Food Processing - September 2024

It’s So Easy Being Green Successful sustainability initiatives can be found everywhere as companies seek strategies that are better for business and the world around them. • 20

R&D Team of the Year: Egglife • 26 The opportunity in GLP-1 diets • 28 Food-safe facility design • 33 Refrigeration and freezing • 36 SEPTEMBER 2024

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CONTENTS FEATURES COVER STORY

It's (So) Easy Being Green Successful sustainability initiatives can be found everywhere in the food & beverage industry.

20

R&D TEAMS OF THE YEAR

Egglife Foods: Born of Necessity A home solution to a dietary problem became a value-added business for an egg producer.

Credit: Derek Chamberlain, generated with Shutterstock AI

26 INGREDIENTS

GLP-1 Diets – Opportunity, not Liability Their appetite suppression must be countered with protein and other nutritional ingredients.

28 PLANT OPERATIONS

Facility Design: Food-Safe First Food safety should be the foundation of any capital project.

DEPARTMENTS

33 EDITOR’S PLATE

7

ROLLOUT

18

ON THE WEB

8

NEW INGREDIENTS

32

FOOD SAFETY

9

39

How to preserve the quality and safety of the products without damaging your bottom line or operational efficiency.

41

36

POWER LUNCH

10

CASE STUDY: INSPECTION

NEWS

12

NEW EQUIPMENT

FOODPROCESSING .COM

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TECHNOLOGY

A Consistent Chill

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8/20/24 PM 8/22/24 3:31 11:18 PM

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EDITOR'S PLATE

The Plastic Waste Solution: Just Eat It The Dept. of Defense has three research centers working on converting plastic waste from troops into food and other onsite necessities.

"B

en … one word: plastics.”

Remember that line from the movie “The Graduate”?

If you think Dustin Hoffman was flummoxed, wait till you read on.

Sustainability is our cover story this month, and much of the discussion and much of the blame in that story is focused on “one word: plastics.” Apparently, a Dept. of Defense (DoD) research project is working on a novel solution: turning plastic waste into food, among other troop necessities.

Did I just hear you gulp?

An article originally in nonprofit digital magazine Undark and revisited in MIT Technology Review has discovered the project, which uses bacteria to devour plastic waste, with the fattened-up microbes eventually becoming a food source.

Gulp again.

In 2019, DoD’s Defense Advanced Research Projects Agency (DARPA) released a call for research projects to help the military deal with two problems.

One was supplying troops with necessities in locales that didn’t have established and secure supply chains. “The overriding goal of the program is to create systems that can rapidly produce materials onsite, when and where they are needed,” the DARPA announcement said.

“Portable, self-contained systems could quickly convert energy-dense waste into food,

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water and chemicals to support expeditionary operations and stabilization missions,” the DARPA announcement theorized.

The other problem was the amount of waste the soldiers leave behind, plastic being a big part of that debris.

“The agency wanted a system that could convert food wrappers and water bottles, among other things, into usable products, such as fuel and rations,” the Undark article relates. “The system needed to be small enough to fit in a Humvee and capable of running on little energy.

It also needed to harness the power of plastic-eating microbes.”

DARPA has set several standards for ReSource (the name of the project) that, if achieved, could fundamentally improve how DoD approaches waste management – shifting away from burning, burying or shipping burdensome waste to onsite material conversion of waste from a worthless liability to a strategic resource.

“In the case of food,” DARPA said in the request for proposals, “the ReSource output would be a basic product composed of macronutrients ready for immediate consumption.”

Plastic-eating bacteria are not new, they’ve been talked about and experimented with for years. But making the little critters into food is novel … and a long way from reality.

However, there are other research

projects around the globe exploring whether microorganisms might one day help feed the world’s growing population, the Undark article says.

You know the problems with plastic waste – from unsightly litter to ocean and ground pollution to microplastics that could be infiltrating everything we eat.

Michigan Technological University was one of three research groups answering DARPA’s call and receiving funding. Undark talked to Stephen Techtmann, a microbiologist at Michigan Tech: “The goal … is not to feed people plastic. Rather, the hope is that the plastic-devouring microbes ... will themselves prove fit for human consumption. While Techtmann believes most of the project will be ready in a year or two, it’s this food step that could take longer," Undark reported.

“His team is currently doing toxicity testing, and then they will submit their results to the Food and Drug Administration for review. Even if all that goes smoothly, an additional challenge awaits.” Namely, the ick factor. n

Written by

Dave Fusaro EDITOR IN CHIEF DFUSARO@ENDEAVORB2B.COM

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8/26/24 10:16 AM

ON THE WEB SEPTEMBER 2024 | VOLUME 85 NUMBER 8

EDITORIAL TEAM EDITOR IN CHIEF

What’s New Online Don’t miss what’s happening this month on FoodProcessing.com.

Dave Fusaro

dfusaro@endeavorb2b.com SENIOR EDITOR

Andy Hanacek ahanacek@endeavorb2b.com CONTRIBUTING EDITORS

Ed Avis, Claudia O’Donnell EDITORIAL ADVISORY BOARD Mohamed Z. Badaoui Najjar, Ph.D.

E

very day, we add more content to www.FoodProcessing.com. Here are just a new of the items added in the past month.

COMPETITION

Vote for our Green Plant of the Year

Our Green Plant of the Year poll is open!

West Liberty Foods, Keystone Potato Products and Perdue Farms have submitted essays on why their plants should be chosen. You get to pick the winner after reading their essays. Read and vote at: www.surveymonkey.com/r/ FPGP24 EHANDBOOKS

PODCASTS

Ed Ballina

Several new podcasts vie for your ears

For those who like to listen, we continue to build our podcast library. In the past month, we've talked to Johanna Velez of Monin Americas on the effect of corporate culture and technology on quality; Bridget Allerton of 84.51 on ice cream trends; Catherine Lochner and Janae Kuc-Langford of Ingredion on health, taste and texture in ready-to-mix protein powders; and Todd Baker of Horizon Systems on the effect of new ingredients on the processing plant. There are many more topics presented by industry experts; see the whole list at: www.FoodProcessing.com/ podcasts

Deep dives on baking, food safety

We've added two new ebooks. The first finds bakeries jockeying for position in the marketplace and even building new facilities. A food safety ebook takes a look at the evolving FDA Human Foods Program and asks what the agency will do about all those state ingredient bans and heavy metals. See our entire library of ebooks at: www.FoodProcessing.com/ ehandbooks

R&D Senior Director– Strategy & Portfolio Sector Food & Beverage, PepsiCo Principal, Operational Excellence Consulting (retired from PepsiCo)

James Davis

Director-Global Sanitation, OSI Group LLC

Leslie Herzog

Vice President of Operations & Research Services, The Understanding & Insight Group LLC (retired from Unilever)

Steven Hill, Ph.D.

Vice President-R&D, QA, Food Safety, Sustainability, Engineering, Regulatory, T. Marzetti

Leslie Krasny

Krasny Law Office

Alvaro Cuba Simons

Operations & Supply Chain Consultant (formerly of Mondelez and Kraft)

Gary M. Stibel

Founder & CEO, The New England Consulting Group

Joel Warady

President, Catalina Crunch

DESIGN & PRODUCTION ART DIRECTOR

Derek Chamberlain dchamberlain@endeavorb2b.com PRODUCTION MANAGER

Rita Fitzgerald

rfitzgerald@endeavorb2b.com AD SERVICES MANAGER

Jennifer George

jgeorge@endeavorb2b.com

EXECUTIVE STAFF VP/GROUP PUBLISHER

Keith Larson

NEWSLETTER

CIRCULATION REQUESTS

Daily food & beverage news

We try to write a "best of" the news every month in this magazine, but all the stories you see on pp12-17 first appeared on our website and in our daily newsletter. Stay up to date – maybe be the first at your company to know things – by signing up for our daily newsletter. bit.ly/3yHyZLZ

Lori Books

ENDEAVOR BUSINESS MEDIA, LLC CEO

Chris Ferrell PRESIDENT

September Griffin COO

Patrick Rains CRO

Paul Andrews CHIEF DIGITAL OFFICER

Jacquie Niemiec

CHIEF ADMINISTRATIVE AND LEGAL OFFICER

Tracy Kane

EVP INDUSTRIAL GROUP

Mike Christian

Endeavor Business Media, LLC

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SEPTEMBER 2024

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8/22/24 11:16 PM

FOOD SAFETY

State Restrictions on Ingredients

Be prepared to navigate a patchwork of state bans on ingredients used in food.

S

tates are taking actions that will require food & beverage companies to eliminate certain ingredients from their products or to cease manufacturing or distributing them in the state. California became the first state to do so with the Oct. 7, 2023, passage of the California Food Safety Act. Effective Jan. 1, 2027, California will ban food or beverage products in the state that contain brominated vegetable oil, potassium bromate, propylparaben or red No. 3.

While some groups touted the passage as an important step in ensuring the safety of food & beverage products, others questioned the scientific basis underlying the decisions to ban these ingredients on safety grounds.

Concerns were also raised that this type of state-specific ingredient ban would disrupt the existing food regulatory system — leading to states now policing food additives that have historically been under the authority of the FDA and USDA — and that costs of complying with the ban would be passed along to consumers.

California seems to have inspired other states to undertake similar legislative efforts. Comparable bills have been introduced in Illinois, Maryland, Missouri, New Jersey, Rhode Island, South Dakota and Washington.

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Some states have introduced legislation to ban additional ingredients from being used in food & beverage products. For example, in addition to the ingredients disallowed by the California bill, a New York bill would ban titanium dioxide (an ingredient that was removed from the California Food Safety Act), azodicarbonamide and butylated hydroxyanisole.

One Pennsylvania bill would ban potassium bromate, brominated vegetable oil and beta hydroxy acids; a companion bill would ban the following dyes: red No. 3, red No. 40, yellow No. 5, yellow No. 6, blue No. 1, and blue No. 2.

California has also continued to act in this space. Subsequent legislation was introduced to ban the use of certain ingredients in food and beverage products used by public schools in the state, including blue No. 1, blue No. 2, green No. 3, red No. 40, yellow No. 5, yellow No. 6 and titanium dioxide.

The FDA is typically slower to ban ingredients that have been in use than the state legislatures proposing these bills. It remains to be seen whether the state action will prompt the FDA to ban some or all the ingredients that are being targeted at the state levels.

