FOOD & TECHNOLOGY Pulsed electric fields Biobased packaging Sustainable proteins WWW.HOLLANDFOODINNOVATIONS.COM HOLLAND FOOD INNOVATIONS
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HOLLAND FOOD INNOVATIONS . MARCH 2015 . NO 1
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Pioneering with pulsed electric ďŹ eld. . . . . . . . . . . . . . . . . . .
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Biobased packaging . . . . . . . . .
Cover:Nutri-Pulse e-Cooker Nutri-Pulse e-Cooker
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FOREWORD
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Content
Innovation 4
Spotlight on innovation
Technology 6
Pioneering with pulsed electric fields
10
In-line monitoring of CIP-system
16
Pilot plant optimization
22
Keeping fruit and vegetables fresh
Sustainability
A wide range of innovations This is the very first edition of Holland Food Innovations! This magazine helps Dutch companies and research organizations and businesses abroad to build bridges and to develop innovative solutions for the production of healthy and sustainable food. We strive to produce a magazine that gives you a comprehensive overview of Dutch innovation in the food
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Producing sustainable cheese
industry. These advancements are invaluable to the
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Sustainable protein
global food industry.
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Biobased packaging
If you are interested in new technologies, this magazine will present you with a wealth of knowledge. For example, in this edition we showcase the different applica-
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Event calendar
tions of the mild conservation technology known as pulsed electric field. There are several industrial applications in the Netherlands, however, there are also a number of challenges to overcome. Sustainable production is a major challenge for the food industry. We broach the subject here on this platform. You can become acquainted with topics such as the various bio-based packaging materials developed in the Netherlands. We also highlight the development of contemporary sustainable proteins. Cooperation is key to a successful innovation. The new cheese factory of CONO is a prime example of collaboration between subcontractors not only leading to a sustainable building but also sustainable production. We have taken great pride in creating this magazine and we hope you enjoy reading it!
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INNOVATION
HOLLAND FOOD INNOVATIONS . MARCH 2015 . NO 1
Spotlight on innovation Dutch businesses are continually developing new concepts, research methods and packaging solutions. The website www.dutchfoodinnovations.com puts the spotlight on the latest innovations from the agrifood industry. Take a look at five of the latest innovations.
Pectin from coffee pulp
Pectcof’s new technology for extracting pectin from coffee pulp can help to make the coffee industry more sustainable. Coffee, the world’s largest food commodity, is of crucial importance to the economy of many developing countries. As coffee production becomes more industrialized, the waste generated is growing into a major environmental problem. Pectcof technology
Protein-enriched fruit juice for seniors
04
is the first step towards the industrial use of coffee pulp biomass,
Carezzo’s protein-enriched fruit juice for senior consumers can
through production
now make the nutritional claim ‘rich in protein’ thanks to techno-
of bio-based mate-
logical and processing innovations developed by NIZO food
rials using green
research. The juice contains 7% protein, or 10 grams per 150 ml
chemistry and
portion, which is additional since regular fruit juice has no protein
state-of-the-art bio-
content. Taste tests show consumers aged 55 and older have a signi-
technology. For
ficant preference for Carezzo over regular medical, nutrition
every kilo of coffee beans consumed, another kilo of coffee pulp
drinks. Carezzo juice is particularly suitable for seniors; it is easy to
and waste remains behind on the coffee plantation. The waste con-
drink and does not affect consumers’ energy intake at their next
sists mainly of pulp and hulls. Pectcof uses this material to produce
meal. The enriched fruit juice was tested by the SenTo consumer
high-grade pectin that can serve as an emulsifier or stabilizer in
taste panel (Food and Biobased research - Wageningen UR).
products such as wine gums and yoghurt drinks. Pectcof ’s technol-
Carezzo has developed a variety of fruit juices, protein-enriched
ogy is currently suitable for extracting pectin only, but by continu-
bakery products, breads, and dairy and fruit-based ice creams, as
ing to develop the technology, the company aims to start extracting
well as high-protein soup for (elderly) hospital patients.
other substances such as antioxidants, caffeine and sugars.
....................................................................................... www.carezzo.nl
...................................................................................www.pectcof.com
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CO2 drying: energy-efficient technology preserves quality FeyeCon introduces CO2 drying. All conventional drying techniques have a major disadvantage. Inexpensive methods (air drying) result in poor product quality, while those that produce higher quality (freeze drying) also run up high energy costs. FeyeCon’s new CO2 drying technology combines the best of both worlds and delivers excellent results a much lower cost than freeze drying. Analyses show that CO2 drying maintains most of the nutritional value of fruit and vegetables, and that the rehydrated produce has a nearly fresh bite and taste. Even in its dried state, CO2 dried produce is very tasty. Aside from fresh vegetables, fruit and herbs, this technology can also be applied to liquid concentrates of temperatureand oxidation-sensitive substances. CO2 drying can be used for the ingredients in instant soups and sauces, cereal products, snacks, and in products sold separately for home use, such as culinary herbs. ................................................................................................................www.feyecon.com
Real-time analysis of facial expressions Noldus Information Technology presents FaceReader. The software automatically analyzes facial expressions, head orientation, gaze direction, action units, and personal characteristics such as age and gender. The system is available as software and as an online application. Researchers can invite participants from all over the world and measure consumer appreciation by gathering objective and detailed information about people’s facial expressions. FaceReader reads and
Elimination of Salmonella without loss of quality
reports on participants’ responses to commercials, ads or products. The technology also allows real-time representation of the circumplex model of affect which describes the distribution of emotions in a 2D circular space, containing arousal and valence dimensions. With more
Micreos makes use of nature’s solutions, relying on phages to
information about preferences and appreciation, researchers can
eliminate pathogenic bacteria such as Salmonella. Micreos has
improve products, but also public health campaigns. Information
developed Salmonelex, which destroys Salmonella rather than
about the level of appreciation also makes it possible to make healthy
merely inhibiting its growth. Salmonelex has no effect on the taste,
products more appealing.
texture or other organoleptic properties of treated food products.
................................................................................... www.noldus.com
Once phages have done their work, they break down into amino and nucleic acids, so they leave no ecological footprint. Salmonelex is easy to apply, either by topical spraying or by adding it to chill tank water. It consists of a watery solution containing two Salmonella-specific bacteriophages, Fo1a and S16, which are produced and purified separately, then mixed in equal concentrations. The two phages utilize different receptor molecules, so they have two modes of action. Micreos expects Salmonelex will soon be listed by the Organic Material Review Institute (OMRI) for use in natural and organic foods. The U.S. Department of Agriculture (USDA) has approved Salmonelex as an antimicrobial processing aid to combat Salmonella spp. in poultry, pork, and beef. Micreos chose to seek approval from the USDA first, because the USA is home to 60% of the global poultry industry. ................................................................................. www.micreos.com
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TECHNOLOGY
HOLLAND FOOD INNOVATIONS . MARCH 2015 . NO 1
Pioneering with pulsed electric field Number of PEF food applications are growing Pulsed electric field (PEF) technology has shown that it is more than just a promising, novel food processing method. In the last few years the technology has definitely found its way to the food manufacturing market. However, implementation is not as straightforward as conventional processing techniques.
present in the raw materials through the electroporation of their cell membranes. As PEF does not inactivate most enzymes, the treated juices still have to be refrigerated. Nevertheless, PEF treatment extends refrigerated shelf life from 6-7 days fresh juice to 21 days, and this has enabled
Thousands of liters of fresh fruit juices have
below 50 degrees Celsius, PEF treated juices
Hoogesteger to increase its market share in
been treated by the hour with pulsed elec-
look and taste like fresh juice and retain
the Netherlands as well as in Europe.
tric fields (PEF) at the Hoogesteger facility
their nutritional value whereas the imposed
“The excellent product quality and
in Zwanenburg, the Netherlands, since
field strength of 15-20 kV/cm effectively
increased export possibilities are benefits
2012. With processing temperatures set
kills spoilage organisms and pathogens
that far outweigh the investment, imple-
This prototype of the Nutri-Pulse e-Cooker has three compartments.
