africa is also seen grinding more cocoa in the next two years. Ivorian grindings were pegged to remain more or less flat this year and next, although growth in neighbouring Ghana will more than offset this. Grind in the latter is seen at 235,000 tonnes this season, versus 215,000 tonnes last season, and 261,000 tonnes in 2013/14.

A director at Saf Cacao, the biggest cocoa exporter in San Pedro, recently told The Public Ledger that although he would like his firm to process more beans

before exporting, European buyers prefer to grind beans themselves for financial reasons.

“We would love to process more but Europe is protecting its manufacturers. There are advantages for them to take beans and process them in Europe, lower taxes for example”, he said. “I am Ivorian and I want this country to grow, because if this country grows then we grow. Our intention is not to sell all our cocoa to let others (process) it and make money.”

Referring to the coming seasons the director said: “We are seeing what is happening in the field and I don’t think farmers will grow more cocoa, but we definitely have the hope to process more cocoa here.” www.public-ledger.com

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China’s dairy industry: Review and outlook

There were both challenges and opportunities for China’s dairy industry and 2012 has represented an important turning point for the development.

Data show there was pacing up of transition from coarse quantitative growth to intensive qualitative efficient growth and from super-conventional unregulated development to steady orderly progress.

From the perspective of challenges, 2012 saw constant upsurge of CPI and overall price hike. The price for dairy cattle feed and fodder, fuel cost and labor cost, which are related to dairy cattle farming, rose comprehensively, so the production cost of raw milk kept on moving up. Although the procurement price for raw milk rose at the same time, yet the growth of cost and expenditure was faster.

More and more smallhold-

er farmers were forced to give up dairy farming. During the year, the input-output efficiency of scaled farming was much better than smallholder farming and scaled farming saw accelerated improvement of proportion in raw milk production. From the perspective of quality vs price, China is one of the Countries that have the highest raw milk price. The too high raw milk price does not only weaken the competitiveness of China’s dairy industry in the world, but also makes it hard for China to export dairy products and there is a huge cost pressure to the domestic dairy processing enterprises. Dairy companies have to readjust their product structure, raise the proportion of high value-added products, sustain and improve the gross profit margin. Meanwhile the too high raw milk price forc-

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es processing companies to restructure their products and produce more “functional products” and “colorful products” of higher price. However the too high prices for dairy products restrain consumption and the per capita dairy consumption quantity of the Chinese residents lingers around the same level.

In 2012 the price for raw milk and milk-based raw materials kept at a high level, products from the international market were more competitive than the domestic made in quality vs price. Meanwhile there were frequent incidences concerning dairy product quality and safety, especially involving famous brands, which hurt consumers’ confidence on dairy products. In order to raise competitiveness, domestic companies paced up acquisitions and mergers overseas, shift-

ed dairy farming and processing to foreign countries and tried to gain consumers’ confidence by introducing 100% imported products. At the same time there was continual significant growth of dairy import to China, especially full-cream milk powder and skim powder, breaking another historical record. In 2012 the import of raw material milk powder was close to 600,000 tons,

up 30% year on year. The huge import brought a serious impact on milk powder processing and even on the whole dairy processing industry in China.

From the perspective of opportunities, the Chinese Government enhanced support and regulation of the industry in 2012. For dairy farming, scaled farming continued to gain Government support and preferential policy treatment and the profit of scaled farming was guaranteed.

Meanwhile processing companies injected more investment for dairy farming and raised the proportion of controllable milk source. For dairy processing, the order of the processing market was gradually purified, the competition of the dairy market became more regulated and orderly, the proportion of marketing cost in the total cost kept on dropping and the profit margin of the dairy processing industry improved, which eased the pressure from the hike of production cost to a certain extent. For international environment, the global dairy consumption was affected by the outbreak of the European debt crisis and slow rally of the global economy especially the developed economic entities. The economic entities, which suffered from the crisis, witnessed negative

impact on dairy consumption. On the other hand, the main economic entities in the world still saw stability or certain growth of production of milk and processed dairy products and hence they relied more on export. Except for whey and lactose, the price for other dairy products fell year on year and the dairy industry waits to be consolidated. The hardship of the dairy-developed economies is an opportunity for China’s dairy industry, especially the implementation of the “going out” strategy lays an opportunity.