Many of the substances targeted by these state-level bans are currently under review by the FDA, including red No. 3, titanium dioxide, brominated vegetable oil,

potassium bromate and propylparaben. James Jones, Deputy Commissioner for Human Foods, acknowledged the California ban, stating the FDA aims to reassess the chemical safety of food additives.

We advise companies to prepare for increased oversight of ingredients used in food and beverage products at the state level, as well as the existing state requirements for packaging materials for food and beverage products, by taking the following actions: → Begin reformulating existing food and beverage products for the California market to comply with the California Food Safety Act. → If developing a new product, closely consider the ingredients and packaging materials used against the backdrop of the proposed and enacted state legislation. → Stay apprised of developments on food additive and packaging material restrictions because the regulatory landscape is changing. n

Written by

Sam Jockel and Ashley Yull ...of law firm Alston & Bird (www.alston.com).

9

8/22/24 11:19 PM

POWER LUNCH

AI Enables Private Label and Brands To Work Together

Retailers and processors can use artificial intelligence to optimize assortments.

P

rivate-label sales had a banner year in 2023, as retailer-owned brands continued to gain share across categories, especially in food. Yet, looking forward, retailers also need to strike a balance between private labels and national brands on shelves, putting a greater emphasis on developing fully optimized assortments.

For this reason, predictive analytics will have a huge impact as retailers and consumer goods companies leverage technology to create the most localized and optimized mix of private-label and national-brand items. The goal is to get both sides working together.

According to research released

by Circana and the Private Label Manufacturers Assn., private label dollar sales grew by more than $10 billion in 2023. For the full year, refrigerated products generated the highest dollar sales — $46.7 billion. General food items grew 10% year over year, the highest growth category in private label behind beauty (+10.5%).

The research showed private labels grew in every category

except tobacco and outpaced the growth of national brands, growing by 4.7% versus 3.6% for brands.

All told, private labels had a very good year, as consumers looked to the products to save money, and the items found their way into more shopping carts.

For example, Kroger’s budget-conscious brand Smart Way was the fastest-growing private label last year, up 4.5% in household penetration. Adding to the trend, Target recently announced its low-price brand Dealworthy.

Yet, with all the trends and momentum circling private-label products, how can retailers derive an optimal balance of private label and national brands? The answer’s in the data.

To be clear, there is no right answer in the debate of private labels and name brands. First and foremost, retailers should focus on providing consumers with a hyper-local assortment of the products their shoppers want.

Using predictive analytics, retailers and brands can localize product mixes that sell best at an individual store level.

With all the trends and momentum circling private label products, how can retailers derive an optimal balance of private label and national brands? The answer’s in the data.

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Advances in how AI can parse data and recommend assortments that generate the most volume and revenue can bring brands and retailers together to find a mix of private labels and national brands.

Together, the companies can identify how best to fit an assortment to every store’s varied demographics and buying habits.

It’s no longer about private brands and national brands competing against one another but how they join forces to build a product mix and assortment that best meets shoppers’ needs.

AI-powered assortment optimization

AI models read large amounts of data (sales numbers, retailer loyalty data, shopper data from programs like Walmart Luminate, macroeconomic data, third-party panel research, etc.). From there, category and brand managers coach the AI to learn and predict how a store-level assortment can be shaped.

Within that learning, brands and retailers can work together to focus on a few issues such as: → Differentiating SKUs – By region and each individual store, retailers can leverage AI to uncover unique assortments

SEPTEMBER 2024

8/22/24 11:27 PM

POWER LUNCH

that differentiate SKUs to drive incrementality. Retailers identify assortments that meet each local community, reacting to a sense of how a region shops.

The assortments discover what products, private labels and national brands, resonate most with each area. → Innovating categories – AI also combs through data to identify potential innovation gaps in product categories. A retailer can spot a potential product trend to introduce within its private-label portfolio to lift an assortment and category.

At the same time, a CPG can see where there are innovation opportunities to present to retailers. Together, brands and retailers can create assortments that distinguish and excite assortments. → Addressing the price gap – Shoppers no doubt buy private brands to save money, as there tends to be a price gap between private labels and national brands. AI can optimize pricing with price elasticity models to identify ideal price points for all products in the assortment, striking an optimal balance of what shoppers are comfortable spending on private brands and national brands.

Consumer goods brands don’t need to view rising private-label sales as a threat. Instead, companies should look at increased sales of both consumer brands and private labels as an opportunity to enhance collaboration.

AI and predictive analytics provide both companies with an unbiased look at how products are performing. It’s up to both

companies to use the data and find ways that lift all brands and deliver an assortment that feels local and special to each store in the network. n

Written by

Kristine Joji EVP OF STRATEGY CONSULTING AT INSITE AI (INSITE.AI)

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8/8/24 1:17 PM 8/26/24 10:47 AM

IN THIS SECTION » Equity fund buys most of Golden State » Former Nestle Waters is merging » Another King's Hawaiian plant

Mars Will Acquire Kellanova for $36 Billion Mars immediately becomes a global snacking powerhouse in the food industry’s biggest-ever transaction.

T

he rumors are true. Mars announced on Aug. 14 it is acquiring Kellogg spinoff Kellanova for $35.9 billion, including the assumption of some dent, making it the largest transaction ever in the food & beverage space.

The deal immediately will make Mars, which had only a few snack products in its portfolio, one of the world’s largest snack providers.

Mars will pay Kellanova shareholders $83.50 per share in cash, a premium of 44% to Kellanova’s 30-day trading price and 33% above its 52-week high reached on Aug. 2. Mars intends to finance the acquisition through a combination of cash and new debt, for which commitments have been secured.

Kellanova of course is the snacking half of the former Kellogg Co., which split into two in October of last year. While WK Kellogg Co retained domestic cereals, Kellanova got snacks such as Pringles, Cheez-It, Rice Krispie Treats and Pop-Tarts, as well as frozen breakfast foods and the international cereal business. Kellanova had 2023 sales of just over $13 billion and net income of $951 million.

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Mars, with an estimated $45 billion in sales, has moved away from its chocolate and candy roots to the point pet food and pet care is now the biggest part of the business.

Outside of its confectionery brands, which it includes in its “snacking” category, Mars owns Combos, Tru Fru, Kind granola bars and Nature’s Bakery – the last three acquired since November 2020. The company is entirely owned by the Mars family.

Snacking is a large, attractive, and durable category that continues to grow in importance with consumers, the Mars news release said. Upon completion of the transaction, Kellanova will become part of Mars Snacking, led by Global President Andrew Clarke and headquartered in Chicago.

Steve Cahillane, chairman and president/CEO of Kellanova, said a few days later he will not be moving to the new company.

“The addition of Kellanova provides Mars Snacking with entry into new attractive snacking categories,” the news release continued. “It will add two new billion-dollar brands – Pringles and Cheez-It – to the Mars business. It will also expand the

Mars health & wellness snacking portfolio with the addition of new complementary products like RxBar and NutriGrain.”

“In welcoming Kellanova’s portfolio of growing global brands, we have a substantial opportunity for Mars to further develop a sustainable snacking business that is fit for the future,” said Poul Weihrauch, CEO and Office of the President of Mars. “We will honor the heritage and innovation behind Kellanova’s incredible snacking and food brands while combining our respective strengths to deliver more choice and innovation to consumers and customers.”

In the announcement, Cahillane said, “This is a truly historic combination with a compelling cultural and strategic fit. Kellanova has been on a transformation journey to become the world’s best snacking company, and this opportunity to join Mars enables us to accelerate the realization of our full potential and our vision.”

The deal has been unanimously approved by the board of directors of Kellanova, but it still requires Kellanova shareholder approval.

SEPTEMBER 2024

8/22/24 11:28 PM

NEWS

Nestle Suddenly Replaces its CEO Nestlé SA on Aug. 22 announced Laurent Freixe, currently an executive vice president and CEO of Zone Latin America, will take over as CEO on Sept. 1. Current CEO Mark Schneider “has decided to relinquish his roles as CEO and member of the board of directors,” the company announcement said.

There were no prior hints of a succession at the top of the world’s largest food company.

Freixe joined Nestlé in France in 1986. “Since then, he has progressed within the company, assuming various positions of increasing responsibility across different businesses, markets and zones,” the news release said.

“He successfully managed Zone Europe during the financial and economic crisis, from 2008 until 2014. He then took over as CEO of Zone Americas, where he accelerated growth. Following the creation of Nestlé’s new zone structure in 2022, Laurent Freixe was named CEO Zone Latin America, where he has been successfully leading through challenging conditions.”

Freixe has been a member of the company’s executive board for 16 years. No word yet on who would replace him in Latin America.

FDA Public Hearing to Reconsider GRAS FDA will hold a public meeting on Sept. 25 to discuss proposed improvements in the agency’s post-market assessment of chemicals in food – including the generally recognized as safe (GRAS) process, food additives, color additives, food contact substances and contaminants.

The agency’s handling of all those topics has met heavy criticism in recent years.

In addition to explaining its plans for an “enhanced systematic process for post-market assessment of chemicals in food,” the agency wants to hear stakeholder perspectives. “This information will help inform our thinking and further the development of the process,” the agency said.

“This is intended to guide our post-market assessment work going forward and includes a transparent process for

PRODUCT OF THE MONTH Bringing new meaning to the goal of increasing the size of your snacking portfolio, Kellanova offered a 26 X 36-inch toaster pastry, the first-ever Pop-Tarts Party Pastry briefly in August and only in New York, Los Angeles and Chicago. With strawberry filling, frosting and sprinkles, the giant Pop-Tart is 73 times bigger than traditional ones. For $60 it was delivered in a three-foot box mirroring the brand's traditional packaging. The stunt was in celebration of Pop-Tarts' 60th birthday.

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identifying and prioritizing food chemicals currently in the market for safety reviews.”

There will be limited in-person attendance and virtual attendance. For the exact time and registration, go to http://bit. ly/4czYixy.

Florida 'Lab Meat' Ban Challenged The Institute for Justice (IJ) — a public interest law firm — filed a lawsuit Aug. 13 challenging a new Florida law that bans cultivated/ cultured meat in the state. In doing so, the firm joins Upside Foods in opposing the law.