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PEF pilot plant of Wageningen UR Food & Biobased Research.
port processes such as extraction, drying and marinating but also cutting and peeling. Senior scientist Ariette Matser from Wageningen UR Food & Biobased Research expects that the use of PEF for extraction processes will increase in the coming years. Though, the exact advantages of various raw materials in comparison with conventional techniques still have to be assessed. According to Mark de Boevere of the Dutch PEF equipment manufacturer Pulsemaster, “PEF treatment of potatoes has many advantages.” Electroporation of potato cells softens the raw material which improves cut quality, reduces French fry breakage and mentation and running costs,” says Hooge-
German Institute of Food Technologies
frying times and reduces fat uptake. Water
steger’s manager of operations, Frank Jans-
(DIL), Fruity Line works with the Pure-
and energy consumption are reduced as
sen. Even though the targeted production
Pulse technology of the Dutch PEF
well. “PEF systems are an excellent alterna-
capacity has not yet been reached, as a result
specialist Cool Wave Processing, a subsidi-
tive for traditional preheaters in potato pro-
of which the production costs are still rela-
ary of the technology and product develop-
cessing,” says De Boevere.
tively high, Hoogesteger is very positive
ment company TOP specializing in PEF for
De Boevere’s company Pulsemaster supplies
about its investment in PEF technology. “We
a range of industri-
went for the best quality for our customers
al-scale PEF equipment
and chose the technology best suited to meet that goal. In this we succeeded,” Janssen says. “In late 2013 we doubled our capacity by installing a second pulse generator. To further cut production costs, we have been
‘PEF has proven to be a very promising technique for the French fry industry’
applying lean production principles.”
under the brand name Conditioner, for both raw material treatment and mild food preservation. “For example, we offer 80 kW systems
mild preservation.
that can handle 50 tons of potato per hour
Market introductions
In addition to the abovementioned juice
but also smaller installations. Depending on
In addition to Hoogesteger, the Dutch fresh
producers, other Dutch food manufacturers
the potato variety, appropriate field
juice producer Fruity Line has recently
are also investing in pulsed electric field
strengths range from 0.8 to 3.0 kV/cm and
implemented PEF technology in its facility
technology. “We have installed several PEF
expected costs are 1 euro per ton.”
in Ochten. While Hoogesteger bought its
units in the Netherlands since 2011,” says
One of the key players in the Dutch agri-
PEF equipment from Elea, a spin-off of the
Elea’s business development manager, Jan
food sector, Royal Cosun has worked
Kasten. These installations include
closely with AVEBE, provider of starch
machines for shelf life extension of fresh
based ingredients, on a feasability study on
juices, such as used by Hoogesteger, as well
PEF by the Carbohydrate Competence
* What is PEF?
as installations for potato and sugar beet
Center (CCC). According to AVEBE’s chief
PEF fuses a high voltage electric pulse
treatment which have resulted in process,
technology officer Marco Giuseppin: “PEF
to perforate the cell wall of raw
product and yield improvement.
has proven to be a very promising technique for the French fry industry. However, the
materials. This breakdown of the cell’s barrier function enables the structure of
Raw material treatment
technology is not yet sufficiently developed
the material to be modified or
PEF processing promotes cell disintegration
to become a technical alternative for our
micro-organisms to be killed.
in raw materials which in turn enhances all
conventional extraction techniques.”
kinds of processes particularly mass trans-
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TECHNOLOGY
HOLLAND FOOD INNOVATIONS . MARCH 2015 . NO 1
A chef demonstrates how the e-Cooker works.
Pulsemaster supplies a range of industrial-scale PEF equipment
Dairy applications
the attention of Cool Wave Processing’s tech-
An important obstacle for PEF treated milk
Wageningen UR Food & Biobased Research
nology and product development partner
in supermarkets is, however, the strict
is currently measuring inactivation kinetics
TOP. TOP wants to bring PEF treated milk as
Dutch food safety legislation for dairy
of micro-organisms in food matrices, other
‘raw milk’ to the consumer. The company has
products which demands certain minimum
than fruit juice, particularly in milk and
formed a consortium with dairy farmers and
treatment temperatures to ensure food safe-
dairy products. The dairy segment also has
retailers to accomplish this.
ty. As PEF is mostly a non-thermal process
PEF for raw material treatment requires sig-
project NovelQ on novel food processing
By splitting the treatment chamber into
nificantly less field strengths than PEF for
methods such as PEF. Wageningen UR
several parallel chambers the total power
mild preservation of liquids, allowing much
Food & Biobsed has worked closely with
rating for the system can be reduced for a
higher treatment capacities. More-over, raw
Hoogesteger on PEF applications. Matser
given total flow rate.
material treatment is not a critical step for
points out that the extremely high field
In addition to capacity limits, PEF preserva-
food safety. At the moment, the treatment
strengths and the ultrashort microsecond
tion faces other challenges, as it is a critical
capacity difference between (single) sys-
pulses are difficult to achieve reliably in high
process step requiring considerable opera-
tems for raw material treatment versus sys-
capacity systems. Single semiconductor
tor skills and knowledge. Furthermore
tems for mild preservation is roughly ten-
pulse switches are not yet available for
thorough knowledge of inactivation kine-
fold: 5,000 l/h for microbial inactivation
these voltages; to reach the proper voltage
tics of relevant food spoilage organisms as
versus 50,000 kg/h for raw material treat-
these switches must be connected in
well as food pathogens is needed to ensure
ment. The differences in cost are in the
series; making high capacity systems more
food safety of PEF treated products. The
same order of magnitude.
complex.
NovelQ project has provided an important
In practice, achieving capacities of 5,000-
“But why would you try to scale up produc-
breakthrough by demonstrating the micro-
10,000 liters an hour for mild preservation is
tion to larger volumes with a single unit?”
bial safety of PEF treated fresh juices. “For
still a major challenge. “I am curious whether
asks researcher Bart Roodenburg from the
the type of PEF systems used at Hooge-
this problem will be solved in the next few
Delft University of Technology. “From a
steger this safety data is now available,”
years,” says Ariette Matser, from Wagenin-
scientific and a technological point of view
says Matser. “But for various other PEF
gen UR Food & Biobased Research. She
there is no reason for building high capacity
systems and products, product safety still
was former coordinator of the EU-funded
systems with only one treatment chamber.”
needs to be assessed.”*
Challenges of Pulsed Electric Fields
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EF
Potato interlaced with PEF treatment
‒ the PurePulse system aims for tempera-
research, testing and prototype development.
One of the frontrunners
tures below 40 degrees Celsius. Legislation
In contrast to mild preservation, e-Cooking
Home to several food manufacturers using
would have to be changed. “We are trying
does require heat development within the
PEF technology, two industrial-scale PEF
to get dispensation from the Netherlands
treated food products, called ohmic heating.
equipment suppliers, a company that has
Food and Consumer Product Safety
At the same time electroporation of cell
invented a unique e-Cooking device and a
Authority,” says TOP’s creative director
membranes facilitates and speeds up the
renowned applied research institute gener-
Dennis Favier, “but much testing and vali-
cooking process. Compared to traditional
ating knowledge on PEF, the Netherlands is
dating is needed to build up the required
cooking, baking and frying, e-Cooking
one of the frontrunners in pulsed electric
food safety dossier.”
