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OfďŹ cial Publication For FiAsia 2009

Established since 1985 |

MICA (P) 004/05/2009

| AUGUST 2009

FiAsia 2009

Highlights Potassium:




Hidden Bone Guardian

Malty Metamorphosis Filling Plants: T Optimisation H E


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volume 21 no. 7


End Of Line Packaging: Go Green! A comparison of the sustainability of ‘pad shrink’ packaging systems versus RSC cases. By Peter Fox, Delkor Systems


By introducing multipacks, snack food producer would be able to save a substantial amount of its packaging volume. By Dietmar Ellwanger, International Packaging Systems



Packaging: Lined Up For Variety


Stabilised rice bran is a source of synbiotics, tocols, y-oryzanols, polyphenols, nutritive protein and healthy mono- and polyunsaturated oil. By Henk Hoogenkamp

MES: Increased Execution Effectiveness Effectiveness of processes have been known to increase by seven to 10 percent with the application of MES. By Ralf Schubert, Schubert


Rice Bran Reinvented


Soluble Fibres: Behind The Crispy Snap In Wafers Trials were conducted to evaluate the effect of adding soluble fibres (polydextrose) for improved gut health on wafer sheets. By Peter Thomson and Laura Willmott, Danisco (UK)


Enzymes: Future Perspectives For Bread The properties of existing enzymes and enzyme combinations are constantly being improved, creating a wider field of use and increasing the demand. By Lutz Popper, Mühlenchemie





Potassium: The Unsung Bone Protector While it is widely known that potassium maintains fluid balance within the body, its role in bone health is less appreciated. By Dr Susan Brown, The Center for Better Bones


Bone & Joint Health: The Calcium Necessity People who avoid dairy products need to ensure substitute food products are calcium-fortified. By the Working Group Of ANZBMS & Osteoporosis Australia

Ricardo’s dairy needed new milk packaging that would stand out from the competition and reduce his operational cost. We offered him a range of processing and packaging options suitable for his product and its potential consumers. So we’re helping to protect the future of Ricardo’s business as well as his milk products. As the industry leader, Tetra Pak works to protect what’s good. Learn more about us at

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volume 21 no. 7


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Filling Plants: Optimisation Toolbox In cases of special requirements, particle counting in the gas and liquid phases can provide very exact information about the system under examination. By Roland Pahl & Georg Wenk, VLB Berlin


Barley: The Noble Grain of Malting & Brewing


Disposable Kegs: An Alternative Beer Container

The importance of malt in the production of premium quality beer is paramount. However, the malting industry is facing a number of considerable challenges. By Mont Stuart, Joe White Maltings

With the rising exports for keg beer and high prices of steel and manufacturers’ cost, an investment in a new type of barrel was needed. By Frank Peifer, Bavarian State Brewery, & Johannes Tippmann, Technical University Of Munich


Beer: The Malty Metamorphosis The resulting effect of increased disposable income is a consumer base that is continually in flux, with consumers moving between wine and other alcoholic beverages. By Fal Allen, Archipelago Brewery

AUTOMATION & Features 70

The Chocolate Challenge

Today, Zaini sweets are no longer made by hand, but they are just as carefully handled by robots. By Claudia B Flisi, on behalf of ABB


Editor’s Note Advertiser’s List Business News Product Highlights Calendar Of Events Product Catalogue Reader’s Enquiry Form Subscription Information

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Market Report: Globally Inspired Flavours, Eco-Friendly And Health-Minded Trends Lead Product Innovations Confectionary makers are thinking outside the bar to drive consumer purchasing over the next five years. Contributed by Susan Whiteside, National Confectioners Association


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FiAsia 2009 Drinktec 2009/Asia Fruit Logistica

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EDITOR’S PAGE managing director Kenneth Tan


assistant editor Tjut Rostina

Bottoms Up! Beer – the world’s oldest and one of the most widely consumed alcoholic beverages takes centre stage this August. Read about the makings of this celebratory beverage: From packaging and processing, to the ingredients that combine to deliver the desired taste, and the trends that the beer industry can look forward to. Quoting an old saying among brewers, Mont Stuart of Joe White Maltings, says: “Malt is the soul of a beer.” The quote is based on the fact that malt provides the sugars for alcohol and chemical components that are essential for fermentation, and most of all, flavour. He further explains the malting process and the challenges that are facing the malt industry. (Page 58) One of the most complicated and cost intensive aspects of beer production is the filling process. VLB Berlin takes on the task of optimising this process by carrying out particle counting, which can give information on the system tested, and indicate the number of particles and germs present. Other techniques that are suggested include a data-logger and high-speed camera, which can improve the filling process. For example, on the basis of the films recorded by the camera, it was possible to identify the cause of a massive contamination of individual valves of an aseptic filling machine. (Page 54) Another area that can be optimised and save cost without compromising quality, is a packaging solution that allows beer companies to transport beer in disposable kegs. The Technical University of Munich and the Bavarian State Brewery carried out tests on disposable kegs, comparing them to the performance of steel kegs. (Page 62) Rounding up the topic on beer is Fal Allen of Archipelago Brewery. He shares his perspective as brew master on the beer paradigm in South-East Asia, exploring the marketing techniques for beer and also the latest flavours to look out for in appreciating the beverage. (Page 67) With insights on the different areas within the beer business, it looks like the industry is set to take on new challenges that the market deals them with. Whether it is minimising costs, optimising processes, or innovating ingredients, beer is poised to move with the times and firmly root itself as the world’s favourite alcoholic beverage.

editorial assistant Audrey Ang senior art director/studio manager Lawrence Lee assistant art director Libby Goh business development manager Randy Teo senior circulation executive Brenda Tan contributors Briffa Kathryn, Claudia B Flisi Devine Amanda, Dietmar Ellwanger Dr Susan E Brown, Fal Allen Frank Peifer, Henk Hoogenkamp Georg Wenk, Johannes Tippmann Kotowicz Mark A, Laura Willmott Lutz Popper, Mont Stuart Nowson Caryl, Peter Fox Peter Thomson, Ralf Schubert Reid Ian R, Ronald Pahl Sanders Kerrie M, Susan Whiteside board of industry consultants Dr Aaron Brody Managing Director Packaging/Brody, Inc Dr Alastair Hicks Agroindustries and Postharvest Specialist UN Food & Agriculture Organisation Professor Alex Büchanan Professional Fellow Victoria University Dr Nik Ismail Nik Daud Head, Food Quality Research Unit Universiti Kebangsaan Malaysia/ President Malaysian Institute of Food Technology Kathy Brownlie Global Program Manager Food & Beverage Ingredients Practice Frost & Sullivan Sam S Daniels Consultant World Packaging Organisation

Executive Board chairman Stephen Tay group executive director Kenneth Tan financial controller Robbin Lim



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Geneva, Switzerland: The W T O / U N E P re p o r t o n ‘ T r a d e and Climate Change’ published in late June this year, examines the intersections between trade and climate change from four perspectives: the science of climate change; economics; multilateral efforts to tackle climate change; and national climate change policies and their effect on trade. “ Wi t h a c h a l l e n g e o f t h i s magnitude, multilateral cooperation is crucial, and a successful conclusion to the ongoing climate change negotiations is the first step to achieving sustainable development for future generations,” said WTO director general, Pascal

B Earwicker, Idaho, US

WTO & UNEP Report On Relation Between Trade & Climate Change

Lamy, and UNEP’s executive director, Achim Steiner. The global economy is expected to be affected by climate change.

Sectors such as agriculture, forestry, fisheries, tourism and transport infrastructure, which are critical for developing countries, are more specifically affected. These impacts will often have implications for trade. Overall, the report highlights that there is scope under WTO rules for addressing climate change at the national level. However, the relevance of WTO rules to climate change mitigation policies, as well as the implications for trade and the environmental effectiveness of these measures, will depend on how these policies are designed and the specific conditions for implementing them.

Kirin Acecook Vietnam Starts Beverage Operations Binh Duong, Vietnam: The joint venture between Japanese beverage company Kirin, and Acecook Food Production, Kirin Acecook Vietnam Beverage, have begun operations of a beverage factory in Binh Duong province, Vietnam. The total investment of the beverage plant is US$60 million, and has an area of over 2.7 hectares (27, 000 sq m). According to IntellAsia, the factory will have capacity of 4 million boxes of finished products per year. The major products of the company includes soft drink with milk under the trademark of Latte, and PET-bottled green tea, Jcha.

F&N Singapore Extends Agreement With Coca Cola S i n g a p o r e : The Coca-Cola Company and Singapore’s Fraser & Neave (F&N) have agreed on transition arrangements that will take effect after their current bottling arrangements in Malaysia, Singapore and Brunei expire on January 26, 2010, and continue till September 30, 2011. F&N’s Malaysian subsidiary will continue to bottle, distribute and sell brands from Coca-Cola for the market in Malaysia during the transition

period, while Coca-Cola will do so the same for F&N brands in Singapore and Brunei. The transition agreements, which will run for 20 months, will allow both companies to independently pursue opportunities in categories other than sparkling fruit-flavoured drinks, isotonic drinks and sparkling beverages. It is currently not the intention to renew these transition agreements when they expire in 2011.





Study Reviews Methods To Prevent Fruit Spoilage Chicago, US: A study in the Comprehensive Reviews in Food Science and Food Safety, published by the Institute of Food Technologists, compiles the results of different studies on the use of natural antimicrobials in fresh-cut fruits and juices to maintain their safety and quality. As a consequence of inappropriate manipulation and storage conditions, both pathogenic and/or deteriorative microorganisms may contaminate a produce. As such, the risk of

microbial diseases and spoilage is increased. “The different natural antimicrobials of animal, plant, and microbial origin, directly or indirectly added to fresh-cut fruits and fruit juices, can effectively reduce or inhibit pathogenic and spoilage microorganisms, thus representing a good alternative to the use of traditional antimicrobials,” says lead researcher Olga Martin-Belloso of the University of Lleida in Spain. “ H o w e v e r, t h e e x t r a c t i o n and purification of some natural

antimicrobials can be difficult, and expensive isolation and purification procedures that may avoid denaturalisation, breakdown, volatilisation, and/or loss of functional properties of active compounds, as well as safety and toxicology evaluations, could be implicated,” she further adds. Extensive research on the effects of each antimicrobial on food sensory characteristics is still needed so that antimicrobial substances of natural origin can be regarded as feasible alternatives to synthetic ones.

Deborah Goh SC, Singapore

Codex Adopts Five Food Supplements Issues

Crown Expands Presence In Vietnam Ho Chi Minh City, Vietnam: Crown Asia Pacific has acquired a beverage can production facility located northeast of Ho Chi Minh City in Dong Nai Province, Vietnam from Interfood Shareholding. Interfood will retain a minority investment interest in the plant. The 250,000 sq ft (76,200 sq m) facility is sized to accommodate additional manufacturing lines. It will have an initial annual production capacity of approximately 600 million two-piece, 33 c ltr aluminium beverage cans. Commercial delivery of cans is scheduled to begin in the fourth quarter of this year. “We are delighted to expand our relationship with Interfood,” commented Jozef Salaerts, president of the company’s Asia Pacific Division. “This is our third manufacturing facility in Vietnam which continues to be a vibrant and growing market for us.”

Rome, Italy: The Codex decision-making body has adopted the recommendations on the scientific substantiation of health claims, the nutritional risk analysis principles, the provisions on gum arabic, the definition and table of conditions of dietary fibre, and the use of eight food colours in food supplements. This is in line with recommendations from the International Alliance of Dietar y/ Food Supplement Associations’ (IADSA). These provisions have become the official Codex standards and guidelines. The adopted recommendations on scientific substantiation of health claims take into account the totality of the available relevant scientific data and weighing of the evidence for substantiating a health claim. Gum arabic was adopted as a carrier at 10 mg/kg. The definition and table of conditions of dietary fibre distinguish three main categories of carbohydrate polymers, refer to monomeric units and leave the decision on whether to include carbohydrates with monomeric units from three to nine, to national authorities. In addition, the use of the following eight food colours in food supplements were adopted: Allura red AC, caramel colour-class IV, carotenoids, chlorophylls-copper complexes, fast green FCF, grape skin extracts, indigotine and iron oxides.





India To Set Up 350 Food Processing Units In 100 Days New Delhi, India: India’s Ministry of Food Processing Industries (MoFPI), which is powering India’s Evergreen Revolution, will help set up as many as 350 food processing units within the next 100 days. This is part of its target of creating 10 million jobs by 2015 at a total investment of Rs 1 lakh crore (US$20.69 billion). Shri Subodh Kant Sahai, minister for food processing industries, said that the Vision-2015 targets formulated in 2005 during the first term of the UPA government, included increasing India’s level of food processing from six percent in

2004 to 20 percent by 2015, value addition from 20 percent in 2004 to 35 percent and share in global trade from 1.5 percent to three percent. Shri Sahai said that the level of processing has gone up to 10 percent with consequent wastage of perishables coming down from Rs 58,000 crore a year to less than Rs 50,000 crore. The value addition has gone up from 20 percent to 26 percent and the food processing sector’s growth rate has gone up from seven percent in 2005 to over 13 percent. Shri Sahai said that the first

Kuka’s Heavy Duty Robots To Cope With Indian Market Mumbai, India: Kuka Robotics (India) has launched its heavy payloads industrial robots in India. These robots were introduced to address the potential demand from FMCG, logistics and food & beverage industry in the country. The heavy duty palletising robots KR 1000 1300 titan PA and KR 700 PA can load goods of 1,300 kg and 700 kg respectively. The growth of industrial robots is gathering pace in India as FMCG, logistics, and food & beverage industries increase their operations in the country. According to estimates, the US$70 billion food & beverage industry, as well as the US$24 billion FMCG industry has an annual growth rate of 20 percent. With the Indian economy expected to grow at the rate of six to eight percent, the US$14 billion logistics industry is poised for a quantum leap, thereby providing a huge potential for palletising robots. Mr Raj Singh Rathee, the company’s MD, says: “As per our internal research, we feel that the demand for heavy palletising robots is likely to grow in India and we feel that there is a large market for them in the FMCG, logistics and consumer goods industry in India.”

phase of the National Institute of Food Technology, Entrepreneurship and Management (NIFTEM) will also be inaugurated during the next 100 days. NIFTEM has been conceived as an apex training institution to build the human resources capacity necessar y for suppor ting the increasing requirements. Outlining some other steps to be taken by his ministry, Shri Sahai said that the ministry will also commission two integrated cold chain projects and the first processing unit in the country’s first mega food park.

Cargill Offers Oils Expertise Online Minneapolis, US: C a rg i l l h a s l a u n c h e d an oils and shortening knowledge centre within its food ingredient website. The centre provides information to food manufacturers seeking to formulate healthier products. “This new knowledge centre is a source of information about fats and oils and serves as a portal to answering questions about current issues and options,” said Lynne Morehart, technical services manager of the company’s oils & shortenings team. Customers visiting the knowledge centre will get an overview of oils and shortenings and learn about issues such as nutrition claims and palm sustainability. It also features a ‘From the Experts’ section, which has a series of questions and answers with key technical oil experts. The ‘Solutions’ section helps customers understand different processes and solutions that can be applied to achieve nutritional goals. The knowledge centre also includes an interactive label calculator to demonstrate how different oils affect the nutrition facts label.





EU Lifts Ban On Odd Shaped Fruit & Vegetables Brussels, Belgium: European Union (EU) rules governing the size and shape of many fruit and vegetables has ceased to exist since July 1, when specific marketing standards for 26 types of fruit and vegetables were repealed.

of EU trade: apples, citrus fruit, However, member states may also kiwiAPFI, fruit,Format lettuces, and PT1/PT2, exempt CC-en34-AZ082 these from the standards 124peaches x 200 mm, 05/09 if nectarines, pears, strawberries, sweet they are sold in the shops with an peppers, table grapes and tomatoes. appropriate label.

“July 1 marks the return to our shelves of the curved cucumber and the knobbly carrot,” said Mariann Fischer Boel, commissioner for agriculture and rural development. “More seriously, this is a concrete example of our drive to cut unnecessary red tape. The changes also mean that consumers will be

Life is liquid. (7)


Your bottom line is our top priority.

able to choose from the widest range of products possible. It makes no sense to throw perfectly good products away, just because they are the ‘wrong’ size and shape.” The change means that these standards will be repealed for 26 products: apricots, artichokes, asparagus, aubergines, avocadoes, beans, brussels sprouts, carrots, cauliflowers, cherries, courgettes, cucumbers, cultivated mushrooms, garlic, hazelnuts in shell, headed cabbage, leeks, melons, onions, peas, plums, ribbed celery, spinach, walnuts in shell, water melons, and witloof/chicory. Specific marketing standards will remain for 10 products which account for 75 percent of the value

Hall B6

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Huhtamäki Sells Australian EPS Business

Danisco Appoints VP Of Corporate Sustainable Development

Albury, Australia: Huhtamäki Oyj sells its EPS (expanded polystyrene) packaging business located in Albury to the Australia-based packaging company Pact Group. The annual net sales of the unit is some E7 million (US$9.7 million), and the agreed value for the transaction is E5 million. The sold unit serves the local fresh foods packaging market. “This transaction supports the execution of our strategic review of rigid plastic consumer goods operations”, says Huhtamäki Oyj’s CEO, Jukka Moisio. “We will continue to review our remaining rigid plastic consumer goods operations in Europe and Australia.” Following the divestment, the company has production at five sites in Australia. The sites in Bankstown, Wacol and Mulgrave serve the rigid plastic consumer goods market. Rigid paper and plastic packaging production in Windsor serves the local foodservice market, and rough moulded fibre packaging production in Preston continue to support the company’s strategic focus areas.

Jeffrey Hogue has been appointed as Danisco’s VP of corporate sustainable development. Mr Hogue replaces Søren Vogelsang, who retires from both Genencor, and from the international scene. Mr Hogue will be leading the company’s Copenhagen-based corporate sustainable development team and the overarching sustainability strategy for the other divisions. He joined Genencor in 1995 and has been responsible for its sustainability strategy and the implementation of a range of initiatives including those relating to social responsibility, environmental health and safety, as well as sustainability performance management and reporting.