The lawsuit argues that Florida’s ban violates the Constitution’s provisions that prohibit protectionist measures that favor in-state businesses at the expense of out-of-state competitors. By targeting cultured meat, which is produced outside Florida, the law seeks to protect local meat producers from competition, undermining the principles of a national common market.

The bill’s sponsors and Governor Ron DeSantis admitted as much when the bill was signed into law on May 1. It went into effect on July 1.

“If some Floridians don’t like the idea of eating cultivated chicken, there’s a simple solution: Don’t eat it,” said Paul Sherman, a senior attorney at the Institute for Justice. “The government has no right to tell consumers who want to try cultivated meat that they’re not allowed to. This law is not about safety; it’s about stifling innovation and protecting entrenched interests."

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8/22/24 11:28 PM

Lindsay Goldberg Fund Buys Most of Golden State Foods Lindsay Goldberg, which calls itself a family- and founder-focused private equity firm, has an agreement to acquire a controlling interest in Golden State Foods.

GSF's founding Wetterau family will maintain an unquantified but “significant” ownership stake.

The joint announcement said the buy-in “will provide [GSF] with additional resources and capabilities to advance its mission to provide unmatched solutions and service to its customers and pursue growth throughout its global business operations.”

Following the close of the transaction, GSF will remain managed and operated from its headquarters in Irvine, Calif. Brian Dick will continue to serve as president/CEO and as a member of the GSF board of directors, and the current management team will remain in place.

The transaction was unanimously approved by GSF’s directors and is subject to regulatory approvals and other customary closing conditions. No financial details were released.

GSF, established in 1947, is a $5 billion (our estimate) processor of liquid, protein, produce, dairy and beverage products and other services, mostly for foodservice customers. The company employs more than 6,000 across 50 locations and supports approximately 125,000 restaurants around the world on five continents.

“Lindsay Goldberg shares our core values and is committed to helping us achieve our long-term objectives while maintaining our

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customer-focused approach,” said Dick. Conrad Wetterau, chairman of GSF’s board of directors, added, “The Wetterau families look forward to strategically partnering with Lindsay Goldberg going forward and continuing to meaningfully engage in the future of GSF, with Stephen Wetterau and myself representing our families by continuing to serve as active GSF board members.”

Two of the partners at Lindsay Goldberg noted their own firm’s “longstanding experience in the quick and limited service restaurant food supply chain.”

BlueTriton (Nestle Waters) To Merge With Primo Water BlueTriton Brands, the company formed after the 2021 acquisition of Nestle’s former North American water business, is merging with Primo Water Corp., a supplier of “large format” water systems (think office water coolers), creating a $6.5 billion “North American pureplay healthy hydration company … with diversified offerings across products, formats, channels and consumer occasions.”

In an all-stock transaction unanimously approved by their respective boards of directors, BlueTriton shareholders are expected to own 57% of the merged company, for the time being called NewCo., with Primo Water shareholders and holders of incentive equity holding the other 43%.

BlueTriton appears to be entirely held by venture capitalists, but Primo has at least some shares listed publicly. The combined company is expected to be listed on

the New York Stock Exchange. The transaction is expected to close in the first half of 2025.

NewCo is expected to be dual headquartered in Tampa, Fla., home of Primo, and Stamford, Conn., which BlueTriton calls home.

Dean Metropoulos – serial savior of several food & beverage companies and the current chairman of BlueTriton – will serve as non-executive chairman of the combined company. Robbert Rietbroek, the current CEO of Primo Water, will serve as CEO, Primo’s David Hass will continue as CFO and Rob Austin, the current chief operating officer of BlueTriton, will stay COO. Primo's brands include Primo Water, Mountain Valley, Crystal Springs, Sparkletts and Alhambra.

The company’s net revenue from continuing operations grew from $1.4 billion in 2021 to $1.8 billion during the 12 months ended March 31, 2024, a compounded annual growth rate of 11%. Adjusted EBITDA grew from $304 million to $399 million over that same period, a compounded annual growth rate of 13%.

BlueTriton owns such former Nestle brands as Poland Spring, Deer Park, Ozarka, Ice Mountain, Zephyrhills, Arrowhead, Saratoga and Pure Life. Through its ReadyRefresh business in the U.S., BlueTriton also serves the home and office beverage delivery segment. The Nestle brands were acquired in February 2021 by an affiliate of One Rock Capital Partners in partnership with Metropoulos & Co. Since the acquisition, BlueTriton's net revenue grew from $3.9 billion in 2021 to $4.7 billion during the 12-month period ended March 31, 2024, a compounded annual growth rate of 9%.

SEPTEMBER 2024

8/22/24 11:28 PM

NEWS

More acquisitions Tilray Brands, which started life as a Canadian marijuana company looking forward to the opening of the U.S. market, instead has added to its U.S. beer portfolio by buying four craft breweries from Molson Coors Beverage Co. The acquired units are Hop Valley Brewing Co., Terrapin Beer Co., Revolver Brewing and Atwater Brewery.

The Tilray Beverages portfolio already includes craft beer, spirits and non-alcohol beverages including SweetWater Brewing Co., Montauk Brewing Co., Alpine Beer Co., Green Flash Brewing Co., Shock Top, Breckenridge Brewery, Breckenridge Distillery, Blue Point Brewing Co., 10 Barrel Brewing Co., Redhook Brewing Co., Widmer Brothers Brewing, Square Mile Cider Co., HiBall Energy and Happy Flower CBD sparkling cocktails.

Calavo Growers Inc. sold its Fresh Cut business to F&S Fresh Foods of Vineland, N.J., for $83 million (subject to closing adjustments). The Fresh Cut business is the former RFG (Renaissance Food Group) fresh cut fruits and vegetables business, which Calavo acquired in 2011.

Cal-Maine Foods, already the country’s biggest egg processor, bought the assets of another egg producer/processor, ISE America Inc., headquartered in Galena, Md. The price was $110 million.

The acquired ISE assets include commercial shell egg production and processing facilities with current capacity of approximately 4.7 million laying hens, including 1.0 million cage-free, 1.2 million pullets, feed mills, approximately 4,000 acres of land, inventories and an egg products breaking facility.

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QualiTech, primarily an ingredient supplier, has acquired Ellison Bakery, a Fort Wayne, Ind., manufacturer of cookies, snack bars,

crunches, toppings and inclusion ingredients for retail, foodservice and private label markets. Terms of the deal were not disclosed.

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Expansions Irresistible Foods, the parent of the King’s Hawaiian brand, will invest an additional $54 million to build a second facility on the site of its proposed new manufacturing plant outside Taylorsville, Ind. Construction has yet to start on the first new facility, which was announced in December 2023, but Irresistible Foods already thinks it needs more capacity beyond the 368,000 sq. ft. that initial plans would provide.

Unilever will spend more than $80 million to expand its plant in Jefferson City, Mo., to add production of Liquid I.V., a powdered hydration mix within its Health & Wellbeing business. Unilever will

add automated packaging lines, a blending room operation and modifications to required infrastructure to make the functional electrolyte powder, which Unilever claims “has become the number one powdered hydration brand in America.”

G&S Foods, a co-packer and private label manufacturer of snack foods, recently cut the ribbon on its new manufacturing facility in Hanover, Pa. Total investment was not disclosed, but new equipment alone cost $50 million. The plant has 348,344 sq. ft. of production space, allowing G&S Foods to expand production, develop new snack products and consolidate operations.

San Diego, Calif.-based Sapporo-Stone Brewing unveiled phase

one of its overall $60 million expansion plan at its two U.S. breweries — phase one being a $20 million expansion of its Escondido, Calif., brewery. The company, which was acquired two years ago by Sapporo U.S.A., also has invested $40 million in its Richmond, Va., facility, and the combined expenditures will double Sapporo-Stone’s capacity to about 700,000 barrels a year.

Vital Farms will add a second egg washing and packaging facility to its production network by building a new plant in Seymour, Ind. The 72-acre site will give Vital Farms the ability to continue growing its pasture-raised egg business, expected to help generate more than $350 million in additional revenue for the brand.

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NEWS

People Cheese producer Sargento announced the retirement of two executives, appointment of a new COO and a raft of subsequent executive changes. Third-generation family owner Mike McEvoy will retire as executive vice president of operations, Kristi Jankowski will retire from her position as executive vice president of innovation, and Michael Pellegrino was promoted to COO. Weeks later, Sargento announced new roles for eight team members across its Consumer Products and Food Service & Ingredients business units: Erin Price, general manager-consumer products; Jeremy Schellin,

general manager-food service & ingredients; Rod Hogan, SVP-innovation (he replaces Jankowski); Chris Regennitter, SVP-Sargento sales; Brian Ginn, VP-consumer products sales; Joy Judski, VP-food service & ingredients sales; Chris McCarthy, VP-strategic planning; and Amy Ehlen, VP-pricing & demand planning.

Poultry processor Wayne-Sanderson Farms promoted David Gadd to senior vice president and general manager of the retail business unit. He was vice president of retail sales, having joined Sanderson Farms in 1997 as a beginning trainee.

Sun-Maid Growers of California promoted Steve Loftus from president and COO to president and CEO. Also, Harry Overly will step down as executive chairman of Sun-Maid’s board of directors to focus on his role as president/CEO of Flagstone Foods.

General Mills hired Asheesh Saksena as chief strategy & growth officer, effective Aug. 26. He succeeds Dana McNabb, following her Jan. 1 appointment to group president of North America Retail.

Devin Cole, head of Tyson’s global McDonald’s business, got the additional title of president of Tyson's international business, replacing Amy Tu, who is retiring.

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ROLLOUT Heat-and-Eat Eggs

Eggland’s Best, the leading branded egg in the U.S., now offers frozen Sous Vide Egg Rounds in two varieties: Bacon & Cheese and Sausage & Cheese. The company’s patented method of production and verification ensures that its eggs have six times more vitamin D, more than double the omega-3 fatty acids, 10 times more vitamin E and 25% less saturated fat than ordinary eggs.

The new rounds are made with these eggs. The egg rounds can be enjoyed on their own, as a sandwich starter or on a salad. The sousvide style ensures a fluffy texture, meaning no more tough, chewy egg, even after heating in the microwave. Sous vide is an innovative cooking technique that involves vacuum sealing food in a specially designed pouch and slow cooking it in water at low temperature until fully cooked. The package is then flash frozen or refrigerated.

