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Food for ‘growth’


ith the food processing sector in India continuing its growth momentum, certainly a lot more was expected from the Union Budget 2011-12, especially on the finer details of policy implementation. By and large, it can be described as a futuristic and reform-oriented one with less short-term impact. Some of the positive highlights in this Budget include higher allocation on infrastructure, commitment to make Goods & Services Tax (GST) a reality, no change in excise duty, promoting research, increasing local manufacturing and encouraging inclusive growth. In addition, the government aims to achieve 25 per cent of GDP contribution from manufacturing by 2020 along with the commitment on raising governance standards and reducing surcharge marginally on corporate entities. In a macro viewpoint for the processed food and fast moving consumer goods sectors, the estimated GDP growth of 9 per cent in 2011-12 and the proposed increase in exemption limit of the income tax should boost the demand from consumers. Specifically speaking, the allocation of ` 300 crore to bring 60,000 hectare under palm oil plantations is likely to help this segment. The budgetary approval to set up 15 additional mega food parks during 2011-12 holds additional promise for the

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food processing industry. In this context, the clustering of food processing units should unleash better productivity, reduced transportation of intermediate products, and hence less food spoilage. Some of supply-side enablers proposed by this Budget include the infrastructure status given to cold storage chains and the excise exemption on cold storage equipment. These measures should result in enhancing the efficiencies in food supply, and thereby, controlling inflation. However, on the flip side, a number of processed food products that were earlier exempt from taxes, will now be levied an excise duty ranging from 1-5 per cent. Besides, the excise duty on certain packaging materials has been raised, which would adversely impact the processed foods. Last but not the least, this Budget does not seem to have offered a clear roadmap for foreign direct investment in food retail. For more detailed perspectives on Budget 2011-12, turn to the ‘Budget Analysis’ and ‘Roundtable’.

Editorial Advisory Board Dr A S Abhiraman Former Executive Director - Research, Hindustan Lever Ltd Prof M Y Kamat Former Head, Food Engg & Technology Deptt., UICT, Mumbai

Manas R Bastia Editor

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Printed by Mohan Gajria and published by Lakshmi Narasimhan on behalf of Infomedia 18 Limited and printed at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Infomedia 18 Ltd, ‘A’ Wing, Ruby House, J.K.Sawant Marg, Dadar (W), Mumbai - 400 028. Modern Food Processing is registered with the Registrar of Newspapers of India under No. 14798/2005. Views and opinions expressed in this publication are not necessarily those of Infomedia 18 Limited. Infomedia 18 Limited reserves the right to use the information published herein in any manner whatsoever. While every effort has been made to ensure accuracy of the information published in this edition, neither Infomedia 18 Ltd nor any of its employees accept any responsibility for any errors or omission. Further, Infomedia 18 Ltd does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition. No part of this publication may be reproduced in any form without the written permission of the publisher. All rights reserved. Editor: Manas R Bastia

April 2011 | Modern Food Processing




LEADERS SPEAK “Enzymes help manufacture products with less toxic inputs, thereby enabling environment protection” ...says G S Krishnan, Regional President, Novozymes - South Asia


BUDGET ANALYSIS Union Budget: Sour short-term, sweet in long run Rajiv Subramanian, Engagement Manager - Consumer & Retail, Tata Strategic Management Group



Budget 2011-12: Basketful of goodies for food sector?


Sula Vineyards: Brewing a sparkling success story



Food logistics: Simplifying supply chain matrix


Sodium chloride management: Sprinkling health, maintaining taste


Health ingredients: Ingraining wellness Courtesy: Chemicals, Materials and Foods Practice, Frost & Sullivan

MARKET INSIGHTS Filling technology: Flexibility and expandability in harmony Thomas Schuhbeck, Head - Test Centre at the Filling and Closing Technology Division, Krones AG



INDUSTRY INSIGHTS Dairy industry: Skimming impurities to stay ahead Shushmul Maheshwari, CEO, RNCOS E-Services Pvt Ltd


FOOD SAFETY Ice cream processing: Getting the right safety mix Subhash Vaidya, Proprietor, Dairytech Consultancy Services


TREND ANALYSIS Quick service restaurants: Catering to changing eating habits Courtesy: Green House and Hestsoft Foods Pvt Ltd


RE G GU ULAR SE EC C TI TIO ON NS S Editorial ...................................................... 7 National News ......................................... 10



World News............................................. 14 Tech Updates ........................................... 18 Events Calendar ....................................... 58 Product Update........................................ 60 Product Index........................................... 67 Advertisers’ List ....................................... 68

Highlights of Next Issue Sector Watch


Industry Update :

Meat (Poultry) Processing Bakery & Snack Foods

Note: ` stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise


Modern Food Processing | April 2011

Details on page no. 58


Nestle India to set up facility in Himachal Pradesh

Nestle India has chosen Himachal Pradesh for its ninth manufacturing facility in the country. The new facility to manufacture chocolate and noodles BUSINESS EXPANSION

Calidris28 to set up production unit in India Luxembourg-based energy drinks-maker Calidris28, which recently forayed into India, said it is planning to set up a production unit in the country in the next three years to cater to the Middle East and South Asian countries. The company said it plans to invest around ` 30 crore in the next two years for BRAND POSITIONING

Britannia positions Vita Marie Gold for women

Britannia Industries Limited, one of the leading food companies in India, recently launched Vita Marie Gold, a tea-time biscuit that is claimed to be light, and yet, filled with nutrition for today’s fully loaded life. Vita Marie Gold is positioned as BRAND RECHRISTENING

ABD relaunches Class as Class 21 Allied Blenders and Distillers Pvt Ltd (ABD), one of the fastest growing spirits company in India, has recently unveiled a new identity for its regular-priced segment vodka brand, Class. Rechristened as Class 21, ABD claims that the new name and identity embodies and connects with the spirit of today’s youth.


may entail an investment of around ` 400 crore. Besides, Nestle also plans to add capacity to its existing units in Punjab, Haryana, Goa & Karnataka; and a new R&D facility in Haryana. The company has already invested ` 360 crore of the proposed investments in a new facility that is coming up at Nanjangud to manufacture instant noodles and another ` 500 crore in its Goa facility, where it manufactures confectionery.

“Overall, the company has budgeted an investment of ` 1,800 crore in the next two to three years,” said Antonio Helio Waszyk, Chairman and Managing Director, Nestle India. About the coffee business, he said, it is not big enough for Nestle. Nescafe was lagging behind Nestle’s other products in the market till October 2010. However, after the brand’s new campaign, it started performing well, with Nescafe now becoming the market leader having a 37 per cent marketshare.

marketing its products, setting up offices and various brand-building activities within India. Kurien Mathew, Managing Director (SAARC Countries), Calidris28, said, “We are currently scouting for a location for the facility and assessing the investment that will be needed to set up the new plant, which will make products for exports to South Asian and Middle East markets.

The company recently introduced its energy drink brands, 28Black and 28White, in the five metros, including Mumbai and Delhi. It now plans to launch the products across India in a phased manner in the next two years.

handy top-up of extra nourishment during tea breaks making them enjoyable and nutritious. These low fat, cholesterol-free biscuits are made of 58 per cent cereal, milk protein and 10 essential vitamins and are the perfect nutrition accomplice for today’s woman. Anuradha Narasimhan, Category Director, Health and Wellness, Britannia Industries Ltd, said, “For the women of today, life is all about doing more, enjoying their work, family and friends all at the same time. While they pack many

activities in a day, they are left with little time to take care of themselves. Britannia has recognised the need for a handy top-up nourishment solution for women and has launched Vita Marie Gold, a teatime biscuit that effortlessly slips into their lifestyle to provide top-up nourishment that they require to do more everyday.” As per the company, one serve (6 biscuits) of Vita Marie Gold fortified biscuits gives 15 per cent of RDA of vitamins and 60 per cent RDA of folic acid.

Deepak Roy, Executive Vice Chairman and CEO of ABD, said, “Class was relaunched as Class 21 to cater to the bold youth of the country. Since vodka is mostly consumed by this segment; we realised that there was an opportunity to create a brand that reflects their attitudes and aspirations. “The name”, said Roy “was inspired by the magical and enviable age of 21. Those under 21, desire to be 21 so that they can attain the freedom.

Those above 21, wish they were 21 again. And those who are 21 wish it could last forever.” With Class 21, ABD aims to attract consumers, with its attention grabbing look and feel.

Modern Food Processing | April 2011


AFTPAI organises seminar for the food processing industry

Harish Rawat (centre) at the inaugural event

Agro & Food Processing Equipment & Technology Providers Association APPOINTMENT

Dr Ashok Gulati to head Commission for Agricultural Costs & Prices Dr Ashok Gulati, Director - Asia for the International Food Policy Research Institute (IFPRI), was appointed Chairman of the Commission for Agriculture Costs and Prices for the Ministry of Agriculture, Government of India. Based in New Delhi, he will PRODUCT SHOWCASE

Del Monte shines at Aahar 2011

In its third year of participation at Aahar 2011, Del Monte pledged its continued focus on its B2B business. Through this event, Del Monte aimed at building TRADE SHOW

Foodex 2011 to be held in September in Bengaluru Against the background of the optimistic growth of the food processing industry, Media Today, will be holding the third edition of India Foodex exhibition. This three-day event will take place in Bengaluru, with concurrent shows - GrainTech India and DairyTech India from September 9-11, 2011. The

of India (AFTPAI) recently organised a seminar, ‘Opportunities & Challenges in Agro & Food Processing India 2011’, in New Delhi. Harish Rawat, Minister of State for Food Processing Industries, was the Chief Guest. The topics at the seminar ranged from energy-saving opportunities in the food processing industry, food safety, to water recycling and easy finance options. In his address, Rawat said, “I am happy to note that AFTPAI has

been formed with a view to work in the allied sectors of the food processing industry and it is organising the inaugural ceremony cum international seminar. The government has declared food processing industries as a priority sector and has introduced a number of policy measures.” He also added, “I hope that the formation of AFTPAI will boost the government’s endeavour towards attaining sustainable growth in the sector.”

be involved in developing appropriate price policy and marketing structures for major agricultural commodities in the country. Dr Gulati served as the IFPRI’s Director in Asia since 2006. During this time, he produced nine peer-reviewed books in collaboration with his colleagues. Shenggen Fan, Director General, IFPRI, said, “He has rendered policy advice to the Government of India, and

interacted closely with the corporate agri-business sector, farmer groups, and civil society organisations.” Prior to joining IFPRI, Dr Gulati served as a member of the Economic Advisory Council of the Prime Minister of India.

and strengthening partnerships with customers and partners across the food and hospitality sectors. Del Monte’s packaged fruit range consisting of pineapple slices, tidbits, fruit cocktail, peaches and prunes, etc, was launched recently. Others like snack dressing, mayonnaise, dry pasta, fruit drinks, whole kernel corn, jalapenos and other veg toppings have made deep inroads into the Quick Service Restaurants (QSRs) and Hotels/Restaurants/Catering (HORECA) markets. The brand has forged

strong bonds of loyalty and partnership with B2B industry players. Yogesh Bellani, Business Head, Del Monte Foods Business, FieldFresh Foods Pvt Ltd, said “Such events like Aahar are great platforms for knowledge upgradation and networking within the industry. Last year, we showcased our worldwide sourcing strengths for B2B products. This year, we present ourselves as a partner in creating customised taste and innovation in a variety of food products.”

exhibition will focus mainly on food & dairy products, spices, fresh foods, coffee and cocoa, food ingredients, food retailing & technologies, grains, etc. These three exhibitions are closely interlinked, forming a composite whole, encompassing the entire food business. To impart more value to the event, a twoday international conference on ‘Food Security through Technology’ for farmers and agri-entrepreneurs is being planned.