Coca-Cola Hellenic Bottling Appoints COO Coca-Cola Hellenic Bottling Company has appointed Dimitris Lois to the newly created position of chief operating officer (COO). He will report to Doros Constantinou, the company’s MD. The appointment will take effect from August 1, 2009. As COO, he will be responsible for the company’s regional business units with the group’s regional directors reporting to him. Mr Lois joined the company in March 2007, and was appointed region director later that year. Prior to that, he held various senior management positions with Frigoglas for 10 years, becoming MD in 2003.

The Pavan Group Turnover Hits US$128 Million Galliera Veneta, Italy: The turnover for Pavan, an Italian manufacturer of machinery and plants for the food industry, has grown by 66 percent in the past five years and reached E90 million (US$128 million) in 2008. Exports to 120 countries represented 95 percent of total sales. Consolidated profits amounted to E6.7 million (a 46 percent increase). CEO Andrea Cavagnis (left) commented: “The year 2009 is going to be a positive year for us again, but without

the growth we have experienced in the past. The crisis in the food industry is less intense than in other sectors.” He added that in spite of the economic and financial crisis, every year five percent of the company’s turnover is invested in the research and develop-ment of products and technologies. “This endeavour for continuous improvement makes us confident enough to face the new competitive challenges which await us in the years to come.”





operate as strategic business units. As a result of the changes, Barry Harris, the director for milk supply, has decided to leave his role, but will continue to advise the co-operative to the end of the year.


director for group manufacturing and supply chain. Andrei Mikhalevsky becomes MD for global ingredients and foodser vices. The global ingredients’ product portfolio ranges from commodities used in high-value markets to specialised dairy ingredients and foodservice products. Andrew Ferrier, the company’s CEO, said that the new structure would mean a more intense focus on efficiency in the core business, enabling it to better serve its global customer base and strengthen par tnerships. He added that the regional consumer brands businesses would continue to

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Auckland, New Zealand: Fonterra has consolidated its core operations into a single business unit and reorganised its senior management team accordingly. The consolidated business unit, Fonterra Operations and Trade, brings together all functions from the farm gate through to the company’s global trade customers. This includes milk supply, shareholder relations, milk collection, NZ operations, offshore milk sourcing and processing, supply chain, sustainability, government relations and global trade. The unit will be led by Gary Romano as MD for operations and trade. Mr Romano was formerly the

Steve Woods, UK

Fonterra Reorganises Operations Unit





Wolf Opens Factory In Hangzhou H a n g z h o u , C h i n a : Wo l f Ve r p a c k u n g s m a s c h i n e n , t h e German-based packaging company, opened their factory in Hangzhou, China on May 29 this year. Members of the company’s Malaysian, Thailand and Indonesia office, as well as customers and suppliers from around Asia Pacific and China attended the opening ceremony. L- R: Gunter Wolf, CEO, Peter The company has invested Speksnijder, GM of China plant, & E100,000 (US$141,063) for its plant Sebastian Wolf, executive director. in China, and spent a year setting up the factory. With the opening of this 1,000 sq m factory, the company’s form-fill-seal machines (models VPP 250 and VPZ 140) will be made available to China and its surrounding regions directly from Hangzhou. The factory also allows the testing of its machines, such as film and product test runs for its customers. Sebastian Wolf, the company’s executive director, says: “These machines are made to compete with our Chinese counterparts in the local market. We will also offer these machines to the Asia Pacific region, and to other parts of the world, depending on the customer’s needs.”

Tetra Pak Inaugurates 100% Green Electricity Plant Hohhot, China: Tetra Pak’s new packaging material plant in Hohhot, Northern China, operates completely on power from renewable resources – often referred to as ‘green electricity’. The company invested E60 million (US$83.8 million) to build the plant, bringing total investment in China to E250 million, with a total capacity of approximately 50 billion packs a year in its four Chinese plants. The Hohhot facility is the first manufacturing plant in Inner Mongolia and among the first in China, to use green electricity. The plant consumes an estimated 20 million kWh of green power annually, which corresponds to an estimated saving of 16,000 tonnes of CO2 a year. The green electricity supplied comes primarily from wind power. The inauguration of the new plant coincides with the publication of Tetra Pak’s 2009 Environmental and Social Report, which details the company’s community and environmental goals and initiatives around the world.

PepsiCo Opens First Overseas ‘Green’ Plant in China Chongqing, China: PepsiCo has opened its first overseas ‘green’ plant in Chongqing, China, as it reiterated plans to invest US$1 billion in the country. “This plant reflects our deep and long-term commitment to China,” said Indra Nooyi, chairman and CEO of the company. “It is also an important milestone in our green journey, on which we are partnering with the Chinese government, industry and others to continue to promote the health and longevity of our planet.” The facility is designed to use 22 percent less water and 23 percent less energy than the average PepsiCo plant in China. To save energy, 75 percent of the plant’s indoor areas feature natural lighting, including a skylight in the packing area and warehouse. The plant is expected to help the company reduce greenhouse gas emissions by 3,100 tonnes; water usage by 100,000 tonnes; and overall energy use by four million kilowatt hours per year, compared to the former Chongqing plant.





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elementary school aged children, and performed a quality evaluation of the products. During the 13-week test period, the children consumed products made with refined flour followed by the test products made with whole grains and soluble fibre. N o s i g n i f i c a n t d i f f e re n c e s i n

consumption were found between the refined flour, whole grain and soluble fibre-enriched foods.

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ChiCaGo, uS: Elementary school children could not differentiate between refined flour or whole grain and soluble fibre-enriched products. According to a report in the Journal of Food Science, researchers at California State Polytechnic University-Pomona studied the consumption of whole grains and soluble fibre-enriched burritos and chocolate chip cookies among

“ T h e s t u d y re s u l t s s h o w potential for both whole grain and soluble fibre-enriched products to be incorporated into the school menus, particularly chocolate chip cookies,” writes lead researcher, Maria Omary.


Hydrosol: Stabilising Systems For Ice-Cream Hydrosol has developed tailor-made stabilising systems for ice-cream. The stabilising systems from the Stabimuls IC range make it possible to create individual ice-cream recipes. It permits adjustment of melt, viscosity and rheology, texture and consistency. The stabiliser is ideal for basic cream and luxury ice-cream to sorbets, sherbets and water ice. The emulsifiers and stabilisers it contains reduce the growth of ice crystals to a minimum even in the event of temperature fluctuations. It is also possible to adjust the stability of the ice-cream to logistic requirements. The range also includes stabilising systems with non-fat content from milk solids. Fat-reduced or low-carb formulations, as well as lactose-free and non-dairy varieties can be produced as required. _____________________________ Enquiry No: P0700

Redpoint Bio: All-Natural Sweetness Enhancer Redpoint Bio has identified an allnatural sweetness enhancer, RP44, aimed at helping the food and beverage industry reduce caloric content, while maintaining the taste of sugar. The enhancer enables the reduction of up to 25 percent of the caloric sweetener in product prototypes, while maintaining the taste quality of the fully sweetened product. It has demonstrated enhancement results with common sweeteners including sucrose, fructose and high-fructose corn syrup. The sweetness enhancer is intended for use in small quantities together with nutritive sweeteners. It acts by amplifying sweetness intensity, thereby reducing the amount of nutritive sweetener required. _____________________________ Enquiry No: P0702

© 2009 Oliver Hoffmann



Lanxess: Ion Exchange Resins Ion exchange resins from the Lewatit product line of specialty chemicals group Lanxess, help to ensure that sugar solutions, syrups and other liquid sweeteners comply with the quality demands of the beverage manufacturers and their customers. Ion exchange resins are used not only for demineralisation, but also for decolourising yellowish brown to brown cane sugar solutions. Ion exchange units exhausted with coloured impurities can be regenerated on site by washing the resin with a sodium chloride solution. Two ion exchange resins tailored specifically to the decolourisation of sugar solutions are available, with the heterodisperse grade S6328A, and the monodisperse grade S6368. _____________________________ Enquiry No: P0701

Solanic: Potato Proteins Potato proteins from Solanic offer functional native potato protein isolates. The ’clean label’ proteins are vegetal, natural and require no allergen or E-number declaration. It can be used in product development and texture creation. Some of the applications that it can be used for include processed meat and fish products, where its combination of emulsifying and gelation offers cost-effective and non-allergen opportunities. It can also be applied in meat-free analogues, glutenfree bakery, mayonnaise and dressings, ice-cream and wine clarification. _____________________________ Enquiry No: P0703

Enquiry Number




Equipment & Services

Heat And Control: Thermal Fluid Heated Fryer Heat And Control’s MasterTherm fryer uses a U-tube heat exchanger that uniformly heats cooking oil throughout the fryer. A small volume of thermal fluid rapidly circulates through the heat exchanger to maintain a consistent cooking temperature and quickly adjust to changes in product load. The heat exchanger features an adjustable feed conveyor to handle breaded on non-coated product, or to drop batter coated products into the oil. It is available in lengths from 10 (3.04 m) to 32 feet, with multiple temperature zones, a variety of product conveyors, stack heat recovery, and continuous fines removal systems. ___________________________ Enquiry No: P0704

Krones: Cost-Efficient Option For PET Hotfill The NitroHotfill process from Krones offers a financially driven alternative to conventional hotfill processes. The process control is based on the ‘Relax-Cooling’ (RC) concept, where the installation of a nitrogen injection dosing feature just before the capper creates a positive pressure of 1.5 to 2 bar inside the bottle. The process can be utilised for the bottle production process in the Contiform H, which also enables aluminium moulds to be used, and reduces the machine’s air consumption dramatically. Depending on the preform and bottle material being used, and the differing as-is parameters, the company says that material savings of up to 30 percent can be achieved. _____________________________ Enquiry No: P0706

Key Technology: Manta For Frozen Potato Key Technology introduces Manta, a large capacity sorter aimed at assuring that the final product is free of foreign material and objectionable process-generated material. Its features include Vis/IR (visible infrared) cameras and raptor laser technology, high intensity LED lighting, high flow ejector valves, and three-way ejection capability. With this application, potato processors can automate inspection of frozen products at the end of the production line to improve food safety and product quality while reducing labour costs. Featuring a two-metre wide scan area, the sorter handles up to 23 metric tonnes of frozen potato strips per hour, based on 7 mm wide cuts. Manta is ideal for sorting all types of potato products on frozen and refrigerated processing lines including: strips, steak cuts, wedges, spirals, waffle cuts, and small whole potatoes. _____________________________ Enquiry No: P0705

Tetra Pak: Chilled Liquid Package For All Ages Tetra Pak adds another packaging solution to its offerings with Tetra Brik Edge, a packaging solution for chilled liquid dairy products designed for consumers of all ages, from children to elderly consumers. The 34 mm diameter ‘SimplyTwist’ screw cap on the packaging requires a low opening force, designed for easy opening. The diameter of the closure also makes it ideal for smooth pouring of thicker dairy products, such as cultured milks and drinking yoghurts. The angled top makes it easier to grip the cap, as there is more space for the hand and fingers. The packaging solution is produced at a capacity of 7,000 packs per hour on the company’s C3/Flex XH packaging line, providing a cost-effective production solution. ___________________________ Enquiry No: P0707


PRODUCT HIGHLIGHTS Equipment & Services

Spartech: Eco-Friendly Packaging

Bosch: Bag Style Flexibility The machine’s low height and the numerous retrofitting options make the SVI vertical bagger series from Bosch Packaging Technology ideal for a range of food applications. This combination allows the intermittent SVI machines to produce bags with corner seal and doy style bags with optional zippers. For corner sealing, the manufacturer can upgrade the machine with an additional modular unit. The series consists of two machines for packaging different bag sizes and lengths: the SVI 4020 packages bag sizes at a maximum 600 mm in length, and the SVI 2620 for bag sizes of up to 400 mm in length. Both machines have an output ranging from 10 to 120 bags per minute. The series also offers heatsealing and polysealing options, with adjustable sealing temperatures.

Spartech has developed the EnviroSeal, a family of sealable, polyester products. The products is said to contain comparable physical performance properties to PVC. These products can be RF welded and heat-sealed to film or cards, and are suited for use in food packaging. Designed for use in blister packaging, clamshells, produce containers, display boxes and containers, the products offer clarity in three custom-designed products – XP20 and XP30 which are FDA-approved for food contact, and XP40. All products in this line are recyclable in PET streams. _____________________________ Enquiry No: P0710

_____________________________ Enquiry No: P0708

Salazar: Molded Pulp Packaging Salazar Packaging, a US based p a c k a g i n g c o m p a n y, h a s developed the Eco Flex Molded Pulp. The packaging solution’s waffled design allows it to bend and snap into a variety of forms for cushioning, corner protection, wrapping, void fill, and end capping. It is available in 13.5” x 11.5” x 0.75”sheets, with 16 sheets per case. Manufactured from recycled newspaper, Eco Flex is a 100 percent post consumer waste material. It is reusable, recyclable, biodegradable, and compostable. Although flexible and easily shaped or separated into smaller pieces, it is strong enough to replace less eco friendly packaging products. The product can be used as top and bottom cushioning product for heavy and/or fragile products including candles, jars and bottles. It can easily be bent around a cylindrical product shipping individually such as a bottle of wine, or olive oil. _____________________________ Enquiry No: P0709

Thermo Fisher: Reduce Solvent Consumption Thermo Fisher Scientific has released the Accela 600 HPLC and Accela 1000 U-HPLC. Both systems are designed to enable rapid method development, while reducing solvent consumption. The systems feature force feedback control (FFC), which enables the delivery of accurate and precise gradients under all operating conditions. This provides the flexibility of quaternary solvent delivery for HPLC and U-HPLC applications. Developed for use with the company’s Hypersil columns packed with five, three and 2.4 micron particle diameter, the Accela 600 provides flow rates of up to five ml/min, and a maximum operating pressure of 600 bar with 90 µl of delay volume. The Accela 1000 has a maximum operating pressure of 1,000 bar with 65 µl of delay volume. This makes it ideal for U-HPLC applications using columns packed with sub two micron particles. _____________________________ Enquiry No: P0711




Equipment & Services

Symrise: Flavour Analysis Ashworth: Standard Weight Spiral Belt For Heavy Duty Ashworth Brothers’ Omni-Pro 075 is able to withstand 150 pounds (68.04 kg) of tension for 100,000 cycles. It retains the same design features that allow the belt to minimise cage bar wear, maintenance costs and downtime in the most demanding high-tension spiral applications. The shorter pitch is ideal for small products and closer transfers. The link design includes a ‘protrusion leg’ that prevents welds from contacting spiral cage bars and permits the belt to run smoother with less system wear. Each link is formed with a coining process to prevent break-in wear, which reduces belt elongation and increases belt life.

Symrise has developed SymStixx, a glass probe that allows researchers to conduct more detailed analyses of foods. This tool produces comprehensive flavour profiles, giving flavourists what they need to develop authentic flavours. The analysis tool is only a few centimetres long and a few millimeters thick, is made of glass with a specialised coating. The instrument can be used by placing it in contact with the sample to be analysed. A GC/MS system is used to detect the flavourings, which are identified via comparison to compounds in a database. The tool will be most useful for meat flavourings in culinary products and for natural flavourings such as vanilla and mint. _____________________________ Enquiry No: P0714

___________________________ Enquiry No: P0712

Watlow: Panel Mount Controller Watlow, a designer and manufacturer of electric heaters, controllers and temperature sensors, has produce the EZ-Zone PM panel mount controller in a 1/8 DIN size. This controller is available with choice of horizontal or vertical configuration allowing it to fit variable cabinet profiles. The product features larger characters and buttons improving usability. Its case slots make it easier to remove the control hardware from the front pluggable DIN chassis by utilising a screwdriver. Other features of the controller include dual channel PID control, cascade control, square-root linearisation, wet bulb/dry bulb capability, as well as ratio and pressure to altitude compensation curves. _____________________________ Enquiry No: P0713

Nizo: Navigator For Fermentation Process Nizo food research has developed the metabolic navigator for bioconversions. It is an instrument that facilitates the development of biological ingredients and helps to improve industrial and food related fermentation processes. Metabolic functions of microbes can be extracted from the genome sequence using computer software programmes (bioinformatics tools). The navigator integrates all knowledge of these microbial metabolic functions into easily accessible metabolic roadmaps. These customised roadmaps can be applied for improving biomass and ingredient yield, as well as quality control of the production medium. ___________________________ Enquiry No: P0715

Some like it hot.

Our belts will handle it! When it comes to baking, steaming, drying and transporting food, steel belts are often exposed to extreme mechanical and thermal stress. Berndorf Band steel belts are made to match these high requirements.

They prove high quality and reliability even at fluctuating operating temperatures and a high number of load cycles. It goes without saying that Berndorf Band belts meet strictest hygienic requirements.