Globally Inspired Shelf-Stable Meals

Mars Food & Nutrition, a business segment of Mars Inc., is expanding into the ready meals space with the launch of Ben’s Original Street Food in the U.S. and Canada, taking this rice side dish brand to the center of the plate. The shelf-stable meals are designed to assist consumers with on-the-go convenience that does not sacrifice flavor or nutrition.

S’mores in a Noodle Cup?

Ramen manufacturer Nissin Foods USA shows consumers it’s no ordinary noodle brand. The company reimagined a classic, summertime fireside dessert with the launch of limited-edition Cup Noodles Campfire S’mores. This gooey, sweet noodle experience is exclusive to Walmart. It combines chocolate, marshmallow and graham cracker flavors with a smoky note for a unique s’mores experience. Simply add water, microwave for three minutes and let it stand for two minutes.

For more than 65 years, Nissin Foods has led the instant ramen industry with innovation and culinary creativity. Earlier this year, the company offered limited-edition Cup Noodles Everything Bagel with Cream Cheese, which combines noodles with sesame seeds, poppy seeds, garlic, dried onion and caraway seeds in a rich cream cheese flavored sauce, which was also exclusive to Walmart where the cups sell for $1.18.

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To create the new products, the Mars Food & Nutrition team engaged consumers in the development, tapped into chefs’ creativity and leveraged AI powered insights. Ready in just 90 seconds in the microwave, the bowls come in four varieties: Bean & Rice Burrito Bowl, Fried Rice with Vegetables, Gumbo with Chicken Andouille Sausage and Jamaican Jerk Style Red Beans & Rice with Chicken. Other recent innovations from the brand include Ben’s Original Plant Powered, Ben’s Original 10 Medley and Ben’s Original One Pan Creations.

SEPTEMBER 2024

8/22/24 11:30 PM

ROLLOUT

Foodservice Sauce Goes Retail

Saucy chicken chain Zaxbys is bringing its legendary sauces to retail customers nationwide. The new product line meets the demand of flavor-craving consumers with three bottled fan-favorite sauces.

Zax Sauce is mayonnaise-based with a tang that comes from a proprietary blend of spices, of which the recipe is kept locked away in a vault, according to the company. Spicy Zax Sauce is the same sauce with heat. The third variety is a vinegar-based hot sauce: Tongue Torch Sauce is fat-free and made with aged peppers, garlic and mustard seeds.

The shelf-stable condiments are produced through a collaboration with Litehouse Inc. The 16-oz. squeeze bottles sell for $4.48-4.98.

Snack Bars for Back to School

Once Upon a Farm, a childhood nutrition brand, is growing its pantry snacks portfolio with organic, Soft-Baked Bars for Kids. Available in four kid-approved flavors — Apple & Oat, Chocolate Oat, Mixed Berry and Banana Chocolate Chip (a Kroger exclusive flavor and available online in August) — each bar contains real fruits and vegetables, 100% whole grain oats and no-added sugar. They are also non-GMO Project Verified and free from artificial flavors and colors.

The company is also releasing limited-edition, back-to-school four packs of some of its beverages, including dairy-free smoothies in Strawberry Banana Swirl and Berry Berry flavors, as well as its Organic Immunity Blends. These juices come in two different combo packs, with two varieties of a flavor.

One combo features pineapple banana dragonfruit and blueberry banana ginger. The other is mango banana spirulina and apple cherry elderberry.

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Milk That’s Easy on the Tummy

Garelick Farms, a farmer-owned brand from Dairy Farmers of America, adds lactose-free milk to its lineup. It is said to be easier to digest while still delivering all the vitamins and nutrients of regular milk. Bottled in Massachusetts, the new milk is manufactured using high-temperature short-time processing, which differentiates it from some other national lactose-free milks that use ultra-high temperature processing.

The gallon jugs come in whole and 2% varieties. The debut is supported with an integrated campaign, “Easy to Digest,” which includes digital advertising, paid and organic social and in-store marketing. The campaign uses humor to highlight hard-todigest situations – like a Red Sox rainout, traffic on I-28 or New England weather and then compares Garelick Farms lactose-free milk as easy to digest.

“Lactose intolerance affects a lot of people, but it doesn’t mean they have to give up on fresh-tasting and nutritious milk,” says Michael Young, general manager.

“We hope this campaign makes people smile as they think about hard-to-digest situations.”

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Written by

COVER STORY

Andy Hanacek SENIOR EDITOR

It’s So Easy Being Green Credit: Derek Chamberlain, generated with Shutterstock AI

Successful sustainability initiatives can be found everywhere as companies seek strategies that are better for business and the world around them.

D

ecades ago, being environmentally friendly and “going green” were buzzwords in most corporate boardrooms. Sure, some companies talked about their sustainability, but it wasn’t typically approached from the perspective of environmentalism.

Today, corporate and operations initiatives that seek to take better care of the planet and the natural resources it provides can be found in almost every corner of the food & beverage industry. In fact, the tables have turned to where companies not engaged in some sort of sustainability project are the outliers.

“The issue of sustainability is embedded into the fabric of our members’ business and their iconic brands,” says John Hewitt, senior vice president of packaging and sustainability for the Consumer Brands Assn. (CBA). “It’s been part of their DNA for many years.”

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COVER STORY

Revisiting recycling

The lower-hanging fruit for sustainability improvements typically has involved packaging — for many years, “reduce, reuse, recycle” has been the mantra of many. Hewitt says even today, the focus of many brands remains on packaging sustainability.

“Recognizing that single-use packaging is — as the name describes — single use, a majority of our companies have committed to making their single-use packaging 100% recyclable, compostable, biodegradable, reusable — something to make that packaging reusable in some way,” he says.

That’s well and good, but many question whether consumers actually recycle or reuse packaging — or if municipalities and infrastructure can handle the material, since those systems aren’t consistent and widespread.

Hewitt says that the industry’s commitment to building out the infrastructure, educating the consumer and embracing technology to get recycling rolling has been one of the biggest changes over the last several years or more.

“Certainly, brands can design for recyclability in many respects, and they've been doing that for a long time, whether it's glass or paper, which have been going in blue

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bins for decades,” Hewitt explains.

“Plastics has been an emerging and growing trend over the past decade, and one of the biggest commitments on the packaging side of the equation is our members’ commitment to helping build out that infrastructure that will collect and ultimately complete circularity for those packaging types.”

Another way to improve the success rate when it comes to plastics, of course, is to outright reduce their use for food & beverage products, which many companies are taking on. Hewitt points to an iconic cereal brand that reduced weight of the bags in the boxes by 17%, removing some 200,000 lbs. of plastic from the waste stream.

“If we remove those materials before they even get in the stream, we never have to worry about things like funding recycling systems, making sure that consumers recycle it properly, collecting it or finding an end market for it,” Hewitt says. “So source reduction remains paramount.”

In a recent webinar covering consumer-packaged goods disruption, Gina Roberts, solutions architect for market research firm Spins (www.spins.com), sees brands demonstrating an evolution in their sustainability efforts through these types of changes – such as choosing glass over plastic to make packaging more sustainable.

COURTESY OF TALKING RAIN BEVERAGE CO.

Talking Rain Beverage Co. embarked upon an initiative to reduce the weight of its packaged products by lowering the amount of plastic used in its bottles and removing the cardboard trays that held the product in packaging.

“What’s kind of unique here is, brands are doing this across many different products and categories, but one that’s interesting to highlight is elevating recycling, which we’re seeing a lot in kid-positioned products,” Roberts says. She points out Globowl baby and toddler foods have married recycling with better health by packaging their products in glass jars rather than plastic pouches, “so not only is the glass packaging promoting recycling, but it’s also negating micro-plastic ingestion.”

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Celestial Tea, much like the cereal example earlier, attacked the plastic packaging issue by removing the outer plastic wrap on its product boxes, reducing its annual plastics use by about 165,000 lbs., Roberts notes.

Talking Rain Beverage Co., maker of Sparkling Ice, reduced the amount of plastics used in its bottles and removed the cardboard trays the bottles were packaged in, partly in an effort to lightweight its product shipments.

“As of this year, we’ve been able to eliminate 1.6 million lbs. of plastic, and the impact on our carbon footprint has been tremendous,” COO Oscar Mayorquin explains, noting that the initiative is ongoing. “We’ve also recently qualified our fifth co-packing facility to run trayless, and by the

end of the year, all our bottling facilities will have the capability to run trayless.”

In addition, Mayorquin says Talking Rain is ramping up a second phase of lightweighting the packaging, turning its focus to the bottles as well as the outer packaging on the products.

“We’re considering new and innovative ways to ensure the structure of the bottle remains firm, while reducing more of the plastic content,” he says. The company also would like to incorporate more recycled polyethylene terephthalate (rPET) content into its bottles, based on early returns on two projects.

Talking Rain has had success using 25% rPET for products coming from its Preston, Wash., facility, and all its AQA brand alkaline water bottles are made with 100% rPET.

However, consumers often aren’t fully educated on where or how to recycle the packaging — or even if it can be recycled. Not to mention that different locales can have different rules or infrastructure. Hewitt says CBA members are trying to clear up some of that confusion through the association’s SmartLabel platform. The association continues to build out the program, which “digitally shares more information than could ever fit on the labels of tens of thousands of products that Americans use every day,” the web site says.

“Preparation instructions are something we're familiar with, as we've been using them ever since we had to fend for ourselves,” Hewitt adds. “But adding recycling instructions to the package has been a major commitment that many of our members have invested in as well.”

In early 2024, PepsiCo Beverage North America announced it would phase in a fleet of 50

Beyond the product

electric semis for shipping in and out of its Fresno, Calif., facility, as well as 75 electric vans for use throughout the state.

COURTESY OF PEPSICO BEVERAGE NORTH AMERICA

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Sustainability goes beyond packaging composition and plastics use, of course, into operational efficiency and use of natural resources. Carbon footprint was on Talking Rain’s mind when it lightweighted its products, and the company went the extra step to dig into its logistics partnerships and analyze the miles its trucks were driving to deliver product.

“One of our supply chain goals is to have our packing facilities located within 350 miles of customers,” Mayorquin says. “Our logistics network optimization strategies have reduced overall average miles per truck shipment by 12% and CO2 emissions per shipment by 8%.”