Exhibitors from India and abroad will participate at the Expo. Last year, trade visitors from over 20 countries like the UAE, the US, Germany, Taiwan, Canada, Malaysia, Singapore, China, Kuwait, Greece, Turkey, the UK, Spain and Japan participated at the event.

Dr Ashok Gulati

April 2011 | Modern Food Processing



100% Pure Apples from New Zealand launched in India

Sir Richard Hadlee (centre) at the launch

New Zealand chose India for the launch of its new apple brand 100% Pure Apples. The launch took place in Mumbai and was attended by New Zealand cricket legend Sir Richard Hadlee. “New SNACKS LAUNCH

Perfetti plans to enter snacks market with Stop Not chips Perfetti van Melle, one of the leading confectionery makers, is planning to foray into the ` 3,000 crore Indian packaged snacks market with its own brand of chips called Stop Not. This is the first time that the multinational company is diversifying into snacks business. RESEARCH PRESENTATION

Cole-Parmer hosts seminar for the scientific & process industry

Rakesh Aggarwal

Cole-Parmer, one of the global leaders offering fluid handling solutions to the scientific and process industry, hosted a multi-city seminar on ‘Metering pump WINE

Global Wines, Kimaya Fashions JV to sell Australian wine Global Wines & Spirits and Kimaya Fashions recently entered into a joint venture to sell premium range of Australian wines under the brand name Kimaya Wines. “To start with, we will be launching two brands Kimaya Chardonnay 2010


Zealand apples are known around the world for their delicious taste, combined with their health attributes. And I think, Indians will really enjoy them – from kids to cricket stars,” said Sir Hadlee. Produced in some of the most nourished orchards, 100% Pure Apples adhere to the strictest quality, traceability and food safety compliances. Through the launch in India, the brand hopes to reach out to not only the increasingly health-conscious consumer, but also to the suppliers of fresh apples. Speaking at the event, Gavin Young,

New Zealand Consul General and Trade Commissioner, said, “It is significant that India has been chosen as the first market for launching this brand. This indicates the growing relationship between India and New Zealand and the importance that New Zealand companies place on this relationship.” These apples are sold in the alternate season to Indian apples and will be available across major stores such as Hypercity, Spencers, Godrej Nature’s Basket, Reliance Fresh and all fruit vendors.

The company is expected to launch two versions of chips called Golz and Diskets. Across the two versions, it is targeting around eight flavours, some of which include thai chilli, tomato chutney and mad masala. The launch is expected to be around April-May this year. Perfetti, a ` 1,200 crore company, accounts for around 30 per cent share of the confectionery market. It manufactures

and markets popular gum, candy and mint brands such as Center Fresh, Alpenliebe, Chlormint, Mentos. The chips market is believed to be worth around ` 1,500 crore and is part of the ` 3,000 crore packaged snacks industry.

technology and its advancement’. The objective of seminar was to share Cole-Parmer’s global expertise with the Indian scientific fraternity and help them discover how to optimise their existing processes through upcoming technology breakthroughs. On the occasion, Rakesh Aggarwal, Director - Operations, Cole-Parmer India, said, “This seminar is one of the initiatives we have taken to come closer to the customers and partner in their R&D. The diversified content of the seminar

made the customers well-versed with the latest technologies and advancements, which offer them a perfect opportunity to re-energise their existing processes through leading advice from our global experts.” The multi-city seminar was hosted in Ahmedabad, Hyderabad and Pune, recently. This premier event offered a unique opportunity to meet global experts from Cole-Parmer, who shared their experience in the field of fluid handling.

and Kimaya Shiraz 2010 in Haryana and then will move onto Delhi, Mumbai and Bengaluru,” said Jatin Virmani, COO, Global Wines & Spirits. The wine will be produced in Australia and then will be imported to India. It is crafted by Australian winemaker Ben Riggs in partnership with Galvanized Wine Group. The JV will launch two more wine brands – Kimaya Sparkle 2010 and Kimaya

Moscato 2010 later in the year. “The price point for the wines would range between ` 1,200-1,500, depending on different states,” Virmani said.

Modern Food Processing | April 2011


FDA alert on food from Japan

The United States Food and Drug Administration (FDA) has announced that it has placed an import alert on all milk, milk products, fresh vegetables and fruits from certain regions in Japan. It announced the alert through FOOD PACKAGING

Recycled plastic inputs record nearly 50 per cent hike US food, drink and consumer product manufacturers increased their use of recycled plastic inputs in packaging by 49 per cent from 2005 to 2010, in addition to reducing package weight, claims a new report from the Grocery Manufacturers’ Association (GMA). And the responding STRATEGIC DECISION

BASF increases propionic prices in Europe and Asia


Milk powder price rise encourages spending on new dairy equipment GEA Group, headquartered in Germany, has reported a surge in orders from the dairy industry in recent months as rising milk powder prices and a recovery in global demand give processors the confidence to invest. Fonterra has just put in a Euro 40-million order with GEA for a new milk powder plant in New Zealand. GEA said the new order comes on the back of a rush of business from the dairy sector that came in at the tail end of


a press release. The move entails that no products belonging to these varieties from the prefectures of Fukushima, Ibaraki, Tochigi and Gunma can enter the US without being proved safe. The statement issued by FDA said, “In addition, FDA will continue to flag all entries from Japan in order to determine whether they originated from the affected areas. FDA will test all food and feed shipments from the affected areas. It further added, “FDA

import investigators operating at ports of entry have radiation detection devices (radiation pagers) available to them for their personal safety. These are extremely sensitive and can help identify shipments of potential concern to target for laboratory analysis.” The World Health Organization (WHO) recently said that detection of radiation in food, after a recent earthquake damaged a nuclear plant in Japan, was a more serious problem than it had first expected.

firms said that they expect to eliminate four billion pounds of packaging waste nationwide between 2005 and 2020, according to two surveys conducted for the GMA. Blind surveys with industry were undertaken during 2010-2011 by McKinsey & Company and Georgetown Economic Services, which sought information related to packaging developments during the period 2005-

2010 and packaging initiatives planned for 2011-2020. Responding firms reported that they achieved the 2005-2010 reductions through various initiatives, including packaging redesigns and increased use of recyclable materials.

BASF has announced a price increase in Europe and Asia for propionic acid – a widely used ingredient across sectors including food, plastics and pharmaceuticals. The German-based giant said it would be raising prices for propionic acid in Europe by Euro 200 per tonne and in Asia by $ 200 per tonne. The increase in tariffs

was effective immediately, or as existing contracts permitted, said the company. BASF is a leading supplier of propionic acid, with facilities at Ludwigshafen, Germany; and Nanjing, China. Propionic acid is used in the production of food preservatives, plastics and pharmaceuticals. However, its major application is in feed grain preservation.

2010. Jürg Oleas, CEO, GEA, described recent demand for dairy processing equipment as ‘quite dynamic’. Important recent projects include Danone Baby Nutrition investing Euro 50 million in its production facility in Cork. A new drying line is planned to be built at the site in expansion plans that will triple capacity to 1,00,000 tonne annually and result in 40 new jobs. Other recent orders include one for an evaporator and a spray dryer from Yotsuba, a big Japanese dairy company, and another from the Chinese dairy manufacturer Mengniu.

According to Axel Wolferts, Head, Investor Relations, GEA, high milk powder prices and the recovery in global dairy demand have persuaded dairy companies to make capital investments. “Currently, the milk powder prices are at a high level, which explains why manufacturers are willing to invest in new plants and process lines,” he said.

Modern Food Processing | April 2011


Glass Packaging Institute has a new President The Glass Packaging Institute (GPI) has named Lynn Bragg as its new President, following the retirement of Joseph Cattaneo. Bragg has wide-ranging experience in government and industry. She has been the President of the Chocolate Manufacturers Association. She was appointed to the US International Trade Commission by the then US President Bill Clinton. Bragg was also legislative director for former US Senator Malcolm Wallop. “I am pleased to have the opportunity to work with the nation’s glass container manufacturers as they offer new and innovative packaging solutions,” said Bragg. Rich Crawford, Chairman, GPI Board of Trustees, said, “Lynn comes to GPI with sufficient experience in the government service and association management realms.” He further added, “We look forward to her leadership as our industry association addresses the challenges and opportunities that present themselves within our ever-changing, ever-evolving field.” Cattaneo will continue to support GPI in a consulting role.


Nestle looks for new recycled paper grades Nestle is collaborating with paper manufacturers to evaluate different approaches for developing ‘new grades of recycled paper’ in the light of concerns about migration oil leakage into foods from packaging using newspaper-based recycled board. “One promising approach is a better selection of waste material to exclude newsprint,” said Hilary Green, Head, R&D Communications, Nestle. She further added that the potential risk posed by mineral oils leaching from recycled cardboard into foods has been on the radar of packaging scientists at Nestle for some time. In this direction, Nestle has applied internal standards to ensure that such migration is avoided. Traces of mineral oil in food are believed to arise by its migration from the inks present both on the printed surface of the packaging and in recycled fibre, principally newspapers, used in the production of packaging. According to Green, Nestle promotes the use of recycled paper/board and other materials from sustainable resource where it makes sense and where there is no risk of migration that would pose a risk to human health or have a detrimental effect on the food.

April 2011 | Modern Food Processing



Bayer’s new pilot plant makes plastics from CO2

A new pilot plant designed to make high-quality plastics that could eventually be used for food packaging is being fuelled by carbon dioxide (CO2) from the NEW RESPONSIBILITY

Atria selects new chief The Finland-based meat processor Atria has recently announced that Juha Grohn had been chosen as its new President and CEO after the sudden departure of Matti Tikkakoski recently. The company has also proposed job cuts as part of the plan to save Euro 4 million a year. The appointment follows the announcement that MARKET FORECAST

Vegetable oil market to touch 169-million tonne mark globally by 2015

The US-based GIA, publisher of offthe-shelf market research, said that the global market for vegetable oils had been forecast to reach POLICY MATTERS

AFFI opposes new food tax The American Frozen Food Institute (AFFI) and a coalition of 16 food group allies have urged the key leaders of the US Senate and House of Representatives to reject a proposal in President Obama’s fiscal year (FY) 2012 Budget request to impose a new food


energy sector, revealed its operator Bayer. Output of polyuthrene from the plant at Chempark, North Rhine-Westphalia, Germany, will be directed to the automotive and building industries, but later uses could include food packaging. The technology at the plant focusses on producing a chemical precursor into which CO2 is incorporated and then processed into polyurethanes. CO2 is used to produce polyurethanes. Bayer MaterialScience is testing the materials,

which are used mainly to produce soft and rigid foams. “As a result, CO2 – a waste gas and key contributor to climate change – can now be recycled and used as a raw material and substitute for petroleum,” said a company statement. If the pilot plant performs as per the expectations, full production will begin in 2015, said the company. The new process helps to boost sustainability in a number of different ways, it claimed.