temperatures are relatively low (below 100
field innovations. Despite the growing prac-
According to Favier, low treatment
degrees Celsius), improving taste, texture,
tical experience with PEF application, food
temperatures and high inactivation rates are
manufacturers currently
typical features of Cool Wave’s PurePulse
investing in PEF technology
technology. Since 2008 technology partner TOP has put a lot of effort in treatment chamber design to get optimal flow patterns for inactivation at relatively low temperatures. For mild preservation purposes, temperatures below 50 degrees Celsius are
‘Food manufacturers currently investing in PEF technology may still be considered pioneers’
may still be considered pioneers. “It is a high risk investment,” says Favier. “Food manufacturers using PEF may be confronted with more production line disruptions or
desirable, in order to fully achieve the bene-
early replacement of certain
fits of PEF, namely, preserving freshness,
machine parts. On the other
color, taste and nutritional value. Cool
tenderness, juiciness and nutritional value.
hand, if a company decides not to invest in
Wave offers capacities of 3000 l/h and has a
Within seconds to a few minutes, foods such
PEF at this early stage, competitors might
pilot facility of 300 l/h.
as meat and fish can be prepared. “The tech-
take the lead and gain market share. This is
nique of e-Cooking also holds promise for
the choice manufacturers have to make but
High speed cooking
industrial applications but this is still
first of all they have to be convinced of the
Pulsed electric fields can also be used for
uncharted territory,” says scientist Ariette
opportunities PEF is offering them.”
high speed cooking such as in the e-Cooker
Matser. As a first step, Wageningen UR
invented by IXL Netherlands. According to
Food & Biobased Research is now working
• ANJA JANSEN •
IXL’s innovation director Hans Roelofs, the
with IXL in a public-private partnership on
A. Jansen is freelance editor
Nutri-Pulse e-Cooker is now almost ready to
applying e-Cooking technologies for mild
be launched on the market for both restau-
preservation. Last year the cooking device
rant and home use, following five years of
won a Global Food Industry Award.
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TECHNOLOGY
HOLLAND FOOD INNOVATIONS . MARCH 2015 . NO 1
In-line monitoring makes CIP-system more efficient Using in-line sensors to continuously monitor a Cleaning in Place (CIP) system, could save time and provide crucial information about the cleaning process. NIZO food research and Schneider Electric are currently developing and testing such a system at FrieslandCampina.
monitored by establishing a number of parameters such as time, temperature and chemical concentration. Most manufacturers record this information and analyze it manually, which is not only labor intensive but also has several drawbacks. Such a snapshot of the current situation is necessarily imprecise, as
in operation the process is usually assumed
the cleaning process is not always exactly the
to run like clockwork. Manufacturers nor-
same, for example due to malfunctioning,
mally only consider optimization of CIP
unplanned waiting times, or the presence of
when facing quality or capacity problems.
more or less residues than average.
Only then is there suddenly a need for data on the cleaning process or for a timesaving, accelerated process. But there are other reasons for optimizing
OptiCIP
the CIP process besides capacity and time.
The food industry has long expressed an
The benefits include the reduction of the
interest in optimizing CIP systems. NIZO
use of energy, water and chemicals.
food research and Schneider Electric took up the challenge, working towards solutions
Optimizing the CIP-system results in saving time, improving the capacity and a reduction of the use of water, energy and chemicals.
010
Optimization
in a project they termed OptiCIP. Over the
“We’ve found that cleaning processes in the
past few years, NIZO developed a method
food industry tend to be based on overkill,”
with an in-line turbidity sensor that provides
Thorough cleaning of processing equipment
says Maykel Verschueren, Processing and
data on the turbidity of the cleaning solution.
is key to securing food safety. Therefore,
Safety Division Manager at NIZO food
Turbidity is a key indicator of the amount of
CIP is standard practice for most food
research. “Processes are designed to clean
residues present and the speed at which it
manufacturers. In the dairy industry, equip-
longer than strictly necessary, just to be
is being removed. This enables operators to
ment is cleaned once to three times a day
sure no residues are left. Optimization and
manage and optimize the cleaning process.
using alkali and acid detergents and/or dis-
continuous monitoring of the cleaning pro-
At the same time, Schneider Electric inde-
infectants. In other industries such as
cess could save time and costs without com-
pendently developed a software tool for
beverage production, cleaning is necessary
promising food safety. We know from expe-
automatically monitoring CIP processes.
too, though less frequently.
rience that cleaning times can be shortened
NIZO and Schneider combined their
Upon installation of the system, its results
by ten to thirty percent.”
knowledge in this new OptiCIP application.
are usually recorded and validated, but once
Usually, the CIP system’s effectiveness is
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The in-line CIP-system is developed with the dairy industry in mind. Other industries, like the beverage industry, can benefit from the system too.
In addition, this type of ‘offline monitoring’
centration, flow and turbidity. “The latter
ing an audit trail that can be used to analyze
is equipment-specific and does not provide
parameter is new in automatic CIP moni-
the process. This is important for tracking
an overview of the cleaning results in other
toring,” explains Verschueren. “Turbidity is
and tracing and quality control.”
process lines. Manufacturing plants often
a key parameter. As soon as the cleaning
consist of dozens of different lines and
solution runs clear, you know the equip-
Pay back period
pieces of equipment that are cleaned inde-
ment is clean. Monitoring this parameter
Verschueren expects the final results of the
pendently.
provides crucial feedback that can prevent
pilot project at FrieslandCampina later this
Now, NIZO food research and Schneider
needlessly long cleaning and saves time.”
year. “We developed this in-line CIP moni-
Electric - a research institute and an ICT
toring system with the dairy industry in
company - are currently developing a fully
mind. We expect to be able to achieve up to
computerized system for continuous CIP system monitoring, and testing it in a pilot project at a FrieslandCampina dairy pro-
‘Turbidity is a key parameter’
thirty per cent shorter cleaning times. With such savings, the pay back period for the system will be short. We think other indus-
cessing plant. The system uses in-line sen-
tries, like the beverage industry, could
sors specifically designed to identify fre-
benefit from the system too. Technological
quently-occurring soil in dairy processing
advances are made every day; I expect the
equipment.
“In-line monitoring of CIP-systems also has
sensors needed for non-dairy fluids to be
other advantages,” Verschueren adds. “It
available soon,” he says.
New parameter
creates a continuous stream of data about
The new in-line system monitors five
the cleaning process. This enables imme-
• FLORENTINE JAGERS OP AKKERHUIS •
parameters that are crucial to the cleaning
diate intervention if something goes wrong.
Editor @ Food Valley NL
process: time, temperature, chemical con-
The data are also consistently logged, form-
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TECHNOLOGY
HOLLAND FOOD INNOVATIONS . MARCH 2015 . NO 1
Producing sustainable cheese CONO Kaasmakers build CO2 neutral factory CONO Kaasmakers successfully finalized the construction of a CO2 neutral cheese factory in 2014. To realize this ambition they had to establish a joint venture agreement with their technical suppliers who serve as partners of sustainable construction.
Betten, director of operations and technology. “Our current cheese factory is stylized for the eighties and therefore outdated. Over time there were sections built-on but the transition between the various divisions are passé. In addition we have no space to
CONO Kaasmakers successfully finalized
with their technical suppliers who serve as
expand any further.” The extra capacity is
the construction of a CO2 neutral cheese fac-
partners of sustainable construction.
sorely needed to capture the surplus milk
tory in 2014. To realize this ambition they
CONO has several key interests for invest-
expected from ending of the milk quota at
had to establish a joint venture agreement
ing in a new cheese factory, explains Wim
the beginning of 2015. “The expectation is
Aerial view of the new cheese factory in the Beemsterpolder, UNESCO World Heritage Site. It was vital that the new building blend in with the open landscape.
012
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that the dissolution of the milk quota will yield fifteen to twenty percent more milk than it does at present. We are a cooperative and we are, therefore, obligated to process the milk from our farmers. Hence, the new cheese factory is an investment in the future,” says Betten.