In May of this year, PepsiCo Beverages North America announced

SEPTEMBER 2024

8/22/24 11:32 PM

COVER STORY

its Fresno, Calif., facility would begin to use 50 electric semi trucks for shipping and distribution, as well as 75 electric vans for its equipment services fleet across the state of California. The project was no small feat, as the 170,000sq.-ft. facility needed to install eight 750-kilowatt Tesla chargers and two Tesla Megapack Battery Energy Storage Systems onsite to power the vehicles, the company’s release said.

Earlier this year, the U.S. Dept. of Energy awarded four of Unilever’s U.S. ice cream plants a $20.9 million award to reduce carbon emissions, and those facilities were expected to replace natural gas boilers with electric boilers and industrial heat pumps using waste heat recovery. The company said the proposed projects would cut 14,000 metric tons of carbon emissions per year.

Many of these larger companies have numerous divisions and plants all across the country (and the globe, in some cases), so how does a sustainability champion decide what projects make the most sense? In the case of Hormel Foods Corp. (whose Fontanini Foods plant in McCook, Ill., won our 2023 Green Plant of the Year, by the way), the company fosters innovative ideas on sustainability initiatives at the plant level, then further encourages teams to think big through a structured recognition program.

“Our associates and manufacturing plants work hard every day to come up with efficiency, utility reduction and environmental improvement projects, and those get funneled up through our ‘Sustainability Best of the Best’ recognition program,” says Tom

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Tom Raymond (left), of Hormel Foods, says the solar power project provides electricity to the Jennie-O Montevideo, Minn., processing plant (below) as well as employees who live in the surrounding community and sign up for it.

COURTESY OF HORMEL FOODS

Raymond, director of environmental sustainability for Hormel. “Then we share those best practices with our other manufacturing plants and the industry through various means, because our team members are getting results.”

Sometimes, however, it takes some patience to see the results.

Take Hormel’s most recent solar power project at its Jennie-O Turkey Store plant in Montevideo, Minn., for example. For perspective, the company has embarked on an ambitious goal to achieve 100% renewable energy worldwide by 2030.

“Like many organizations, we've taken on some big challenges with some aggressive targets over the

course of a longer period of time,” Raymond explains. “It takes progress every year on a lot of projects to get to those targets.”

Raymond says Hormel continues to build its on-site renewable energy assets in order to take what the company considers a longer-term, more resilient approach to meeting the goal. From a financial aspect, he says, the Montevideo solar project allowed the company to get good, clean power affordably into the plant, which made it a priority project for that location. The eight-acre, two-megawatt Montevideo solar field came online in September of last year, just as the Minnesota winter season was closing in.

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“Now that we’re in the first summer with that project active, we’re really starting to see the true benefits, with the solar project providing about 10% of the on-site clean energy to that facility,” Raymond says. “The sun comes up, and you’re seeing returns come across live.”

What makes the project unique, Raymond says, is that Hormel expanded it to help its employees in Montevideo and the surrounding community as well.

Hormel uses one megawatt and feeds the other megawatt into the local grid, allowing employees to sign up to use that renewable energy in their homes and save money on their electric bills.

“What really sold us on the concept of essentially leasing that land for free to the community was the tie-in to our team members that work at that facility,” Raymond says. “That’s an easy sell to say we can add that extra megawatt capacity and bring our team members into the project for financial savings in their households.”

Of course, now that the solar project is up and running in Montevideo, Raymond says the plant has begun digging into how it can drive up the percentage of renewable energy it uses.

“We would love to find ways to increase that 10% to 20% on-site, and I think we’ve capped our solar capacity within the existing fence line, but we haven’t necessarily capped our energy efficiency or other renewable technologies,” he says.

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Hewitt says he is excited about what artificial intelligence might bring to the table in terms of improving efficiency or reducing carbon emissions. However, he gets really energized when looking ahead to molecular recycling.

“We believe with the appropriate transparency and accountability provisions, [molecular recycling] can really help complete the packaging circularity we are all committed to achieving,” he says. The process takes the polymers in the package waste, breaks them down into monomers, which can then be recombined to manufacture a plastic water bottle or shrinkwrap sleeve around a meat package, for example.

“In order to have a truly complete circular economy, there are packaging types that are difficult to recycle or have other considerations,” Hewitt explains.

“Molecular recycling helps fill that void and bridge that last gap to circularity.”

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COVER STORY

The process isn’t too far down the path to fruition, Hewitt says.

Work is underway on molecular recycling beyond the lab.

“It’s not theoretical; it’s not happening in some university lab today,” he says. “This is happening in actual bricks-andmortar facilities in the U.S. that are creating jobs and fueling that circular economy.”

Regenerative agriculture is another area in which companies are dabbling — and learning for the future. Although agriculture is outside the manufacturing facility, Hormel is trying to connect the dots from farm to plate for consumers through its Ecosystem Services Market

Consortium work with Target, Minnesota business leaders and The Nature Conservancy.

Raymond explains it as a multi-year pilot project in Minnesota designed to accelerate the adoption of regenerative agriculture practices — and Hormel just extended it for a third year to continue to take measurements in the field. The company is trying to gain real data on science-backed benefits of regenerative agriculture for the entire food supply chain, even to the end consumers.

“A growing number of consumers understand the concept of lower-intensity food and food with a lower environmental impact, or what a better carbon footprint is for

products, whether it’s clothes, cars or food,” he says. “But if you were to say something is from regenerative fields, it’s still very complex to understand.”

When it comes to sustainability initiatives, companies have certainly embraced them, but as the technologies and opportunities continue to grow, education and patience will be required.

“We continue to battle our way to reach our sustainability goals and targets, and you’re going to see us simply keep chipping away at that stone,” Raymond says.

“And if it’s one small chip at a time, that’s OK — we’re going to keep chipping away with more projects.” n

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R&D TEAMS OF THE YEAR

M

any innovative food products are born as solutions to problems; Egglife is one of them.

Peggy Johns, a longtime employee of Rose Acre Farms, had some food sensitivities, so she tried re-creating some of her favorite foods in her home kitchen without ingredients like gluten. She shared her ideas with her employer, and Rose Acre Farms assembled a team to commercialize the product.

Rose Acre Farms happens to be the country’s second largest egg producer, so

eggs were an obvious and handy ingredient. Early development came a time when gluten-free dieting was on a steep rise, and it (fortuitously) was just at the start of the protein craze.

A protein-packed, low-carb tortilla-like wrap was created; so was a value-added processing business for a commodity company like Rose Acre Farms.

“There’s so much you can do with eggs, so much white space,” says Jihan Miller, vice president of R&D and quality at Egglife Foods,

EGGLIFE FOODS: BORN OF NECESSITY Written by

Dave Fusaro

EDITOR IN CHIEF

A home solution to a dietary problem became a value-added business for an egg producer.

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PRODUCT DEVELOPMENT

our small-category R&D Team of the Year. “Almost anything you can make with flour you can make with eggs.”

In 2019 Miller – originally from Colombia and with a background in animal proteins (dairy, meat and eggs) – joined the company, which had existed for about a year as a project within Rose Acre Farms.

Although there were some prototypes for her to sample, Miller was instrumental in scaling and commercializing the recipe, and Egglife as a stand-alone business was formed.

“Our first facility was in a garage in a corn field outside of someone’s house,” Miller recalls.

Later in 2019, Egglife moved into its own building in tiny Wolcott, Ind., not far from Rose Acre’s hen houses. The first commercial products were produced at the end of 2019, and Egglife wraps have grown to 14,000 stores in 50 states since and last month entered Canada.

“Now we have a lab, benchtop testing, some processing equipment, a pilot plant,” she says. The plant in Wolcott has two commercial lines for producing the wraps, which currently come in original (plain), garden salsa, everything bagel, southwest and sweet cinnamon. Roasted garlic and herb, just launched. The typical front-pack statement is attractive:

less than 1g carbs, 5g protein, less than 35 calories and zero sugar.

They can be used in any application consumers would use a flour wrap or tortilla: tacos, bagel dogs, pinwheels, wrap sandwiches, personal pizza – even a crepe.

The R&D team at Egglife includes an R&D manager, four food scientists, a process engineer, two technicians . Being 25 miles from West Lafayette, Ind., Egglife also leans on the food science and engineering departments at Purdue University. The marketing team is in Chicago.

The cross-functional Egglife team meets weekly, sometimes more often if a project is in the works. Miller says their unique product development process is

You Chose Egglife Foods Egglife is the small-company winner of our R&D Teams of the Year poll – for which you readers and website visitors voted for the winners.

Runners-up were Bitchin' Sauce and Tindle Foods.

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a hybrid of stage-gate and agile.

“It keeps us structured but also enables us to move fast when we see an opportunity.”

There are many potential tangents for egg whites and wraps “although we do have guardrails,” says Miller. Clean label is first and foremost, followed by low carbs and high protein. Within those guardrails – and with eggs always at the center – ideas can come from or take products anywhere.

The company expends great effort to listen to consumer ideas.

With a lot of trade secrets and unique technologies, Egglife manufactures its own products – no co-manufacturers are used.

As a result, “We work closely with our equipment suppliers to alter machines for our unique needs,” she says.

For now, egg white wraps is the only product Egglife produces.

But Miller hints that next year the company will enter a new product category, “a logical extension of what we’ve already done,” while staying close to the company motto of “simple, delicious, nutritious.” n

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Photo: Erhan Inga / Shutterstock.com

INGREDIENTS

GLP-1 Diets

OPPORTUNITY, NOT LIABILITY Despite the excitement over GLP-1 drugs for weight loss, their appetite suppression must be countered with extra protein and other nutritional ingredients.

Written by

Claudia O'Donnell CONTRIBUTING EDITOR

I

t seems everyone is talking about GLP-1 drugs for weight loss. The results indicate this is more than hype or a trend; there are real and considerable improvements in body mass thanks to their appetite suppression.

While many in the food industry worry about their negative impact on sales, there are opportunities in providing users of Ozempic and other drugs with the right kinds of foods to maintain general health in the face of reduced appetite.

In the first half of 2024, online searches increased for formulated foods and dietary supplements in food formats (e.g., nutritional beverages) that included high-protein products targeting GLP-1 users. Many of these foods and drinks are being labeled GLP-1 companion products.