Tikkakoski would be stepping down with immediate effect. Grohn has held a number of posts in Atria since 1993 – including Managing Director of the Scandinavian unit as well as posts in the Finland and Baltic divisions. He is also responsible for the group’s raw meat procurement. Martti Selin, Chairman, Board of Directors, lauded Grohn’s knowledge of the meat industry and also said

that he has ‘open and straightforward management style’. Grohn’s appointment came at a time when the company made plans to cut costs and its workforce as part of an efficiency drive. The firm said it was bidding to save Euro 4 million annually by the end of 2012.

169 million tonne by 2015. Recently, the researchers have announced the release of a global report on vegetable oil markets. “Key factors fuelling market growth include recovery from economic recession, increasing global population, and growing demand from emerging markets backed by strong economic growth, and increasing standard of living,” said the report. Vegetable oil market is extremely vulnerable to vagaries in the economic, agricultural and trade policies, and the recent economic downturn was

no exception, which led to a brief slowdown in the world market. The global crisis resulted in difficulties for the oil and fat industry. High price volatility and lack of working capital to fund production weighed down the global edible oil market. “Demand for vegetable oil is, however, on track with the recovery in global economy. Both oil and edible oilseed prices appreciated by around 15 per cent in 2009, on account of growing demand for palm oil from food sector,” the report said.

tax on consumers and food companies. The ‘food safety fee’ proposed by the administration was intended to offset the cost of implementing the Food Safety Modernisation Act (FSMA), which was expected to cost $ 300 million annually. “Food safety is the number one priority of frozen food producers,” said Kraig R Naasz, CEO & President, AFFI.

He further added, “We are committed to help modernise our nation’s food safety system by implementing the FSMA, but we believe a new tax on food is the wrong approach for funding that effort.”

Modern Food Processing | April 2011


GSK links preservative to Lucozade recall

GlaxoSmithKline (GSK) has withdrawn one of its Lucozade products after consumers complained of an unpleasant smell and taste that the company believes is linked to the preservative potassium NEW INVESTMENT

Coca-Cola invests £ 5 million in UK recycling facility Coca-Cola Enterprises (CCE) is investing £ 5 million to develop a purposebuilt polyethylene terephthalate (PET) recycling facility in Lincolnshire. CCE has committed to a ten-year joint venture deal with ECO Plastics to develop its existing site in Hemswell and guarantee a 40,000 tonne annual supply of

sorbate. The Food Standards Agency (FSA) and the Food Safety Authority of Ireland (FSAI) have both issued alerts about the recall of Lucozade Sport Lite Summer Berries. The food safety agencies said a small number of drinks produced may have an unpleasant smell and taste, and there may be a possible risk of mould growth. GSK said it has suspended the manufacture and supply of Summer Berries after a ‘very small number of

production batches’ gave rise to a ‘high number of consumer complaints’. A company spokesperson said, “During the production process, a small amount of potassium sorbate is added to the Lucozade Sport Lite Summer Berries. Occasionally, potassium sorbate can be broken down allowing the formation of a compound, which can create an unpleasant taste and odour.” GSK is conducting an investigation to determine the rootcause of the problem.

recycled food-grade PET to the drinks giant. ECO Plastics will provide a further £ 10 million to fund the development, which will open next year with the creation of up to 30 new jobs. The new reprocessing capacity will double the UK’s current production of food grade PET, where two-thirds of UK plastic packaging is currently exported for reprocessing, and CCE sources most

of its recycled food-grade PET from mainland Europe. CCE hopes to use 25 per cent recycled plastic in all of its bottles by 2012.

April 2011 | Modern Food Processing



BERICAP develops closure for smaller bottle neck

Mettler Toledo’s new detector boosts quality and flexibility on food manufacturing lines

Consumer studies have shown that smaller neck sizes between 32-35 mm for bottles are more convenient for drinking compared to 38 mm neck diameter. Realising this, BERICAP has developed the DoubleSeal™ 33 closure, which was brought into the market on a 33 mm neck finish developed by Sidel. The 33 mm solution is targeting the ‘On-the-go’ packs for juices, energy drinks and tea. Especially, when people want to drink from the bottle directly, the 33 mm diameter provides a better drinking comfort for the consumer. It is also an alternative closure diameter for larger bottle sizes for juices and milk when light weight is the main target. Neck and closure together weigh less than 6 gm, and therefore, supports the effort of the industry to save costs and reduce CO2 emission. BERICAP’s DoubleSeal™ 33 is equipped with a folded tamper evidence band for safe breaking and a specific design of the sealing lip for tight sealing to ensure product Bottle with BERICAP’s integrity. The DoubleSeal™ 33 can be decontaminated with all standard new DoubleSeal™ decontamination methods. 33 mm closure

To help food manufacturers respond to new regulatory pressure and ensure shorter production runs of a variety of products, Mettler Toledo Safeline has expanded its Profile range of metal detection systems. Designed with productivity and flexibility in mind, these latest Mettler Toledo Safeline innovations feature the most advanced detection technology for rigorous contaminant prevention and can be customised for any application. The Profile metal detectors meet HACCP audit requirements and comply with the leading GFSI standards including ISO 22000, BRC, IFS and SQF 2000. The new Profile systems focus on rectangular apertures to facilitate inspection of products on conveyorised lines. Their ability to be formatted with fixed and multiple frequency configurations enable food producers to select a platform that best fits their applications. The Profile LS range of metal detector offers customers a selection of optional software suites, each designed to address specific functions. Software can also be upgraded at a later date Mettler Toledo Safeline’s new Profile metal detection system as per processor needs.

PepsiCo develops world’s first 100 per cent plant-based PET bottle

3M brings innovation in microbiology testing to beverage industry

Building upon its heritage as an innovator and leader in environmental sustainability, PepsiCo has developed the world’s first PET plastic bottle made entirely from plantbased, fully renewable resources. This has enabled the company to manufacture a beverage container, with a significantly reduced carbon footprint. PepsiCo’s ‘green’ bottle, which is 100 per cent recyclable, is made from bio-based raw materials, including switch grass, pine bark and corn husks. In the future, the company expects to broaden the renewable sources used to create the ‘green’ bottle to include orange peels, potato peels, oat hulls and other agricultural byproducts from its foods business. This process further reinforces PepsiCo’s ‘Power of One’ advantage by driving a strategic beverage innovation via a food-based solution. Combining biological and chemical processes, PepsiCo has identified methods to create a molecular structure that is identical to petroleum-based PET beverage containers. Indra Nooyi, Chairman and CEO, PepsiCo, said, “Through this sustainable business model, PepsiCo aimed at PepsiCo’s ‘green’ bottle is bringing to life the essence of 100 per cent recyclable performance with purpose.”

3M Food Safety has launched 3M™ Petrifilm™ Aqua Plates, a micro-organism testing tool, for bottled water in beverage and food processing plants. “We are excited to bring this product to the beverage bottling industry. For companies in this sector, this innovative method provides a new alternative testing process to traditional agar petri dishes,” said Bob Young, Senior Technical Service Specialist, 3M Food Safety. Containing a water-soluble gelling agent, nutrients and indicators, 3M Petrifilm Aqua Plates test for the four most common contaminants that threaten a company’s product: heterotrophic count, coliform, yeast and mold, and enterobacteriaceae. Today’s beverage and food processors often produce their own agars or purchase premade dishes. Both practices require a large investment in employee time, excessive refrigeration space and unnecessary waste. Bringing modern convenience to the water and beverage industries, 3M’s sampleready plates replace conventional agar petri dishes by offering a reliable, simple way to assess product safety.


Modern Food Processing | April 2011


BEST’s new machine improves sorting efficiency for fresh berry

Modified atmosphere processing can boost food quality

The Belgium-based BEST has improved mechanical setup of its Primus Gemini system, and now it can sort and grade berries on a single run – instead of two – to detect discoloured and soft products. Based on the success of the BEST Primus sorter in the fresh blueberry industry, the company has developed a brand new machine that can offer solutions to the needs of the berry processors for the fresh and individually quick frozen (IQF) fruit market. The new state-of-the-art sorter, called Primus Gemini, combines all latest optical BEST components, implemented in a brand new and improved mechanical set-up. Conventionally, fresh blueberries needed to be sorted on two separate machines, one to take out the discoloured products, the other for soft berry detection. The new Primus Gemini sorter allows the blueberry farmer to first sort his berries based on colour, reject the off spec products and further inspect the blueberries again and remove the structural defects using laser technology. Both sorting steps are integrated into a single sorter. This allows the processors to limit the risk of damaging and separate both the good berries and the reject streams.

Modified atmosphere processing is a technique that offers significant potential to the food industry. In order to evaluate its advantage, Campden BRI, the UK-based food research group, is working on a glove box capable of maintaining an atmosphere of less than 1 per cent oxygen. Lynneric Potter, Packaging Technologist, Department of Food Manufacturing Technologies, Campden, said, “Modified atmosphere processing is the preparation of a product in an atmosphere other than atmospheric air. It is a novel technique and can be used alongside modified atmosphere packaging (MAP). We are researching this technique on a small scale so are using a glove box in which we can pump different gases and reduce oxygen levels to below 1 per cent.” Processing fruit, vegetables, meat, fish and other foodstuffs in a modified atmosphere could significantly improve quality and shelf-life, said Campden BRI officials. Working through hermetically-sealed gloves in the glove box in an atmosphere of less than one per cent oxygen, researchers were able to dice fruit and vegetables without the enzymatic browning caused by cutting in an oxygen-rich environment.

Scientists extend shelf-life of soft fruit using plasma beams

Imaging system controls baking process to improve sandwich bun quality

Experts at The University of Nottingham have joined forces with colleagues at Loughborough University to look into how cold plasma technology might be used to prevent fruit from going mouldy quickly. The cold plasma expertise is already used in the medical world to safely clean bacteria from wounds. But now the team is hoping that the technology can be applied to soft fruit, like strawberries, so that bugs that cause moulds can be eradicated before the fruit is packed. This would give products an extra five days of shelf-life and help prevent the large amount of spoilage and waste currently experienced by the soft fruit industry. It was a chance discovery that led them to believe that cold plasma technology might be useful in the fruit sector. They had previously been using the technology – which involves a tiny controllable beam of plasma – to control micro-organisms and to clean surfaces. “While we were doing that we discovered that we could treat soft fruit with cold plasma,” said Dr Cath Rees, Senior Lecturer in Microbiology at The University of Nottingham. It is difficult to keep soft fruit ‘fur free’ for long, as it bruises easily when handled and becomes contaminated. The plasma technology would help eradicate moulds early in the packing process.

The Georgia Tech Research Institute (GTRI) seems to have mastered the art of baking perfect buns every time. Its researchers have developed a production-line system that automatically inspects the quality of sandwich buns exiting the oven and adjusts oven temperatures, if it detects unacceptable buns. “By creating a more accurate, uniform and faster assessment process, we have closed the loop between the quality inspection of buns and the oven controls to meet the specifications required by food service and fast food customers,” said Douglas Britton, Senior Research Engineer, GTRI. During existing inspection processes, workers remove a sample of buns each hour to inspect their colour. Based on this assessment, they manually adjust the oven temperature if buns appear too light or dark. “Automated control over the baking process is vital to produce a consistent product,” he added. Working with baking company, Flowers Foods, and Baking Technology Systems (BakeTech), a baking equipment manufacturer, Britton and GTRI’s Research Scientist Colin Usher have successfully tested their new inspection system. Made of stainless steel, the system is dust and water resistant, and mounts to existing conveyor belts as Testing the new system on a BakeTech machine wide as 50 inch.