BERNDORF BAND GMBH A-2560 Berndorf, Austria Phone: (+43)2672-800-0 Fax: (+43)2672-84176 Enquiry Number




BSK, JKT, Indonesia


End Of Line Packaging:

Go Green

A comparison of the sustainability of ‘pad shrink’ packaging systems versus RSC cases. By Peter Fox, director of sales, Delkor Systems

Standards For Sustainable Packaging One organisation that has tried

to define sustainability is the Sustainable Packaging Coalition, an industry-working group dedicated to transforming packaging into a system that encourages a sustainable flow of materials. T h i s g ro u p l i s t s t h e s e ideal attributes of sustainable packaging: a) Beneficial, safe and healthy for

Katrine Thielke, Copenhagen, Denmark

The term ‘sustainability’ is heard in boardrooms everywhere these days because it is a concept that embraces both environmental and bottom-line business concerns. F o r p ro d u c t p a c k a g e r s , sustainability means reconciling what can be conflicting goals: minimising whatever negative impacts their packaging may have on the environment, while adequately protecting products during shipping and handling. Packagers today are facing increasing demands for ‘sustainability’ from every direction – consumers, retailers and non-profit watchdog groups – with few of these groups offering specific guidelines on how to measure it. What’s more, packagers are encouraged to achieve these dual goals while also controlling the costs of packaging to their customers.

individuals and communities throughout its life cycle b) Meets market criteria for performance and cost c) Sourced, manufactured, transported and recycled using renewable energy d) Maximises the use of renewables or recycled source materials e) Manufactured using clean production technologies and best practices f) Made from materials healthy in all probable end-of-life scenarios g) P h y s i c a l l y d e s i g n e d t o optimise materials and energy h) Effectively recovered and utilised in biological and/or industrial cradle-to-cradle cycles While not all of the criteria for sustainable packaging listed above are necessarily achievable in every packaging application, a pad shrink packaging system represents a significant step




toward sustainability in secondary packaging. This system reduces both the amount of material required to create the packaging and the amount of waste added to the environment throughout the product cycle. tHe Pad SHrink Packaging SYSteM The pad shrink packaging system was developed primarily as a means to control packaging material costs, and secondarily as a means to reduce end-of-life

Figure 1 Raw Material Weight Comparison Raw Material Type Weight (lbs) Pad and overwrap

Raw Material Type Weight (lbs) RSC Container

Corrugated Pad 0.016

Corrugated Case 0.218

Shrink Film 0.019

BOPP Tape 0.002

Adhesive 0.004 Total RM Weight (lbs) 0.039

Total RM Weight (lbs) 0.220

0.039 Total RM Weight (lbs)

0.220 Total RM Weight (lbs)

Pad shrink system has 82.3 % less RM weight (lbs) when compared to RSC container

disposal costs for customers. It achieved those primary goals by reducing secondary packaging costs for users by up to 50 percent as compared to trays, and 75 percent compared to traditional corrugated cases (see Fig 1). The pad shrink packaging system combines three materials to build a stable secondary package bundle that replaces the traditional corrugated container. • A flat corrugated pad forms a base for rigidity • A hot-melt adhesive (applied to the flat pad) temporarily bonds the primary containers to the pad during packing • A l o w c o s t , re c y c l a b l e polyethylene (PE) shrink-film securely encapsulates the assembled package

For product packagers, sustainability means reconciling what can be conflicting goals: minimising whatever negative impacts their packaging may have on the environment, while adequately protecting products during shipping and handling.

The resulting compact bundle often adds to savings by allowing an additional layer of packages to be added to each pallet load. As such, the product density is increased and transportation energy and costs is reduced. The system is typically used to ship a variety of primary containers, including cans, rigid plastic bottles, glass jars, plastic

jars, tapered plastic cups and paperboard canisters. QuantiFYing tHe enVironMental adVantageS While a packaging system that uses fewer raw materials, and results in less waste for landfills was presumed to be more ‘green’, US-based Allied Development Corporation recently confirmed this thesis empirically in a study. In order to help secondary packagers make informed decisions about the system that best meets their packaging and environmental goals, the company compared the total environmental impact of a pad shrink system versus a traditional corrugated RSC case. Allied used an environmental life cycle analysis tool to compare the environmental impact of various complex packaging scenarios. The study examined the following factors: • Materials Raw materials include corrugated cardboard, PE film, glue and biaxially oriented polypropylene (BOPP) tape. The total weight of the materials needed by each system was considered for the




comparison, along with the amount of energy and greenhouse gasses associated with their production and disposal.

82% Less Packaging To Landfill Or Recycle 200,000 lbs per year

• Transportation The energy consumed for transportation was used to calculate its contribution to greenhouse gas production. While the transportation distances were the same for both packaging systems, greenhouse gas production varied with the weight and volume of materials shipped.

Figure 2




• Energy Electrical energy was used for manufacturing packaging materials and operating the packaging equipment. Total energy consumed was used to calculate the amount of greenhouses gasses produced.

Pad Shrink

RSC Case

Figure 3 62% Less Process Energy Consumption 4

3 MJ per Unit

StudY aSSuMPtionS As in all formal studies, it is important to understand the basic assumptions made about the test conditions. Following is a list of the underlying assumptions: • PE resins are shipped via rail car, and require no secondary packaging. PE film is usually shipped by truck and requires protection such as cores, liner bags, and end caps. • Materials used in the pad shrink system and corrugated cases were assumed to be sourced and used in the same manner. • Transportation distance for all raw materials was assumed to be 250 miles (402.3 km). Rail car shipments were assumed to contain 200,000 pounds (99.9 tonnes) of raw material. Truck shipments were assumed to be 40,000 pounds of raw materials. • Final product distribution to retailers assumed a distance





Pad Shrink

of 500 miles. The volume of stretch film used for wrapping individual pallet loads was assumed to be equal for both types of shippers. • Manufacturing processes for each component (corrugated case, corrugated pad, and shrink film) was based on a typical large scale converting process. • In addition to the energy needed to produce raw

RSC Case

materials, the study calculated the process energy required to produce the finished package components. This includes e n e rg y f o r p ro d u c t i o n , warehousing and support space in each facility. • The method of disposal for all packaging was assumed to be landfill, although corrugated cardboard and PE film are recyclable. Reusable items such as pallets were assumed




Figure 4 55% Less Greenhouse Gas Emissions 0.2

lbs per year





Pad Shrink

RSC Case

Figure 5 Figure 5 11% Less Transportation Energy To Point-Of-Sale

MJ per Unit





Pad Shrink

to be reused 20 times. • Production volumes were assumed to be the same for the pad shrink system and the corrugated case packaging. Final study results were based on a total volume of five million bottles, which translates to 833,333 pad shrink shippers or RSC cases. tHe reSultS When comparing the pad shrink

RSC Case

packaging system to conventional corrugated containers, the study found that pad shrink system reduced the amount of material to be recycled or disposed of in a landfill by 82 percent. (See fig 2) Due to less raw material input and less material handling, the pad shrink system reduced the amount of process energy consumption by 62 percent. While shrink-film requires more energy per pound to manufacture as compared

to corrugated cardboard, its significant reduction in energy consumed during transportation and processing still made it a clear winner, according to the study. (See fig 3) Greenhouse gas emissions were found to be 55 percent lower with the pad shrink system. This was the result of less emission during transpor tation, and combined with reduced process energy consumption and savings in raw materials. (See fig 4) Due to the system’s lower weight and greater product density, it was found to cut the amount of energy consumed in transporting the products to the point-of-sale by 11 percent. (See fig 5) round uP The results of this independent study demonstrated that pad shrink packaging system fulfils many of the eight characteristics for sustainability identified by the SPC. The study data also supports the financial and environmental advantages of using the system rather than RSC cases for end-ofline packaging. This is due to the system’s 75 percent reduction in the volume of material – material that neither has to be manufactured, transported or disposed of in a landfill. Today, all packagers need to be good stewards of natural resources and to act with environmental responsibility as they compete in their various markets. By comparing the sustainability of packaging system alternatives, secondary packagers can make informed choices that will benefit both their businesses and the environment. For more information, ENTER No: 0720





LiNED Up For Variet y ld wou ing r e uc ag prodits packnical d o f h fo ack ount o d of tec stems n s , y l am hea g S cks tipa bstantia anger, ckagin l u a m u lw cing ave a s mar El tional P u d iet rna ntro to s By i e able e. By Dnt, Inte b olum rtme v epa d CONSUMERS can take home all their favourite varieties in a single supermarket item in the form of a multipack option containing either 15 or 20 portions. Up until 2007, a multiple option was offered in the form of snack bags grouped in a larger tubular bag. Australian snack food producer, Smith’s, decided to put this type of packaging option to the test and investigate the possibility of developing a space-

efficient multipack or SEMP for short. The aim was to reduce the size of the outer packaging for the same content volume. DONE UNDER A SECOND Implementing the new carton packaging concept meant investment in a packaging line at the company’s Tingalpa location in Queensland. The company specified an output of 80 multipacks a minute, leaving

three quarters of a second for erecting, filling and closing the cartons. The target specification stipulated an efficiency factor in excess of 90 percent. The planned pack sizes were boxes containing either 15 or 20 bags of content weighing 19 grm, and 10 of the 28 grm adult serving sized bags. The boxes would contain either one type or a variety of snacks. The specified target in feed rate was 1,600




single packs per minute. Although the pack design and packaging scheme were fixed for the present operations, the line also had to be flexible for conversion to variant configurations in the future. IT TAKES TWO The packaging line delivered is 4 0 m e t re s i n l e n g t h a n d incorporates units from four different manufacturers. Its nerve centre is formed by TLM technology. Over 14 machine frames, eight F2 robots and 10 F44 robots are installed. The products are fed by 10 dual track systems,

Suction tools designed to ensure maximum care of the product engage the packs and place them into the boxes, during which the robot’s carbon arm moves at speeds of up to five metres per second.

providing feed technology. Weight checking at the end of the line is performed by a scale, and a laser coding device takes care of product identification.

Before the automation system was implemented, an option was suggested which proved fundamental to the machine’s mode of operation. The suggested solution was for the packaging design to use a combination of separate box and lid instead of a single cohesive blank. This allows the actual box body to be erected, glued and transported to the filling station at the required cycle speed. Using an attached lid would add to the complexity of each individual process: positioning, filling and closing.

To keep pace with the required capacity, two TLM units switched in sequence to feed cartons onto the line simultaneously. The two F2 robots position the open boxes that were erected from flat blanks, into a continuously running chain transport system. On this track, the boxes run through the downstream packaging line made up of ten F44 picker stations.

BOXED UP The snack portions in their primary packaging are loaded manually into the hopper. The feed systems are arranged at an orthogonal angle relative to the chain transporter movement direction. The bags are transferred individually to the product conveyors, moving them into the working area of the robot arms. Suction tools designed to ensure maximum care of the product engage the packs and place them into the boxes, during which the robot’s carbon arm moves at speeds of up to five metres per second. Transmitted light scanners installed at the entrance area of the product conveyors provide data on the location of the bags and their rotational position. If mixed packs are on the day’s production schedule, then the hoppers along the packaging line are filled with the required flavours. As there are 20 tracks, this is the maximum number of different products that can be packaged. To add packaging variants with a changed type c o m p o s i t i o n , t h e re l e v a n t parameters are entered at the control panel of the packaging line control system. FIVE MINUTE MAKEOVER The benefit of the TLM concept is that the many mechanical functions are now taken care of by the software, and machineresetting processes are no longer required when changing formats. All that is needed is to introduce an additional tool. As a result, providing the flexibility that brand name manufacturers wish to offer their retail customers do not involve increased packaging costs. Smith’s currently works without any tool changes: As the




display cartons have the same footprint (290 mm x 240 mm) and differ only in terms of height (105 mm or 132 mm), the grippers fit both carton types. All that is required for the format change is to change a plate in the feed magazine, which takes around five minutes. The selection of mixtures type is also taken care of by the software, and takes place at the control panel. KEEP IT SIMPLE Alongside speed and flexibility, the third fundamental re q u i re m e n t w a s t h e achievement of greater line efficiency. A no-frills advisor y phase ensures an approach that allows those involved to clearly identify potential bottlenecks. The line control system with its divided intelligence concept subscribes to the idea of simplicity. Each unit of the packaging line is equipped with its own processing unit and linked by means of an optical bus. T h e h a rd w a re a n d t h e algorithms used by the software are consequently able to fulfil their function without a complex architecture. This creates a robust operating status whose stability is not compromised by a high incidence of data or where computing performance is required. This is an essential prerequisite for high availability, given that around 110 axes have to be synchronised at any one time in the Tingalpa plant.

An F2 robot transfers the cartons to a vacuum transport system, which offers the benefit of fixing the packs in a given position to allow positioning of the lids.

This synchronisation output paves the way for improved product feed handling processes. The drive system of each individual feeding lane is adjusted separately to the speed needed to transfer enough crisp bags of the relevant type to the product conveyor. This helps eliminate the otherwise customary surplus output. In order to ensure that this individual control system works correctly, each of the twenty feeding lanes is linked via an interface to the control system



of the F44 unit. An encoder acts as a transducer to transmit pulses to the drive system of the feed unit. The more products the picker requires, the higher the pulse frequency. READY TO GO Integrating the 20 encoders presented something of a challenge in terms of control engineering. The success of the implemented solution is due to the open-ended control system architecture, which is designed to accommodate this type of added feature. On the chain transport system, the filled cartons are conveyed to the final section of the line – the carton closing station. An F2 robot transfers the cartons to a vacuum transport system, which offers the benefit of fixing the packs in a given position to allow positioning of the lids. This prevents unsightly defects on the box design. For more information, ENTER No: 0721

Enquiry Number






Execution Effectiveness Effectiveness of processes have been known to increase by seven to 10 percent with the application of MES. By Ralf Schubert, head of engineering and assembly, Schubert

Modern production plants are no longer defined by the manufacturing of products, but instead, by customer orientation and the resulting ser vice features such as adhering to deadlines, flexibility, delivery time and product variety. Above all, product diversity and the shorter product life cycles result in complex processes. In order to achieve competitive advantages, production companies must structure the efficiency of their internal processes as optimally as possible and improve it continuously. This is nothing less than lean manufacturing. Manufacturing execution systems (MES) can help by contributing to increased transparency, responsiveness and economy. Measuring Up Malfunctions lead to deviations from the planned sequence. Examples of these kinds of malfunctions, which are detected by the MES, are missed deadlines, machine

downtimes, missing materials, sick employees or sudden quality shortcomings. The system is assigned to the production management department within the company. It serves as a link for a continuous vertical integration between the company management and the production department. Orders for a certain period

are transferred to the system from the ERP (Enterprise Resource Planning System). The orders contain data necessary for execution. These include the lot number or the minimum expiration data of the product. All processes are planned in detail by the MES, while taking the current production status into account. Before the start




of a production order, data are passed on to machines, quality sensors, marking devices and other devices, as well as working instructions to employees. After completion of an order, feedback to the ERP is carried out with processed information like the actual produced quantity, waste quantity and material consumption. An MES ideally provides the production management department with all the functions it requires. These functions can be divided into the three function groups: production, quality and personnel. Strength In Unity The unification of all functions in a software system and the connection of all elements involved in production to the MES enable horizontal integration. Unnecessar y double data acquisitions and interfaces are avoided. An escalation management system is assigned to the function groups, which quickly indicates faults via operating terminals, by phone or with instant messaging. A line control panel with integrated quality monitoring was developed, with several MES functions within the control panel. The functionality necessary for vertical integration is included. If integration with an ERP is not desired, data can be entered manually. The connection to the machines and devices is made via Ethernet and OPC or XML. The overall equipment effectiveness (OEE) is used for the output analysis of lines, sub-lines and machines. This characteristic number is determined by three subor-

The unification of all functions in a software system and the connection of all elements involved in production to the MES enable horizontal integration.

dinate characteristic numbers, which are the availability, the output and the quality. One of the control panel’s features is integrated quality monitoring for entering, as well as archiving and evaluating quality and process data. The reflected light scanner and the cameras for the F44 robots can be directly connected to the control panel. For example, a scanner in the manufacturing process can

detect bad products and output warnings long before the products reach a picker line. The data is shown in trend graphs, bar graphs and pie graphs. From industries in which MES’s are already used in all areas, it is known that the effectiveness of the processes can be increased by seven to 10 percent. For more information, ENTER No: 0722





CAMA: WRAP-AROUND CASE PACKER The wrap-around case packer from Cama, for the chocolate industry, can package up to 360 bars per minute. Flexibility is one of the main characteristics of this system. The plant can change its format depending on the different types and configurations of the product. The system can also be tailored to handle different product configurations at a speed of 30 wrap around cases per minute. __________________________________ Enquiry No: P0723

Markem-Imaje has developed the 5800 high-resolution, large character inkjet printer. The printer is the next-generation solution for printing clear, consistent text, graphics and GS1 compliant barcodes on cases, trays and shrink-wraps. Ideal for use in corrugate printing applications, the compact modular design of this updated printer can be integrated into existing production lines, carton erectors or tapers. The 5800 hot melt inkjet printer is the latest printing solution to utilise the TouchDry hot melt ink technology. This sustainable, instant dry, solvent-free ink is claimed to never bleed or fade for the life of the case. The inks can be delivered on a wide range of substrates and environments ranging from 0 deg C to 40 deg C, with print speeds of up to 182 m/min. __________________________________ Enquiry No: P0725


CERMEX: SHRINK BUNDLER Cermex’s TSi high-speed shrink-bundler without sealing bar is specially designed to handle small products with a maximum height of 220 mm. This is particularly applicable to the packing of small bottles of yoghurt or shrink-wrapping liquid cartons. The system features the integration of a vertical feeder, which ensures extraction via a belt system. The feeder is equipped with a photocell for synchronisation with the shrink-wrapper. Other features include a continuous 45 deg C selecting system to achieve speeds of up to 16,000 cartons/hour. The machine has a working height of 800 mm, and a removable injection table to facilitate access to the film, in particular for maintenance purposes. __________________________________ Enquiry No: P0724

The Invospeed is a continuous shrink bundling machine from Clearpack. The equipment can be used for containers of various shapes and sizes, and its modular design can be upgraded to include pad or tray handling retrofits. The machine can run in single, twin or triple lanes to give a speed of up to 100 cycles per minute using a single film reel. It also features controls, which allow product data recording and communication with the line control. The machine operates continuously in accordance to the overlapping principle, and is paired with the servo-drive technology. __________________________________ Enquiry No: P0726

Enquiry Number





Bran Reinvented

Stabilised rice bran is inexpensive and a sustainable source of wholesome nutrition providing functional properties for a host of food, beverage and meat products. By Henk Hoogenkamp

The world economic financial crisis has severely affected the food industry. In many cases it has come to a point that the socalled extenders such as soy are now replaced by cheaper alternatives. Extending the extender so to say. There is little doubt that the food, beverage and meat industry is competitive and highly complex. Food research will increasingly need to focus on health, wellbeing, nutrition and affordable or enhanced value. Stabilised Rice Bran Until only a few years ago, rice byproducts were considered waste material. Patented technology now allows massive increases in total output, higher volume throughput and cheaper solutions by using modern stabilising equipment and innovative technologies. Stabilised rice bran is a source of synbiotics, tocols, yoryzanols, polyphenols, nutritive protein and healthy mono and polyunsaturated oil. The main fractions are protein, oil and fibre.