Green cheese factory To ensure that the building and the factory design are as ecologically sound as possible CONO established a joint venture project with its technical suppliers and partners in sustainable construction. The project was initiated with a roundtable discussion
Wim Betten, director of operations and technology at CONO: “The new factory is an investment in the future.”
attended by all suppliers. Betten elaborates: “It was rather uncomfortable in the beginning but we wanted to achieve more than we have been able to by working with each
Joint venture partners
party individually. In this way company B presents a solution for the residual energy
Visser & Smit Bouw is the chief contrac-
Cofely has developed a sustainable ice
of company A.”
tor of the new construction. “Efficient sus-
water installation system with reduced
CONO also believes that the duration with
tainability is also our priority.”
energy usage. The entire building will be
to one another is a crucial element in the
Elten has automated the new cheese
nal installation also provides the air-conditi-
process. Peter Schurink, the project leader
warehouse. The forklifts will become
oning for the office spaces. “Innovation in
explains: “A tiny connecting piece that
obsolete and energy saving robots are set
construction provides the perfect opportu-
merges for a shorter period of time than the
to replace them. “We build cheese treat-
nity to combine hot and cold.”
plate material surrounding it, can inevitably
ment lines that are energy efficient and
create many problems and expenses.”
have a long lifespan.”
which durable substances blend in relation
cooled by this system and the multi-functio-
The Urgenda Foundation participated in
Tetra Pak has installed separators that save an estimate of 35% energy in compa-
the roundtable discussion alongside
Siemens has integrated the automation in
rison with other separators in its class. It is
mechanical engineers and the architect’s
the new cheese factory with a standard
used for cleansing and skimming of milk
firm. The foundation deals with regional
energy management system. Energy usage
and whey. “At Tetra Pak sustainability
sustainability and is supporting CONO
can be monitored directly on-screen during
means constantly searching for food pro-
with its knowledge and experience in
the production of the cheese as a result of
cessing systems with a longer production
upscaling green ventures. “To fast track the
this system. “This approach leads to a more
time and which operates more efficiently.”
preservation of the Netherlands it is impor-
heightened awareness as well as improved
tant to work together and share expertise,”
saving measures.”
says Marjan Minnesma, director of
The Urgenda Foundation functions as the consultant for sustainable construction.
Urgenda. The other contributors to the dis-
De Klokslag has been responsible for the
cussion and partners in sustainable con-
construction of the cheese production
struction were Visser en Smit bouw as chief
system with open drainage trays. “We
contractor; Tetra Pak for the installation
designed and built a new assembly hall
Source: Publication of CONO titled, De
process of the factory and the cheese pro-
expressly for the drafting of the complete
Nieuwe Tijd, op weg naar de groenste
duction; Cofely for the cryogenics; De
production line.”
kaasmakerij ter wereld, 2013
Klokslag for the cheese production
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TECHNOLOGY
systems; Siemens for the automation, machine components and energy management; Elten for cheese treatment systems and Kuipers Woudsend for the tank farm (see textbox).
HOLLAND FOOD INNOVATIONS . MARCH 2015 . NO 1
CONO Kaasmakers drain curds manually which will also be done this way in the new cheese factory. According to CONO this
Sustainable or efficient?
ensures more flavor.
Is it possible to combine the production of the most sustainable cheese with the most efficiently produced cheese? “Of course profits also have to be made,” Betten laments. “If we save five percent energy with one technique but it is expensive or occupies too much space then we will not opt for it. Being sustainable means being
c
responsible as well.” Nevertheless CONO has invested €80 million in the new factory. “No aspect of the old factory will be incorporated into the new one.” The entire cheese production line is new. The process, however, is an exact replica of the previous one. “We still stir the curds manually in open drainage trays because we can retain more flavor in the curds this way and ultimately in the cheese. All other major cheese producers use automated drainage machines. In this instance we have chosen the process that delivers the most flavor not which is the Photos: CONO Kaasmakers
most efficient or the cheapest. In other words, we have intentionally decided to continue raking, in contrast to the large cheese producers.” Because cheese production no longer takes place via drainage trays at most companies, CONO together with De Klokslag, has had to design them from scratch. improved separation procedure between
programmed to make provision for this.
Construction and processing
water and milk. “We can accurately assess
“But we will only use this capacity if it is
Cheese production in general is energy and
what we are losing in fat and protein and
absolutely necessary.” After completion in
water intensive. Reusing these resources is,
act accordingly.”
October 2014 the whole production process
therefore, at the top of the agenda in the new cheese factory. This saves approxi-
went into an evaluation phase which will
Winning back land
‘Being sustainable means being responsible as well’
014
last at least another two years. “We have to
The construction was
deliver cheese of an equally high quality to
approved with the vision
that which is being produced in the existing
that it will stand for ‘100
cheese factory.” Until then production will
years’. “As a result, intelli-
continue on the old line. Once the quality is
gent choices have to be
exactly the same as it is now the old cheese
made regarding the mate-
factory will shut down and the land ren-
rial and equipment used,”
dered back to the Beemsterpolder.
mately 15% gas; 8% electricity; 76% tap
says Betten. Eventually it will be possible to
water and 47% wastewater per annum. The
produce two times the amount of cheese on
• DIONNE IRVING •
residual is also reduced by 45% due to the
the new line. The system has already been
Editor @ VMT
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1
powered by
Global
competence in food
Photos: CONO Kaasmakers
www.capitaloffood.com
GLOBAL COMPETENCE IN FOOD: WE HELP TO GROW YOUR BUSINESS IN INDIA, CHINA, BRASIL, TURKEY, DUBAI, JAPAN EN THAILAND FOR INFORMATION: 030-303 64 50 KOELNMESSE/RS VISION EXPO PANOVEN13 3401 RS IJSSELSTEIN WWW.KOELNMESSE.NL
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TECHNOLOGY
HOLLAND FOOD INNOVATIONS . MARCH 2015 . NO 1
Pilot plant optimization Pilot-scale tests approach real conditions New technologies are enabling soft drink, juice and dairy producers to more efficiently and safely test product innovations at pilot scale. OMVE Netherlands has developed a pilot-scale processing line with an inline carbonator and aseptic filling equipment. This eliminates the need for post-treatment, while maintaining product quality and bottle integrity.
develop customized solutions for them. After all, no two processes are exactly the same.” There are clear advantages to using a pilot plant. Coopman lists them: “It enables companies to build up expertise; a pilot plant makes testing more flexible; you can run several tests per day; it’s easier to try out small adjustments to the process; you waste less product; production lines can keep running without any downtime; and cleaning and maintenance don’t affect production either.” “Also, time-to-market for new products is expected to get shorter and shorter,” Coopman continues. “Which is why even pilot plants have to run more efficiently. But there’s more. Modeling of processes can be
The new pilot-scale processing line consists of an inline carbonator and aseptic filling equipment.
improved too. Food companies are optimizing their pilot plants in terms of both set-up and computerization.”
Food safety regulations keep getting strict-
and pilot scale (50 to 200 liters per hour).
er. This even has consequences for pilot-
The equipment is used by large local com-
In-line system
scale projects, when used to produce
panies and multinationals.
OMVE has developed an inline system for carbonated drinks which incorporates a
products for consumer tests. For example,
016
most soft drink, juice and dairy products
Greater efficiency
carbonator immediately before the aseptic
offered to consumers for sensory tests must
“No innovative food company can do with-
filler, making the test system more reliable
be sterile. To meet this challenge, OMVE
out a pilot plant these days,” says Michael
and safer for liquid products with a carbon
Netherlands has developed a semi-automat-
Coopman, CEO at OMVE Netherlands.
content of less than 5 grams per liter. Coop-
ic bottling solution for low-carbonated
“Over the past two decades most beverage
man explains: “Sterilization is necessary for
drinks. OMVE is specialized in small-scale
manufacturers have invested in such facili-
products with low CO2 content. In pilot
processing equipment for R&D and pilot
ties. We have kept pace with these develop-
plants, this is usually achieved by putting
facilities in the food industry. The company
ments and have specialized in the necessary
the full bottles in a hot water bath. How-
mainly develops equipment for liquid food
test equipment for pumpable products. We
ever, that heat treatment can affect the test
testing at lab scale (10 to 50 liters per hour)
collaborate closely with our clients and
product, or even the packaging material.