“My wife is on a wellness journey. Type 2 diabetes runs in her family, and we've seen them struggle,” says Chris Quevedo, director of commercial partnerships and business development at The Every Company (every. com), a manufacturer of egg protein from fermentation. “Ozempic has helped her control her pre-diabetes.”

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Although Ozempic has reduced his wife’s diabetes risk, her suppressed appetite has made consuming a nutritionally adequate diet challenging. “To meet her caloric/nutritional needs, she should consume a small meal and a protein shake, but doing both at once makes her sick,” says Quevedo.

According to a Harvard Medical School news webpage, the FDA has approved 10 GLP-1 drugs to treat type 2 diabetes or weight loss. Brand names include Rybelsus, Victoza, Ozempic, Wegovy, Mounjaro and Trulicity. All impact dietary choices.

“I've become engaged in the innovation of GLP-1-friendly foods because of my wife,” says Quevedo.

The market and dietary needs

Consumers and the food industry are keenly aware of the shifting landscape and emerging opportunities. According to Mintel's 2024 Global Consumer Food & Drink Report, 13% of U.S. adults agree that “diabetes drugs that reduce appetite are a good solution for weight loss.”

Additionally, J.P. Morgan predicts that by 2030, the number of GLP-1 drug users could reach 30 million, or about 9% of the U.S. population. Driven by diabetes and obesity concerns, this market is expected to surpass $100 billion.

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Photo: Erhan Inga / Shutterstock.com

INGREDIENTS

“These medications, which mimic the hormone glucagon-like peptide-1, help reduce blood sugar levels and suppress appetite, leading to lower calorie intake,” says Jing Zhou, senior manager of nutrition science, global scientific and regulatory affairs at Ingredion Inc. (www.ingredion.com). “As GLP-1 users tend to eat less, ensuring proper nutrition becomes crucial. Consumers managing their metabolism should grasp that what they eat matters as much as what they avoid.”

Recommended dietary changes include ensuring adequate fiber, vitamins and minerals that help address the reduced appetite and possible GI issues. Control of digestible carbohydrates is also crucial due to the diabetic status of many GLP-1 users.

“However, maintaining adequate protein levels is a particular challenge,” says Zhou.

“High-protein diets aid in building

and preserving muscle mass, promoting satiety and supporting overall health.”

Mark Messina, director of nutrition science and research for Soy Nutrition Institute Global, notes the importance of muscle in the body. “Weight loss results in a loss of fat (adipose tissue) and fat-free mass, about half of which is skeletal muscle mass,” he says. “Because muscle is the primary driver of metabolic rate and favorably influences glucose regulation, maintaining muscle mass is important for everyone, especially as one ages.”

The muscle loss during weight loss is driven by an increase in muscle protein breakdown, not a decrease in muscle protein synthesis. “Therefore, approaches that stimulate muscle protein synthesis may mitigate the loss of muscle mass, such as resistance exercise training and increasing

Nestle is developing the Vital Pursuit line of products for GLP-1 users. Apparently some components for a Southwest Chicken Fajita sandwich melt will be included when the line debuts later this year.

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Abbott’s new Protality shakes are marketed to consumers on a weight loss regimen.

dietary protein intake,” Messina further explains.

One study found that during weight loss, increasing protein intake by 50% from 0.8g/kg body weight (the current RDA) to 1.2g/kg body weight reduced the loss of fat-free mass by 45%.

Since GLP-1 medications reduce caloric intake, additional protein must come from concentrated, high-quality sources.

Messina offers tofu as a good example of a higher-quality food, as protein accounts for 50% of the total calories in some types of this soy food. Protein supplements in powdered form, such as those based on whey and soy, are especially convenient ways to consume additional protein. These supplements can be added to various beverages, are shelf-stable and can be consumed in quantities determined by the consumer.

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Packing-in protein

Formulating food products for individuals who need to prevent muscle loss but find it challenging to increase protein intake is a complex task. The Every Company addressed this issue by introducing Every Boost at the 2024 IFT Expo Startup Pavilion.

This innovative protein was developed by incorporating a DNA sequence that produces chicken egg white protein into yeast, which then ferments sugars to produce the protein.

The method creates a nature-equivalent animal protein without

Crafting the Future of Beverages Expertly engineered solutions for a diverse beverage market

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using animals. It requires significantly less water, energy and land than traditional agricultural methods.

The final ingredient is free from sugar, genetically modified organisms and rDNA, says Nick Toriello, chief commercial officer.

Every Boost boasts valuable properties: a neutral taste, a clear, colorless appearance and very low viscosity in solution. "It can effectively Elo Health’s GLP-1 Muscle Retention Protein Formula is formulated to tackle muscle loss, digestive issues and nutrient deficiencies from GLP-1 therapy.

enhance protein content across various products,” Quevedo explains.

At the IFT Expo, attendees sampled a protein syrup in cold brew coffee with approximately 8g/fl. oz. of Every Boost. Potential labels for this ingredient include “egg white protein (from fermentation)” or “egg white protein from yeast.”

Protein also impacts other crucial food characteristics beyond nutritional quality.

“Taste and texture remain crucial for consumer satisfaction and longterm adherence to weight loss and wellness goals,” says Tara Kozlowich, director of global segment marketing at Ingredion’s Healthful Solutions Protein Fortification.

Ingredion offers plant protein ingredients in a variety of protein levels to support protein claims. This summer, the company launched Vitessence Pea 100 HD (84% protein dry basis), which helps maintain the softness of protein nutrition bars over shelf life. Its plant protein concentrates (55-60% protein dry basis) enhance nutrition with fiber and micronutrients, while flours from peas, lentils, chickpeas and faba beans (10-20% protein) diversify options.

Finally, Ingredion’s Homecraft Prista flour and Vitessence Prista protein concentrate — both sourced from North America — maintain clean flavors and nutritional integrity.

While not mentioning GLP-1 on product labels, The Simply Good Foods Company's Owyn protein shakes have a webpage titled “Protein Shakes While on GLP-1 Medications” to explain the product’s benefits. Its Dark Chocolate non-dairy protein shake contains a 25g blend of pea protein and organic pumpkin seed protein that

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INGREDIENTS

provides 17% of the Daily Value for protein. Its Pro Elite High Protein Chocolate Shake, which contains 32g of the two proteins, meets 38% of the Daily Value for proteins.

New products include Abbott’s launch of the Protality brand.

Abbott notes that whether weight loss is pursued through “GLP-1 medications, undergoing a weight-loss surgery or following a calorie-restricted diet,” people risk losing 11-50% muscle. Protality has a blend of “fast- and slow-digesting protein[s] designed to feed muscles for up to seven hours.”

The Daily Value for protein is achieved with milk protein concentrate and sodium caseinate.

In June, Elo Health announced its GLP-1 Muscle Retention Protein Formula, designed to address muscle loss, digestive issues and nutrient deficiencies from GLP-1 therapy. Each serving includes 1B CFU of probiotics, psyllium husk fiber, 15 essential vitamins and minerals, an optimal electrolyte ratio and 24g of high-quality protein (whey or pea options).

Pure Protein (www.pureprotein. com) also launched All in One Protein Powder in June. Its Rich Chocolate version contains 25g of protein (whey and collagen for a 32% daily value per serving), fiber, vitamins and minerals. The company notes that GLP-1 consumers can meet their nutritional needs with individual supplement purchases. Still, that approach is more complex and adds cost on top of the already expensive GLP-1 injections. The product label doesn’t mention GLP-1, but the website explains its benefits for this group.

In a high-profile May announcement, Nestlé unveiled its Vital Pursuit brand will comprise

companion products for “GLP-1 weight loss medication users and consumers focused on weight management.” Mintel's 2023 US Prepared Meals Report notes that 42% of U.S. adults opt for packaged meals for convenience,” a factor that should help drive the success of the Vital Pursuit line.

The product line includes fiber-rich, high-protein items with essential nutrients like vitamin A, potassium, calcium and iron, tailored to a weight loss user’s appetite.

Twelve SKUs are set to launch in the fourth quarter of this year, including bowls with whole grains or protein pasta, sandwich melts and pizzas.

“While GLP-1 companion products are intended to support successful weight loss with these

drugs, label claims, descriptions and statements must be carefully managed," warns Lauren Swann of Concept Nutrition, a food labeling consultancy. "This includes messaging on all branded online products and e-commerce pages, which are extensions of labeling subject to compliance with regulations.

“Communicating a food’s benefits to GLP-1 users without implying a drug claim can be a potential challenge food processors face in marketing these high protein foods, beverages and supplements,” Swann advises.

With a little care in labeling and the thoughtful use of dietary proteins, the market for GLP-1 companion foods will surely grow. n

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INGREDIENTS Plant-based butter substitute

Beleaf PlantBetter, a plant-based butter substitute, has been launched in North America after a successful year in Europe. It’s a proprietary blend of oilseed and tropical oils along with oat milk and other natural ingredients. It matches the sensory qualities, versatility and functionality of traditional dairy butter and can easily be integrated in current production processes. It captures the distinctive aroma, taste and texture of traditional butter and is composed of easily recognizable ingredients from all-natural sources.

Initially designed for bakery applications – other applications will come later – the ingredient provides sensory excellence, cost savings, reduced input price volatility and easy processing.

Bunge; Chesterfield, Mo. www.bunge.com/North-America

Marbling plant-based meats

Marbled steaks and bacon with meat and fat layers are standards in the meat segment. However, offerings in the plant-based alternatives category often lack marbling or fat layers and an authentic, fibrous structure. The ingredient supplier has joined forces with portioning system manufacturer Handtmann. Planteneers’s fiildMeat and fiildTex series

are the bases for these meat and fat alternatives, which are produced with a flexible coextrusion system from Handtmann. The products can be plant-based alternatives to steak, filet strips or bacon.

Planteneers GmbH; Ahrensburg, Germany +49 (0)4102 / 202 191; www.planteneers.com

Stevia for sugar reduction

SoPure Andromeda products are natural stevia-based sweetener blends suitable for formulating clean label beverage products. They provide superior taste performance with enhanced fresh fruit flavors that neutralize bitterness and minimize aftertaste while offering faster onset of sweetness and a clean label. It addresses crucial taste and cost concerns that beverage manufacturers face today while providing up to 64% in cost savings on sweetener components compared to traditional sugar.