Looking into 2013 China’s dairy industry is foreseen to witness significant changes concerning both the domestic and international market environment. After the readjustment in 2012, the global economy especially Europe and America shall recover and there shall be improvement of consumption demand. The continuation of Greece in the Euro Zone is a cardiac stimulant to the European economy and the US Democrats and Republicans are hopefully to reach a compromise on the “fiscal cliff”. These shall stabilize the Western economy. At the same times, QE currency policy

shall be exercised in more and more countries, which surely will spur price hike of global fundamental products including produce and oil once again.

The price for raw milk and processed dairy products is projected to surge again in the main economies. Although the huge supply would restrain excessive price hike to a certain extent, yet China shall see rising cost of dairy import. In China in 2012, the Ministry of Agriculture and the Ministry of Finance jointly promulgated the “Prospering Dairy Farming Alfalfa Development Action”. Alfalfa growing shall be going on extensively in the main dairy farming regions in 2013. The policy is conducive to optimization of dairy cattle feed structure, reduction of feed and other farming cost, improvement of raw milk quality and yield and upgrading of dairy farming.

This report illustrates in a panorama way the situation of China’s dairy industry in 2012 including production of raw milk and processed products, dairy consumption, dairy trade, price trend of raw milk and processed products, operational status of the dairy industry, the competition of the dairy market, the revenue of key dairy companies and investment. The report also covers the trend

of the world dairy market; production, consumption and trade of the key dairy producing and trade countries; the impact from the world dairy market to China’s dairy industry and forecast on the trend of China’s dairy industry in 2013.

This report is the result of collaborative collective work of BOABC Dairy Research Team. The senior analysts of BOABC Dairy Research Team are members of the “think tank” of relevant government authorities and associations, who have sound relationship with the authorities and associations and keep good relations with key dairy companies, related sectors and enterprises as well. This advantage is solid valuable professional support to the composition of this report and guarantees the accuracy, authoritativeness, scientific justifiableness and forward looking of the data quoted in the report. BOABC believes this report is important reference for both domestic and foreign investment agencies, dairy companies, suppliers of ingredients for dairy products and equipment suppliers in making strategic decisions, and it is also important reference for industrial associations and research institutes. www.researchandmarkets.com

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PAKAGING TRENDS US demand for meat, poultry and seafood packaging to reach in 2017

Demand for meat, poultry, and seafood packaging is forecast to increase 3.2% annually to $9.7 billion in 2017. Gains will be driven by increased meat, poultry, and seafood production along with accelerated foodservice revenue increases. Prospects for packaging will further benefit from the significant shift to case-ready packaging among grocery retailers as well as the growing share of smaller sized items and items that are further processed for convenience of preparation. Heightened demand for single portion and other smaller sized products will reflect the significant level of one and two person households in the US as well as efforts among processors and retailers to hold down selling prices, especially in beef.

These and other trends are presented in the new study from The Freedonia Group “Meat, Poultry, & Seafood Packaging”.

Flexible packaging demand growth will outpace that of rigid packaging as a result of solid prospects for pouches and high barrier film, along with inroads into rigid packaging due to sustainability benefits via reduced material use and significantly lower shipping costs. Rigid packaging growth will be limited by maturity and/or competitive drawbacks in corrugated boxes, metal cans, folding cartons, and paperboard sleeves.

Poultry packaging applications will achieve the fastest growth through 2017,

driven by poultry’s advantages of lower cost and a more favorable nutritional profile. Meat will continue to be the largest application though growth will slightly trail the overall average. While seafood applications will accelerate from their 2007-2012 performance, advances will lag the overall average due to the growing share of seafood demand that is met by imports.

The ready-to-eat market will record the fastest growth, driven by an expanded variety of prepared food for takeout from gro-

cery stores and other retail locations as time-constrained consumers continue to seek meal options that are economical and eliminate or reduce preparation time. Gains in the fresh and frozen market will be fueled by the growing significance of caseready packaging and MAP to extend the shelf life of fresh meat, poultry, and seafood. In the processed market, advances will reflect an increased emphasis on higher margin items that are designed to offer convenience. www.freedoniagroup.com

US meat, poultry and seafood packaging demand in million dollars (Source: The Freedonia Group).