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1
In the new inline carbonation system CO2 is added to the desired level after sterilization.
Standard PET can’t handle such high temp-
plants include very few manual operations
real situation on a small scale,” Coopman
eratures for instance.”
anymore,” Coopman explains. “We are
continues. “As a consequence, the processes
The solution was to rethink the process. “In
automating all our processes and so contin-
in the pilot plant more closely resemble
collaboration with several beverage manu-
ue to collect more and more data. You see,
industrial-size processes. Our innovations
facturers we developed a new way of pro-
automation doesn’t just save time and
may not revolutionize the industry, but we
cessing and placed several pieces of equip-
reduce errors, it also generates lots of useful
are pushing boundaries by making effective
ment inline. Now, the test product is steri-
information we can gather from all that
adjustments and improvements to existing
lized at the very beginning of the process
data. We can make temperature profiles and
lab-scale equipment and software. We’re
instead of at the end. The product is steri-
working on new
lized in UHT or HTST equipment with a
filtration and
heat exchanger. After sterilization it is sent to a carbonator, where CO2 is added to the desired level. Then the end product flows to an aseptic filling machine. It’s a closed system which eliminates the need for post-treatment. Food safety risks are lower
‘Automation generates lots of useful information, for example, temperature profiles’
evaporation equipment too. We’re optimizing those processes at lab scale.
than in process with stand-alone equip-
Every time, we
ment. This way, the test product is safer and
see it as a chal-
the process is faster than before.”
link those to certain product characteristics.
lenge to create a perfect small-scale version
Also, this data enables us to more accurate-
of the large-scale process,” Coopman ends
Automation
ly determine maintenance intervals. And
proudly.
While developing the inline carbonation
we’ve taken the opportunity to make the
system, the company also further optimized
interface more user-friendly.”
• FLORENTINE JAGERS OP AKKERHUIS •
the processing software. “Modern pilot
“We’re getting ever better at simulating the
Editor @ Food Valley NL
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SUSTAINABILITY
HOLLAND FOOD INNOVATIONS . MARCH 2015 . NO 1
Sustainable protein The challenge of diversification
The quest for sustainable protein is well underway. The search for solutions focuses on four distinct directions: new proteins from agricultural bulk products, more efficient utilization of existing protein sources, upcycling of animal-based waste streams, and exploiting new sources of protein.
Western consumers are gradually getting used to products like insect burgers, algae juice and seaweed cookies. Even supermarkets are starting to sell food products containing sustainable protein. The protein transition is clearly in full swing. These type of new products, however, do not represent the only source of sustainable protein.“In order to make real progress in sustainability, we need to cast the net wider than just new sources of protein,” says Charon Zondervan, managing director of the Protein Competence Center (PCC) in Wageningen. “We can make great strides using known proteins from agricultural bulk crops. And we can make much more efficient use of waste streams from agriculture, but also animal-based by-products such as blood, bones and fish waste and offal.”
Joint Effort The world needs new sources of protein. Consumption of meat, fish, dairy and eggs puts a major burden on the environment. Worldwide, meat consumption is growing as the number of people with disposable income increases. Even in China and India, consumers are eating more animal products. This makes it a priority to find sustainable protein that can supplement or substitute traditional sources. The Protein Competence Center (PCC) was 018
established in May 2014, combining knowThe protein revolution is clearly in full swing.
018-021_HFI01_ART_5_sustainable_protein.indd 18
ledge and research to accelerate the protein
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1
Thanks to new technologies, there are a range of functional potato proteins.
Legumes like soybeans have traditionally been a vital source of plant protein.
transition. Seven food and feed manufac-
tein with a special amino acid composition
to improve the texture of gluten-free bread.
turers are part of the effort: Agrifirm,
that makes it very valuable nutritionally.
Apart from these functional proteins,
AVEBE, Darling Ingredients International,
AVEBE has invested eight years in the
AVEBE is also working on potato proteins
DSM, Duynie, FrieslandCampina and Van-
development of production processes
for enriching food products. “Such proteins
Drie Group. They are working with six
resulting in a protein suitable for human
do not have to meet the same criteria as the
research institutes: Hanzehogeschool
consumption.
original, soluble and functional protein, yet
Groningen, RUG, NIZO food research,
In the fall of 2015, AVEBE will open a new
they have the same excellent nutritional
TNO, University Medical Center
potato protein production facility. This will
value. These potato proteins are suitable for
Groningen (UMCG) and Wageningen UR.
considerably increase AVEBE’s capacity for
enriching food for athletes and seniors, but
PCC works on all facets of sustainable pro-
producing food-grade proteins which are
also snacks, breakfast cereals and beverages.
tein, with particular emphasis on the technological and biological functionalities of protein from agricultural bulk products. “To begin with, such protein sources have great advantages over insects and algae because of the scale they’re grown,” Zondervan explains. “Secondly, consumers
In this way, we can meet
‘A totally different approach to the entire food industry is needed’
more readily accept proteins from these
consumer demand for high-protein and lowfat, low-sugar food products,” says Harkema. He expects the demand for potato protein to rise sharply in
sources, and finally, you don’t have to deal
marketed under the Solanic brand. “Potato
the next few years. “Consumers are making
with the complicated and time-consuming
proteins are not a new product,” says Jaap
better informed choices and are asking for
Novel Foods approval regulations that apply
Harkema, marketing manager at Solanic,
products that contribute to a healthier life-
to novel proteins.”
“but so far they were only suitable for feed
style. Our products enable the food indus-
applications. Thanks to new technologies,
try to meet those consumer expectations.
PCC and the industry are working on four
Solanic can now create a range of functional
Our potato protein production will ulti-
possible solutions:
proteins with foaming, emulsifying or gel-
mately equal the amount of protein present
1.
ling properties. Our proteins can replace
in four billion egg whites.”
milk proteins, egg whites and gelatin. This
2.
Proteins of New Agricultural Bulk Crops: Potatoes
is a timely development because the ‘free
More Efficient Utilization of Legumes: Soy
One of the PCC partners is AVEBE, a
from’ trend keeps gaining attention. Using
Dutch manufacturer of potato starch for
potato protein, you can make products free
Legumes like soybeans, peas and lupin have
food applications. Apart from starch, pota-
from allergens and free from animal pro-
traditionally been an important source of
toes also contain one to two percent of pro-
tein.” These potato proteins can also be used
plant protein for human and animal
018-021_HFI01_ART_5_sustainable_protein.indd 19
019
13-03-15 14:34
SUSTAINABILITY
HOLLAND FOOD INNOVATIONS . MARCH 2015 . NO 1
consumption. “Not everyone is equally convinced that legumes are a sustainable source of protein,” says Jeroen Willemsen, specialist new proteins. “Soy protein in particular has a reputation for not being sustainable, but the reality is not so black and white.” Willemsen explains: “First of all, engineers from the Dutch company Blonk Consultants have calculated that soy protein has less environmental impact than other legume proteins in terms of carbon emission, fossil energy consumption and land use. To be truly sustainable, no forests should be cut down to grow soybeans.” “Secondly, and more importantly,” Willemsen continues, “eating a legume-based substitute is considerably more sustainable than eating meat. It takes six kilos of plant material to produce one kilo of animal protein. Environmentally, it’s always better for people to consume plant-based proteins than to feed them to livestock,” he says. “So leguminous proteins are a sustainable choice. Meat substitutes, for example from Ojah, are being applied in ever more products, like salads, burgers and snacks. These are sold in Dutch, Belgian, Swedish and German supermarkets.” “Research is being done into varieties of legumes like soy and lupin that can be grown in western Europe,” Willemsen continues. According to the World Wildlife Fund (WWF), 75% of the world soybean
Another sustainable source of animal protein could be fish protein.
harvest is used as feed and only 25% for human consumption. The WWF and soy
020
producers, traders and processors have
make use of the protein from blood, bones
tein for human consumption. The main
drawn up a list of sustainable growing cri-
and other by-products. Another sustainable
challenge is to make upcycling of fish waste
teria. In December 2011, Dutch feed com-
source of animal protein could be fish pro-
economically viable.” Aartsen is working
panies that use soy in their products signed
tein, which is relatively unknown, but has
with a number of companies from the
a letter of intent to switch to sustainably
great potential according to PCC. Fish
Dutch fishing industry to identify the
sourced soy for the production of Dutch
waste is a by-product of the fish processing
opportunities and means for commercial-
meat, dairy products and eggs by the end of
industry, but is also produced in large
izing fish waste and offal.