April 2011 | Modern Food Processing



“Enzymes help manufacture products with less toxic inputs, thereby enabling environment protection” …Says G S Krishnan, Regional President, Novozymes - South Asia. He joined Novozymes in 1991 as a Technical Manager overseeing the food and beverage segment. In this interview with Mahua Roy, Krishnan provides insights on enzyme technology as a sustainable alternative, with special reference to the responsible efforts taken by Novozymes towards a clean and green future.

Changes in the Indian enzyme industry in the last decade When we started operations, people were only aware of the standard applications of enzymes, like its usage in the brewing industry, alcohol preparation, etc. Also textile and detergent industries were employing enzyme technology, to some extent, at that time. Now things are changing, and enzymes are not restricted to few industries. Several novel applications are coming up in different sectors such as the oils and fats, among others. I think it is mainly the awareness regarding biotechnology that is playing a key role in the growth of the enzymes industry.

Enzyme technology: A sustainable alternative It is more of a myth that enzyme technology is always expensive. Of course, in certain areas, specifically for new applications, it might look as a costly proposition vis-à-vis the corresponding chemical process. But people have to look at the overall advantages from the environment point of view, also. On account of their catalytic function, small quantities of enzyme can often replace large quantities of chemicals, energy and water. The immediate


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benefits of enzyme application include savings in raw materials, chemicals & energy, and improvements in terms of quality. This is often the key to enhance efficiency in our customers’ production processes. Novozymes’ Life Cycle Assessments (LCAs) show that enzymes, in many cases, can reduce material and energy consumption, CO2 emissions, and harmful impacts on the environment. In a broader perspective, enzymatic solutions help specific industries manufacture products with less toxic inputs, thereby enabling environment protection. Often, this reduced impact contributes to the sustainable development of industries as well as society as a whole. As far as the demands of the market are concerned, industrial biotechnology is more of a hi-tech application, and here, people are very much aware of enzyme applications. The only question that remains is, to what extent they are going to adapt to biotechnology and enzyme application in particular. It is going to be a slow process in India. This is because environmental concerns are slowly becoming serious in the country; while elsewhere in the world, such issues are being addressed stringently.

Solutions by Novozymes for the food industry Novozymes offers bioinnovative products, including industrial enzymes, beneficial micro-organisms, biopolymers and other proteins. Today, food and beverage manufacturers are witnessing increasing demand for quality products, with fewer additives & preservatives, and produced with high ethical standards. The emphasis is on developing products and solutions in order to reduce the usage of conventional chemicals. In response to industry concerns about the effects of the naturally occurring chemical acrylamide, Novozymes created Novozymes Acrylaway®. Acrylaway

has been proven to substantially reduce acrylamide by up to 90 per cent in a broad range of foods, including biscuits and snacks. The healthy improvement of these foods is achieved without altering the tempting flavour or visual aspect of the products. Other than that Novozymes offers solutions for the brewing, bakery, oils & fats, starch, juice segments, etc.

Industry-academia collaboration Novozymes believes in close co-operation and co-ordination with the academia as ultimately, innovations can take place with the active involvement of scientists. Specifically in a country like India, there are several new opportunities and applications, which we aim to leverage upon, based on what the market demands. If there is a close co-operation between industry and academia, it will definitely support our constant endeavours.

Challenges faced by the enzymes industry There has been a clear indication as far as the regulatory authorities are concerned, that they are planning to bring out a regulation, which is going to be in line with the international standards. But since the regulation is being delayed, our concerns revolve around what benefits it will bring to us, or whether it will pose new challenges. Here I would also like to add that going forward, for new application development /innovation in India, regulatory approvals will remain a major area of concern.

Ideology inspiring Novozymes’ new technologies Continuous innovation in close coordination with customers is our ideology. By working together with our customers, we gain a holistic understanding of their markets and priorities, enabling us to anticipate their needs for the future and develop

The broader public now demands top quality products. As a result, food manufacturers need to produce and market their products & processes in a natural, effective and environmentfriendly way. Enzymatic solutions help the industry to meet this pressing challenge. solutions that give them a competitive edge. At the same time, we help customers make the most of their resources and optimise their processes, saving time & money, while reducing their impact on the environment.

The future of enzyme industry An emerging lifestyle trend is the growing consciousness of consumers regarding food and diet. People have never been more aware of what they eat. No longer are health and sustainability welcomed by only a small market segment – the broader public now demands top quality products. As a result, food manufacturers need to produce and market their products & processes in a natural, effective and environment-friendly way. Enzymatic solutions help the industry to meet this pressing challenge. When it comes to India, I foresee a tremendous scope for enzymatic solutions. With the growing middle class, increasing spending capacity and globalisation, the food and beverage industry is all set to witness a boom. Keeping in mind the opportunities the country would offer, Novozymes recently inaugurated an R&D facility in Bengaluru. The R&D centre will undertake protein engineering work and will act as a resource base for the company’s global discovery projects. It will also serve as an application technology excellence centre for local enzyme applications.

April 2011 | Modern Food Processing



Union Budget

Rajiv Subramanian Engagement Manager - Consumer & Retail, Tata Strategic Management Group

Sour short-term, sweet in long run


he verdict on the Budget has been a mixed one. The fine balance between inflation and growth along with the focus on social inclusion has been welcomed by many. However, another section is questioning the absence of ‘big ticket’ reforms to spur growth. At a macro level, the GDP growth estimates of around 9 per cent in 2011-12 should augur well for the consumer sector. In case of the processed food and FMCG sector, there has been an overall positive feedback. While this is prompted by a mix of some negatives and a larger number of positives, one significant and often unsaid positive is the status quo on standard rate of Central Excise Duty at 10 per cent.

On a positive note The proposed rise in exemption limit is expected to increase the disposable income of consumers, which will prove beneficial for the food and FMCG sectors. This is likely to have an incremental positive impact. In case of edible oils, it has allocated ` 300 crore to bring 60,000 hectare under palm oil plantations to help the segment, albeit in the long term. The Budget has also increased the disposable income of the elderly consumer. First, the age for income tax exemption for senior citizens is reduced and, second, the exemption limit is increased. This should encourage consumer companies targeting this section of the population. But, the big positive for these sectors from the Budget is the strengthening of the rural story. The Budget has allocated more than ` 1,60,000 crore towards the development of the social sector on heads like Bharat Nirman, Food Security and Mahatma Gandhi National Rural Employment Guarantee Act. Further, there is the proposed interest rate subvention on farm loans and also the indexation of National Rural Employment Guarantee Act wage rate to Consumer Price Index. With a definite positive impact on rural incomes, we are likely to see some reallocation


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of resources within companies for building rural infrastructure to leverage on this opportunity. Supply-side enablers include the infrastructure status given to cold storage chains and the excise exemption on cold storage equipment. The Budget proposal realises the importance of cold chain in increasing efficiencies in food supply, and thus, controlling inflation. The decrease in income tax surcharge from 7.5 to 5 per cent is a limited, but much welcome proposal for companies in times of margin pressure.

Small negatives The increase in Minimum Alternate Tax (MAT) from 18 to 18.5 per cent and the levy of 1 per cent Excise Duty on hitherto exempt goods like Ready-to-Eat foods, coffee or tea pre-mixes, sauces, ketchups, soups, food mixes, etc, were small negatives that emerged from this Budget. However, their impact is likely to be negligible.

GST and DTC Significant progress indicated towards implementation of Goods and Services Tax (GST) and Direct Tax Code (DTC) is a big positive. GST implementation proposal should bring down the indirect taxation on consumer goods – a welcome relief for consumer product companies struggling with rising input costs and pressure on pricing. No reference to FDI in retail was a disappointment for many. It would be interesting to study what consumer product companies think. It is known that retailers and consumer product companies have been at loggerheads over margins. However, organised retail serves as a focussed channel for consumer product companies when it comes to new as well as evolved products. And, any further expansion of organised retail should help in this regard. For details, email:


Basketful of goodies for food sector? Budget 2011-12 has been termed as forward looking and growth-oriented. It has been hailed by many in the food industry for announcing a slew of positives including the thrust given to agriculture & infrastructure development, establishment of mega food parks, and accordance of infrastructure status to cold chain among others. However, food inflation remains a cause of worry. Rakesh Rao finds out how the industry experts rate the Budget.

Vinita Bali, Managing Director, Britannia Industries Ltd The Finance Minister has presented a balanced Budget, with projected fiscal deficit at 4.6 per cent in 2011-12 as against 5.1 per cent in 2010-11. This is going to be challenging though. The Budget offers several positives for the food industry to grow, which include removal of distribution bottlenecks, acceleration of milk production, setting up of additional mega food parks and storage

capacity enhancement, with incentives for capital investments in modern cold-storage facilities. Some other plus points of the Budget are additional allocations for infrastructure development, strengthening of public-private partnership model, and enhanced allocations for educational institutions like IITs, IIMs and others. It has also reduced the corporate surcharge from 7.5 to 5 per cent. However, the Budget did not give a timeline for GST, which the industry was expecting.

Ashutosh Chakradeo, Head – Buying, Merchandising & Supply Chain, HyperCITY In the Budget, the Finance Minister has taken a few positive steps, which will boost consumer demand through improved focus on agriculture. Initiative on vegetable clusters should go a long way in controlling food prices. Also, the reformed Agricultural


Modern Food Processing | April 2011

Produce Market Committees (APMC) Act will definitely help in direct procurement from farmers, which in turn will help retailers to offer the best prices to consumers. However, the Budget left much to be desired in terms of a clear timeline and roadmap on the roll out of the GST. Also, the Budget does not give a clear way forward for FDI in retail.


Nadia Chauhan, Joint Managing Director and CMO, Parle Agro Pvt Ltd The Budget announced a 1 per cent hike in the excise duty of sugar confectionery, which will have an impact on the confectionery industry. It could lead to price hikes or reduction in the size of the confectionery. Any change in the MRP would impact marketshare significantly. We could see an increase in the number of ` 1 brands and heading in this direction over time, the 50 paise category could get eliminated just as the 25 paise category did in the past. This would be a hindrance to the entry of a

lot of local brands, in terms of confectionery, in the 50 paise category. Moreover, a large number of consumers today prefer to spend either 50 paise or ` 1 for confectionery products, as this is the dominant price point. Paying ` 1.50 or ` 2 is paying double, which consumers may not be ready for.