Item

% Annual growth 2007 2012 2017 2007-2012 2012-2017

Packaging demand 7014 8240 9650 3.3 3.2 Fresh & Frozen 3974 4630 5390 3.1 3.1 Processed 2711 3185 3720 3.3 3.2 Ready-to-Eat 329 425 540 5.3 4.9

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THE CORRECT TOOLS PAKAGING FOR THE BEST INFORMATION TRENDS

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NEWS AND TECHNOLOGY New UN food safety and nutrition standards will benefit consumers

The UN food standards body Codex Alimentarius has agreed on new standards to protect the health of consumers worldwide; these include standards on fruit, vegetables, fish and fishery products and animal feed. Codex also adopted codes on the prevention and reduction of ochratoxin A (a carcinogenic contaminant) in cocoa, guidance on how to avoid microbiological contamination of berries and on use of claims for food that is labelled “non-addition of sodium salts” including “no added salt” on food packages, to assist consumers in choosing a healthy diet.

The Codex Alimentarius Commission, jointly run by the UN Food and Agriculture Organization (FAO) and the World Health Organization (WHO), sets international food safety and quality standards to promote safer and more nu-

tritious food for consumers worldwide. Codex standards serve in many cases as a basis for national legislation and provide the food safety benchmarks for international food trade.

Safe limits on contamination One of the important work areas for Codex is setting safe limits and giving guidance along the food chain on prevention or reduction of contamination. In fact,

72 - Italian Food & Beverage Technology - LXXIV (2013) november

food can become contaminated by heavy metals, fungal toxins or bacteria and viruses.

The Commission adopted two important codes: prevention and reduction of ochratoxin A in cocoa and of hydrocyanic acid in cassava, both important products for developing Countries.

Fresh berries can be a healthy part of the diet but are also prone to microbiological contamination and have been associated with several foodborne illness

outbreaks caused by viruses (Hepatitis A, Norovirus), bacteria (E. coli), and protozoa. The new Codex text gives advice to producers and consumers on how to prevent this contamination.

Fair practice in food trade and protecting health of consumers The Commission adopted a number of commodity standards that will protect consumers from fraud and ensure fair practices in the food trade: fresh and processed fruit and vegetables (e.g. avocados, chanterelles, pomegranates, table olives, date paste, and tempe) and fish and fishery products (smoked fish, abalone). The standards help buyers and sellers establish contracts based on Codex specifications and make sure that the consumers get from the products what they expect.

The Commission adopted the nutrient reference values on sodium and saturated fatty acids, which are nutrients associated with non-communicable diseases (NCDs), to be included in the Guidelines on Nutrition Labelling. This is part of Codex’s on-going efforts to promote healthy dietary practices and address the increasing public health problem of diet-related NCDs. The Commission also adopted the revised and updated guidelines on formulated supplementary foods for older infants and young children to ensure the health and nutrition of the vulnerable population group. Furthermore, it adopted hundreds of safe maximum limits for pesticide residues and veterinary drugs and provisions for food additives.

Guidance on control for food and animal feed As animal feed can cause contamination in eggs, meat and milk products, the Commission adopted guidance to Countries on how to control animal feed and assess the risk of contamination. The Commission also adopted guidelines for National Food Control Systems to assist Countries in implementing food control.

Into the future Because of the volume of trade and need to harmonize national standards, the Commission agreed to create a new Codex Committee on Spices and Culinary Herbs, which will be

hosted and chaired by India. The Commission approved its Strategic Plan 2014-2019, which will guide the work on protecting health of consumers and ensure fair practices in the food trade over the next six years.

Resistant bacteria remain an important issue The third joint EFSA and ECDC report on antimicrobial resistance in zoonotic bacteria affecting humans, animals and foods shows the continued presence of resistance to a range of antimicrobials in Salmonella and Campylobacter, the main bacteria causing foodborne infections in the European Union (EU). Nevertheless, co-resistance (combined resistance) to two critically important antimicrobials, remains low. The report is based on data collected by EU Member States for 2011.

A high proportion of Campylobacter bacteria ,the primary cause of foodborne diseases in the EU, found in humans, food-producing animals and food was resistant to the critically important antimicrobial ciprofloxacin whereas low resistance was recorded for erythromycin, a second critically important antimicrobial. Overall in the EU, co-resistance

to critically important antimicrobials was low, which indicates that treatment options remain available so far for severe infections with these bacteria. In addition, high resistance was recorded for commonly used antimicrobials.

In Salmonella multidrug resistance, or resistance to at least three different antimicrobial classes, was high overall in the EU. In humans, a high proportion of Salmonella was found to be resistant to commonly used antimicrobials and this was also the case for animals, especially pigs and turkeys.

High resistance to ciprofloxacin in isolates from poultry was also observed; nonetheless, there were low levels of co-resistance to critically important antimicrobials among Salmonella from humans, food-producing animals and food.