2015.
quantities aboard fishing vessels.
“Upcycling fish protein is a supply chain
3.
Traditionally, by-catches and offal were not
issue,” Aartsen says. “In principle, fish pro-
used, but simply thrown overboard.
tein is a valuable source of protein that can
“On a worldwide scale, this source of pro-
be fractioned with the right technology.
Waste and offal from animals used for
tein is increasingly being put to good use,”
However, separating waste streams during
human consumption could be utilized more
says Frans Aartsen, founder of Holland
processing, storing the valuable compo-
efficiently. Technological advances have
Aqua aquaculture consultancy. “Technically
nents and reprocessing these into new
enabled the meat processing industry to
speaking, fish waste is a great source of pro-
products with added value is economically
More Efficient Use of Animal Protein: Fish Waste
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13-03-15 14:34
1
viable only if the fish protein supply is large
humans and animals. A quarter of the
helps PCC and NGOs, for example to
enough and its quality is stable. In The
world population eats insects as part of
develop new concepts for the marketing of
Netherlands, fish is processed at numerous
their regular diet. Mealworms, crickets,
novel protein products on the market and
locations. This hinders the commercializa-
locusts and buffalo worms are currently
to increase awareness among consumers.
tion of a specific by-product stream. Col-
most popular. Peters has high expectations.
“There are countless initiatives to make
laboration in waste stream processing
“I expect insect protein to start playing an
protein more sustainable. There’s also
might make a difference.”
important part in human protein consump-
research being done into for example beet
4.
tion,” she says. “After all, insects are healthy
tops, duckweed and roadside grass. How-
and growing them is environmentally much
ever, using novel sources of protein for food
Introducing New Sources of Protein: Insects
better than raising cattle. Insects are
production is a great challenge,” says PCC’s
Utilizing traditional sources of protein is
cold-blooded, their production cycle is
Zondervan. “Supply chains have to be rein-
one approach to the sustainability issue, but
short and farming them takes up a lot less
vented. New varieties have to be developed,
another approach is looking for new sourc-
space. Once the legislative hurdles have
new technology needs to be designed, for
es of protein fit for human consumption,
been taken, I expect investors to invest in
biorefinery for instance. And last but not
such as insects, algae or duckweed. Market
large-scale production of insects. True,
least, production plants need to be
opportunities for these new sources depend
many people still have to get used to the
equipped to process different kinds of pro-
largely on EU Novel Foods legislation and
idea. But in the meantime, supermarkets
tein. That’s the real bottleneck. Currently,
on the possibilities for production.
are already selling products that contain
investments are aimed at commissioning an
“Legislation in the West is a huge obstacle
our company’s insect ingredients.”
expensive production line that needs to run
to introducing novel proteins on the mar-
for many years to become profitable and is
ket,” says Marian Peters, spokesperson for
The Challenge: Diversification
designed to process one type of protein.
New Generation Nutrition (NGN), a sup-
The use of protein from sustainable sources
Diversification of protein sources requires a
plier of insect ingredients for the food
will certainly increase in the near future. In
totally different approach to the entire food
industry. “I believe the production of
2012, the Platform for New Protein Prod-
industry.”
insects as a source of protein would have
ucts (Platform Nieuwe Eiwitproducten, or
soared by now in The Netherlands if regu-
Het Planeet for short) was established. This
• FLORENTINE JAGERS OP AKKERHUIS •
lations had been less strict.”
is the first-ever trade association for sus-
Editor @ Food Valley NL
Insects are a valuable source of protein for
tainable protein producers. The platform
A quarter of the world population eats insects as part of their regular diet.
021
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13-03-15 14:34
TECHNOLOGY
HOLLAND FOOD INNOVATIONS . MARCH 2015 . NO 1
Keeping fruit and vegetables fresh PerfoTec has developed a laser capable of making miniscule perforations in packaging. These customized perforations allow the fruit to ‘breathe’ thus prolonging its freshness a few more days. This system is perfectly aligned with the current focus on reducing food waste.
systems on the packaging lines of Marks & Spencer and are in discussion to expand to other product groups.
Soft fruit is its prime market Since 2005 the company has installed approximately 100 laser systems worldwide. “But the bulk of it is in Europe,” explains technical director, Martijn de Bruin. Soft fruit is the prime market for PerfoTec followed by cut vegetables such as sachets of pan-ready vegetable mixes; broccoli rosettes; beans; spinach and salad melanges. Potatoes also benefit from perforated packaging. This way, green discolouration of the peel and the sprouting of germs is delayed. Harvested vegetables and fruit from various plants have different respiration speeds; some breathe at a more rapid pace while others
AMAP technology Fresh vegetables and fruit need a minimal amount of oxygen to thrive. If they receive too much oxygen they get old rapidly. When there is too little oxygen an anaerobic The camera checks every micro-perforation according to diameter and shape.
situation will arise leading to faster decay. With PerfoTec’s laser system, packaged fruit and vegetables can reach its maximum
022
Several major European retailers are already
2014. The company succeeded in increasing
shelf life by applying miniscule perforations
using the laser system of PerfoTec. Super-
the shelf life from 5 to 7 days for grapes, 5
in the packaging that regulates the
markets are able to reduce the volumes of
to 10 days for raspberries and 4 to 8 days
respiration within. In this way fresh
fruit and vegetable waste with this system.
for strawberries. As a result of the extended
packaged fruit, vegetables and potatoes
The British supermarket chain Marks &
shelf life food losses in shops have been
can last a few days longer. It saves money
Spencer conducted various tests with fresh
reduced by 50% resulting in significant
and leads to less food waste.
grapes, raspberries and strawberries in
savings as well. PerfoTec installed 21 laser
022-025_HFI01_ART_7_perfotec.indd 22
13-03-15 14:36
1
minium converters.
Liner bags
The laser makes highly accurate round perforations which is essential for AMAP technology (see box). The system is available in three sizes, the PER30, 100 and 200/300/400. The smallest variant, PER30, was introduced in 2014 due to market demand for a smaller and cheaper laser. The patented respiration meter measures the breathing speed of fresh products with-
PerfoTec has developed ‘liner bags’ (crate
in four hours, allowing companies to
bags for bulk packaging) that create the
The British supermarket chain Marks & Spencer conducted vari-
respond to seasonal variations in respira-
ideal atmosphere during transportation from
ous tests with fresh grapes, raspberries and strawberries in 2014.
tion. The device measures the respiration
the farm (often abroad) to the vegetable
speed (oxygen usage and CO2 production).
processor. In order to use this packaging
These details are converted into the neces-
the grower or wholesaler needs equipment
breathe at a relatively lower tempo. The res-
sary transmission for each packaging.
to measure the respiration speed. With
piration speed also varies according to the
The camera checks every micro-perforation
these details PerfoTec can supply perforat-
season or region even for the same variety
according to diameter and shape. This is
ed crate bags. These liner bags are also
of fruit or vegetables. In the past the quanti-
not only a measure of quality but also a
suitable for temporary storage of products
ty and size of the perforations were deter-
means to measure the oxygen permeation
so the client has more flexibility when it
mined via trial and error. Now with the res-
of the perforated packaging. If necessary
comes to fluctuations in supply and
piration control the speed at which the
the laser can be adjusted automatically to
demand.