Natasha D’Costa, Senior Research Analyst - Chemicals, Materials and Food Practice, South Asia and Middle East, Frost & Sullivan The continued food inflation remains a major concern for the overall industry. However, the introduction of increased subsidy on nutrient-based fertilisers could improve crop production efficiency, thereby resulting in better per acre yield as well as help lower prices. Currently, less than 50 per cent of the country’s farmers in highly micronutrient depleted areas have access to necessary fertilisers. Additionally, the augmentation of food storage capacity would enable reduction in wastage, and thereby bring down the food prices. The Budget has announced the setting up of mega food parks, which will encourage entrepreneurship and enable efficient utilisation of resources necessary to reduce food wastage and augment production efficiency. The clustering of food processing units will ensure greater production

and reduced transportation of intermediate products, thereby reducing the risks of food spoilage. The Indian food industry will continue to be affected by rising prices as the Budget does not clearly align the measures to combat this issue. However, a ray of hope exists in the increased subsidy on nutrient-based fertilisers. The introduction of mega food parks is another such measure, which will attract investments into the food industry and help combat overall efficiency issues, thereby increasing supply. However, some stakeholders in the industry remain skeptical, as such measures need to see fruition quickly and efficiently – a factor that the industry is not confident about.

Dr D N Kulkarni, President, Agri Food Division, Jain Irrigation Systems Ltd This year’s Budget is straight forward and there is nothing extraordinary about it. There is no paradigm shift in the policies. Only minor changes have been made in tax structure. The food processing industry is uncertain about how mega food parks are going to work, particularly for fruits & vegetables sector, as there is no specific plan for raw material supply chain development for processing industry. There should have been some programme for farm aggregation as fragmentation of farming land is hampering the supply chain. There is a mention of cluster approach, but there is no special financial provision or concrete plan for implementation. The fruit pulp and juices have been included under excisable items, and hence, the profit margins of the processors will be affected. Government

has missed the opportunity to revolutionise the agro-based industry and make agriculture a sustainable profession. Water and energy are important aspects in agriculture, and at present, these issues have not been tackled in a manner required to make agriculture a profitable business. There is also a need to develop processing varieties, provide incentives for import of new genetic materials for higher yield, and training of farmers on a large scale to encourage adoption of new technologies. Unless this happens, food processing industry will not develop in India. However, the vegetable cultivation programme around cities is a welcome step.

April 2011 | Modern Food Processing



K S Narayanan, Managing Director, McCain Foods India Pvt Ltd The Union Budget 2011-12 has unveiled a slew of measures that is expected to provide a boost to the agriculture sector, while also addressing issues pertaining to food inflation, cold chain infrastructure and storage facilities that will benefit the food and beverage sector in India, by and large. For instance, providing cold storage an ‘infrastructure status’ is a welcome move, as it will help curb losses in the overall food chain that have been propelled due to supply-side constraints and exacerbated by huge gaps in post-harvest storage infrastructure for agricultural produce,

especially fruits and vegetables. This will also help in providing easy access to quality raw materials that are required by the food and beverage segment. The expansion of cold chain infrastructure is expected to provide a fillip to the frozen food segment. In addition, the Budget has also announced the augmentation of storage capacity, which will enhance food security, going forward. However, a major area of concern is that a number of processed food products that were earlier exempt from taxes, will now attract an excise duty ranging between 1-5 per cent, which could have been avoided. Excise on certain packaging materials has also gone up, which will impact the processed food sector adversely.

Devendra Shah, Chairman, Parag Milk Foods Pvt Ltd The Budget 2011-12 as presented by the Finance Minister is forward looking and growth-oriented. The most pressing issue for dairy farmers during the past two years had been pertaining to shortage of fodder and resultant increase in the cost of milk production. With an allocation of ` 300 crore for accelerated fodder development programme and full exemption from basic customs duty to de-oiled rice bran cake, both the marginal and large dairy farmers would be

benefitted. Further, the accordance of infrastructure sub-sector status to cold chains in the country would help the industry in developing deep-rooted procurement and distribution network. Another positive measure in the Budget that will give a fillip to the food processing industry has been the approval to set up 15 additional mega food parks during 2011-12. Some of the misses in the Budget include lack of incentives on exports of consumer food products, technology mission for improvement of milk productivity and consideration of milk processing equipment for viability gap funding along with cold chain equipment.

Balram Yadav, Managing Director, Godrej Agrovet Ltd Initiatives announced in this year’s Budget are expected to boost India’s crop and livestock yields. The government has finally begun to pay serious attention to the livestock sector, with ` 300 crore dedicated to the creation of a National Mission for Protein Supplements. Together with continued funding for pulses and ` 300 crore for fodder development programme, a serious attempt has been made to address India’s crippling protein deficit. Likewise, we welcome the allocation of ` 300 crore for oil palm cultivation on 60,000 additional


Modern Food Processing | April 2011

hectares, which will help reduce India’s dependence on imported edible oil. We believe this funding should flow directly to farmers, at ` 50,000 per hectare, and hope the support provided to the oil palm sector continues in future Budgets too. While reduction of import duty on micro-irrigation products by 2.5 per cent was positive, subsidy increases and infrastructure status should also have been granted, given the immense future challenge of water scarcity. Finally, the ` 1 lakh crore credit for farmers and 3 per cent interest subvention will help rejuvenate investments across the agricultural sector, thereby increasing long-term productivity.


Sula Vineyards

Brewing a sparkling success story Transforming the economy of Nashik and opening up a world of opportunities for the indigenous wine industry in India, Sula Vineyards has brought a sparkle to the ‘Made-in-India’ tag the world over, quite literally. Mahua Roy


Stanford graduate, Rajeev Samant, gave up a high-paying job in the Silicon Valley to follow his entrepreneurial instincts. He set up Sula Vineyards at his 30-acre ancestral land in 1999. The rest as they say, in a clichéd manner, is history.

translates into more concentrated aroma. “It is rightly said that wine is made in the vineyard. The quality of the grapes thus is of utmost importance. The grapes are tasted by our winemakers in the vineyards for sugar, sugar-acid balance, aroma and flavour maturity. This ensures deliverance of consistent quality of wines,” states Ajoy Shaw, Chief Winemaker & Associate VP Winemaking, Sula Vineyards.

‘Wine is made in the vineyard’ The first batch of grapes for the production of white wine was planted in 1996. The varieties, French Sauvignon Blanc and Chenin Blanc, were chosen after deep research of the soil and climate in Nashik. Renowned Californian winemaker Kerry Damskey was an integral part of this initial study. “The first crushing happened in Harvest 1999, and in 2000, the first batch of white wine was sent to wine-tasters. Armed with positive reports, the journey of Sula wines began in India,” says Dr Neeraj Agarwal, Senior Vice President – Vineyards Operations, Sula Vineyards. Major part of the efforts are spent in the cultivation of high-quality grapes. The berry size acquires much significance. A smaller berry size

Vineyards laden with wine grapes


Modern Food Processing | April 2011

White grapes entering the balloon press

White winemaking Four variants or types of wine are produced at Sula Vineyards – White, Red, Rosé and Sparkling. Around 26 SKUs are produced from different varieties of grapes. The processing of wine is the most interesting phenomenon of biotechnology. A simple textbook reaction of fermentation has been optimised to perfection at this facility. The procedure for white wine is thus explained: Step 1: The harvested grapes are sent to the balloon press, which expands to squeeze out the juice, and thus separates the skin from the fruit. The juice obtained is then transferred to tanks. Heat exchangers are used to lower the temperature of the juice considerably, to avoid fermentation at this stage and to retain the fresh aroma.

Yeast inoculation in the fermentation tanks


Step 2: After one day of settling in the tank, the clear juice is decanted and transferred to another tank where yeast inoculation takes place. The temperature is maintained at 15-17oC and the fermentation is carried out for 20-25 days. Step 3: Then comes the clarification and filtration stage, where a series of filters up to a mesh size of 0.5 micron is used to ensure a clear solution. This is followed by bottling, packaging and dispatch. In Sparkling wine, a process of double fermentation takes place. White wine is inoculated with yeast & sugar and filled in bottles, and the fermentation is allowed to take place for a period of one year. This is followed by the process of disgorging, where the yeast is brought to the mouth of the bottle and immobilised by freezing the wine with the yeast in the neck of the bottle and then the ice plug is removed quickly. After this, corking, wirehooding and foiling is completed, followed by dispatch.

The testing times All entrepreneurial stories have the hint of a sensationalised beginning, full of hurdles. This story is no different. For any product launch, the initial stages include market research, market survey, financial & market feasibility. Samant faced roadblocks at this very stage. He had a tough time convincing growers to cultivate wine grapes. Then another challenge was to convince the financial institutions for the funding of this enterprise. And the biggest challenge was the creation of the market itself for wine in India, which was practically nonexistent in the late 90s! Braving all odds, Sula emerged a winner, and today garners a whopping 60 per cent share in the wine market in India.

When it comes to red winemaking, the balloon press is not used to separate out the skin and juice because the colour and flavour of red wine resides in the skin of the grapes. After the crushing of grapes, the skin and juice are cooled down and kept together for three days to extract maximum colour. This is followed by 7-8 days of fermentation with more skin contact, an ageing process of 8-10

months, filtration, bottling, packaging and dispatch. In Rose wine, red grapes are used, but the contact time is reduced to give a beautiful pink colour. “At Sula, we manufacture wine with minimum intervention. We believe in control of the process, not its manipulation. Thus, we avoid the use of any external fining agents. Once the juice is fermented, the removal of protein is carried out, using simple substances like clay to bind protein and ease its separation, making the wine heat stable. This is followed by heat stabilisation. We also undertake measures to clarify the wine and ensure removal of tartarate crystals, which may affect the aesthetic appearance of wine,� points out Shaw. At regular intervals, samples of wine are subjected to stringent quality checks. This ensures a high quality of wine being offered to the consumer, consistently. The important tests include monitoring the brix level, pH, total & volatile acid content, SO2, alcohol and enzymatic levels, residual sugar content, etc.

Stringent QC ensuring consistent quality of wine

Bottling line in motion

Red, red wine

Best practices at the vineyards Sula Vineyards repeatedly practise and preach the conservation of its resources. A highly environment-conscious organisation, it has taken numerous steps to maintain its reputation as a responsible processor. Irrigation management: The growers are constantly informed about the best practices in irrigation. They are also oriented about the relationship between soil nature and amount of irrigation. Highly sophisticated measurement machines from Australia are employed to check moisture levels in the root zone. The amount and duration of irrigation are decided accordingly. Water reuse: Wastewater generated in the plant is treated, and thereby used to water the sprawling lawns in the facility. Rainwater harvesting is also carried out. Double cavity walls: To save on energy, double cavity walls are used in the fermentation tanks. “Insulated stainless steel fermentation tanks are

Sula Wine ready for dispatch

April 2011 | Modern Food Processing



Dr Neeraj Agarwal Senior Vice President – Vineyards Operations

There are hardly any research institutes concentrating on study of winemaking. Also, there is practically no funding from the government. We depend on our in-house R&D. The need of the hour in this sector is encouraging the study of compatible varieties of grapes, suitable for winemaking under Indian climatic and soil conditions. used, with PUF as insulator that ensures minimum loss of energy. Thus, whatever energy is used to chill the tanks, does not get radiated out. This helps us to cut down a considerable amount of our energy costs,” elaborates Shaw. Solar panels: The facility also uses renewable energy measures to counter environmental issues. During the process of fermentation, a large amount of sugar and acid crystals get coated on the walls of the fermentation tanks. In order to remove these residual wastes, solar panels are used to heat water to around 65oC, and this heated water is used to remove

Ajoy Shaw Chief Winemaker & Associate VP - Winemaking

Globally, wine has traditionally been sealed using corks. But Indians are not habituated with the use of a corkscrew. Sula, thus, pioneered the screw cap for wine packaging. World over, people are talking of lowering carbon footprint. The future could see bag-in-box packaging of wine, or something even more futuristic, yet sustainable.


the coated residues. The hot water generated is also used as input in the boiler, which reduces the energy required to heat it further to bring it up to filler line sanitation temperatures at bottling. Vermicompost: The waste generated after the pressing of the grapes is sent to the vermicompost pit. This is converted into manure by earthworms. Thus, more organic matter and humus is generated, which is suitably used as manure for the grapes, back in the vineyards. Integrated pest management: Sula Vineyards professes the use of biopesticides. It has successfully harnessed the use of fungus Beauveria bassiana to control caterpillars, stem borers & sucking pests, which are the most rampant pests damaging the vineyards. Also, about 40 days before the harvest, all chemical treatments to the vineyards are discontinued.