“If we do not want to lose a number of antimicrobials which today provide an

effective treatment against bacterial infections in humans, then joint efforts in the EU, including the Member States, healthcare professionals, industry, farmers and many others are needed”, said Bernhard Url, EFSA’s Director of Risk Assessment and Scientific Assistance.

ECDC Director Dr. Marc Sprenger added: “With harmonised surveillance of antimicrobial resistance in isolates from humans and animals, we can inform effective actions to prevent further spread of antimicrobial resistance in humans. To facilitate comparability of data across the EU, ECDC will continue encouraging EU Member States to use the methods and guidelines issued by the European Committee on Antimicrobial Susceptibility Testing (EUCAST). In addition, ECDC will keep coordinating the European Antibiotic Awareness Day, a European health initiative that provides a platform and support for national campaigns on the prudent use of antibiotics in humans.”

Multidrug resistance, co-resistance and resistance to commonly used antimicrobials needs to be carefully monitored. Antimicrobial resistance is a serious threat to public health as it leads to increasing health costs, extra length of stay in the hospital, treatment failures and sometimes death.

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Can a vegetarian diet reduce mortality?

Another study has added to the growing body of evidence that a vegetarian diet is associated with a lower risk of death. Published in JAMA Internal Medicine, the study by Orlich et al. has examined all-cause and cause specific mortality in a group of 73308 American men and women Seventh-day Adventists.

Previous studies have reported mixed results with some suggesting that nuts, fruit, cereal fibre, polyunsaturated fatty acids, n-3PUFAs, green salad, Mediterranean dietary patterns, “healthy” or “prudent” dietary patterns, plant-based diet scores, plant-based low carbohydrate diets, and vegetarian diets are all associated with reduced mortality. Whereas high glycemic load, meat, red meat, processed meat, eggs, potatoes, increased energy intake and animal-based low-carbohydrate diets

are all associated with increased mortality.

Orlich et al. report that the European Prospective Investigation into Cancer and Nutrition, Oxford cohort study, found British vegetarians were just as likely to die at any point as meat eaters. Using a questionnaire the scientists assessed the participant dietary patterns and split them into five groups: non-vegetarian, semi-vegetarian, pesco-vegetarian (includes seafood), lacto-ovo-vegetarian (includes dairy and

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egg products), and vegan (excludes all animal products). Among the participants 8% were vegans, while 29% were lacto-ovo-vegetarians and another 10% were pesco-vegatriation, 5% were semi-vegetarians and 48% were non vegetarians. Vegetarians were found to be older, more highly educated, more likely to be married, drank less alcohol, smoked less and exercised more.

The researchers then used a national database to see

how many of the participants died during the 6 years of follow up. They found 2,570 deaths among the participants; the overall mortality rate was six deaths per 1,000 person years. The adjusted hazard ratio (HR) for all-cause mortality in all vegetarians combined vs non vegetarians was 0.88 or 12% lower, according to the study results. The association also appears to be better for men with significant reduction in cardiovascular disease mortality and ischemic heart disease death in vegetarians vs non-vegetarians.

The results indicate that in women there were no significant reductions in these categories of mortality; the study cautions however that they can’t say the participants’ plant-based diets prevented their deaths, because there may be other unmeasured differences between the groups.

Rssl.com

Olive oil assays may help assure authenticity When the label on a bottle of olive oil misrepresents what’s inside, shoppers may not be getting what they thought they paid for.

Mislabeling is also of concern to chefs, retailers, and America’s olive growers and olive oil processors, especially those newly entering the domestic olive oil market. They face tough international competition: an estimated 98% of all olive oil consumed in the United States is imported.

Help may be on the way in the form of laboratory assays developed by U.S. Department of Agriculture (USDA) researchers and their colleagues. These tests add to the array of options for quality-control analyses of olive oil.

Agricultural Research Service (ARS) chemist Tal-

winder Kahlon’s assay relies on PCR (polymerase chain reaction) technology to compare olive DNA to that of canola and sunflower plants.

Oil from these plants is sometimes mixed with olive oil, but not disclosed on the label. Kahlon’s test focuses on key regions of two genes, matK and psbA-trnH, which occur widely throughout nature, including in olive, canola, and sunflower. The DNA sequence of specific regions of these two genes, Kahlon notes, provides a reliable basis of comparison, and can be used to detect the presence of the non-olive oils at concentrations of 5% or higher.

Though using PCR technology to detect specific plant DNA in olive oil isn’t new,

the team’s approach offers several improvements.