Rice Bran

Rice Germ

White Rice


Until 2007, it was an underutilised resource for value added food. The reason being: an endogenous enzyme lipase activated during milling rendered the bran unsuitable for consumption, because of pro-oxidative mechanisms leading to rancidity. Patented technology and e n g i n e e r i n g b re a k t h ro u g h now allow the inactivation of lipase enzyme by heating the rice bran at 130 to 140 deg C for a short time, yielding a

stabilised bran without any of the traditional drawbacks. Stabilised rice bran is inexpensive and a sustainable source of wholesome nutrition with a low ecological and environmental footprint providing functional properties for a host of food, beverage and meat products. As such, it modulates, enhances and differentiates existing and new food products by providing solutions through application creativity and cost reductions. Compared to soy isolate, stabilised rice bran is on average 70 percent lower in price. The once obscure and illused rice bran can now be used successfully in a sustainable food chain. Formulation Economics It is difficult to take costs out of food formulations while maintaining quality that customers have come to expect. Many leading consumer brands mandate their R&D department to do just that. An example: The economic realities have long time users of functional soy ingredients rethink their position. Efforts to reduce or eliminate expensive soy isolate are part of a trend. Meat processing companies have long known that it needs to break their dependence on inflated inclusion levels of soy ingredients. Using stabilised rice bran in food and processed meats is a budget-minded approach. This approach seems to resonate with businesses that need to drive down formulation costs. Soy Backlash As the high-end food and processed meat formulae try to survive a shaky 2009 and beyond, it is out with the overload of soy ingredients, and in with a



Using stabilised rice bran in food and processed meats is a budget-minded approach. This approach seems to resonate with businesses that need to drive down formulation costs.

Rice Fibre Necessity Stabilised rice bran contains a n a p p ro x i m a t e i n s o l u b l e versus soluble fibre ratio of five to one. Rice bran exhibits a high digestive tolerance that occurs along the whole digestive tract with no excessive fermentation in the large intestine that would cause flatulence or abdominal pain. Of the 100 percent ingested fibre, it is estimated that some 10 percent is hydrolysed in the small intestine. Some 80 percent progressively ferments in the large intestine and the remainder excreted in the faeces. To combat the fast rising obesity epidemic, the World Health Organization (WHO)

advises a well-balanced diet derived from different sources. • Carbohydrates: 55 - 65 percent • Fat: 15 - 30 percent • Protein: 10 - 15 percent Based on these guidelines, the WHO also recommends choosing foods that avoid excessive glycaemic fluctuations. Low glycaemic index (GI) foods include most vegetables, fruits, beans and unprocessed grains. Hyper and hypoglycaemia can ultimately lead to diabetes type two. Therefore, the consumption of healthier complex carbohydrates will regulate blood glucose diffusion after a meal, as well as manage caloric intake,

Lotus Head, JHB, S Africa

balanced approach of functional ingredients that are able to provide additional cost-savings without altering the nutritional profile. Soy foods and soy support ingredients are rightfully known for their health benefits. Soy foods generally contain good quality mono and polyunsaturated fats, protein and other benefits such as moderate amounts of phytochemicals. Yet, unfortunately, the consumption of soy foods may inflict intestinal bloating and discomfort due to indigestible carbohydrates stachyose and raffinose. The latter two carbohydrates restrict universal application of soybased ingredients in foods and processed meats. There is no question that the soy industry has done well in creating awareness to soy’s health benefits. Even though the soy food market continues to grow, it has been unable to capture interest in all demographic age groups. There are questions regarding soy protein manufacturing issues of using ecologicalunfriendly processing aids such as huge amounts of fresh water and/or alcohol-hexane to extract and isolate protein fractions from the white soy flakes. The latter process is not universally considered ‘natural’, and so, contributes to the confusion of consumers’ perception about a true functional ingredient.

Buck, Massachusetts, US




provide sucrose substitution and extended energy release. It also assists to balance intestinal flora due to its prebiotic effects. Fibres are generally defined as complex carbohydrates that remain undigested in the small intestine. Prebiotics are characterised with fermentation by intestinal microflora and possess a resistance to gastric acidity and GI absorption. Most fibres meet these requirements, though a true prebiotic also stimulates elective growth or activity of intestinal bacteria associated with health and feeling of comfort. Sad But True It is a sad conclusion to see that with progress of food intake by affluent consumers, a strong decline in consumption of dietary fibre is associated with rapidly increasing numbers of degenerative diseases. The USDA reported that only one in five Americans consume the recommended daily amount of fibre. In the old days, fibres hardly deserved nutritional accolades. Fibres used to be cheap byproducts of other processes such as rice milling, much like sweet dairy whey when manufacturing cheese. Dair y whey was a major burden for farmers and dairies; a waste liquid with no real value. In the last twenty years or so, dairy whey has achieved star status and is considered the ‘white gold’ for the dairy industry. Previously unknown protein components such as peptides and lactoperioxidase have catapulted whey protein into the premier league of functional food ingredients. A similar pathway lies ahead for rice bran. A s a re s u l t o f m o d e r n lifestyles, diets have become

deficient in fibres, some of which have dropped to an alarming 15 grm per day, compared to a recommended daily intake of 25 – 30 grm per day. For optimum health, there needs to be a certain balance between the intake of soluble and insoluble fibre. The simplest e f f e c t o f d i e t a r y f i b re i s normalising transit time in the digestive tract. The physiological benefit of fibres is as complex as the fibres themselves. Insoluble fibres keep moving through the colon, while soluble fibre swells and moves slowly through the small intestines. Subsequently, the waterswollen soluble fibres trap bile acids squirted into the small intestines from the gall bladder to assist fat digestion. In a way, bile acids act as a fat emulsifier that contain liver cholesterol and stored in the gall bladder until the moment of food intake. Dietary soluble fibre traps much of the bile acids and prevents absorption. This mechanism draws the cholesterol out of the blood, and usually results in a healthier cholesterol profile. Dietary Essentials Initially, the term ‘dietar y fibre’ was used to describe the remnants of plants and fruits resistant to hydrolysis by human alimentary enzymes. Now, it is generally accepted that dietary fibre is more than just a non-nutritional compound in food. It is an essential element with a host of physiological functions and potential health benefits. The insoluble fibre is the most abundant carbohydrate structural material in nature, and makes up for some 60 percent of all fibre in most plant foods. The primary component is cellulose

uiz Baltar, Rio de Janeiro, Brazil


The consumption of soy foods may inflict intestinal bloating and discomfort due to indigestible carbohydrates stachyose and raffinose.

that is insoluble in water, dilute acid and dilute alkali. The linear polymer of beta-Dglucose molecules is indigestible by the human body due to the lack of enzymes that hydrolyse these beta linkages. As such cellulose material is not interactive with other molecules such as free fatty acids. Hemicellulose is also insoluble in water, though soluble in dilute alkali, which contain various heterosaccharidic polymers consisting of two or more sugars such as xylose and galactose. Resistant starch passes undigested through the small intestine and into the large bowel, where it is fermented and excreted. Lignan is an important component of dietary fiber as well. It is resistant to enzymatic breakdown in the small intestine, and bacterial breakdown in the large intestine. As such, nearly all lignin present in food is recovered in the faeces.


It is well documented that fermentation of complex carbohydrates that escape digestion have beneficial effect on colonic health; increasing stool volume, shorter intestinal transit time, production of shortchain fatty acids and a decrease of colonic pH. Bacteria that may ferment the complex fibre present in stabilised rice bran are likely from the glucidolytic flora. As such, it increases to the detriment of proteolytic species such as clostridium perfringes. This is due to the promotion of acidic conditions in the gut. In a way, the insoluble fibre can be seen as a prebiotic. Functional Rice Fibre Discussing dietary fibre always includes functional properties as well as organoleptical parameters. Generally, insoluble fibres are higher in molecular weight and size. In contrast, soluble fibre is smaller in size. I n s o l u b l e f i b re c a n b e considered for bulking and structure building in foods, while soluble fibres are more sugarlike and taste sweeter. High-fibre

Georgereyes, Los BaÒos, Philippines

Sanja Gjenero, Zagreb, Croatia


At a potential annual world availability of approximately 70 million metric tons, stabilised rice bran is a perpetual winner because rice is the overwhelming favorite staple of at least 60 percent of world’s population.

foods increase the feeling of satiety and provide more nutrients with fewer calories. In short, increasing the intake of insoluble fibre promotes bowel regularity, and increasing the intake of soluble fibre supports healthy lipid and glucose levels already in normal range. It is usually easier to formulate with soluble fibre than with insoluble fibre. To increase the inclusion level of insoluble fibre, it might be useful to reduce its particle size into smaller molecular

weights. Reducing chain-length at point of manufacturing can have significant impact further down the processing lines. Also, increasing inclusion level of fibre typically reduces calorie, while increasing dietary values. The FDA defines a ‘good source’ of fibre as providing a minimum of 2.5 grm of fibre per serving. An ‘excellent source’ contains at least 5 grm per serving. In the EU, these guidelines are at least three percent and six percent of the product formulation respectively. The verdict is still out, but it is generally accepted that the optimum ratio of insoluble versus soluble fibre is 2 : 1 to 3 : 1. Stabilised rice bran has a natural ratio of approximately 5 : 1, which makes it a good choice for food formulators. The intrinsic value of stabilised rice bran is more than the individual components alone. Besides the protein and oil component that enhance thermal stability, rice bran has a complex fibre structure that shows synergistical behaviour. This occurs when it is used in conjunction with structuring and gelation support ingredients such as milk protein and soy protein. Future enzymatic technology progress will no doubt make the natural rice fibre more accessible to digestion. These developments will further enhance the performance of the activated rice fibre act as a prebiotic substrate for the intestinal flora. It is obvious that soon stabilised rice bran can allow product positioning as several health-promoting phytonutrients protect against cellular damage, and a host of other chemical reactions in the body. For more information, ENTER No: 0730




Soluble Fibres:

Behind The


trials were conducted to evaluate the effect of adding soluble ďŹ bres (polydextrose) for improved gut health on wafer sheets. By peter thomson and laura Willmott, food technologists, Danisco (uK) WAFERS as we know them today, were first developed in Holland in the middle of the 19th century. Since then, wafers have been used in many food applications from confectionery bars to icecream cones. As one of the main focuses in the food industry is to develop healthier products, trials were conducted to evaluate the effect of adding soluble fibres (polydextrose) for improved gut health on wafer sheets. the test Control and high fibre wafers were made according to the basic wafer sheet formulation. After baking, the wafers were

cut to the same size and stored at ambient temperature, in sealed containers. The wafers were subjected to testing on days 1, 7, 30, 90 and 180. Analysis of wafers included, abrasion (sieve technique),

texture/snap test, sensor y, moisture and water activity, and moisture migration using standard ice-cream. Texture analysis was carried out using a texture analyser, with texture exponent software. Supports were positioned 40 mm apart, with the upper blade central to supports. The wafer was positioned at the centre, with its square pattern faced upwards, and diamond pattern downwards. Moisture analysis was carried out using a moisture analyser. Water activity of the wafers was measured at 25 deg C using a water activity meter. Texture analysis was also carried out on the wafers with ice-cream using a 2 mm cylinder probe and a heavy-duty platform (HDP/90) with holed plate. Ice-

Basic Wafer Sheet Formulation

Flour, White plain improved polydextrose oil, vegetable lecithin, liquid salt sodium bicarbonate Water

Control Wafers

Polydextrose Wafers

39.19 0.86 0.63 0.28 0.11 58.93

38.17 2.67 0.84 0.61 0.27 0.11 57.33




Figure 1: Moisture content and Aw of wafers over 180 days. 10.00


9.00 0.500



6.00 5.00



Moisture (%)


4.00 0.200

3.00 2.00


1.00 0.00

0.000 Day 1 Control

Day 7

Day 30


cream sandwiches were placed on the HDP, ensuring that the probe was centrally positioned over the hole in the platform.

Day 90

Control (Aw)

Day 180 Polydextrose (Aw)

Force (g) 450 400 350 300

Results & Discussion The wafers containing polydextrose had lower moisture content than the control wafers from day one. The wafers containing polydextrose also appeared to absorb less moisture over time, therefore remaining crispier than the control wafers. It also has lower water activity than the control wafers. Texture Analysis Once the trigger force is attained, the force is seen to increase until a time where the sample fractures and falls into two pieces. This is observed as the maximum force and can be referred to as the ‘hardness’ of the sample. The distance at the point of break is the resistance of the sample

250 200 150 100 50

0 -50


Control Day 1





3.0 3.5 4.0 Distance (mm)

Polydextrose Day 1

Fig 2: Measurement of the hardness and resistance of wafers to bend or snap on day one.

to bend, and so relates to the ‘fracturability’ of the sample (ie: a sample that breaks at a very short distance has a high fracturability). On day one and seven, the wafers containing polydextrose had a higher fracturability than

the control wafers, snapping after a shorter distance, while the control wafers bent more before snapping. In fig 2, the wafers with polydextrose had a sharper, narrower peak, indicating a cleaner, crisper snap and a crisper wafer than the control. On day 30, the control wafers were harder than the wafers containing polydextrose, requiring greater force to snap the wafers. At 90 days, it can be seen in fig 3 that the control wafer has a much larger curve, indicating that the wafer is much softer, as it bent further before it snapped. The wafers containing polydextrose were still crispier, snapping much more cleanly with less force, and with less bending before the point of fracture, which was also shown at 180 days. Wafers With Ice-Cream Once the trigger force of 5 grm has been attained, the probe proceeds to penetrate the sample to the specified distance. The probe then returns to its start position. The fluctuations are a result of the sample fracturing, and if there are large inclusions in the sample, these also Force (g) 550 500 450 400 350 300 250 200 150 100 50 0


-50 Control Day 1




Control Day 90


3.0 3.5 4.0 Distance (mm) Polydextrose Day 90

Fig 3: Measurement of the hardness and resistance of wafers to bend or snap on day 90.




add to fluctuations in the force readings. The area under the curve is taken as an indication of the hardness, and the linear distance as an indication of fracturability. The sample consisted of two layers of wafer with ice-cream in the middle. The initial small peak shows the force as the probe penetrates the first layer of wafer. At 30 days, greater force is required to penetrate the wafers containing polydextrose than the control wafers, indicating that the wafers containing polydextrose were less soft than the control wafers.

Taste When tasted as plain wafers, the wafers containing polydextrose were lighter and crispier than the control wafers. After being in contact with ice-cream for one month, the wafers were all of a similar, soft texture. However, the overall preference was for the wafers containing polydextrose, which when tasted were less soggy in texture than the control. The Roundup The addition of polydextrose lowers the moisture content of the wafers as compared to the control. It also appears to

reduce the amount of moisture that is picked up over a storage time of 180 days, resulting in a crispier wafer at the end of this period. The wafers containing polydextrose also had lower water activity. From this study, the results show that the crispiness of wafers can also be improved when adding soluble fibres. This helps to enhance the nutritional profile of a food product, and thereby, helps to maintain good digestive health.

For more information, ENTER No: 0731

Döhler: Fruit Active Plus

Danisco: Specialty Carbohydrate Litesse Polydextrose from Danisco is a speciality carbohydrate, which has a caloric value of 1 kcal/grm and is ideal for use in confectionery, bakery & cereal, dairy, as well as beverage applications. The product may help with the reduction of calories, fat and sugars within foods as well as improving the texture and mouthfeel and increasing the fibre content of products. It is also a soluble dietary fibre, and can be used to develop products with claims such as ‘source of fibre’ and ‘high fibre’. In the EU, a claim that a product is a ‘source of fibre’ requires that the product contain at least 3 grm of fibre per 100 grm, or at least 1.5 grm of fibre per 100 kcal. While a ‘high fibre’ claim requires a product to contain at least six grm of fibre per 100g, or at least 3 grm of fibre per 100 kcal. __________________________________ Enquiry No: P0732

The Döhler Group has developed FruitActive plus, a range of juice concentrates and plant extracts, which contain a high level of polyphenols. Polyphenols are characterised by their antioxidant capacity, and are able to capture so-called free radicals, which are capable of damaging body tissue and cell components. The company said that the ingredients’ portfolio will enable customers to enhance existing products, develop range extensions or new product lines by using these antioxidant ingredients. ___________ Enquiry No: P0733

Enquiry Number




Jana Kollárová, Zilina, Slovakia




Perspectives For Bread

As in the past years, the properties of existing enzymes and their combinations are constantly being improved, creating a wider field of use and increasing demand. By Lutz Popper, head of research & development, Mühlenchemie The current market for bakery enzymes is estimated to be worth about US$200 million. Although the share of bakery enzyme of the total enzyme market at five percent will not increase, their consumption will rise with the increasing demand for enzymes in general, to an estimated volume of almost US$300 million by 2011. In the same period, the total market for food enzymes is expected to grow at a rate of almost six percent to about US$1.2 billion. The growth is supported by the perception that enzymes are a natural way to improve efficiency and quality and that chemicals can be replaced, avoiding labelling or omitting ‘e-numbers’. Declining prices due to competition of supplier and

consolidation of the food industry provide an additional impetus. Most of the new enzymes will be produced with genetically modified organisms, and some of the enzymes will even be ‘protein engineered’ (ie: Their original sequence of amino acids will be modified, although there is some market resistance against enzymes from genetically modified organisms). As in the past years, the properties of existing enzymes a n d i t s c o m b i n a t i o n s a re constantly being improved, creating a wider field of use and increasing the demand. The most efficient driving force for growth will still be innovation. Markets For Development Three markets have been selected to visualise the development

of the bakery enzyme segment: the US, EU and China. For the US, the average annual growth rate is estimated to be 7.2 percent until 2010, with revenues of about US$70 million at the end of the period. The EU starts from a higher level, but due to a smaller growth of 4.5 percent, the market will have a volume of only US$80 million in 2010. The expected growth rate of the Chinese market is stronger with an average of 9.5 percent until 2013 (Fig 1). However, the starting point is also much lower, with revenues being only 13 percent of those in Europe. The Asia-Pacific region is expected to grow at a similar rate as the US, while Africa’s and Latin America’s growth will be closer to the development of the European market. (Fig 2) The general enzyme requirements and trends differ significantly between developed and emerging markets. Developed markets are mainly looking for: • reduction of prices of classical enzymes • new enzymes with new functionalities • enzymes for replacement of chemicals • enzymes for increasing the shelf-life of baked goods with soft crumb




100 80

Average Growth Rate: 9.5% Modif from Frost & Sullivan, 2007

90 70 60 50 40 30 20 10 0




2006 2007








Fig 2: Bakery Enzymes Market World Revenue Forecasts, 2006 - 2011 100 2006 2011 Growth Rate

80 70

7 6











10 0

As ia Ea st ,C M

Af ric a

Pa ci fic As ia

Am er ic a La tin



Annual Growth Rate (%)



Eu ro pe

• Acrylamide Acr ylamide is a potentially carcinogenic substance found in baked and fried food items. Potato products, wafers, biscuits and crispbread are most affected.