product breathes can be determined within
capture the variations in thickness of alu-
four hours thus indicating the optimal num-
minium. According to PerfoTec their laser
ber of perforations needed to ensure a
is the only one in the world that has this
control. Then the client uses these measure-
longer shelf life. “This respiration control is
capacity with its patented closed-loop-feed-
ments to determine how many perforations
vital,” De Bruin says. Growth conditions
back-camera system.
and what size they need to be, with Perfo-
such as the weather and irrigation influence
The laser system is installed directly onto
Tec available to assist. These details are pro-
the respiration. De Bruin makes an example
the packaging machine. According to De
grammed into the system. An operator can
of iceberg lettuce. “A supplier first retrieves
Bruin, they have not yet encountered a
choose a programme dependent on the
the lettuce from the Netherlands and once
machine to which the laser system could
product to be packaged. PerfoTec employees can monitor laser
this is no longer available he retrieves it from Spain and then from Egypt. All this influences the shelf life of the lettuce.” With PerfoTec’s system the permeability of the packaging can be adjusted to the varying
‘This respiration control is vital’
systems worldwide, via a remote support programme, when there are any disruptions. Film converters can micro-perforate but there are safety mar-
degrees of respiration of the lettuce from the various countries and retains a perfect
not be fitted. “We always maintain contact
gins surrounding that, explains De Bruin.
atmosphere in the packaging. According to
with the supplier of the packaging
“Our clients, producers of fresh fruit and
De Bruin quality is a choice. “We can main-
machines. Occasionally they will tell clients
vegetables, know their product better than
tain the ideal atmosphere so that the prod-
about us when they purchase a machine.”
filmconverters. We provide our clients with
ucts, such as fresh lettuce for example,
The PER30 laser is available for an estimat-
the opportunity to fine tune the packaging
remains fresh for as long as possible.”
ed cost of € 49.500. The respiration meter is
which prolongs its shelf life by a few extra
estimated to cost around €13.000.
days.”
In summary, the company’s laser system
Uncomplicated for the client
• DIONNE IRVING •
consists of three units: the laser with intelli-
PerfoTec strives to ensure that the system is
Editor @ VMT
gent camera, the software and the respira-
relatively uncomplicated for the client. First
tor. It is designed for the integration within
the client measures how fast the different
all possible packaging machines and alu-
products breathe with the respiration
The laser system
022-025_HFI01_ART_7_perfotec.indd 23
023
13-03-15 14:36
Be inspired by the Dutch Food Industry
www.hollandfoodinnovations.com
HFI dummy art kathelijne.indd 7 022-025_HFI01_ART_7_perfotec.indd 24
10-10-14 14:36 16:32 13-03-15
HFI dum
14 16:32
Holland Food Innovations delivers independent information about the innovations developed in the Netherlands through interviews with experts from the Dutch food industry and feature articles.
Distribution The magazine is published 4 times a year. First edition: March 2015. Worldwide circulation: 10,000 copies.
Content
New products and processes Product development Food safety Sustainability Entrepreneurship Investment opportunities in the Netherlands
Target group 1 2 3 4 5
Food technologists Quality managers Product developers Engineers Researchers
The editorial team consists of VMT and Food Valley NL. VMT is the Dutch trade journal for the Dutch food industry. Food Valley NL is a leading guidance and support partner who connects companies from all over the world to innovative companies and knowledge institutes in the Netherlands.
HFI 4 pagina's 2.indd 2
HFI dummy art kathelijne.indd 8 022-025_HFI01_ART_7_perfotec.indd 25
United States This enormous market is looking for innovative technologies and is essential for the Dutch food industry. Holland Food Innovations will be an excellent platform to present the Dutch Food Industry to the North-American market. South-East Asia This region develops in a high rate. The Asian consumers demand variety in food. Local food companies are searching for knowledge to meet the consumers’ needs. Holland Food Innovations can fill this need for knowledge. Germany and France Both countries have a large market and organise Europe’s biggest food fairs . With Holland Food Innovations we can reach a worldwide audience.
10-10-14 10:24
10-10-14 14:36 16:32 13-03-15
SUSTAINABILITY
HOLLAND FOOD INNOVATIONS . MARCH 2015 . NO 1
Biobased packaging Sustainable, functional and attractive Biobased plastics are set to replace petroleum-based plastics. These materials offer great benefits, but are relatively unknown in the food industry. “Slowly but surely, more suppliers will switch to biobased packaging,” predicts Karin Molenveld at Wageningen UR Food & Biobased Research.
There are many reasons to seek alternatives to petroleum-based plastics: fossil fuel depletion, a wildly fluctuating oil price, the need to reduce carbon emissions, an accumulation of plastic litter and the need for packaging materials with new characteristics. In response, researchers have deve-
The food industry is taking its first steps towards
loped a whole new generation of plant or
using biobased packaging materials.
plant-waste based packaging materials, some with characteristics such as breathability or antimicrobial properties. There are already countless applications for them. The food industry is taking its first steps towards using biobased packaging materials. “These materials and their applications are rather unknown,” says Karin Molenveld, Senior Scientist Biopolymers at Wageningen UR Food & Biobased Research and author of the recently published Biobased Packaging Catalogue. “That’s a shame, especially since some biobased materials have specific characteristics, like more suitable barrier properties, that make them a better choice than traditional packaging materials. And some biobased materials are particularly attractive to see or pleasant to touch. That creates interesting marketing opportunities, for example for packaging luxury products or creating special designs. And finally, the price of these materials is generally more stable than that of oil-based plastics, which is a major plus for the industry.” The recently published Biobased Packaging Catalogue provides an overview of all commercially available biobased packaging materials in The Netherlands in 2014. The
026
026-029_HFI01_ART_2_biobased_packaging.indd 26
entries include a description of the raw materials used, the packaging materials
13-03-15 14:37
1
Avantium bottles
Biobased PEF soft drink bottle A very promising material is PEF, a biobased plastic being developed by the Dutch chemical company Avantium. PEF is based on industrial sugars derived from corn, woodchips and sugar cane. It was patented long ago, in 1946, but has only now become economically viable for manufacturing. PEF is strong and widely applicable, for bottles, films, and textile and carpet fibers, for instance. In the summer of 2014, Avantium announced it had attracted €36 million in capital from new investors including Coca Cola, Danone, ALPLA and Swire Pacific. This enabled Avantium to optimize the PEF production process and start building a commercial-size plant that should be operational by 2017. “PEF’s potential is huge, particularly for bottling soft drinks,” says an enthused Gert-Jan Gruter, Avantium’s CTO. “PEF’s oxygen barrier is ten times greater than PET’s, and it’s four times better for carbon dioxide and twice for water. On top of that, the material is fully recyclable. We’re hoping to see PEF become the new international standard for food, beverages and other applications.” “The first volumes of PEF this plant will produce will go to our investment partners,” Gruter says. “Shortly after that, other manufacturers will be able to buy our PEF material. Our focus is on bottles right now. Other types of packaging will follow later.”
available and their possible applications, as
according to Molenveld. She notes: “Sus-
altogether. Reuse and recycling are sustain-
well as a list of suppliers.
tainable packaging has many facets. Using
able solutions too.”
biobased packaging materials is just one
“A frequent misconception is that biobased
Misconception
way of approaching the issue. Don’t forget,
is the same as biodegradable. That is not the
Both industry and consumers are showing
most environmental benefits are gained by
case. Some biobased materials are not bio-
increased interest in sustainable packaging,
avoiding losses and reducing packaging
degradable and compostable, while in fact some petroleum-based plastics are. ‘Biobased’ refers to the material’s origins, while ‘biodegradable’ refers to the end of its
Abbreviation
Material
Origin
EPS
Expanded polystyrene
Petroleum-based
PBS
Polybutylene succinate
Petroleum-based/biobased
PE
Polyethylene
Petroleum-based
is particularly important to end users. After
PEF
Polyethylene furanoate
Biobased
all, that determines what to do with the
PET
Polyethylene terephthalate
Petroleum-based/biobased
packaging after use.”