For instance, the olive, canola, and sunflower “DNA barcodes” that the scientists developed, to serve as the basis for comparing these plants’ DNA, are based on not just a single olive tree or sunflower or canola plant.

Instead, each barcode is a broadly representative composite, known as “consensus DNA.” Olive oil is made up of triglycerides, which are molecules composed of fatty acids and these fatty acids are the focus of the approach that ARS chemist Jiann-Tsyh (Ken) Lin developed. The assay is based on ESI-MS (electrospray ionization-mass spectrometry) and enables scientists to glean details about variations in specific triglycerides of interest, referred to as regioisomers. From that, users can develop ratios of regioisomers that can be used to determine whether

the sample contains undisclosed oils.

The value of ESI-MS for analyzing plant fatty acids has been recognized since at least 1994, but Lin’s ESIMS protocol helps make this application simpler.

Lin developed the protocol for his research with castor, a plant that produces an inedible, top-quality industrial oil. About six years ago, he chose olive oil as a model for testing his assay.

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The new App for iPhone developed by Pavan Pavan has designed the new App “ONBOARD” for food technologists and line operators in dry pasta, fresh pasta and snack pellets manufacturing plants, and now it is available on App Store.

Quick and precise tool for everyday work flow and operations, the App has two main sections, Mass Balance and Mollier Charts.

The function Mass Balance provides useful tools to calculate dough recipes and drying parameters.

Single-ingredient recipes which consist of one dry ingredient and water and are typically used in dry pasta production; multi-ingredients recipes, typically used in fresh pasta production, with the possibility of inserting up to 8 different ingredients and calculating the absolute and relative quantity of each ingredient as well as the quantity of water necessary to obtain a given moisture of the final dough.

The function Mollier Charts provides data relating to the saturated steam diagram, with the possibility of selecting either temperature or humidity as a starting point.

All the calculations and re-

sults can be sent via email to share the information and recipes with co-workers.

The App by Pavan also gives the chance to explore the company world: watching video clips of plants in operation and discovering the activities of the Pavan’s Food Master, a series of seminars in food technology to provide specific training for managers and skilled staff involved in the production of dry pasta, fresh pasta, and snack pellets.

ONBOARD is available also for iPad. (Pavan - Via Monte Grap-

pa 8 - 35015 Galliera Veneta - PD - Italy - Tel. +39 049 9423111 - Fax +39 049 9423303 - email: info@pavan.com)

Private Label conference and exhibition in Bologna Marca by BolognaFiere, which will be held 15th and 16th January 2014 in Bologna, is the only Italian event devoted entirely to Private Label in large-scale distribution.

The 2013 show ended successfully with the participation of 5,500 industry professionals (including 501 international visitors). These results consolidate Marca as a key event where the world

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of industrial production has the opportunity to meet the Italian and international distribution system.

Private label produce is continuing to experience a growth from 10,1% in 2001 to 18,1% in 2012 (source SymphonyIRI Group). This data confirms the growing credibility amongst consumers for private label products due to their excellent balance between price

and quality. Marca, the only Italian exhibition devoted exclusively to the world of the private label, has in recent years become a crucial appointment for the business community that has the opportunity of developing its business with the leading mass distribution labels. These labels as well as being key players on the Technical Committee also participate at Marca, thereby enhancing the appeal of the event.

This event represents an outstanding opportunity for exhibitors interested in developing their international business to meet qualified international operators and buyers. Marca 2014 will support an important programme of hospitality and B2B meetings with the ex-

hibitors. Meetings will be held in the International Lounge, the meeting point for foreign buyers.

Marca 2014 will feature a theme area devoted to Fresh Food Produce where Italian producers operating in the variable weight food segment (fruit and vegetables, meat, fish, fresh-cut and ready-to-eat food) will have the opportunity to exhibit their products and promote the excellence of Italian fresh produce.

Moreover, Marca is a platform for training and information in the sector through: conferences and debates on the most topical issues; presentation of surveys of the outstanding Report on the Development of the Private Label, conducted in cooperation with Adem Lab – a spinoff of the University of

Parma; information newsletters on activities performed by the leading national and international labels for the development of brand products, relations with industrial suppliers, development of the various markets, strategies pursued by outstanding private labels; analysis of the new private label launches in a dedicated exhibition space where the private labels on the Technical Committee will exhibit new items launched in 2013 or due for launch in 2014, allowing participants to take stock of the latest market trends; training courses designed to inform private label suppliers about the private labels’ brand policies and about partnership policies between suppliers and distributors. www.marca.bolognafiere.it

Ucima chooses Cibus Tec to shape Food Pack A strategic partnership to promote the Made in Italy food&bev processing and packaging technologies and to create the sector’s most exhaustive trade show on international scale. These are the targets of the agreement signed by UCIMA, (Italian Packaging Machinery Manufacturers Association), the National Trade association that represents and supports the Italian packing and packaging machinery manufacturers and Fiere di Parma, the most important Italian exhibition centre specialized in food industry trade shows.