Howtian Group; Iselin, N.J. 480-586-0015; www.howtiangroup.com

Fava bean protein isolate

Nutralys Fava S900M fava bean protein isolate is the first protein isolate derived from fava bean, the company claims. Delivering 90% protein content across various applications including meat substitutes, non-dairy alternatives and baked goods, this product also offers a clean taste, light color and functional excellence while meeting the demand for sustainable, nutritious and indulgent plant-based foods. Its high protein concentration allows for low usage ratios, making it an attractive option for food brands looking to optimize formulations and cost-in-use.

Roquette; Lestrem, France +33 3 23 55 40 00; www.roquette.com

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Next generation protein bars

Optibar is a specific blend of collagen peptides optimized for bar production. It has excellent solubility, so it creates smooth bars with an indulgent mouthfeel that lasts throughout their shelf life – even at very high protein levels of as much as 60%. When used as a sugar-free binder in cereal bars, the sugar content can be minimized and appropriate “low sugar” or “no sugar” claims can be made in bars that stay crunchy throughout their shelf life.

Gelita USA; Sergeant Bluff, Iowa www.gelita.com

Enhancing taste

Sante and CTC (clear tomato concentrate) utilize the naturally occurring components in the tomato to help elevate the eating experience with clean label ingredients. The umami and kokumi components within Sante allow for significant salt reduction and/or added sugar removal from some applications, while Lycofibers add pleasing mouthfeel with the opportunity to remove unwanted ingredients like emulsifiers. These ingredients give a variety of food applications a natural upgrade.

Lycored; Branchburg, N.J. 877-592-6733; www.lycored.com

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PLANT OPERATIONS

FACILITY DESIGN:

FOOD-SAFE FIRST Whether you’re building new construction, an expansion or a renovation, food safety should be the foundation of any capital project.

PHOTO: GUTEKSK7 / SHUTTERSTOCK.COM

Written by

Andy Hanacek SENIOR EDITOR

T

o an outsider, a food or beverage processing plant might seem to be four boring walls with some doors and maybe a couple windows, and a roof with some cooling and ventilation equipment. Yet, designing a processing plant with food safety in mind goes well beyond the basics, no matter if a company is renovating an older plant or building a greenfield facility.

Design in mind

For Milwaukee-based Palermo’s Pizza, facility design has been atop the to-do list for the past year-plus, with the company first purchasing and renovating a food-processing facility in Jefferson, Wis., to make frozen pizzas, and now planning a new, greenfield plant in West Milwaukee. Nick Fallucca, chief product & innovation officer for Palermo’s, explains that the challenges the company faces are not unique.

“The entire industry is working toward advancements in the concept of food safety culture,” he says. “We learned a lot from opening our Jefferson facility and are grateful to have an outlet to apply that education so quickly.”

Moving forward on a greenfield project, where a “blank slate” basically awaits the

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demands and desires of the company, can have its pros and cons, Fallucca says. On the positive side, having a blank slate allows a proactive approach when it comes to creating a food-safe facility as well as a mindset and culture built around food safety. However, having fewer physical restrictions can overwhelm the decision-making process.

“With a blank slate, anything is possible with the appropriate budget,” Fallucca explains. “Do we restrict access here? Permanent wall or temporary wall? … There are a lot of what-ifs, [and] at some point, we must make a choice and understand that choice may turn into a lesson down the road.”

On the flip side are renovations and expansions, which present a different set of circumstances. In June, SunOpta’s Modesto, Calif., processing plant completed a $26 million expansion that allows it to produce more than 60% more oatmilk. As Joe Gerhardt, senior plant manager in Modesto relays, the expansion represents the second-largest capital project in the company’s history — therefore, SunOpta wanted to apply best practices to make the facility as efficient as it could possibly be.

“At SunOpta, we start by examining our ingredients — how they will be procured, stored and delivered into the processing system to ensure optimal freshness,” he says. “We then consider the types of equipment, instrumentation and routing that would be optimal for

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production, food safety, quality assurance and maintenance.”

Concept to construction

PHOTO: COURTESY OF PALERMO VILLA INC.

Palermo’s Pizza purchased and renovated a plant in Jefferson, Wis., in 2023 to produce frozen pizzas, and the company will be able to apply lessons learned as it designs a brand new plant to be built in West Milwaukee, Wis., over the next year.

PHOTO: COURTESY OF SUNOPTA

SunOpta recently completed a $26 million expansion of its Modesto, Calif., processing plant, allowing it to produce more than 60% more oatmilk.

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When it comes to turning facility design into bricks, mortar, concrete and steel, careful consideration of the spacing, layout and flow of the inner workings of the facility, as well as the materials used and ability to keep it all clean and in good working condition, is imperative to avoid future problems.

“Ensure that the equipment you are designing for the facility fits the overall footprint and that there is good flow of materials to and from the production lines, as well as a good flow of employees in and out of the processing space,” Fallucca adds.

At SunOpta’s Modesto facility, Gerhardt says the company followed a similar approach, with an additional influence upon its design process.

“Placing oneself in the shoes of the maintenance personnel responsible for the equipment is often an overlooked aspect of the overall design criteria,” he says.

From a food safety perspective, poorly maintained equipment can cause serious issues for the product stream when equipment wears or breaks down — so designing easier maintenance access and capability into the overall plant can impact its food safety future.

When designing operations, selecting equipment and figuring out the best ways to install that machinery with food safety in mind, SunOpta focused deeply on getting the smallest details properly designed.

“We made a conscious effort to eliminate harborage points both

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PLANT OPERATIONS

overhead and at the interface of equipment to their permanent location,” Gerhardt says. “The elimination of flat surfaces whenever possible was also implemented, along with drain considerations to limit any standing water.”

He says SunOpta does not differentiate between food safety and human safety in its approach, making these decisions a type of “win-win,” and they protect both the operators working in the facility and the customers who eventually consume the product.

Gerhardt says SunOpta is committed to raising the bar on food safety not only within its walls, but also for the greater food and beverage industry at large.

Designing a new facility around food safety still requires post-construction strategies, and SunOpta supports its investments with rigorous testing protocols, optimized sanitation systems, validated operator training and a culture that empowers employees to stop production anytime they feel product may be at risk.

Palermo’s is approaching its West Milwaukee plant design with a ready-to-eat (RTE) and audit-ready mindset, “to encourage our stakeholders to make decisions that align with designing food safety into the space and our programs.”

The company is leveraging the concept of first-pass quality, determining the best way to set up the process so that product is handled only one time — as increased handling leads to more chances for a food safety incident. In addition, Fallucca says, Palermo’s wants to create a facility that takes comfort and employee health into account.

“When people are in a healthy environment, they are more

engaged, and that engagement makes all the difference when it comes to food safety,” he says. “We will do everything we can to design safety into [West Milwaukee], and

we are fortunate to have a team of problem-solvers that are focused on one mission: to deliver a great pizza experience. That starts with safety first, always.” n

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TECHNOLOGY

A CONSISTENT CHILL Processors of frozen and refrigerated products seek solutions that preserve the quality and safety of the food and beverage products without damaging their bottom line or operational efficiency.

Written by

Andy Hanacek SENIOR EDITOR

F

ood & beverage safety and quality often depends on temperature — how consistently chilled or frozen a product remains during and after processing makes an enormous difference in the shelf life of that product.

Of course, the business of chilling and freezing isn’t as simple as turning down the temperature. Many of the standard external

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pressures faced by food & beverage processors also impact their chilling and freezing operations — sustainability, energy use, food safety and regulations, to name a few.

“The top challenge is ensuring product is at proper temperature throughout the supply chain, from production to consumer,” explains Alex Cotraviwat, founder and CEO of Klimon (which is “No Milk” spelled backward), an almond-based, dairy-free, frozen ice creamlike dessert. “We solve the issue by working with experienced, top-tier frozen carriers and distributors and a robust program of temperature monitoring.”

Antonio Mundarain, processing manager-ice cream for Tetra Pak U.S. and Canada,

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TECHNOLOGY

Hand-in-hand with that are government regulations pushing the industry more toward environmentally friendly refrigerants.

“Traditional refrigerants often have high global warming potential (GWP) and ozone depletion potential (ODP), which contribute to climate change and environmental degradation,” Mundarain says. “As a result, processors must invest in new technologies and systems that utilize low-GWP and -ODP refrigerants, which can be more costly and require significant changes to existing infrastructure.”

Addressing needs

Companies offering solutions to processors looking to freeze or chill with greater success have focused on a variety of areas in which the freezing/chilling

operation could be improved.

Cotraviwat says companies like Klimon continue to seek more cost-effective frozen transportation that doesn’t sacrifice product quality in exchange.

According to Mundarain, many ice cream processors look to create premium-level products with exceptionally small ice crystals but still minimizing operational costs.

“The delicate balance between quality and efficiency remains paramount,” Mundarain says.

“Manufacturers of ice cream equipment and refrigeration systems are diligently working to enhance efficiencies and align more closely with these customer aspirations.”

To that end, Tetra Pak’s continuous ice cream freezers have increased heat transfer efficiency

PHOTO: ZMICIER KAVABATA / SHUTTERSTOCK.COM

points to energy efficiency and the regulatory pressures around it as one of the primary challenges that processors face today.

“Freezing and chilling processes require substantial energy, and with rising energy costs and environmental concerns, processors are under significant pressure to find more energyefficient methods,” he says.

Processors look to optimize their equipment’s functionality and operational efficiency, improve insulation and explore alternative cooling technologies, he adds.

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Klimon is an almond-based, dairy-free, frozen, ice cream-like dessert that relies upon proper temperature monitoring and maintenance through its supply chain to preserve product quality.

COURTESY OF KLIMON

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with a new cylinder design, and they have implemented an improved cooling regulation system, he says. “These enhancements ensure that the ice cream is frozen more uniformly and quickly, preserving its texture and flavor,” Mundarain explains.

That speed and uniformity is key to consistent product quality in many different food and beverage segments.

On extrusion lines, Tetra Pak uses advanced software to analyze and optimize the airflow inside the tunnels, and with an improved evaporator design, processing gets extended running time out of their production lines. Product quality and the efficiency and reliability

of the system are enhanced, and operational costs are reduced as a result, Mundarain explains.

Other companies, such as Messer North America Inc. and Linde Plc, have stepped up to meet the needs of processors manufacturing all sorts of frozen or chilled food and beverage products. There is a wide variety of freezing equipment available for processors to match to the particular application needed — based on maintaining food quality and safety.