Fig 1: Bakery Enzymes Market China Revenue Forecasts, 2003 - 2013

Revenues (Mio $)

Types Of Enzymes The enzymes used most widely in the baking industry are – more or less in order of decreasing importance – fungal α-amylase, hemicellulase (comprising pentosanase and xylanase), lipolytic enzymes (lipase, phospholipase, galactolipase), glucose oxidase, protease (endo-peptidase), intermediate heat-stable α-amylase, and glucoamylase. Recent enzyme developments include asparaginase for avoiding acrylamide formation, and sulfhydr yl oxidase as dough strengthener. Other newly developed enzymes also include feruloyl esterase as rheological tool, for improved flavour formation and possible improved nutritional value of baked foods, and more specific lipolytic enzymes not acting on triglycerides for bread and cake applications in recipes.

Several oxidases have been proposed and are being used for improving the baking properties of flour, in particular dough stability and mechanical tolerance.

Revenues (Mio $)

I n e m e rg i n g m a r k e t s , t h e following are in place: • classical enzymes are used • bread prices are regulated in some areas, not allowing for ingredients and adding to costs • the volume yield is the main target • coping with varying wheat proper ties is the major challenge • compensation for performance losses of composite flours is requested

M Wiese, CA, US

• segregation of enzymes from conventional and genetically modified micro-organisms.



Myrone D, Winnipeg, Canada


Fig 3: Comparison of Glucose Oxidase and Sulfhydryl Oxidase in Steamed Bread

AAc, + 40 ppm

AAc, + 40 ppm

GOX, 10 u/g

GOX, 40 u/g

SOX, 7.2 mu/g

SOX, 21.6 mu/g

GOX, 120 u/g

SOX, 72 mu/g

Wheat flour: DNS/CWRS; basic treatment: 40 ppm ascorbic acid (AAc); over-proofed samples only

The substance is formed during the Maillard (caramelisation) reaction. At present there are no defined limits for acrylamide in food, but national ‘warning thresholds’ exist. The amino acid aspargine is the key factor in acrylamide formation. In a Swedish study, adding aspargine increases acrylamide from 80 ppb to as much as 6,000 ppb. It forms mostly in the crust, which indicates an influence of temperature and/or humidity. Darker products have higher

acrylamide values. The addition of sugars or their enzymatic removal h a s n o e f f e c t o n acrylamide. Temperatures above 200 deg C, lower final product humidity and baking powder, increase acr ylamide values, whereas yeast fermentation reduces them. The decomposition of the precursor asparagine by asparaginase, is an effective means to reduce the acrylamide formation. • Oxidase Several oxidases have been

proposed and are being used f o r i m p ro v i n g t h e b a k i n g properties of flour, in particular dough stability and mechanical tolerance. The common principle of most oxidases applied in baking is their action on mono or oligosaccharides, or other glycosides, creating a carboxyl group and hydrogen peroxides. The hydrogen peroxide then acts as a non-specific oxidant, oxidising available electron donors in dough, including sulfhydryl groups. This results in the creation or protection of dough-strengthening disulfide bridges. In addition, oxidation gelation of pentosans via feruloyl residues may occur, increasing the water absorption. An undesirable side effect of the above oxidases is their action on unsaturated lipids, which creates an unpleasant ‘off’ flavour. In particular, bakery items from frozen and sheeted dough, such as croissants, may be severely affected. Therefore, the use of glyco-oxidases as a general flour-improving enzyme is not recommended. Sulfhydr yl oxidase (SOX, EC specifically oxidises sulfhydryl groups in protein and peptides. Hydrogen peroxide is also formed in this reaction. However, in relation to the number of oxidised sulfhydryl groups, much less hydrogen peroxide is formed by SOX than by glycoside oxidases (GOX). In baking trials, SOX from S cerevisiae, showed good potential, in particular when applications involve lamination steps and prolonged fermentation. A comparison of glucose oxidase and SOX in steamed bread baking trials is shown in fig 3. F u r t h e r m o re , a p a r t i a l replacement of ascorbic acid used as a dough stabiliser was





• Ferulic Acid In wheat or rye flour dough, ferulic acid contributes to the mechanical stability by absorbing water and stabilising gluten. An excess of stability can result in a yield with limited volume during the bread making process. As other hemicellulases, ferulic acid esterase is able to soften the xylan/gluten complex with the release of water from the gel and by breaking down covalent linkages. Unlike the most often used hemicellulases, exerting an endo-1,4-ß-xylanolytic action on the xylan polymer, ferulic acid esterase cleaves the side chains between the galactose residue and the ferulic acid. Both activities improve the expandability of the dough, and so can be used to increase the volume yield. The enzyme has a significant effect on the dough rheology. When applied in the alveograph, it was possible to achieve a significant reduction of the P/L ratio, while the energy remained constant over a wide dosage range. At prolonged resting times of 120 minutes, the energy was close to that of untreated flour even when the P/L was diminished to 0.46, instead of the initial ratio of 0.66. The extensibility of the dough could be increased by about 30 percent. Obviously, the enzyme is capable to partially hydrolysing the linkages between gluten and arabinoxylan, and/or to breakdown the pentosan gel.


possible. Steamed bread with reduced ascorbic acid had a brighter crumb colour. The reason for this effect is not yet known. In butter croissants made from frozen dough, no formation of ‘off’ flavour was noted, while GOX-treated samples developed a strange smell.

Other newly developed enzymes also include feruloyl esterase as rheological tool, for improved flavour formation and possible improved nutritional value of baked foods, and more specific lipolytic enzymes not acting on triglycerides for bread and cake applications in recipes.

This results in the release of water from the gel, which is then available for gluten hydration and softening. The enzyme also reduces the viscosity of flour suspensions, such as wafer batters.

Future Growth Areas The globally rising wheat price increases the tendency to replace expansive wheat with high gluten content, and good baking properties by cheaper wheat. The lack in gluten content and baking performance can at least partially be replaced by adding functional ingredients such as enzymes. Another area is shelf life, which encompasses factors such as microbial stability as well as crumb softness. Both are increasingly required due to the continuing trends of bakeries merging to larger units with centralised production, and would have longer distances to transport from factory to shop. Other areas of growth includes water binding, specific xylanases, green labelling, browning for microwave products, taste, health related foods (fibreenriched products, protection of micronutrients), egg replacement and mycotoxin degradation. For more information, ENTER No: 0734




: Potassium The

g n u s n U

E N O B ctor e t o r P Typo_queen, US

While it is widely known that potassium maintains fluid balance within the body, its role in bone health is less appreciated. by dr susan e brown, director, the center for better bones

Deborah Goh SC, Singapore

body balaNce As it happens, the body has its own system of priorities for ensuring survival. Maintaining proper fluid balance inside and outside of the cells is a high priority. The maintenance of systemic acid-base (pH) homeostasis is also held in very high priority, as alterations in blood pH balance can result in death within minutes. The body produces various acids through its metabolic

G Taatgen JR, Groningen, Netherlands

POTASSIUM is a mineral of great importance to the body – in fact, the adult adequate intake for potassium at 4,700 mg is nearly four times that of calcium (1,200 mg). While it is widely known that potassium, along with sodium, ser ves to maintain critical fluid balance within the body, its role in bone health is less well appreciated.

A diet high in fruits, vegetables, and legumes provides nutrients such as vitamins C, E, A, and B, quercitin, and many other phytochemicals also promote bone health.

processes. As such, there is a need to neutralise or buffer these acids with alkaline (base) compounds. To ensure acid-base balance, the body maintains diet-

derived alkaline reserves in the blood, other fluids, and tissues. In addition, bone stores extra backup alkaline reserves. This is available for transfer into the




Neutralise Metabolic Acids The role of potassium in bone health relates to the ability of selected potassium salts to neutralise bone-depleting metabolic acids. As discussed in metabolic acidosis, it ‘eats away’ at bone, much like acid rain eats away at a limestone statue. It is, however, largely neutralised by potassium compounds, and to a lesser degree, magnesium compounds, obtained from fruits and vegetables. Fruits, vegetables, seeds, and most spices contain high amounts of potassium compounds. These compounds (known as potassium salts) include alkalising forms of potassium, including potassium citrate, potassium malate, and potassium gluconate. Within the body, these potassium salts are metabolised to yield potassium bicarbonate, which in turn provides the body with bicarbonate for neutralising metabolic acids. If these mineral salts are not consumed in adequate amounts, alkalising bone mineral compounds are drawn upon to help reduce lowgrade metabolic acidosis. This causes increased bone resorption and enhanced loss of minerals in the urine.

Potassium Potential A variety of population-based studies document the positive association between high intake of base-forming potassium and magnesium foodstuffs, with bone health. For example, several studies with adults have found a positive association between fruit and vegetable intake, as well as bone mineral density. In addition, urinary potassium, as a marker of potassium intake, is positively associated with bone mineral density in children.

Chris Windras, UK

blood when alkaline compounds in the blood, other fluids, and tissues run short. Bone (and the hydration layer around bone) provides the only substantial extra reservoir of base available to titrate excess metabolic acids. When we exhaust all other available alkaline reserves, alkalising compounds are drawn from in and around the bone. This drain of alkalising compounds from bone, leads in turn to enhanced bone breakdown and loss of both mineral and matrix.

Eating a medium baked potato or one large banana can conserve about 60 mg of calcium within the body.

Overall, a beneficial effect on bone mass from high potassium fruit and vegetable intake has been shown in premenopausal and postmenopausal women, in the elderly, in children, and in men. By neutralising metabolic acids, potassium conser ves calcium within the body and reduces urinar y calcium loss. Potassium bicarbonate supplements equivalent to that found in seven to eight servings of fruits and vegetables, were found to reverse the urinary calcium loss induced by high salt intake. Calcium Conservation Research Along the same lines, the ‘DASH Intervention Trial’ found that simply increasing fruits and vegetables from 3.6 to 9.5 servings a day decreased urinary calcium loss from 157 mg per day to 110 mg per day.

Looking at it another way, bone health expert Dr Robert Heaney explains that eating a medium baked potato or one large banana can conserve about 60 mg of calcium within the body. To put this into perspective, a urinary loss of an extra 60 mg of calcium per day would result in an 18 to 21 percent loss of total skeletal calcium over a decade. Furthermore, Dr Sebastian and colleagues at the University of California, were not only able to decrease urine calcium and phosphorus loss, but also lower bone breakdown, and stimulate new bone formation in postmenopausal women. This is done by adding enough alkalising potassium salts to neutralise metabolic acids. An Apple A Day… Fruits and vegetables provide mineral salts with alkalising compounds (as potassium citrate) useful for neutralising net endogenous acid. In addition t o p ro m o t i n g a n a l k a l i n e environment, a diet high in fruits, vegetables, and legumes provides nutrients such as vitamins C, E, A, and B, quercitin, and many other phytochemicals also promote bone health. Unquestionably, potassium is one of the most important key bone nutrients, and consuming the recommended amount of 4,700 mg potassium a day should be a top priority for everyone. About The Foundation The Better Bones Foundation is a non-profit, public interest research and education organisation. It is dedicated to rethinking nature, causes, prevention, and best treatment of osteoporosis. The organisation is committed to the development of natural programmes for the regeneration of bone health worldwide.

For more information, ENTER No: 0740




caLcIUm & the GroWInG sKeLeton Clinical, longitudinal, retrospective and cross-sectional studies in children show inconsistent findings with respect to the effect of calcium intake. A number of caveats need to be considered when evaluating studies of

P Crabbe, Bristol, UK

CALCIUM deficiency reduces bone mass by increasing bone resorption to preserve the ionised calcium in the extracellular uid. Secondary hyperparathyroidism and increased bone resorption occur in both calcium and vitamin D deficiencies. From birth to puberty, the skeleton increases in mass about seven-fold, and a further threefold during adolescence. Bone mass then remains relatively stable during early adulthood. For about the first five years after menopause, women lose bone at a rate of about two to three percent, and then continue to lose at about one percent per annum to the end of life. During this time, there is a decline in intestinal calcium absorption, and an increase in urinary calcium excretion. Men also start to lose bone at about the age of 50, but rather more slowly than women. The rate of bone loss in older men and women is about the same and calcium absorption decreases with age.

of higher intakes are more likely to occur in individuals with previously low habitual calcium intakes. Although a prospective observational study has estimated that 26 percent of adult calcium is laid down during the two years of peak skeletal growth, in this study, the calcium intake explained less than

FeodoraU, Germany

Gaston Thauvin, Paris, France

calcium status during childhood and adolescence. Factors affecting calcium balance are likely to change with stages of development. Calcium kinetics studies have demonstrated that net calcium retention is greatest when the growth spurt is at its peak in early pubertal children, compared with prepubertal or late pubertal girls.

Bone & Joint Health:




people who avoid dairy products need to ensure substitute food products are calcium-fortiďŹ ed. By sanders Kerrie m, nowson caryl, Kotowicz mark a, Briffa Kathryn, Devine amanda & reid Ian r, the Working Group of anZBms & osteoporosis australia. In a three-year calcium supplementation study, a positive effect on bone mineral density (BMD) was observed in pre-pubertal twin pairs, but not pubertal or post-pubertal twin pairs. When baseline habitual calcium consumption is low, larger increments in BMD occur with increased dietary calcium. Sustained beneficial effects

one percent of the variance in maximal bone growth. Others have estimated two to five percent of the variance in adolescent bone gain, and later peak bone mass is associated with calcium intake during adolescence. While there is some data linking calcium intake to skeletal accrual of calcium, the effect size appears to be small,




lumbar spine and total hip BMD over an 18-month period in post-menarcheal, but not premenarcheal twin pairs. Nevertheless, a recent metaanalysis demonstrates that although the point estimates for the 19 RCT are positive in favour of benefit, the confidence intervals usually cross zero. More studies are required for children with low calcium intakes and in prepubertal children. Interaction With Other Dietary Components Calcium is predominantly found in dair y foods, but smaller amounts are found in bony fish, legumes, some nuts and in calcium-fortified soy beverages or breakfast cereals. L o w f a t o p t i o n s a re a preferred choice for many individuals, and can also be a good source of calcium. Some

dietary constituents can impair calcium bioavailability by forming insoluble calcium complexes. These substances include phytates (found in cereals, bran, soybean and seeds) and oxalates (found in spinach, rhubarb and walnuts). Some vegetarian diets may, therefore, adversely affect calcium balance, particularly if the calcium content is low due to the avoidance of dairy products. However, lacto-ovo vegetarians appear to have similar calcium intakes to omnivores who avoid any milk based products and similar urinary calcium excretion. • Sodium Sodium is an important determinant of urinary calcium excretion. A high salt intake has been associated with lower bone mass in some, but not all studies. The varying ratios of calcium to sodium in the diet may explain

Qtea, Turku, Finland

A Virviescas, Cundinamarca, Colombia

and a positive association is not a consistent finding. Most, but not all randomised controlled trials with children and adolescents using either dairy supplemented foods or calcium supplementation, demonstrate some beneficial results. Increasing calcium intake from a mean baseline of 730 mg/ day to 1600 mg/day increased

For those who do not wish to consume dairy products, calcium fortified soy products such as soy milk, provide similar amounts of calcium.

inconsistent findings between studies, although higher calcium intakes levels (1,800 mg/day) or lower daily sodium excretion levels (less than 2,000 mg/day) is associated with a slowing or cessation of bone loss. • Protein The effect of protein intake on bone density is uncertain, and evidence exists for beneficial effects of both

low and high protein intakes. While an adequate protein intake is important for supporting bone growth in children, and maintaining bone mass in older adults, higher intakes of protein, particularly animal protein, may be associated with increasing urinary calcium losses. The benefit of additional calcium from dairy products, however, outweighs the possible injurious effects of extra protein. High calcium foods such as dairy products contain a range of other essential nutrients. Calciumfortified soy products act as a substitute for those unable or unwilling to ingest dairy products. There is little evidence that the small amounts of various mineral and vitamin additives present in some marketed calcium supplements improve the effectiveness of the product. • Vitamin D Adequate vitamin D status is essential for calcium uptake in the gut, as well as bone development and remodelling. The addition of vitamin D in doses less than 400 IU (International Unit) per day is unlikely to have a significant effect on bone health in a younger person, and those aged over 70 years who require more than 600 IU to affect bone status. The recommended daily intake (RDI) for calcium is 1,000 mg/ day, and the estimated average requirement (EAR) is 840 mg/day for women aged 19 – 50 years, and men aged 19 – 70 years. This increases to 1,300 mg/day for RDI and 1, 100 mg/day for EAR in women over 50 years and men over 70 years. T h e re i s n o a d d i t i o n a l allowance for pregnancy and lactation except for the teenage pregnant or lactating female.




Calcium supplements are a useful way of helping individuals who are unable to consume sufficient calcium from dietary sources.