The agreement will finalize in the creation of a new show, Food Pack, dedicat-

INTERNATIONAL EVENTS IN ITALY 15 - 16 January 2014: Marca, int. Private Label conference and show BolognaFiere email: marca@bolognafiere.it - www.marca.bolognafiere.it 18 - 22 January 2014 - Rimini: Sigep, int. confectionery, pastry and ice cream show.

Rimini Fiera - email: riminifiera@riminifiera.it - www.sigep.it 2 - 5 February 2014 - Rimini: RHEX, int. food and catering show. Rimini Fiera - email: riminifiera@riminifiera.it - www.rhex.it 8 - 11 June 2014 - Sirmione (BS): 11th world tomato congress. Fiere di Parma - email: wptc2014@fiereparma.it - www.worldtomatocongress.com 21 - 24 October 2014 - Parma: CibusTec, int. food equipment show. Fiere di Parma email: cibustec@fiereparma.it - www.cibustec.it 3 - 6 May 2015 - Rho (MI): TuttoFood, int. food show. Fiera di Milano - email: info@ tuttofood.it - www.tuttofood.it 19 - 23 May 2015 - Rho (MI): Ipack-Ima, int. packaging, food processing and pasta exhibition. Ipack-Ima - email: ipackima@ipackima.it - www.ipack-ima.com

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ed to food&bev packaging that will run besides Cibus Tec, starting from the next edition, scheduled October 28th to 31st 2014. Cibus Tec and Food Pack aspire to become the World’s most important trade show for the Made in Italy food&bev technologies. The partners of this joint venture are pondering a further agreement with Koelnmesse, organizer of Anuga FoodTec, to share international development strategies both for their historical European trade shows in Parma and Cologne and overseas new projects (Brazil, India, etc.).

Cibus Tec and Food Pack 2014 will represent the following exhibiting sections: food processing (mainly fruit and vegetable, milk and dairy, meat and cured meats, fish, ready meals, Fresh cut, bakery and cereal based products, confectionery, frozen, liquid and semi liquid foods) technologies and solutions for packing, coding, marking, labelling, end of line, handling, storage, logistics, environmental technologies, food safety solutions, automation, ancillary equipment and components, ingredients. www.fiereparma.it

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Alba & Teknoservice - Villafranca Padovana..........................................35

Acma Volpack............................................................................................ 47

East Afripack – (EAK).............................................................................77

ASM.......................................................................................................... 53

FBF Italia - Sala Baganza.........................................................................1

Cavanna.................................................................................................... 48

Foodexecutive.com..........................................................................65-71 Fratelli Pagani - Milano.........................................................................43 Italo Danioni - Milano...........................................................................59 Metra - Verona......................................................................................49

Comav....................................................................................................... 53 Firex.......................................................................................................... 39 Gimat........................................................................................................ 38 Grasselli.................................................................................................... 40 Idecon....................................................................................................... 54

Mini Motor - Bagnolo in Piano..............................................................17 Ilpra.......................................................................................................... 48 Moriondo - Besana................................................................................29 Nol-Tec Europe - Gorgonzola................................................................55 International Clip...................................................................................... 42 Omac Pompe - Rubiera.........................................................................33 Labs........................................................................................................... 37 Pavan Group - Galliera Veneta...................................................... cover 3 Pigo - Caldogno............................................................................. cover 4 SCA - Fiorenzuola D’Arda.....................................................................63 Tecno 3 - Corneliano d’Alba.......................................................... cover 1

Marpatech................................................................................................. 52 Menozzi Luigi & C..................................................................................... 42 Re Pietro................................................................................................... 44 Stalam....................................................................................................... 36

Tecnowerk - Arsiè.......................................................................... cover 2

Tecno 3..................................................................................................... 45

Varvel - Crespellano................................................................................2

Velati.......................................................................................................... 41

Wolhfarth - Sordio................................................................................39

Verinox...................................................................................................... 38

Company Index

Advertiser Index

Inox Meccanica......................................................................................... 40