Cryogenic freezing and chilling equipment can help processors in this arena, using N2 or CO2 in contact with the product to bring temperatures down quickly and safely. Products can be frozen or

chilled individually or in batches, with various applications from spraying and mixing gases into a mixture, tumbling product or immersing the products in liquid to bring the temperature down rapidly. Regardless, to get the quality that is needed, consistent application and speed are crucial.

In a white paper on the subject, Messer’s experts point out: “More consistent food temperatures and more repeatable processes contribute to food quality and food safety. Both the flow of cryogen and the way food items move through a chiller or freezer are important to maximizing heat-transfer efficiency — and line productivity.” ■

Go Digital With Food Processing This magazine you hold in your hands is just the tip of a very big iceberg.

Food Processing offers so much more on the internet: → The Daily News – Our e-newsletter gets delivered to your inbox every morning to keep you up to date on the news of this fast-changing business. www.foodprocessing.com/subscribe → Webinars – Sit in as we review our Top 100 list and the financial health of the food industry on Sept. 24, then analyze the results of our R&D Survey on Nov. 13. www.foodprocessing.com/webinars → Podcasts – Listen in as expert guests discuss taste, texture and health attributes in formulations or the effect of new ingredients on the plant. www.foodprocessing.com/podcasts

It’s So Easy Being Gree n Successful sustaina bility initiative can be found s everywhere as companies seek strategies that are better for business and the world around them. • 20

→ Ebooks – Download and read at your convenience our deep dives into food safety or the new rules coming for combustible dust. www.foodprocessing.com/ehandbooks SEPTEMBER

2024

R&D Team of the Year: Egglife • 26 The opportunity in GLP-1 diets • 28 Food-safe facility design • 33 Refrigeration and freezing • 36

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CASE STUDY

Capping Off Brand Integrity

A Mettler-Toledo vision system makes sure caps are correct, maintaining brand image.

C

alifia Farms sees a future where plant products replace dairy. Since its launch in 2010, this California-based food processor has grown to become an iconic maker of high-quality oat milks and almond milks, as well as plantbased creamers, brewed coffees and more. With distinctive, curvy bottles that stand out in the dairy aisle, Califia’s brand recognition contributes to its market success.

“Last year, we began shopping for a new vision system to inspect the caps on our main packaging line. We wanted to be able to

confirm that every bottle on the line is correctly capped, so we could be sure customers get the highest quality product and protect our reputation,” says Keith Meadows, director of engineering at Califia Farms (www.califiafarms.com).

“We also wanted to be able to quickly identify any issues with the upstream filling and closing equipment to maximize production efficiency. Our new inspection system needed to do all this and more.”

“We talked to three different vision system manufacturers and considered the quality of the

The V31 vision system keeps an eye on Califia Farms bottles even as they fly by at speeds up to 1,000 bottles per minute.

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equipment, its suitability for our application and the reputation of the supplier,” adds Martha Cervantes, QA continuous improvement specialist at Califia.

“Our sales rep and solutions engineer, Angelica Amancio of Pacific Packaging and Inspection, suggested the V31 would be a perfect fit for us, and then Mettler-Toledo’s great customer service sealed the deal.”

Mettler-Toledo Product Inspection’s modular V31 vision system can be configured to inspect caps, lids and/or labels at speeds up to 1,000 packages per minute.

At Califia, the V31 identifies and rejects high caps, damaged caps, broken shrink bands and other cap-related problems.

“We’re very happy with the capabilities and accuracy of our V31,” said Meadows. “Compared to vision systems that only inspect from two sides, our V31 was customized with three different cameras for superior performance.”

Califia installed its new V31 vision system on its most versatile, high changeover packaging line.

The bottles, which range from 10.5 to 72 oz. in size, are closed with either a combination foil seal and closure or with a cap with a tamper-evident band.

“Floor space is tight at our facility, so we needed a compact vision system. Our V31 was super easy to

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Califia Farms sometimes changes the line four or more times a day for different bottles. Preset recipes on the vision system’s control panel accommodate these changeovers in less than five minutes.

install and slid right over our existing conveyor,” says Patrick Fischer, senior engineering maintenance manager at Califia.

“The V31 is incredibly adaptable.

Between our many products, bottle sizes and cap types, we’re sometimes changing this line over four or more times a day,” adds Cervantes.

“All we need to do on the V31 is select a new preset recipe on the control panel and turn the wheel to raise or lower the camera height.

Changing it over takes less than five minutes.”

Adds Fischer, “We asked Mettler-Toledo to equip our V31 with a traceability capability so we can easily identify which station on the capper is having an issue if the vision system sees an uptick in cap

Califia Farms products vary in type and size but not in their distinctiveness, so perfect capping is important for perception of quality.

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defects. They also provided a custom air nozzle to blow any lingering condensation off the caps right before inspection to maximize accuracy.

“Since we’re processing products with nuts and other allergens, cleaning and sanitation are important considerations for us,” he continues. “We love the fact that our V31 is connected to our central clean-in-place system, so it runs a cleaning cycle automatically and we finish up with a quick hand wipe.

It’s really simple.”

“We’re really tuned in to the feedback we get from consumers,” concludes Meadows. “The cap samples we pull always look good, but we want to go a step further and inspect every single cap on the line,.

Our new V31 vision system helps us keep our customers happy, which is the most important thing.” n

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EQUIPMENT Enclosed severe duty motor

The new, cast-iron, totally enclosed, fan cooled (TEFC) severe duty Baldor-Reliance SP4 motor has NEMA Super Premium (IE4) efficiency; reduces motor losses by as much as 20% for significant energy savings; and extends motor life, reducing maintenance and increasing uptime. This model is designed for applications in hazardous environments with certifications that make it suitable for areas with explosive gases and combustible dust. The model also

features an IP55 rating, ensuring protection against dust and water spray, making it reliable for harsh and dirty conditions. These motors are compatible with pumps, fans, compressors and conveyors, and they cover a power range of 25 to 300 hp. (Rolled steel models, which were launched earlier this year, are available in ¼ to 20 hp).

ABB Motors and Mechanical ; Fort Smith, Ark. 479-646-4711; go.abb/motion

Disinfection measurement

Disinfection processes are becoming increasingly important. A new generation of Memosens disinfection sensors uses amperometric technology to output measured values continuously and instantly for chlorine dioxide, free chlorine, total chlorine, free bromine and dissolved ozone. Real-time measurement technology allows for

FOODPROCESSING .COM

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immediate responses to process changes, optimizing the dosing of disinfectants and reducing costs.

A unique feature of these chlorine sensors is their ability to remain active and ready to measure as soon as chlorine is detected, even after extended periods without chlorine, unlike other sensors that struggle to provide accurate readings after such intervals.

Endress + Hauser; Greenwood, Ind. 888-363-7377; www.us.endress.com

Thermal bypass valve with pressure relief

The TBV-PR (Thermal Bypass Valve with Pressure Relief) integrates temperature control and pressure relief into one valve. It is engineered to safeguard equipment from damage caused by excessive pressure while maintaining optimal operating temperatures. The thermal actuator controls flow throughout the system based on temperature changes, while the pressure relief safety feature protects the system from excessive pressure buildup. When pressure exceeds a predetermined threshold, the valve automatically opens, sending flow through the bypass to restore safe operating conditions. The valve will direct cooler fluid through the bypass and hotter fluid through the system’s heat exchanger/cooler. Its compact design and durable construction make it ideal for a wide range of applications.

ThermOmegaTech; Warminster, Pa. 877-379-8258; www.thermomegatech.com

Circular kneader-mixers

Circular kneader-mixers are suitable for kneading, mixing, massaging, seasoning and other applications. Over more than 50 years, this unique mixer has been evolving and adapting technologically. All are made of 100% stainless steel and have tilting bowls. Models include the Model A-50, with a 50-liter capacity and two wheels for movement; the A-85/ AO-85-A, with a capacity of 85 liters and four wheels plus vacuum and automatic options; the AO-120-A, with 120-liter capacity, four wheels and vacuum and automatic options; and the high-capacity A-160/ AO-160, with 160 liters capacity, a vacuum option and an independent trolley, suitable for any standard 200l lifter. All handle dough gently without smearing. The double direction of the rounded shape blade makes for perfect kneading and mixing of a wide range of products.

Industrial Fuerpla; Benetússer, Spain +34 963 750 362; fuerpla.com

Opacity sensor

Inaccurate measurements can disrupt your production. The EMX OPAX-1000 Opacity Sensor is a high-speed, highly accurate instrument designed to seamlessly integrate into your system, providing precise and rapid opacity measurements to support on-theline decision-making. It provides reliable performance and consistent results with its IR and UV sensor options and boasts versatile applications and user-friendly features (simple setup, rugged design, and high-resolution output) for efficient monitoring.

EMX Industries; Garfield Heights, Ohio 800 426 9912; www.emxindustrialsensors.com

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Floor scale certified sanitary

provide superior protection against bacteria and mold growth. The rugged design incorporates four welded-seal load cells with PTFE cable for steam cleaning and washdown areas. The top plate opens 75 degrees and is held in place with safety bars to support thorough cleaning routines.

The RoughDeck QC-X quick clean extreme floor scale now holds NSF Certification for use in meat and poultry processing. These scales are designed to safeguard against microscopic bacteria in food processing, pharmaceutical and chemical applications. The base is composed of solid, 304 stainless steel, vertical plates that

Rice Lake Weighing Systems; Rice Lake, Wis.

800-472-6703; www.ricelake.com

V cone blender for pilot plants A new 1 cu ft (28 liter) capacity Vee Cone Blender, model VB-1-SSIS, for laboratory and pilot applications features an intensifier bar and air brake. It’s constructed and finished to sanitary standards and is equipped with an internal spray line with intensifier bar for rapid dispersion of liquid additions throughout the batch and a pneumatically actuated brake to stop rotation for

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loading or unloading the batch.

Two inclined cylinders with smooth internal surfaces rotate end-overend, allowing complete discharge through a lever-operated butterfly valve. The absence of residual material, combined with easy internal access through the cylinder doors and discharge valve, allows rapid sanitizing and visual inspection of all material contact surfaces, preventing cross-contamination between changeovers.

Munson Machinery; Utica, N.Y. 800-944-6644; www.munsonmachinery.com

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