Packaging pioneers “Globally, wine has traditionally been sealed using corks. But when it comes to India, we realised that Indians are not habituated with the use of a corkscrew. Sula, thus, pioneered the screw cap for wine packaging,” elaborates Shaw. This was a consumer-centric innovation by Sula, which indeed revolutionised wine packaging in India. He adds, “Also, if improperly stored, the cork begins to dry and could break & crumble, thus affecting the taste of the wine. It could also lead to the formation of 2,4,6-tricholoroanisole in as much as 5-8 per cent of the bottles, giving even the excellent and most expensive wine, a slightly corked taste.” Efforts are now being concentrated towards sustainable packaging of wine. Sula has already started using PET packaging for some of its low-end wine. “This is just the beginning. With a lighter product, the carbon emission goes down. World over, people are talking of lowering carbon footprint. This is a step towards that. The future could see bag-in-box packaging of wine, or something even more futuristic, yet sustainable,” says Shaw.

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Appetite for research When it comes to viticulture or research about wine, there is little exposure to the same in India. “There are hardly any research institutes concentrating on viticulture or winemaking or soil study. Also, there is practically no funding from the government. We depend on our inhouse R&D. The need of the hour in this sector is encouraging the study of compatible varieties of grapes, suitable for winemaking under Indian climatic and soil conditions,” says Dr Agarwal. The market for wine is growing in the country, owing to globalisation and experimentation by the huge young population, who view it as a comparatively healthy alcohol, full of natural anti-oxidants. Also, tourism is giving a boost to the wine industry in India. “India is located in the sub-tropical region, with adequate sunlight. Thus, photosynthesis is good, coupled with suitable temperature and soil quality. We can produce better quality and quantity of grapes and wine, more than that in Europe. The only thing required is long-term research,” says Dr Agarwal.

Great tasting times ahead! Last year, about 5 lakh litre capacity expansion was undertaken at this facility. There is a proposal of putting up a new state-of-the-art barrel room and a bottling line as well. The total capacity at the Nashik facility is 50 lakh litre, whereas in the offsites, there is an additional capacity of 20 lakh litre. “The growth rate of Sula has been 30-35 per cent over the years, and by 2015, we plan to double the same,” says Shaw. At the World Economic Forum in Davos, 2006, Sula was served as the official wine. Shaw also reminisced of the time in 2002 when the first consignment of Sula wines was exported to Italy. “We made wine in a country not known to make wine, and then sent it to the largest producer of wine. It was a proud moment, a big achievement for the Indian wine industry. It showed what potential we had,” he concludes.


The growth of organised retail and changing lifestyles have necessitated a drastic change in food & beverage (F&B) supply chain management (SCM) in India. Of late, the F&B logistics segment has witnessed important developments, especially after the advent of multinational food majors, large retail chains and increasing number of efficient logistics service providers in the country. However, the segment needs to decode the supply chain intricacies to ride smoothly on the growth path.


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Prasenjit Chakraborty


he changing lifestyles and eating habits have the most profound and visible impact on the F&B sector. It has brought about a paradigm shift in terms of people’s perception as well as expectations from the segment. Moreover, rapid growth in organised retail has added to the lucrativeness of the F&B sector. Today, people demand fresh food and on-time delivery. And here comes the significance of logistics. According to Frost & Sullivan’s recent research titled ‘Strategic analysis of Indian logistics market’, the country’s food processing industry spends around 8 per cent of its revenues on logistics and SCM functions. Transportation represents the largest component of this cost. But, the share of warehousing within this cost is significantly higher when compared to most other industries, primarily due to the extra care and infrastructure needed to store food products and protect these from environmental impact, besides dealing with the shorter shelf-life of majority of the products offered by this industry. India has the potential of becoming the food basket of the world, with almost 52 per cent of the total cultivable land available as against an average of 11 per cent worldwide. Moreover, with the abundant labour that is economically-viable, India stands at an advantage. “One of the key impediments to India becoming

a global food supplier is the lack of right marketing strategies and an inefficient supply chain, apart from outdated agricultural practices & small landholdings, which are not conducive to mechanisation for attaining scale advantages,” says K S Narayanan, Managing Director, McCain Foods India. Currently, India has a highly complex food supply chain, with numerous stakeholders right from farmers, wholesalers & agents, to food manufacturers, and retailers, who work in complete silos.

Supply chain challenges The major SCM challenge faced by the Indian F&B industry is the high risk of product damage and expiry by the time it reaches end-consumers. In addition, high distribution costs and complexity added by the multiple participants in the distribution chain is also a concern. The traditional supply chain of Indian F&B industry comprises several middlemen right from manufacturers to retailers/consumers. Typically, the F&B industry’s product transportation involves special care to protect them in different weather and climatic conditions. Certain extra-sensitive products require temperature-controlled dedicated vehicles/containers for their distribution. Food products mainly need cold chain storage facilities or multiple temperature facilities, which vary across different food segments, with controlled atmosphere provisions

K S Narayanan Managing Director, McCain Foods India

One of the key impediments to India becoming a global food supplier is the lack of right marketing strategies and an inefficient supply chain, apart from outdated agricultural practices & small landholdings, which are not conducive to mechanisation for attaining scale advantages. in warehouses for storage purposes. This is because they are highly prone to spoilage, if constantly exposed to changing environments. “The companies need to ensure refrigerated warehouses or perishable goods cargo centres for the storage of food products within every point of the supply chain until the sale points in retail outlets are reached. Majority of F&B manufacturers in the country (especially the small and medium-sized enterprises that dominate the market) do not have financial resources to build (or even rent) such specialised transportation and warehousing infrastructure to safeguard and enhance their product shelf-life,” says Srinath Manda, Programme Manager – Transportation & Logistics Practice, South Asia, Middle East (ME) and North Africa, Frost &

Raw materials suppliers Dealers Food manufacturers

C&F agents


Distributors Stockists


Source: Frost and Sullivan Analysis

Figure 1: Food & beverage industry’s standard supply chain (India), 2010

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Srinath Manda Programme Manager – Transportation & Logistics Practice, South Asia, ME & North Africa, Frost & Sullivan

As a primary measure to reduce the complexity and improve efficiency of the food value chain in India, the manufacturers should rework on their supply chain model to reduce the number of middlemen in the system. Sullivan. Hence, lack of such specialised transportation and warehousing resources is a major challenge for the F&B industry. “As a primary measure to reduce the complexity and improve efficiency of the food value chain in India, the manufacturers should rework on their supply chain model to reduce the number of middlemen in the system,” he opines. In addition, they should also rework on their procurement patterns, manufacturing & warehousing locations, and transportation practices to achieve rapid demand-supply balance attuned with consumption side of the market. It has been seen that logistics and transportation cost in India is high as compared to developed countries. On account of poor quality of infrastructure and inadequate services, the cost of logistics in India is steep. “In fact, the annual logistics cost in India is valued at ` 6,750 billion ($ 135 billion) and is growing at 810 per cent annually. The logistics cost by value accounts for about 13 per cent of India’s GDP – much higher as compared to countries like the US (9 per cent), Europe (10 per cent) and Japan (11 per cent). As a result, manufacturers have to bear the cost, which reduces their margins or the cost is sometimes passed on to consumers,” points out Narayanan. Further, unlike in developed nations, Indian retailers do not have efficient


control over the food supply chain. For instance, in advanced countries, large retailers are the channel masters of food supply chain, taking over from the food manufacturers. “In India, with limited superstores, no economies of scale, too many intermediaries, there is no real channel master managing the demandsupply situation,” laments Narayanan.

Modern retail: Making its impact The growth of organised retail sector in the country has brought in the need for faster replenishment at stores. The Indian organised retail sector is synonymous with retail chains having large number of stores and hypermarts with huge sales volume. Hence, it calls for agile supply chains connecting several sourcing locations across the country, with various destination points. A traditional retail market-oriented distribution chain of F&B companies relies on middlemen like distributors and stockists for physical movement of goods. However, the organised retail sector participants hold F&B manufacturers responsible for ensuring regular and timely delivery of goods directly at their stores or at the retail entity’s own warehousing facility. Further, in some cases pertaining to the pack sizes, packing and pricing have to be customised to suit a particular retail chain’s needs. “This adds to higher burden on logistics and supply chain activity of F&B companies. To meet the stringent quantity orders and dynamic delivery timelines of organised retail, F&B companies need to engage professional logistics and supply chain service providers, who have the expertise in supply chain planning and management of the execution with a scientific approach,” exhorts Manda. The companies also need to streamline & standardise their procurement, materials management and production functions to meet the regular stream of orders from the organised retail clients. “The changes in lifestyle and retail revolution have resulted in significantly high levels of alternative options for

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end-consumers, thereby leading to low brand loyalty, especially in case of food & beverages. Gone are the days when consumers waited for days to buy their preferred branded products (eg, oil, tea & coffee, and nutritional foods among others),” says Manda. Hence, continuous availability of products in all retail outlets has become extremely important for F&B manufacturers. And, any failing (or being complacent) to match the consumer purchase & demand volumes from even remote parts of the country could result in significant loss in sales. In addition, competitive pricing has gained importance in case of similar products eroding the scale of profits, as enjoyed earlier. Sanjiv Mediratta, Executive VP, Innovation & Supply Chain, Indian Hospitality Corporation, says, “Front-end is moving on a faster pace than back-end, which include logistics, resulting in demand-supply gap that lead to high cost and non-availability of timely logistics support. Non-perishable replenishment is faster in retail outlets, which is not the case with chilled, fresh or frozen food items. This is purely due to poor and insufficient logistics infrastructure in the country,” he says. Hence, only those companies that can efficiently manage their supply chain function and attain the lowest costs of manufacturing & distribution

Sanjiv Mediratta Executive VP, Innovation & Supply Chain, Indian Hospitality Corporation

Front-end is moving on a faster pace than back-end, which include logistics, resulting in demand-supply gap that lead to high cost and non-availability of timely logistics support. Nonperishable replenishment is faster in retail outlets, which is not the case with chilled, fresh or frozen food items.


Ajay Mittal Chairman & Managing Director, Arshiya International

Global market forces like changing consumer preferences, stringent government regulations and pressure from stakeholders for waste reduction & incorporation of greener practices have made logistics players offer state-ofthe-art services. can offer their products at best prices for consumers, and gain a leading position in the market.