PHA
Polyhydroxy alkanoate
Biobased
PLA
Polylactic acid
Biobased
Holistic Approach
PP
Polypropylene
Petroleum-based
Designing biobased packaging requires a
PS
Polystyrene
Petroleum-based
holistic approach. “The entire design pro-
TABLE - List of abbreviations of different packaging materials.
026-029_HFI01_ART_2_biobased_packaging.indd 27
life cycle. This is why we don’t speak of bioplastics but of biobased plastics. The difference between biobased and biodegradable
cess has to be taken into account
027
13-03-15 14:37
SUSTAINABILITY
HOLLAND FOOD INNOVATIONS . MARCH 2015 . NO 1
and every department in the company has
Marketing
design are all a perfect match.” (see textbox
to be involved in the design,” says Molen-
“Technically, the sky is the limit,” says
1, ed.)
veld. “New materials often make new solu-
Molenveld. “The real challenge is to develop
“Multinationals like Heinz, Danone, Procter
tions feasible, both technically and in terms
new, cost efficient and practical solutions to
& Gamble and Coca Cola are actively look-
of design. One example is Danone’s polylac-
pack food products more sustainably. We’re
ing for more sustainable packaging for their
tic acid (PLA) yoghurt container. While
advocating a case by case approach. Every
products, like the biobased plastic bottle
designing the new container, Danone discovered that its wall could be made much thinner than those of the original polystyrene container. That meant great savings in terms of material, and hence a cost reduction, along with a new, more attractive design.”
Avantium developed in collaboration with Coca Cola and
‘Demand will only increase in the years to come’
Danone (see textbox 2, ed.). Such projects are a real incentive for the development of biobased plastics,” Molenveld concludes.
Biobased plastics have many environmental and other advantages and can replace con-
new packaging design requires a thorough
• FLORENTINE JAGERS OP AKKERHUIS •
ventional plastics entirely in the long run,
evaluation of the interaction between prod-
Editor @ Food Valley NL
Molenveld says. “Demand will only increase
uct and material, as well as the marketing
in the years to come. The time is right and
and end-of-life aspects. After all, packaging
The Biobased Packaging Catalogue is available in
the materials are available.” She forecasted
is a great opportunity for communicating
PDF format from
that ‘drop ins’ will be the most popular
with consumers. Zandonella’s Biofoam ice-
www.groenegrondstoffen.nl/serieG_G.
products at first; these are biobased plastic
cream containers are an excellent example
packaging materials that are identical to
of this comprehensive approach. The
To order a hard copy please contact:
petroleum-based plastics and can be intro-
product, packaging material and packaging
secretariaat.bbp@wur.nl
duced without requiring any additional changes. For food producers looking to replace oil-based plastics out of concern that the latter might contain harmful additives new biobased materials are also an interesting alternative.
Petroleum-based
Application
Biobased alternative
PE
Film, small bottles
Bio-PE
One key characteristic of packaging is bar-
Starch blends
rier properties. These properties are often
Starch hybrids
different in biobased materials than con-
PLA blends
ventional materials. “Packaging designers
PHA
needs to take these barrier properties into
PHA blends
account,” Molenveld explains. “PLA is more
PP
water vapor permeable than PE. This can be
Films, small bottles and
Bio-PBS
thermoformed products
PHA blends
both a pro and a con. It’s good for products
PLA blends
that ‘produce’ water like fresh bread and vegetables. Molds on tomato vines grow slower when packaged in PLA. But it also
Bio-PP under development PS
Hard plastic packaging and foam PLA (foam, films, and hard packaging) Cellulose (pulp trays)
means PLA-packaged foods may dry out faster. Another example is PEF, a biobased alternative to PET. PEF has better barrier
Starch blends PET
PEF under development
bon dioxide and is excellent for bottling soft drinks.”
026-029_HFI01_ART_2_biobased_packaging.indd 28
Bio-PET PLA
properties for water vapor, oxygen and car-
028
Bottles, trays and blisters
TABLE – Fossil-based plastics, their application and biobased alternatives (Source: Wageningen UR Food & Biobased Research 2014)
13-03-15 14:37
1
Biobased foam designer packaging
water, PaperFoam only 50%. After sieving, all that water needs to
Biofoam and Paperfoam are two innovative foam-based packaging
evaporate through heating. That’s why it takes a lot less energy to
solutions that received worldwide media attention in 2014 for
produce PaperFoam than paper.”
combining innovativeness and sustainability with appealing design. In collaboration with a design agency and French champagne
Biofoam Biofoam is a PLA rather than
house Veuve Cliquot, PaperFoam developed a thermal champagne packaging that makes it possible to transport a gift bottle of champagne ready-chilled. Geerts
PS-based foam. The biobased,
explains: “The request seemed simple,
compostable material was
but the solution turned out to be slightly
developed by Synbra Tech-
more complicated than we thought. A
nology in Etten-Leur, The
cold bottle of champagne condensates and
Netherlands. Ice cream maker
that condensation made the packaging
Zandonella from Landau, Germa-
sticky, because starch attracts water. So we
ny, used the material to package its
had to adjust our formulation. We worked with
organic gourmet ice cream and went on to win Bioplastic Magazine’s Global Bioplastics Award in December 2014. The lid and outer layer of the ice cream box are made of BioFoam. The inside is coated in a film of thermoformed PLA, making it extra smooth. The box is
researchers from Wageningen UR Food & Biobased Research and evaluated various additives and ran a series of tests. This resulted in a formulation that worked well.”
wrapped in paper. The air trapped in the foam keeps ice cream cold for up to an hour outside the freezer.
The gift packaging for chilled champagne was nominated for the 2014 Food Valley Award, the annual Dutch agrifood innovation
“Biofoam is a good substitute for traditional EPS or styrofoam,” says Jan Noordegraaf, Managing Director of
award. PaperFoam is also used to package totally different products, ranging from electronics to
Synbra Technology. “Smart use of this new, sustainable material can help food producers set them-
eggs to cosmetics.
selves apart. Zandonella did a great job. They sell
Currently a trans-
organic ice cream and made sure their packaging
parent film is
matched the sustainability level of their product.
being developed
Their packaging is biodegradable and its carbon
that can be used
footprint is 60-70% lower than conventional plastic
to cover the foam-
foam. We’ve received a lot of interest in Biofoam,
based injec-
particularly from frozen food producers,” says Noor-
tion-molded
degraaf.
shapes.
PaperFoam PaperFoam is a packaging material based on potato position, it looks a lot like paper, but the material is more sustainable and can be molded into a variety of shapes. It also weighs less than paper and cardboard and is shockproof. Mark Geerts, CEO at the PaperFoam company, says:
Paperfoam packaging
starch, natural fiber and a special premix. In terms of com-
“PaperFoam is sustainable because it has a small carbon footprint and is biodegradable. Paper pulp contains 97% 029
026-029_HFI01_ART_2_biobased_packaging.indd 29
13-03-15 14:37
COLOFON
HOLLAND FOOD INNOVATIONS . MARCH 2015 . NO 1
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030-032_HFI01_COL_colofon.indd 31
13-03-15 14:39
www.dutchfoodinnovations.com
Pluckr: automated grape de-stemming technology
CO2 drying: energy-efďŹ cient approach to high quality
e-Cooking, PEF technology for fast, low temperature preparation, preserving vital ingredients
Foodlife, part of the JFTP Group
FeyeCon
IXL Netherlands
Creating novel structures with 3D food printing
Hydrocolloid-like functionality from enzymatically treated potato starch
Natural flavoring for sodium-reduced meat products
TNO
AVEBE
Corbion Purac
20150301 FV - Advertentie 201503 v03.indd 1 030-032_HFI01_COL_colofon.indd 32
3 maart 2015 10:53 13-03-15 14:39