For those who do not wish to consume dairy products, calcium fortified soy products such as soy milk, provide similar amounts of calcium. The skeletal benefit of increasing calcium intakes may be greatest in those with lower baseline calcium intakes, although this is not a consistent finding between studies. caLcIUm sUppLementatIon Although calcium intake can be increased by dietary means, long-term adherence to high calcium diets is poor. Calcium supplements are a useful way of helping individuals who are

unable to consume sufficient calcium from dietary sources. The ability to adapt to low calcium diets and intestinal calcium absorption deteriorates with age. An extra 500 – 1,000 mg elemental calcium per day will usually suffice for most people. When checking the true calcium content of foods and supplements, it is the elemental calcium that matters. Calcium carbonate contains 40 percent elemental calcium by weight compared with 21 percent in calcium citrate. Although calcium citrate is more soluble and its bioavailability may be approximately 25 percent greater than that of calcium carbonate, it is generally more expensive. Since calcium carbonate requires an acid environment to dissolve, and calcium citrate does not, the latter supplement is preferable for people with achlorhydria and those on medications that inhibit gastric acid secretion. There is some evidence that taking calcium supplements in the evening may be advantageous by suppressing the nocturnal rise in bone resorption. It has also been suggested that divided dose regimens may lead to greater total calcium absorption (1/3 dose in the morning, 2/3 dose in the evening). It is critical that calcium and oral bisphosphonates are taken several hours apart as calcium binds with these medications and prevents their absorption. Calcium supplements are generally well tolerated and do not have major effects on the absorption of other micronutrients. Occasional adverse effects include constipation, bloating and flatulence. For more information, ENTER No: 0741

the Bone maKe-Up


one is composed of type one collagen hardened by crystals of hydroxyapatite. the physiology of calcium metabolism is primarily directed towards maintaining the concentration of ionised calcium in the extracellular fluid. this is protected and maintained by a feedback loop through calcium receptors in the parathyroid glands. parathyroid hormone increases the renal tubular reabsorption of calcium, promotes intestinal calcium absorption by stimulating the renal production of 1,25-dihydroxy vitamin D and, if necessary, resorbs bone. the integrity of the system depends critically on the vitamin D status. the body’s calcium reserve is stored in the skeleton and is affected by the dietary calcium intake and absorption on the one hand, and losses of calcium through the skin, kidney and bowel on the other. Intestinal calcium absorption has an active saturable component and a diffusion component. at low calcium intakes, calcium is mainly absorbed by active transport, but at higher intakes an increasing proportion of calcium is absorbed by simple diffusion. as calcium intake increases, net absorbed calcium also increases, steeply at first but then, as the active transport becomes saturated, more slowly until only about 5-10 percent of the calcium is absorbed.

Paula Pandey Chhetri, Dilworth, US

Lintilla, Canada

However, it is difficult for most older women and men to meet a dietary intake of 1,300 mg per day, as many in this group eat only small amounts of foods and are generally on low energy intakes. People who avoid dair y p ro d u c t s n e e d t o e n s u re substitute food products are calcium-fortified. To achieve a daily calcium intake of 1,000 – 1,300 mg, at least three servings of dairy per day is recommended with at least one of those being calcium fortified.

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Particle Meters For tHe gas PHase The correlation between particle counting in ambient air and classical air germ collection has shown that in ‘normal’ air, there is a close connection between the number of particles and the germ content in the air under examination. Tests in filling plants, on the other hand, show that where

there is a high germ load, for example in the vicinity of the empty bottle entry in recycling systems, this relationship becomes worse. In such cases, there is a disproportionately high amount of germs compared with the particle content of the air. Additionally, the particle count can give no indication about the type of germs found, even though the connection between the number of particles and the germ content present in the air is known. Particle counting in the gas phase has, however, found a permanent

Filling Plants:


Toolbox in cases of special requirements, particle counting in the gas and liquid phases can provide very exact information about the system under examination. By roland Pahl & georg Wenk, VlB Berlin

Petr Vins, Central Bohemia, Czech Republic

FILLING is the most technologically complicated and the most cost-intensive aspect of industrial beverage production. Both the potential for optimisation in this area and the risk of inefficient, and therefore uneconomical production caused by insufficient process control are high.




the particles present in the liquid and their size distribution. Particle counting is tested, for example, for its applicability in validating bottle-cleaning m a c h i n e s u s i n g s t a n d a rd contaminated bottles. If the constitution of the contamination in these bottles is known, it will be possible to evaluate accurately what proportions of the various added components are still present. Apart from the filling process, it is applicable in other areas within the field of brewery, where the separation of solid-liquid systems is required. Cre-art Cubatao, SP, Brazil

Data Logger For Temperature & Pressure The miniature data logger (see arrow in fig 1) is used to record and control the temperature profile in bottle cleaning machines, in order to increase the product security during filling.

Figure 1 Core Temperature In A 30 Litre Keg 70

Temperature in 째C

60 50 40 30 20 10 0 00:00



03:00 04:00 05:00 Time In hh:mm



Particle Meters For Liquids The advantage of particle counting in liquid phases as opposed to haze measurement is that it provides more accurate information about

Christian Kitazume, Wuppertal, Germany

place within the beverage industry in the area of cold aseptic filling of biologically unstable beverages. Particle meters can be implemented here in order to monitor HEPA filters, which in cold aseptics have the task of producing sterile air for the generation of overpressure in the insulator room. The particle meters provide conclusive proof, for example, of breaches in the sterile filter system. Particle counting is tested, for example, for its applicability in validating bottlecleaning machines using standard contaminated bottles.




High Speed Camera The high-speed camera, type MotionScope M1, has been used for the process optimisation of labelling machines. With an output of over 60,000 bottles per hour and the intricate processes in the labelling machine, an effective control of the individual functions is only possible when the machine is at full capacity.

Figure 2 Internal Temperature And Pressure In A PET-Bottle 80





50 40


Pressure in mbar

70 Temperature in °C

A fur ther application is the determination of the core temperature in kegs, in order to achieve the desired size of the pasteur units (PU). Due to its size, the data logger can be placed directly into the extractor tube of the keg, at the ‘cold spot’. The recorded data in fig 1 gives an example of a 30 ltr keg, where the desired core temperature (58 deg C) is reached after two hours. The corresponding heat retention time for the desired PUs must be held only after this time. The diagram in fig 2 shows how the test bottle loses its structure and cannot be used after 20 minutes at a core temperature of 62 deg C. This is recognisable by the rapid loss of inner pressure caused by a volume increase of the bottle when the bottle bottom is inverted. This shows that this bottle would not be suitable for pasteurisation at 62 deg C and would have to be further optimised, for example by changing the bottle shape. The data logger, with a diameter of 15 mm and a height of 35 mm, can record temperature in the range between zero deg C and 150 deg C (± 0.1 deg C) and pressure between 10 mbar and 15 bar (± 30 mbar) simultaneously. In total, 16,000 individual measurements can be gathered at programmable inter vals and be read subsequently on a laptop.

30 20 00:00




Time In hh:mm

Figure 3

An example is given in fig 3, where the objective is to test whether the label creases inwards when it is removed from the gluing palettes. The highspeed camera, with a speed of 1,000 images per second and extremely short shutter speeds of up to 0.05 milliseconds, is suited to this task. The camera also provides a service for the optimisation of the filling process in the filling machines. For example, on the basis of the films recorded by the camera, it was possible to identify the cause of a massive contamination of individual valves of an aseptic filling machine: fruit pulp from orange juice.



–– Temperature in °C

1000 02:00 –– Pressure in mbar

When the filling valve is opened, the filling liquid first falls out of the valve in a broad plug flow. Subsequently, the product flow tapers off as a result of its mass inertia and loses contact with the edge of the filling valve opening. After the product flow accelerates within the filling valve, it meets the edge of the filling valve opening at high speed and is diverted to the bottle holder on the valve by way of the bottle mouth, before a stable product flow is finally attained. All Filled Up In cases of special requirements, particle counting in the gas and liquid phases can provide exact information about the system under examination. The data logger is being used to improve the pasteurising ability of PET bottles, while the high speed camera makes it possible to rapidly identify and remove faults during labelling or filling processes.

For more information, ENTER No: 0750

Enquiry Number






Noble Grain


David Thomson, Szekesfehervar, Hungary

The importance of malt in the production of premium quality beer is paramount. However, the malting industry is facing a number of considerable challenges. By Mont Stuart, regional sales manager, Joe White Maltings

patryk specjal, Warsaw, Poland

Of Malting & Brewing Beer was one of the earliest alcoholic beverages produced and has been an integral part of civilised societies for over 5,000 years. The key raw material used in the production of beer is malted barley, known as malt. This is produced by the controlled germination of barley that is subsequently kiln dried. As many brewers through the ages have said, ‘malt is the soul of a beer’ because it provides the sugars for alcohol and a number of other chemical components that are essential for fermentation, as well as beer colour, body and most of all, flavour. The Inside Story As it turns out there were good reasons for barley to become the preferred cereal for brewing. It tended to be lower in protein and especially gluten, such that loaves of barley bread were very crumbly compared with the superior texture of bread produced from wheat. Therefore, barley was favoured for beer brewing and wheat for




©Tom Roschi Photography

components will be modified to varying extents during the malting process.

A germination vessel being filled with grain (above) and malting barley being steeped (left)

baking. The cereal is grown in all major cereal producing regions around the world. Breeding over the years has resulted in the development of varieties that are suited to malting. As such, they are known as malting barleys. A typical malting barley will consist of starch (60 percent), protein (9 –12 percent), complex polysaccharides like ß-glucan and arabinoxylan (3 – 4 percent

each) and smaller quantities of polyphenols, lipids and other components. The major tissue of the barley grain is the endosperm, which consists of numerous cells containing starch embedded in a protein matrix. These cells are surrounded by thin cell walls, which are composed of ß-glucan and smaller amounts of arabinoxylan. These chemical

Malting Process The malting process involves three stages – steeping, germination and kilning. Steeping involves alternating periods of soaking the grain in aerated water, and then draining the water away to allow the grain to respire freely. Germination is initiated during this stage. For Australian barley, this would typically involve eight hours under water, followed by 10 hours air rest and two hours final immersion at approximately 16 to 18 deg C. The grain is then germinated for periods of four to six days under controlled temperature and humidity. Germination is then arrested by kiln, drying the ‘green malt’ (or germinated grain) under a controlled temperature program from 50 deg C up to a maximum of 85 deg C over 20 – 24 hours. As many of the enzymes produced during germination are unstable at higher temperatures, the temperature profile has to be carefully controlled to limit their inactivation. Therefore, the aims of the malting process are to: • Modify the starchy endosperm by degrading endosperm cell walls, which improves the accessibility of starch during the first stage of brewing (mashing) and minimises levels of high molecular weight carbohydrates, like ß-glucan, that can interfere with mash and beer filtration. • Optimise the synthesis of hydrolytic enzymes during germination and their retention during kilning. • Develop colour and flavour during kilning.




• Ensure that the malt is capable of complete starch hydrolysis (conversion) during mashing to produce optimum extract levels and therefore, optimised alcohol yield.

• Population Growth Firstly, the significant ongoing human population growth, in conjunction with the increasing demands of the biofuel industry is putting massive pressure on the supply of cereal grains for food and biofuels. The increasing affluence of developing countries is also leading to an increasing demand for beef, which itself requires cereal grains. As a consequence, barley has to compete with other cereals like wheat, maize and oilseeds. Therefore, the supply

©Tom Roschi Photography

Malt Industry Challenges The importance of malt in the production of premium quality beer is paramount. However, the malting industry is facing a number of considerable challenges.

A precision seeded barley crop in early growth stage, South Australia.

of malting barley is under extreme pressure in the forthcoming years. • Climate Secondly, the influence of climate on barley production is critical. While the significance of climate change is questioned by some, there is a general view that over the last few years we are seeing

more extreme climatic events. For example, below average winter and spring rainfall in cropping regions, rain at harvest time or more severe frost events can all adversely affect the production of good quality malting barley. To c o u n t e r t h e s e m o re extreme events, barley breeders are using traditional breeding

Luis Rock, Buenos Aires, Argentina

Barley Origins B arley (Hordeum Vulgare) as we know it today, is a cereal that originated from the wild grass Hordeum Spontaneum, which grew naturally across the middle eastern regions. It was one of the first cereals to be cultivated and was used by the ancient Egyptians firstly as a food source and ultimately for beer production. Some 3,000 years ago, the Babylonians used sprouted barley flour to make a crude loaf of bread, which was broken up, put into vessels holding water and the crude mixture would then naturally ferment to produce an alcoholic ale (beer).

Indeed the barley ale was soon to become a staple in the diet of the peoples in this region. Some have even estimated that in Mesopotamia 5,000 years ago, that 40 percent of the Sumerian grain crop was used for Ale. As civilisation spread from the Middle East into western and northern Europe, barley ale became the preferred beverage in regions that could grow barley and were too cold to produce grapes. This was much to the disgust of the Gre eks and Romans who thought that wine was the more sophisticated alcoholic beverage.




methods to develop barleys that can grow with reduced rainfall, are resistant to sprouting in the event of harvest rain or are frost tolerant. B re e d e r s a re s e a rc h i n g through the world’s barley germplasm for genes that have these traits. For example, in the case of frost tolerance they have identified two genes in barley varieties that are adapted to cold conditions in the highlands of Japan. These Japanese varieties are currently being crossed with malting varieties to develop a frost tolerant variety. Traditional breeding can take up to 12 years to develop a new variety, but using tools such as genetic markers for specific traits, they are able to screen large populations to select barley lines that have the desirable trait. This can speed up selection and as a consequence, variety development. Therefore, we are confident that traditional breeding can continue to develop malting barley varieties that will meet the environmental challenges of the future. • Sub-Soil Moisture Retention & Crop Yields Thirdly, there is also a need for growers to optimise their subsoil moisture retention and crop yields to ensure they can sustain a profitable business. Over the last 20 years, growers in Australia have adopted a number of strategies that have a significant influence on their crop yields and grain quality. For example, growers have adopted direct drilling at sowing, which retains the stubble that remains from the previous years’ crop, as such, avoiding unnecessary cultivation of the soil. In conjunction with the use of ‘Global Positioning Satellite’

technology to sow between last season’s rows, they are able to reduce the evaporation of subsoil moisture. Since the early 1990’s, these practises that are among a range of other initiatives, have resulted in a 100 percent increase in water use efficiency to levels in the range 20 – 22 kg of grain/mm, moisture/hectare. In a country like Australia where the most of the grain is produced without irrigation,

Considerable effort is being applied by all maltsters to improve the energy utilisation (carbon footprint) and water efficiency of the process.

this is an amazing result and a testament to the ingenuity and persistence of the country’s cereal farmers. • Energy & Water Efficiency Fourthly, the malting process uses significant volumes of water for steeping, germination and hygiene, along with electricity and gas, especially during kilning.

Considerable effort is being applied by all maltsters to improve the energy utilisation (carbon footprint) and water efficiency of the process. A reduction in their carbon footprint is essential in the current environment. The application of advanced water treatment processes enables recycled water to be used for cleaning or for supply to neighbouring public facilities, for example, golf courses. At present, many brewers do not allow the use of recycled water for malting. However, given the growing trend towards social and environmental responsibility amongst the larger brewers, it is hoped that the use of recycled water for malting will be allowed in the future. The other option to reduce the water requirement is to develop barleys that require only a single wet steep. In addition, if the germination time could be reduced, this would also reduce the carbon footprint of the malting process. For example, a barley variety with thin endosperm cell walls might achieve this result. Traditional breeding methods are currently being utilised to develop malting barley varieties that have these attributes. Looking Ahead Therefore, while there are considerable challenges to the malting industry relating to barley production and the malting process, considerable efforts are being made to ensure a sustainable industry for the future. This will ensure that ‘the soul of beer’ will always be available for brewers and more importantly, the beer lovers of the world. For more information, ENTER No: 0751




RIGHT before the start of the economic crisis, the European b re w i n g i n d u s t r y h a d i t s advantages in the globalisation of markets. However, steadily declining sales in the domestic markets has started off export activities for the industry. The brewers soon realised that investment for new barrels is needed, as exports for keg beer were rising. This is obviously caused by high steel and manufacturers prices, at least in 2008. On one hand, there are long rotations of the barrels because of the distance. On the other

Disposable Kegs:

An Alternative Beer Container With the rising exports for keg beer and high prices of steel and manufacturers’ cost, an investment in a new type of barrel was needed. by Frank peifer, bavarian state brewery, & Johannes tippmann, technical university of munich h a n d , t h e o rg a n i s a t i o n o f collecting and returning the barrel plays an important role. Sometimes, external transporters perform this work, and so, other than the brewery and the importer, there is also a third party involved in the circulation chain. Stainless steel scrap prices, as in the summer of 2008, also increased the desire to find another use for the material. Consequently, breweries started a call for a disposable barrel-system. This call has been renewed by the imbalance of the global capital markets. Currently, there are several alternatives for

disposable barrels. test reQuirements The first requirement of the disposable barrels is to ensure that the product quality is unchanged as compared to the quality in the usual stainless steel barrel. The advantage in costs compared to the reusable barrel must be apparent for the brewery and the importer. This requires a specific consideration of each individual export activity. Due to the varying conditions, there are individual decisions on the advantage and disadvantages of switching from

reusable to disposable barrels. Handling must be as simple and safe as it has been for the returnable barrels. For local distribution, all relevant information must be made available. The best way is to offer instructions in different languages, including picture-statements on the disposable barrel. The disposal and possible reuse of the container materials has to be locally regulated. This refers to a 100 percent clarification of the legal situation within the importing country, in terms of material use and disposal provisions.