India vis-à-vis developed countries Indian F&B logistics scenario is at a nascent stage when compared with that of the developed nations such as the US and European countries. Most distinguishing variation between these two worlds is that developed nations have a significantly organised and consolidated status on F&B manufacturing, retailing as well as logistics services provided. “The F&B manufacturing industry in India is highly unorganised and fragmented. So, the retail and logistics sectors are not likely to witness drastic changes for at least another decade,” opines Manda. According to Ajay Mittal, Chairman & Managing Director, Arshiya International, F&B logistics is a specialised function catering to critical requirements of the F&B industry like short lead-times, temperaturecontrolled storage and movement of sensitive products. Global market forces like changing consumer preferences, stringent government regulations and pressure from stakeholders for waste reduction & incorporation of greener practices have made logistics players offer state-of-the-art services. An important aspect of F&B


logistics is the maintenance of cold chain that deals with storage and distribution activities. Cold chains also ensure the required temperature range for maintaining the shelf-life of a given product. “Globally, the integration of the various logistics functions such as pre-cooling facilities, cold storages, refrigerated carriers, packaging, warehouse and information management systems have resulted in robust cold chains. Due to fragmented players and lack of infrastructure support, India is still lagging in terms of availability of a seamless food supply chain. This area calls for investments, with a focus on incorporating international practices for matching the quality of services provided by foreign counterparts,” says Mittal.

The planned investment in cold chain facilities will give a boost to the food processing industry. With proper infrastructure support, India has the potential to become a food processing hub. The changing landscape The F&B SCM in India has witnessed several developments in the past ten years, as a result of the advent of multinational food majors, large retail chains and emergence of several logistics service providers. Most prominent among them are deployment of latest technologies & practices in packaging & distribution, increasing use of logistics technologies for enhanced labelling & tracking of products, and growing usage of cold chain logistics to enhance lifespan of products. However, most remarkable development in this direction is the opening up of supermarkets across the country. Even foreign retail chains are

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leaving no stone unturned to establish themselves in the Indian market. This is one trend that has the potential to bring about the desired efficiency in the F&B supply chain. Due to the lack of cold chain infrastructure, a large percentage of all the food produced in India gets wasted. An efficient and effective supply chain will ensure that consumers are offered value-added food products while farmers are paid remunerative prices. “Moving away from small stakeholders towards collaboration between partners has been gaining momentum. Demand management supported by technology like RFIDs for tracking and tracing is also being undertaken by some pioneers in this field. Importantly, the focus is also on development of cold chains to ensure that products reach end-consumers from the point of origin without spoilage,” observes Mittal. Many private companies are also developing cold storage facilities with state-of-the-art infrastructure along with the capability to handle end-toend logistics to service not only Indian companies but also foreign firms looking to enter the Indian market. Cold storage segment is likely to gain momentum as the government has provided a fillip to it by giving infrastructure status. “We believe that conferring infrastructure sub-sector status to cold chains and post-harvest storage entities is likely to drive massive investments and operations in this segment of the Indian logistics industry. It will, thus, lead to the development of sustainable cold chain logistics infrastructure in the country,” says Manda. The planned investment in cold chain facilities will give a boost to the food processing industry. With proper infrastructure support, India has the potential to become a food processing hub. Overall, the sector will witness adoption of cold chain practices of international standards that are muchneeded to reduce wastage and bring down cost to the consumers while also enhancing quality.


Sodium chloride management

Sprinkling health, maintaining taste The rise in cardiovascular diseases (CVD) is paving the way for salt management techniques in processed food. Companies worldwide are responding to these trends and coming up with integrated salt management strategies.

Mahua Roy


aking a difference with its presence as well as absence is how salt impacts our lives. Common table salt, sodium chloride, has numerous significant attributes. “These functions reach beyond taste, contributing to food safety, inhibition of microbial growth, food preservation,

bitterness reduction (even in chocolate) and colour development (especially in meat, cereals and bread). In addition, it plays an active role in fermentation control in cheese & related products, minimalisation of ice-crystals in frozen products (including ice cream) and strengthening gluten in bread dough for uniform texture, grain & dough strength,� elaborates Roger Clemens, Presidentelect, Institute of Food Technologists, the US.

Real need for salt reduction? There is a reason for lifestyle diseases having been named so. Significant and gradual changes in the lifestyle have led to a sudden surge in the non-communicable diseases, eventually leading to death. In India, 19 per cent of deaths due to non-communicable diseases are attributed to heart-related problems like hypertension, atherosclerosis, etc. In the economic context, this amounted to actual loss in GDP by about $ 1.35 billion in 2006 and is estimated to amount cumulatively to a total of $ 17 billion by the year 2015, as per the World Health Organization (WHO).


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CVD is the leading cause of death and disability worldwide. High blood pressure (BP), cholesterol and smoking are the major risk factors. Among these, high BP accounts for 62 per cent of strokes and 49 per cent of coronary heart disease. “The need for salt reduction or replacement is imperative. The call for salt replacers from processed food companies has been outstanding for more than a decade, as the medical community has recognised the potential short- and long-term impact on specific and general health conditions. Also, the focus on reduction of sodium in processed food has become a priority as healthcare costs continue

to soar, resulting in government and industry partnership to prevent health risks through regimented reduction of added sources of sodium,” says Dr Guy J Hartman, Director - Creative & Applications North America, International Flavours & Fragrances (IFF). United States Food and Drug Administration (USFDA) research reports have indicated that 77 per cent of the salt intake comes from processed food and just 6 per cent is the ‘added’ content (Figure 1). The externally added content of salt can be monitored and reduced, but food companies have to work in tandem to reduce the remaining amount.

Salt reduction pledges According to the 2010 market report, Innova Market Insights recorded nearly 3,000 global food and drink launches marketed on a low sodium platform in 2009, double the level witnessed in 2006. Also, the ongoing efforts by top companies worldwide are as follows: To reduce the average amount of sodium per serving in key global food brands, in key countries, by 25% by 2015

To cut sodium levels by 20% by 2015

To cut sodium levels by 10% by 2012

To reduce the amount of salt in Kellogg’s Rice Krispies and Kellogg’s Corn Flakes by 30% Has removed 3,640 tonne of sodium from their product portfolio with, for example, 10-15% reduction in powdered soups in Europe & South America since 2005, and 25% across Knorr recipe kits in South Africa Heinz Baked Beans and Heinz Canned Pasta, claimed to have reduced salt by around 33% and in children’s pasta ranges by 59%

Has announced 33% salt reduction in the UK

Roger Clemens President-elect, Institute of Food Technologists, the US

Sodium and chloride are essential nutrients. In the mid 70s, there was a call for sodium reduction in food products. This prompted its significant decrease in foods. The public health results were most unfortunate. Thus, there is an important public health responsibility to become more aware of unintended consequences that may develop due to reduction of sodium chloride. Market scenario The global market for low-salt foods is estimated at $ 50 billion. Foods claiming no salt, where salt replacers or alternative seasonings are used, are worth approximately $ 16 billion, according to the 2010 market report, by Leatherhead. “Given the current global sales of flavours of around $ 15 billion, the market for salt replacers represents a sizeable opportunity for the growth of the flavour industry. The reason it is so widespread and significant is that many staple foods are within scope for reduction, for eg, salty snacks, bakery foods – bread, cereal products – breakfast cereals, soups, sauces, condiments, meat, poultry, cheese, as well as, all processed Readyto-Eat/Ready-to-Cook (RTE/RTC) foods,” says Dr Hartman.

Salt replacement Consumer preference for salty taste depends on the individual’s habitual salt intake and can change across the consumer age and location span. Preference for salt is not hereditary, and the environment has a strong influence on the preference, which is influenced by the salt concentration in the foods people consume. This also shows the difficulty in reducing salt content in products in

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Dr Guy J Hartman Director - Creative & Applications North America, IFF

There is a limit to the amount of sodium reduction possible with current flavour tools, depending on specific applications. There are challenges in rebalancing formulations to address the flavour aspect, and enhancing the functional elements salt provides; therefore experienced & talented applications technologists and flavourists are essential. different countries; consumer liking for salt is dependent on the levels present in products within the specific countries. In addition, it may also be dependent on their liking towards salt replacers, which could also be influenced by their level of exposure to these ingredients. “There are a number of commercial solutions available in the realm of ingredients and some of the common and commercially available salt replacers are potassium chloride, potassium lactate, and magnesium & sodium salts. None of them are, however, without their flavour drawbacks – whether it is bringing the addition of bitter or metallic

notes or failing to provide the full-bodied profile delivered by salt,” says Emmanuel Frenck, VP - Sub-Saharan Africa Flavours Division, Firmenich. Firmenich’s product portfolio includes Modulasense Salt Enhancer range to ensure that sodium reduction targets are achieved while still delivering the same consumer experience. Similarly, Germanybased K+S Kali launched a new brand of food grade potassium chloride called KaliSel, which it claimed to be a costeffective salt replacer in food. “There are several categories of commercially available salt replacers. These include salt replacers based on mineral substances; organic salt replacers – yeast extracts; biochemical salt replacers working on the taste buds; and combination of all these. Our successful innovation is the salt replacer, which is a combination of KaliSel and yeast extracts,” says Dr Beate Deuker, Communication Manager, K+S Kali GmbH. But IFF has a different take on the same, as Dr Hartman says, “Technically speaking, there are no commercially available salt ‘replacers’, since by definition a replacer provides a 1:1 alternative having identical functionality and taste of salt. IFF conducts fundamental taste receptor research for more than a decade. The current scientific understanding of the human salt taste mechanism remains to be elucidated and is still a matter of debate.

Emmanuel Frenck VP - Sub-Saharan Africa Flavours Division, Firmenich

The biggest drawback in using salt replacers is managing the cost. Salt is one of the low-cost materials in the food processors’ raw material portfolio. It provides high quality taste at an extremely low cost, but has often resulted in high usage levels. No salt replacer acts as a direct replacement at the same cost.


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12% 77%

6% 5%

Naturally occurring While eating Home cooking Processed and restaurant foods Figure 1: Sources of salt consumption (in percentage) Source: USFDA

Therefore, a technical replacement cannot be unquestionably confirmed.”

Integrated salt management Generally, the process of reducing sodium is multifaceted because, depending on the type of food, salt and sodium can act as a tastant and/or flavour enhancer/modulator and/or texturiser, due to its effect on the moisture binding properties of proteins. “Initially, processors can simply reduce the amount of salt in their products to the point where the taste becomes compromised or is recognisably different from the original. This continuing approach over time will lead to consumer adaptation towards a low-salt flavour. After the limits of reducing salt have been exhausted, alternative mineral salts

Tried and tested strategy One of the reasons that the food industry adds large amount of salt to processed foods is because it makes unpalatable food edible at no cost. If high salt foods are consistently consumed, the salt taste receptors are suppressed and habituation to highly salty foods occurs, with greater demand for profitable high salted processed foods. Food manufacturers often argue that the reason for the high salt content of their products is because of consumer taste preferences, ie, individuals prefer these saltier products and if the salt content was lowered, it would lead to consumer rejection. However, one important factor to be considered is that as salt intake falls, the specific salt taste receptors in the mouth become more sensitive to lower concentrations of salt and this adjustment takes only one or two months. Consumer experience in the UK has confirmed this, ie, where salt has been reduced in major brand products, there has been no reduction in sales and no complaints about taste. Source: Journal of Human Hypertension, 2008, the UK


can be used, most typically, potassium chloride. But these carry some negative flavour off-notes, so their utility is limited unless masking flavours are employed to counterbalance the off-notes,” explains Dr Hartman. This strategy proves to be a long-term success story to ensure a healthy product range. The US and the UK have traditionally dominated activity in this area, reflecting the greater levels of concern over health issues, but initiatives by some leading multinationals have resulted in changes on a multi-country or even an international level. Unilever claimed to be the first company to set worldwide goals for salt reduction across its entire food portfolio of over 22,000 products, but there have also been significant changes undertaken by major companies on a regional level.