The compatibility of the system with existing installations determines the conversion and installation costs. Disposable Barrel Description The disposable barrels discussed in this analysis, are constructed based on the ‘Bag in Box’ principle. The beer is filled into a special foil bag. After reaching the filling-volume, the foil bag

in and out of the bag, over a long period. The fitting consists of three plastic parts and requires no mechanical spring for the closing process. The entire barrel, with the exception of the fitting area, is wrapped in plastic foil to keep off moisture. To fill the kegs, special machines or the reconstruction of existing facilities is required. The weight of a 20-ltr barrel is 1 kg, while the weight of a 30-ltr container is 1.4 kg. There is an advantage in

Connecting the disposable keg to an existing dispense system (above).

surface is close to the protective PET-bowl. The gas is then applied into the PET-bowl. Maximum allowed gas pressure is 3.5 atm. That is normally more than enough to squeeze the beer out of the bag. The seven-layer construction of the foil bag contains a UVimpermeable aluminium-layer and anti-oxygen barriers. The execution of the inner bag also prevents migration of gases

The lightweight container is almost 100% recyclable and takes little space in its waste phase

weight compared with the conventional stainless steel barrel of approximately 33 kg/h ltr. This logistical advantage can increase the volume of beer with every shipment. The disposal of the emptied kegs is usually done on the spot. The container is quickly dismantled to the basic components of foil, carton and PET ball. With the included venting tool, and a short swivel on the fitting, the valve opens to deflate the PET-ball into a flat disc. System Evaluation T h e m a n u f a c t u re r o f t h e disposable Key Keg contacted the department of processdispersed systems to carry out tests on its product. During this testing programme, the stability and quality of the beers in these disposable kegs were assessed. With the help of the Bavarian State Brewery Weihenstephan, beer in the Helles and Hefeweissbier range were tested with transport simulations using




the disposable kegs and stainless steel barrel. The filling of the stainless steel barrels was carried out on the automatic keg-plant, while the disposable kegs were filled by hand. The Results After a 14-day stress test with approximately 100 kg for each barrel, and a temperature of 42 deg C for eight hours, and 28 deg C for 16 hours, no damage was found on the barrels. This corresponds to the temperature in the containers. A second, 21-day test was followed. This time, the kegs went through 45 deg C for eight hours, and 28 deg C for 16 hours. No significant difference between

the disposable and stainless steel keg was found at the end of this process. A 6-month test was conducted later, with the temperature maintained at 28 deg C. There was still no difference between the two kegs, and no difference in beer colour was seen. The microbiological samples taken were also clear of any findings. During cleaning of the dispensing machine, the disposable barrel has to stay on the line at a minimum pressure of 2.5 atm, so that the valve in the fitting can be completely closed. The results from the series of tests demonstrate the suitability of the disposable system for beer. Even under extreme transport conditions, no difference was

found between the disposable kegs and the stainless steel kegs. Experiences From Practice The described simulation of an overseas shipment was carried out in practice. The used barrels (30-ltr disposable kegs) were also hand-filled. The results coincided exactly with the results of the simulation. In addition to possible financial incentives, the clear advantage of the system is its easy dispensing and consistent quality from the first until the last glass, at many locations far from urban gastronomy - often more desire than reality. For more information, ENTER No: 0752

Finn-Korki: Closure For Beer The RipCap wide mouth closures from Finn-Korkki is suitable for bottled beer. It is a ring pull closure made from aluminium with a diameter of 42 mm, and is suitable for beverages like beer or cider, on glass, plastic and metal bottles. The company said that the wide mouth ring pull cap has been developed to meet the demands of brewers seeking a distinctive packaging for their bottled beer. __________________________________ Enquiry No: P0754

Buhler: Eco Steep Technology Buhler’s Eco Steep is the further development of flat bottom steeps. The system does not have any space below the floor deck, and this reduces the amount of steeping water by up to 35 percent. At the same time, it also increases the level of sanitation. It contains a certain number of Eco sockets that are uniformly distributed in the steep bottom. These sockets are for feeding and discharging steeping water, as well as for pressure aeration during the wet phase and for CO2 extraction during the dry phase. The arrangement of the ECO sockets leads in highly uniform temperature distribution in the steeping barley bed. The result is a very homogenous steeping process - the base of homogenous finished malt. The system is made of stainless steel and can be automatically cleaned by means of a CIP cleaning device. __________________________________ Enquiry No: P0753

Together Together we we realize realize your your visions visions

Consulting Consulting -- Engineering Engineering -- Global Global Manufacturing Manufacturing ZIEMANN Asia-Pacific Co., Ltd. ZIEMANN Asia-Pacific Co., Ltd. Bangkok, Thailand Bangkok, Thailand Tel. +66 (0)2 6556260-62 Tel. +66 (0)2 6556260-62

Taking Taking care care of of brewing brewing




For those who have grown up here in Asia, the general impression of beer is a cold, yellow, fizzy beverage that is light tasting and perfect for quenching thirst over a game of football or a day at the beach. What they do not realise is that there are hundreds of different beer styles and thousands of different beer brands, with a range of flavours to rival that of any other beverage. So, while thirst quenching is one of the things that beer excels at – it is surely not the only thing. The challenge now is how to prove that to people? Beer Makeover Throughout the later 20th centur y, wine makers have convinced people that wine is a complex, sophisticated drink for those with discerning taste. During that same period of time, beer marketers have done just

the opposite for their product. Countless commercials have been produced over the years with rather simplistic storylines revolving around images of scantily clad women and guys watching appreciatively with a frosty ‘cold one’, or some variations of that theme. It is no wonder then, that the impression of beer has been reduced to that of a onedimensional image of mindless fun. What might have worked for blue-collared drinkers in the 1970’s and 1980’s now seems to have waning traction in the 21st century. With disposable incomes on the rise, consumption habits have also moved in the same direction. The resulting effect is a consumer base that is continually in flux, with consumers moving between wine and other alcoholic beverages. The challenge is to not only win

over consumers who have since moved away from beer because of those earlier perceptions, but to also broaden its appeal to a new segment of consumers such as women and white collar workers. Brewers will have to help shift this paradigm and create a new understanding and appreciation of beers. After all, if wine, a product that contains but a single ingredient and is processed by stepping on that one ingredient, can be perceived as sophisticated and complex, then surely beer with its four ingredients and complex brewing process can be all those things and more. A Flavourful Experience The first quality about beer that brewers can impart to any beer fan is that it can be many things – from light, thirst quenching and sprightly to complex, full and contemplative. The golden




Paul Pasieczny, Lublin, Poland

Metamorphosis The resulting effect of increased disposable income is a consumer base that is continually in flux, with consumers moving between wine and other alcoholic beverages. By Fal Allen, brewmaster, Archipelago Brewery




pilsners that are prevalent in every country are fine beers, but they are not the only beers. The beverage comes in many styles with a myriad of flavours – from toasty and caramel brown ales, to deep dark chocolaty stouts; from hoppy India pale ales, to sour Lambic beers; fruity real ales, to spicy, clovey ‘German’ wheat beers. Beers are made with four main ingredients, which consist of malt, hops, water, and yeast. However, they can also incorporate fruits, herbs, spices, wood, and other fermentable ingredients like honey. The large variety of ingredients in beer gives it a broad pallet with depth and complexity. This range of flavours lends itself very nicely in pairing with a wide array of foods – and this is especially true for the spicy and diverse cuisines of South-east Asia. Brewer’s Art To engage consumers, brewers need to focus more on the art of brewing like what raw materials are used. Just as wine makers talk about the varietal grapes and their terroir, brewers can discuss the grain varieties used and their terroir or country of origin, as well as hop varieties and their unique contribution to flavour and aroma. The blending of these raw materials to create flavours and the selection of yeast for its character could also be other areas brewers could tap on to educate fans of the various nuances of the brewing process. Beer can be an ‘occasional’ beverage. As we associate champagne with weddings, beer needs to create occasions where it will become a natural fit. Already it is a common drink for relaxing at the end of a hard day with friends. Brewers not only need

Beer can also incorporate fruits, herbs, spices, wood, and other fermentable ingredients like honey. This range of flavours lends itself very nicely in pairing with a wide array of foods.

to reinforce already established occasions, they also need to forge ahead into new territories and create situations where beer is the obvious choice. Beer and food pairings, a celebratory toast, complex dark beers sipped by the fire side, sprightly fruit beers served at ladies night parties, a bridal ale, or a graduation beer – these are but a few examples of the new ways beer might be ‘occasionalised’. Dispelling Myths Brewers need a myth makeover. They need to dispel false myths

To engage consumers, brewers need to focus more on the art of brewing like what raw materials are used.




like beer is fattening. Beer has no fat at all and no cholesterol. And, beer unequivocally has less calories than white wine or spirits. • Beer Belly The ‘beer belly’ is actually not the result of beer (well, at least not beer alone). It has a lot more to do with the food that people tend to eat while drinking and a sedentary lifestyle than it does with beer. • Lowbrow Blue-Collar Drink Beer can have a multitude of flavours and aromas. Almost any

term used to describe wine can be used to describe beer and it can be enjoyed by anyone of any income. • Beer Is A Man’s Drink Maybe the most ridiculous myth yet, beer is no more a man’s drink than ice-cream is for ladies only. Some women may not enjoy the light lagers ubiquitous throughout the world, but they may love a less bitter brown ale, or an espresso like stout or a lively fruit beer. Getting people to think of brewers as akin to that of brewing artisans may be a bit

of a romantic notion, but it is hardly far from the truth. Brewers themselves must now take the next step. They need to help eradicate old myths and perceptions and create the right ambience and ritual around their beers. Only by developing a sense of beer’s ability to bring people together can we hope to build a deeper appreciation of beer’s rich culture, and how it has developed alongside our own. For more information, ENTER No: 0755


HEINEKEN: DRAUGHTKEG The desire to offer consumers the option of having draft beer at their personal convenience led to the development of the Heineken DraughtKeg, which features the company’s ‘Intelligent Pressure System’. The system works like a mini draught machine. It comes with an integrated carbon dioxide cylinder and easy-to-install tap. According to Asia Pacific Breweries, the pressure unit guarantees constant pressure in the container. The keg does not come with its own cooling unit. As such, it needs to be refrigerated for a recommended 10 hours, or to a minimum of five deg C for optimum enjoyment. The cold temperature also helps to minimise the amount of foam in the beer. Designed for ease of transport, each recyclable steel keg measures 280 mm by 175 mm, and weighs 5.5 kg when full. The 5-ltr keg serves up to 20 glasses of draught beer. After opening, the beer will stay fresh for up to 30 days, if stored in a refrigerator. __________________________________ Enquiry No: P0756

Harnessing a recent development in the draught system known as ‘Twin Ice’ technology, Tiger sought to give beer lovers the coldest most refreshing beer experience, giving rise to the creation of Ice Freeze Tiger. This dispensing technology blends the cold beer (below 3 deg C) with ice-crystallised beer (below -2 deg C), forming a draught icy lager. Besides making it possible to keep the beer for longer, it also creates an ice crystal texture, giving a different taste sensation, without the fear of dilution. The draught system is similar to the regular draught system except that it is supported with an additional ice cooling system known as ‘Twin Ice’ and a dual dispensing tap system. The cooling system is a single integrated unit with a compact cooler that superchills liquid beer to create the ice-crystallised product. The dispensing tap enables the dispensing of liquid beer and ice-crystallised beer separately. __________________________________ Enquiry No: P0757

The Qchoc QC-400 is a newly developed all-in-one machine capable The Qchoc QC-400 a newlyofdeveloped capable of producing 400 kg isbatches chocolate all-in-one from basicmachine ingredients. It is of producing 400 kg batches of chocolate from basic ingredients. It is existing out of a pre-mixer, a ball mill and a taste changer, all of proven existing out of a pre-mixer, a ball mill and a taste changer, all of proven design and durability. design and durability.

The Qchoc QC-400 is easy to connect, easy to operate and easy to clean. The Qchoc QC-400 is easy to connect, easy to operate and easy to clean.

• •• •• •• •• •• •

No foundations required. No foundations required. Extremely low power consumption. Extremely low power consumption. Excellent product fineness and homogeneity. Excellent product fineness and homogeneity. Very good particle-size distribution. Very good particle-size distribution. Consistent product quality. Consistent product Process expertise notquality. required. Process expertise not required.

C Co o cc o o aa ,, C Co om mp po ou un nd d & & C Ch ho o cc o o ll aa tt ee EE q qu u ii p pm m ee n n tt W W W. D U Y V I S W I E N E R . N L W W W. D U Y V I S W I E N E R . N L

P.O. Box 10 P.O. 1540Box AA10 Koog a/d Zaan 1540 AA Koog a/d Zaan The Netherlands The Netherlands

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Phone: +31 75 6 126 126 Phone: Fax: +31 75 6 126 158 126 377 Fax: 75 6 158 377 Email: +31 Email:

Enquiry Number

Qchoc Qchoc QC-400 QC-400


e e all-in-one all-in-one solution solution for for hiqh hiqh quality quality chocolate chocolate with with an an excellent excellent taste! taste!




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In competitive markets, even a small cost or efficiency advantage can be determinant in holding or winning share. By Claudia B Flisi, on behalf of ABB Since 1913, Zaini has been producing chocolates for the Italian market. Today, the sweets are no longer made by hand, but they are just as carefully handled by robots. The original factory produced hand-crafted chocolates, cocoa and candies, but as the business grew, machinery was incorporated to help employees meet the growing demand. To d a y, t h e c o m p a n y ’s factories in Italy might not look out of place in Willy’s Wonkavision room. For example, at the Senago plant, the picking

system has been working since 2005 to organise and box a wide range of bagged candies and chocolates. The system has the ability to see up to 130 different product variations and adjust its activity accordingly. The Idea Zaini had asked PRB Packing Systems to develop a system for handling a vast range of their products for packaging. The system had to be flexible, easy to operate, and easy to modify, since the products and boxes for shipping change frequently. This made the assignment especially difficult. In competitive markets, even a small cost or efficiency advantage can be determinant in holding or winning share. An additional consideration is the seasonal nature of the candy business, with huge volumes between September and December, less so for Valentine’s Day through Easter, then tapering off till the following September. Flexibility on the production line means employees are free to handle more demanding assignments. Automation Rescue The proposed solution had to

be reliable, flexible, precise, adaptable, and easy to operate, with equipment sensitive to changes in product format. PRB Packaging Systems came up with a combination of the FlexPicker and its own F-30 vertical case packaging machine. This combination was capable of dealing with products that when they arrive at this phase of the production cycle, are not always aligned on the production line, but follow each other in a determined distance. Over Hurdles The biggest challenge was to ensure that the robot could handle up to 40 formats and 130 different iterations: Zaini’s range of bags holds from 50 grm to one kilograms of chocolates or sweets. The bags’ contents have different sizes and shapes (eg: small squares, rounded eggs, hard candies). There are also differentsized packages for shipping and display, depending on the content and weight of the bags. “In addition, the formats change ever y day,” obser ves Dario Stringhetti, a technical specialist at the company. As the pre-bagged items roll

down the production line, a telecamera sees the format and predisposes the robot to the proper a c t i v i t y. This is so that it can sort and place items in the appropriate containers. The camera has deliberately not been mounted on the robot arm to prevent damage to the camera as a result of vibration from the robot’s movements. The ‘pick and place’ robot proved equal to the chocolate challenge. It can handle 90 packages weighing 50 grm each per minute, and 35 one kilogram packages a minute. It also work two 16 hour shifts a day, five days a week. Before the installation, no ‘pick and place’ robot had ever taken on this level of complexity in a food or confection line. “The robot could go even faster but we don’t do that for logistical reasons,” notes Mr Stringhetti. For more information, ENTER No: 0760




Market Report:

Globally Inspired Flavours, Eco-Friendly And HealthMinded Trends Lead Product Innovations Experimenting with flavours, flexibility and variety, confectionary makers are thinking outside the bar that will drive consumer purchasing over the next five years. Contributed by Susan Whiteside, VP of communications, National Confectioners Association (NCA)

Even in economic uncertainty, the confectionar y industr y continues to post gains. With insights from 40 industry experts, including manufacturers, market researchers, chocolatiers, nutritionists and confectionery makers, NCA’s Industr y Trend Report captures the confectionery trends and influences that will foster growth of the industry through 2014. Top line category trends include ‘chocolate explosion’ , ‘health benefits’, ‘flavour fusions’, and ‘international influences’.

influences on US confectionary product launches, insiders point to Europe as the birthplace for international confectionery trends now and in the coming years. Although Europe is most frequently perceived as the origin of confectionery trends, Japan appears to be an emerging influencer in the candy industry. Twenty percent say the US market for confections will influence product pricing and economic issues overseas.

Global Influences International spices and ethnic flavours will also have a large influence on new US products and flavour development overall, 58 percent of experts say. While Asian and Latin flavours will serve as the biggest

What’s Next? Experts believe that the next ‘big’ trend in confections will be healthier confectionery options, specifically a growing demand for health benefits and ‘better for you’ ingredients, according to almost nine out of ten (88

percent) experts. A l re a d y, w e a re s e e i n g consumers embrace portioncontrol sized treats and the potential heart health benefits of higher cacao content in chocolate. More than sweet and good to eat, manufacturers will take steps toward social r e s p o n s i b i l i t y. A c c o rd i n g to 65 percent of experts, ecofriendly manufacturing efforts, like recyclable packaging, will influence product development and consumer purchasing. Choc-Full-Of-It America’s favourite flavour, chocolate, will emerge as one of the largest growth drivers for the industry. Experts predict that consumers can expect to find chocolate and cocoa popping up more frequently as a key ingredient in main courses alongside salmon, chicken and steak, according to 73 percent of experts surveyed. Not just for dinner, 38 percent of insiders say to be on the lookout for cocoa and chocolate in appetisers. Embracing versatility may mean more of an emphasis on global influences and flavour pairings, according to the survey. Consumers are going to become more open to chocolate and flavour infusions that include spices, salts, herbs and floral flavours, according to 43 percent of experts. For example, exotic fruit pairings such as mango will b e c o m e m o re p ro m i n e n t , and ethnic flavours will start to emerge in popularity, with herbs being incorporated into chocolate dishes.




In the chocolate and cocoa category, the potential health benefits of the antioxidants found in chocolate will continue to be evidenced as new and positive health-related findings are discovered. Nearly half of those surveyed say consumers can expect to see more research into the potential health benefits of milk chocolate and dark chocolate, including exploration of naturally occurring cocoa compounds, and positive effects on mood and blood pressure levels. Additionally, a third of the experts say consumers will become more knowledgeable about the global origin of the chocolate they enjoy. Embracing origins helps consumers to breakdown cacao percentage and connect the provenance of the cocoa bean to the final product. All chocolate begin with cocoa beans, the fruit of the cacao tree. The tree, Theobroma Cacao, produces pods that hold cacao beans. These trees grow only in tropical regions around the world within a close proximity to the equator. Therefore, many exotic locales can lay claim to a connection with chocolate including areas like Africa, the Dominican Republic, Malaysia, Indonesia and South America.

fortified products. And there is no sign of a slow down, experts say. Forty-three percent say health-related influences will be the leading influence on new product development in the confectionery industry overall. Within the health categor y, drivers include:

Better For You Consumers are finding new ways to incorporate traditional candy as part of a healthy, active lifestyle. Since 2005, the confectioner y industr y has responded to market demands by introducing hundreds of portioncontrolled, calorie-controlled, reduced-fat, sugar-free and

• Fortified Products Twenty-five percent point to fortified products – confections with added vitamins, minerals or protein.

00dann, Brooklyn, US

• Portion Control Portion control has been cited

consumer demand. Candy, chocolate and gum continued to lead the snack category in sales and ranked third in overall food sales in 2008. The confectionery industry also posted a 3.7 percent gain for the 52-week period ending April 19, 2009. As classic candies remain tried and true favourites overall, a maturing American palate is trending toward twists, turns and more

as the leading influencer by 35 percent of industry leaders. The popularity of snack-sized products and 100-calorie packs, which give consumer the full flavour of their favourites, in smaller, reduced calorie options, is expected to continue.

Out-Of-The-Box In 2008 alone, more than 6,000 new confectionery and snack products debuted to meet

innovative product creations. Experts say limited editions – which allow confectionery makers the freedom to experiment with flavours in a variety of ways – will continue to prevail. Limited-time product extension will be big, experts think, such as introducing dark chocolate versions of classic milk chocolate candies. Experimental limited editions will also include more entertainment promotional ties and new twists on old favourites, such as unconventional flavour combinations. For more information, ENTER No: 0761




Food Ingredients Asia 2009 This year’s installation of Food Ingredients Asia (FiAsia) will take place from September 9 – 11, at Bangkok’s Queen Sirikit National Convention Center, in Thailand. About 8,000 visitors from over 30 countries are expected at the event, which will bring together key players in the ASEAN region. The event also offers visitors the opportunity to forge new partnerships; learn about the latest industry trends; and discover new and profitable product innovations.

Country Pavilions Visitors to the show can look out for country pavilions that will be featuring their specialities. With the US being a key supplier in the region, the US Department of Agriculture (USDA) will host a pavilion to showcase the country’s leading products. With economic pressures, it means that low cost ingredients solutions have never been more important. The China pavilion will bring many of the industry’s most cost-effective suppliers to




Functional foods have emerged as a key growth area in the food ingredients industry, and Asia is becoming a major supplier of functional ingredients. To explore this trend, the theme of this year’s Fi Asia conference will be, ‘What’s New in the World of Functional Food Ingredients?’ the show. Visitors can explore reformulation options and meet the suppliers in person here. Conference For Functional Foods Functional foods have emerged as a key growth area in the food ingredients industry, and Asia is becoming a major supplier of functional ingredients. To explore this trend, the theme of this year’s Fi Asia conference will be, ‘What’s New in the World of Functional Food Ingredients?’ T h e c o n f e re n c e w i l l b e hosted by the Food Science and Technology Association of Thailand (FoSTAT). It will focus on how functional ingredients can produce great flavour plus health benefits, and also provide companies with a way to differentiate their products. The ASEAN Market South-east Asia (SEA) has emerged as a staging ground for extensive R&D activities, which means that ingredients and products are

rapidly being introduced into the region. The safety standards in many countries, such as Thailand, also ensure that ingredients meet international quality requirements. The event provides the region’s central forum for those in the food processing industry to share their knowledge. C o n s u m e r s i n S E A a re increasing their appetite for a wider range of convenient, processed foods resulting in a 34 percent increase in food ingredient imports over the last five years. A growing middle-class is also expressing a preference for healthier foods, novel flavours, convenience, and new food experiences. These evolving tastes are creating opportunities for producers who can meet these demands. Queen Sirikit National Convention Center Bangkok, Thailand September 9 – 11, 2009 _________________ Enquiry No: 0773




Asia Fruit Logistica 2009 THIS year’s Fruit Logistica will take place on September 2 – 4, 2009, at the Hong Kong Convention and Exhibition Centre. The three-day trade exhibition runs alongside Asiafruit Congress, Asia’s annual fresh produce business conference. Trade exhibitors and visitors going to the event can look out for the latest products in the market and within the whole supply chain. Participants at the congress will also be able to attend talks and seminars which includes, ‘China: The Licensing Challenge’, ‘Indonesia: Spotlight On An Emerging Market’, as well as ‘Asia: The Sourcing Opportunity’. “Strong interest on both the

Drinktec 2009

exhibitor and visitor side has come from every part of the fresh produce business and from all over the world,” says Gérald Lamusse, MD of Global Produce Events, the jointv e n t u re c o m p a n y t h a t i s organising this event. “More than 200 exhibitors have signed up so far and we’re

DRINKTEC 2009 will take place from September 14 – 19 at the New Munich Trade Fair Centre in Germany. The fair for beverage and liquid food technology, is also a forum for science and research, for exchanging news and views, and also for networking. Manufacturers and suppliers from all over the world – global companies and SMEs alike – meet up here with producers and retailers of beverages and liquid food products. Manufacturers come along

expecting as many as 3,500 trade visitors to come to Hong Kong for this year’s show.” Exhibitors at this year’s event come from more than 30 different countries worldwide. They include markets in Asia, such as China, South Korea, J a p a n , Ta i w a n , T h a i l a n d , Malaysia, Indonesia, and the Philippines, as well as supplying countries such as the US, Australia, New Zealand, France, Italy, Spain, Netherlands, and, for the first time, Brazil and Chile. Hong Kong Convention & Exhibition Centre Hong Kong, SAR China September 2 – 4, 2009 _________________ Enquiry No: 0771

to present the latest technology for producing, filling and packaging beverages of all kinds, as well as liquid food – including raw materials and logistics solutions. A feature of the event is that machinery systems and plants are set up here and demonstrated in action. At the heart of the supporting programme are two forums; both of them situated in Hall B1. Independent experts from all over the world will be giving their lectures in these forums. The lectures are organised into blocks which includes the following themes: Consumers through the ages; Environment & Packaging; Water The Resource; Practical Operations: Filling & Packaging Systems; News From The Brewing process; Products With A Future; Service In Focus. Drinktec 2009 is expected to attract around 1,500 exhibitors from around 70 countries, and around 70,000 visitors from over 160 countries. New Munich Trade Centre Munich, Germany September 14 – 19, 2009 _____________________________________ Enquiry No: 0772

Don’t Miss the Best Proc

essing & Packagin g Show

ow in Indonesia


11 - 14 November 2009 Venue : Jakarta International Expo. Kemayoran. Jakarta

Food & Pharma Processing & Packaging Indonesia 2009 The 10th International Food & Pharmaceutical Processing & Packaging Technology Exhibition FEATURING The Technology, Machinery, Materials System and Supplies for • Food & Beverage Processing & Packaging • Pharmaceutical Processing & Packaging • Bottling • Plastic • Refrigeration • Automation • Material Handling • Quality Control and Testing system


Enquiry Number


Exhibition Organizer KRISTA EXHIBITIONS Jalan Blandongan No.28 d/g. Jakarta 11220. Indonesia Phone + 62 21 6345861, 6345862, 6333581, 6345002 Fax +62 21 6340140, 6342113 Email : Website :

calendar of events 2009 78

8 – 11: Interfood Indonesia Jakarta International Expo Kemayoran Jakarta, Indonesia Krista Exhibitions E-mail: Web: ❑ To Exhibit ❑ To Visit ❑ General Enquiry

11 – 14: FHM 2009 Kuala Lumpur Convention Centre Kuala Lumpur, Malaysia Malaysia Exhibition Services E-mail: Web:

Asia Pacific Food Industry

❑ To Exhibit ❑ To Visit ❑ General Enquiry

11 – 14: Propak Malaysia Kuala Lumpur Convention Centre Kuala Lumpur, Malaysia Malaysia Exhibition Services Web: ❑ To Exhibit ❑ To Visit ❑ General Enquiry

12 – 15: Vietfood & Pro+Pack 2009 Ho Chi Minh City International Exhibition And Convention Center Ho Chi Minh City, Vietnam Vietnam National Trade Fair And Advertising (Vinexad) E-mail: Web: ❑ To Exhibit ❑ To Visit ❑ General Enquiry

13 – 17: Food Expo 2009 Hong Kong Convention And Exhibition Centre Hong Kong, SAR China Hong Kong Trade Development Council E-mail: Web: ❑ To Exhibit ❑ To Visit ❑ General Enquiry

25 – 26: 16th Australian HACCP Conference Sebel Parramatta Sydney, Australia Advancing Food Safety E-mail: Web: ❑ To Exhibit ❑ To Visit ❑ General Enquiry

27 – 29: Natural Products Expo Asia 2009 Hong Kong Convention & Exhibition Centre Hong Kong, SAR China Penton Media Asia Limited E-mail: Web:

Quality circulation, readership and timely business information for busy executives on-the-go!


❑ To Exhibit ❑ To Visit ❑ General Enquiry

*All details subject to change without notice. Please check with organisers for updates.

➲September 2 – 4: Asia Fruit Logistica 2009 Hongkong Convention And Exhibition Centre Hong Kong, SAR China Global Produce Events E-mail: Web: ❑ To Exhibit ❑ To Visit ❑ General Enquiry

9 – 11: Fi Asia 2009 Queen Sirikit National Convention Centre Bangkok, Thailand CMP Asia Trade Fairs E-mail: Web: ❑ To Exhibit ❑ To Visit ❑ General Enquiry

14 – 19: Drinktec 2009 New Munich Trade Fair Centre Munich, Germany Messe München E-mail: Web: ❑ To Exhibit ❑ To Visit ❑ General Enquiry

23 – 24: China Int’l Food Safety & Quality Conference + Expo Landmark Hotel & Tower Beijing, China World Services E-mail: Web: ❑ To Exhibit ❑ To Visit ❑ General Enquiry

25 – 27: Vietfood 09 National Convention Centre, Hanoi Hanoi, Vietnam AMB Exhibitions E-mail: Web: ❑ To Exhibit ❑ To Visit ❑ General Enquiry

➲October 1 – 3: Food & Hotel Vietnam 2009 Saigon Exhibition & Convention Center Ho Chi Minh City, Vietnam Singapore Exhibition Services E-mail: Web: ❑ To Exhibit ❑ To Visit ❑ General Enquiry

7 – 9: Biofach Japan 2009 Tokyo Big Sight Tokyo, Japan Nürnberg Global Fairs GmbH E-mail: Web: ❑ To Exhibit ❑ To Visit ❑ General Enquiry







Things To Do... Attend the following shows!

INTERFOOD INDONESIA August 8 - 11, 2009 Jakarta, Indonesia

Sweets China 22. - 24.10.2009

FHM 2009 / PROPAK MALAYSIA August 11 - 14, 2009 Kuala Lumpur, Malaysia

Shanghai Exhibition Center In conjunction with:

ASIA FRUIT LOGISTICA 2009 September 2 - 4, 2009 Hong Kong, SAR China

China Candy Festival 2009 Feature Zones:

FI ASIA 2009 September 9 - 11, 2009 Bangkok, Thailand

Building ➲December 2 – 5: propAk inDonesiA Visions Jakarta International Expo Centre Jakarta, Indonesia PT Pamerindo Buana Abadi for E-mail:

Sweet Business

22 – 24: sWeets chinA 2009 Shanghai Exhibition Center Shanghai, China Koelnmesse E-mail: Web: ❑ To Exhibit ❑ To Visit ❑ General Enquiry

23 – 24: Fi inDiA 2009 Bombay Exhibition Center Mumbai, India UBM International Media E-mail: Web: ❑ To Exhibit ❑ To Visit ❑ General Enquiry

27 – 29: chinA FooDtech 2009 China International Exhibition Centre Beijing, China CIEC Exhibition Company E-mail: Web: ❑ To Exhibit ❑ To Visit ❑ General Enquiry

➲November 11 – 14: ALL pAck inDonesiA Jakarta International Expo Kemayoran Jakarta, Indonesia Krista Exhibitions E-mail: Web: ❑ To Exhibit ❑ To Visit ❑ General Enquiry


11 – 14: BusAn int’L seAFooD & Fisheries expo 2009 BEXCO Busan, Korea BEXCO Exhibition E-mail: Web:

















Your One-Stop Shop for Sweet, Snack, Confectionary

Exhibitor Profile Manufacturing, processing and packaging technology for Sweets & Snacks: Processing technology and equipment Machines and plants Packaging technology Packaging materials

❑ To Exhibit ❑ To Visit ❑ General Enquiry

Raw materials and ingredients Refrigeration and air conditioning technology automation/ data processing/ control technology Safety, quality management Analysis, Iaboratory and measuring equipment


in the ed for a listing To be consider ils ta de nd se ents, Calendar of Ev ent, ev of e m na g: in of event includ ntact co r’s d organise date, venue an low. be n ve gi s addres details to the t Editorial Dep ustry c Food Ind ifi c a Asia P d Media Pte Lt Eastern Trade ta Road el 1100 Lower D ing ild Bu L #04-04 EP 06 92 16 e or Singap 88 Tel: 65 6379 28 05 28 79 Fax: 65 63 @ od fo ap l: E-mai

Operating equipment and auxiliary devices for confectionery production Service firms, organizations, publishers 78% of visitors to International Sweet & SnackTec China 2008 will recommend the show to their colleagues.

REGISTER ONLINE NOW TO VISIT THE NO.1 SWEETS SHOW IN CHINA! Koelnmesse Pte Ltd Ms Lynn How Tel: +65 6500 6712 Fax: +65 6294 8403


❑ To Exhibit ❑ To Visit ❑ General Enquiry

Sweet & SnackTec Zone

Enquiry Number

14 – 16: heALth ingreDients JApAn 2009 Tokyo Big Sight Tokyo, Japan CMP Japan E-mail: Web:

Product Catalogue ASIA PACIFIC REGIONAL ENGINEER Valiant Equipment is a quality supplier of meat & vegetable processing and packaging lines to the Asia Pacific region. The company is highly aggressive in providing excellent support to our customers. Our business growth has led us to seek a highly competent Regional Engineer to join our organisation. EXCELLENT remuneration based on the individual’s achievements awaits the successful applicant. THE JOB ❑ ❑ ❑ ❑ ❑

Strategise and spearhead the Asia Pacific region growth plan for our Technical Services Centre based in Kuala Lumpur, Malaysia Lead engineering team to achieve organisational objectives Conduct installations, demonstrations and training on all processing machineries to customers and prospects Provide front line support to customers’ engineering staff for equipment problems or faults Support of all our equipment with monthly maintenance and service calls to all customers around the region


Enquiry Number

• • • • •



Minimum of 10 years’ experience in servicing of equipment systems, preferably in the Meat Processing & Packaging industry A Degree in Electrical Engineering and preferably with Mechanical Engineering experience Sound knowledge and understanding electro-pneumatic control systems is a MUST Excellent trouble-shooting mindset Self driven, independent, results oriented team player and a fast learner Willing to be based in Kuala Lumpur, Malaysia Must be willing to travel extensively


Interested candidates are invited to write-in by 31st August 2009 to:

Valiant Equipment Sdn Bhd


33 Jalan PBS 14/2, Taman Perindustrian Bukit Serdang, 43300 Seri Kembangan, Selangor, Malaysia Email: • Website:




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If your answer is YES to any of the above Pictures Credit: ilker, izmir, Turkey & Brian Lary, Madison, US

ASIA PACIFIC FOOD INDUSTRY has the solution for you! Randy Teo Business Development Manager Tel: 65 6379 2867 | Fax: 65 6379 2805

Talk to us for your advertising needs. We have: • Specially tailored packages to suit your every budget • Customised programmes to give your products the maximum exposure that they need – all within your budget • Exclusive loyalty programmes for our existing clients As our advertisers, we provide a personalised partnership, with one common goal: To strategically position your company for MAXIMUM EXPOSURE IN BOTH PRINT AND eMEDIA! Call us now – and give your business a competitive edge!

Enquiry Number



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August ’09

To: The Circulation Executive, Circulation Department,

From: Your Name: (Surname) _________________________________ (Given Names) _____________________________ Your Job Title: ______________________________________________________ Name of Your Company: ____________________________________________

Do you want to receive (continue to receive) Asia Pacific Food Industry? ❑ YES ❑ NO (Not valid without signature)

Company’s Business Address: ______________________________________ ________________________________________________________________________

Signature _____________________Date___________

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ENTER INFORMATION CARD NUMBER(S) (Refer to Advertising Index for Advertisers’ enquiry numbers)

E-mail: ____________________________

Type of products we need to purchase IN the next 6 months ❑ Processing Equipment & Solutions ❑ Packaging Tools & Machinery ❑ Ingredients & Additives ❑ Software & Applications

Reader Information ✔ Tick one box only ❑


❑ 84 Food/Beverage Manufacturer ❑ 81 Ingredients & Additives Supply ❑ 72 Manufacturer/Distributor of Process- ❑ 85 Storage Handling & Distribution ing Machinery and Equipment ❑ 80 Raw Material Supply ❑ 30 Manufacturer/Distributor of ❑ 88 Distributors and Retailers of

Packaging Machinery and Materials

Food Products

❑ 86 Design/Consultancy Services ❑ 75 Research institutions, Trade Associations, Government Bodies, Statutory Boards, etc. ❑ 77 Embassies and Trade Commissions ❑ 78 OTHERS (please specify) ____________________________________________

✔ Tick one box only ❑ MAIN INDUSTRY SECTOR

❑ 5 Confectionery, Snacks & Tibits ❑ 4 Fish, Crustaceans Molluscs, Seafood, and Preparations Thereof ❑ 11 Beverages - Non Alcoholic and Alcoholic ❑ 3 Vegetables & Fruits ❑ 6 Edible Oils and Fats

❑ 10 Coffee, Tea, Cocoa, Spices and ❑ 13 Cereals & Cereal Preparation Manufactures Thereof ❑ 14 Multiple Edible Products ❑ 1 Dairy & Milk Products & Preparations ❑ 2 Meat & Meat Preparations ❑ 9 Flour/Vermicelli ❑ 7 Additives/Flavours/Seasoning ❑ 12 Lubricants & Chemicals ❑ 8 Condiments & Sauces, Sugar, ❑ 15 OTHERS (please specify)

Sugar Preparations & Honey


✔ Tick one box only ❑ MY JOB FUNCTION IS

❑ 34 Senior Management ❑ 32 Purchasing/Procurement/Sourcing ❑ 28 Packaging Engineering ❑ 35 General Management ❑ 36 Maintenance Engineering ❑ 29 Process Engineering ❑ 22 Production Engineering ❑ 36 Academic ❑ 06 Consultancy/R&D ❑ 31 QA/AC ❑ 14 Marketintg/Sales ❑ 27 OTHERS (please specify) ___________________________________________________________________________________ THE NUMBER OF EMPLOYEES AT OUR COMPANY/FACTORY IS 1 ❑ 1-9

2 ❑ 10-49

3 ❑ 50-99

4 ❑ 100-299

5 ❑ 300-499

6 ❑ 500 or more

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August ’09

Enquiry Number


APFI August09  
APFI August09  

Asia Pacific Food Industry