Interesting salt management secrets from the East R





Adding soy sauce to certain foods could enhance the perception of saltiness, enabling food manufacturers to cut salt content without affecting taste Dried bonito is a stock made from fish & seaweed and is used extensively in Japanese cuisine. Research on bonito found it to enhance saltiness Purple bamboo salts have been recently reported to improve the chemical and sensory properties of meat products, while reducing sodium content. The salts were suggested to improve the formulation of meat, compared to commercially available sodium chloride A further potential sodium reduction technique is the use of rice vinegar to enhance the perception of salt flavours The use of round salt – a noncaking salt product produced by Indian researchers – has also been touted as a potential replacement for commercially available salt in meat and baking products Source: Journal of Food Science

So what’s the catch? The biggest issue is management of cost. Salt reduction or replacement will definitely come at a price as salt is the most inexpensive ingredient. “The biggest drawback in using salt replacers is managing the cost. Salt is one of the low-cost materials in the food processors’ raw material portfolio. It provides high quality taste at an extremely low cost, but has often resulted in high usage levels. No salt replacer acts as a direct replacement at the same cost. However, at Firmenich, we have worked on a number of strategies with our customers in order to manage and minimise the cost impact and maintain the profitability of the product for the manufacturer,” claims Frenck. Sodium levels are important even at the processing level, especially for bakery and meat. Reformulation can be successful only if these challenges are addressed. “There is a limit to the amount of sodium reduction possible with current flavour tools, depending on specific applications. There are considerable challenges in rebalancing formulations to address the flavour aspect, and enhancing the functional elements salt provides; therefore experienced & talented applications technologists and flavourists are essential,” voices Dr Hartman. One should also not overlook the importance of sodium at the functional level. One needs to consider all possible drawbacks and lessons from history before implementing a strategy. “It is critical to remember that sodium and chloride are essential nutrients. In the mid 70s, there was a call for sodium reduction in food products. This prompted a significant decrease of sodium and chloride in foods meant for infants and children. The public health results were most unfortunate. Thus, there is an important public health responsibility to become more aware of unintended consequences that may develop following the reduction of sodium chloride from the food supply and

Dr Beate Deuker Communication Manager, K+S Kali GmbH

There are several categories of commercially available salt replacers. These include salt replacers based on mineral substances; organic salt replacers – yeast extracts; biochemical salt replacers working on the taste buds; and combination of all these. decreased consumption by the general population,” echoes Clemens.

Ensuring a delicious future Naturally, while deciding product formulations, food processing companies are giving health prime focus. Breakthroughs in R&D are promising better-for-you products. “Since 2006, we have reduced average sodium content per serving in our portfolio mix by 6 per cent and are on track to achieve our global reduction target of 25 per cent by 2015. We have recently launched the Lay’s Classic Salted with 25 per cent less salt. This product uses microlight salt, which is a unique highpurity, food grade salt that is finer and well-ground and enhances the salty taste perception in mouth due to its higher surface area. Therefore, it requires lesser quantity for achieving appropriate salty taste,” says a PepsiCo India official. Many such similar efforts by companies worldwide are directed towards the common goal of keeping the consumer as ‘King’ and being viewed as a responsible brand. “This is one of the most dynamic areas of development in the food industry worldwide, and a high proportion of ingredient suppliers, flavour houses and food manufacturers’ innovation budgets are being channelled towards finding good quality solutions. It is likely that there will be a rapid expansion for salt management in food globally,” concludes Frenck optimistically.

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Health ingredients

Ingraining wellness The market for health ingredients is slowly evolving. The major driving forces for the segment include rise in living standards, emergence of new products, and increase in lifestyle-related diseases. However, the lack of consumer awareness and proper regulations hinders the development of health ingredients industry, which otherwise holds immense potential to pave the path towards a healthier India.


apid urbanisation, an expanding middle class, and changing lifestyles have led to the transformation of the Indian social fabric. As a result lifestylerelated diseases and obesity are witnessing an upward trend. At the other end of the spectrum is poverty and malnutrition. Today, the highincome urban population is driving the demand for functional foods, and in turn, the growth for ingredients such as Omega 3 fatty acids, probiotics and prebiotics, among others. The health ingredients market is highly concentrated with large multinationals, which hold majority of the marketshare. Technical and R&D capabilities, consistency in product quality, and economies of scale allow them to maintain a competitive advantage over local participants and deter new entrants.

The ingredient line-up Ingredients comprise various fatty acids, prebiotics, probiotics, etc. The long and short of fatty acids: Omega 3 and Omega 6 are long chain polyunsaturated essential fatty acids that the human body cannot synthesise, and therefore must obtain


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from external sources. The recommended intake ratio of Omega 6 to Omega 3 is 5:1. However, the Indian diet is disproportionately weighted towards Omega 6, with the average intake ratio being 10:1. Docosahexaenoic Acid (DHA) and Eicosapentaenoic Acid (EPA) are the Omega 3 fatty acids with established health benefits. Cold-water fatty fish are the best sources, but with majority of the Indian population being vegetarian, this is not a viable option. Alpha-linolenic Acid (ALA) is an Omega 3 fatty acid, which is found in flaxseed oil, walnuts, soyabeans, etc. However, the conversion of ALA to DHA and EPA in the human body is extremely limited. This leaves DHA from micro-algae as the only source for food fortification in India. Bournvita Li’l Champs by Cadbury and Slice of Health by Ocean Nutrition, Canada, are recent examples for this. The friendly gut bugs: The human intestinal tract plays host to about 400 different species of bacteria – not all benign. The beneficial micro-flora helps maintain the intestinal balance and prevent ailments such as diarrhoea, colitis, candidiasis, irritable bowel syndrome, etc. Antibiotic usage,


stress and unhealthy lifestyles create an imbalance and may cause an increase in the intestinal concentration of pathogenic bacteria vis-à-vis beneficial strains. Probiotics aid in rebalancing and maintaining the gastrointestinal system. The World Health Organization (WHO) and the Food and Agriculture Organisation (FAO) define probiotics as “live organisms, which when administered in adequate amounts, confer a health benefit on the host.” Certain fermented foods and cultured milk products are a natural source of probiotics. Probiotics are commercially produced for enduse in food products and dietary supplements. The genera Lactobacillus and Bifidobacterium are widely used for commercial production. Lactobacillus acidophilus and Bifidobacterium bifidum are the most common strains. Currently, dairy products are the key end-use segment for probiotics in India. Probiotic yoghurts from Nestle and Amul are the most ubiquitous in this category. The versatile ingredient: FAO defines prebiotics as, “a non-viable food component that confers a health benefit on the host associated with the modulation of microbiota.” Inulin and Fructo-oligosaccharides (FOS) are most widely used for food fortification; for example in Britannia’s Nutrichoice Hifibre digestive biscuits. In addition to its growth and/or activity promoting function, scientific studies indicate additional health benefits. There is a growing use of Inulin as a sugar and fat substitute in India. Clinical study data from studies in Europe and the US point towards its growing applications in weight management, cancer prevention, enhanced mineral absorption and satiety.

The India story The Indian market for health ingredients is at a nascent stage of growth at present. However, while the aforementioned ingredients – Omega 3 fatty acids, probiotics and prebiotics are new entrants, food fortification

with vitamins and minerals has been ongoing for quite some time. Horlicks by GlaxoSmithKline (GSK) and iodised salt from Tata are prime examples. Moreover, a number of factors, both standalone and inter-related, along the entire value chain deter the growth of health ingredients industry. Some of these include lack of consumer awareness, unclear legislation, and lack of scientific studies on the Indian population. The health ingredients market has witnessed single-digit growth rates in the past. Over the next three to five years, it is expected to continue. Additionally, a switch in consumption attitudes is expected to occur gradually, with increased consumer acceptance of packaged and fortified foods. Vitamins and minerals segment is expected to witness double-digit growth due to several private and public sector initiatives such as the mid-day meal schemes and vitamin fortification of edible oil by Cargill, India.

Micronutrient deficiencies and bottom of the pyramid opportunity India is home to 35 per cent of the world’s malnourished children, with the largest number of Vitamin A deficient children. A large number of women suffer from iron deficiency and anaemia. Besides, iodine deficiency is suspected to result in a 15 per cent reduction in intellectual capacity. This has prompted the government to launch various initiatives including the India Micronutrient National Investment Plan (IMNIP), and the Integrated Child Development Services (ICDS) scheme. These drive the demand for vitamin and mineral premixes. For the private sector, significant opportunity lies at the so-called ‘bottom of the pyramid’. A huge opportunity is available with 350 million consumers having an average daily income of $ 2, and 40 million additional households moving

up from below poverty line annually. Some firms have already started tapping into this pool. GSK has launched a ` 85 variant of Horlicks branded as Asha Horlicks. Coca Cola has introduced a powdered beverage, Vitingo, fortified with iron, folic acid, zinc, vitamins A and C priced at ` 2.50 for an 18-gram sachet. The sheer size of the rural market and the increasing purchasing power will encourage FMCG firms to launch products targeted at this segment.

Vying for bigger share of the pie India is a global hub for all raw materials in food ingredients. These ingredients stand to attain large marketshares, if marketed in the right manner. However, they also face stiff challenges. For instance, fortified foods, an emerging segment in India, will greatly benefit from clarity in regulation and consumer acceptance. However, the onus is on the government to expedite development through regulation. Additionally, large food & beverage firms need to invest in the market to improve consumer awareness and expand into new end-use segments and compatible with the Indian palate, can promote increased adoption. Courtesy: Chemicals, Materials and Foods Practice, Frost & Sullivan. For details contact Anish Charles on email:

April 2011 | Modern Food Processing



Filling technology

Flexibility and expandability in harmony

Volumetric filling system designed to fill PET gallon containers for the US market

The fierce pressure on costs throughout the beverage industry, and the increasingly stringent quality requirements entailed by consumer expectations, pose a multiplicity of fresh challenges for soft drinks bottlers. A coherently harmonised line concept, designed for maximised flexibility and modularisation, will be able to meet the requirements for optimum versatility and expandability, while providing cost-efficient operations and securing a long-term future in the soft drinks market.

Courtesy: Krones AG

Thomas Schuhbeck


illing systems contribute immensely to the quality of a product. Hence, priority needs to be accorded to choosing the right filling system. The filling technology has to be optimally matched to the requirement profile of the filling job concerned, in order to avoid performance- and quality-related problems. In addition, cost-efficiency aspects like change-over times for different products and container formats have to be taken into account in order to minimise unproductivity and upgrade overall line efficiency. The increasingly stringent hygiene requirements nowadays also call for continual optimisation of existing filling systems and the development of new ones.

Level-controlled filling Depending on the type of bottle involved – glass, returnable or non-returnable PET – different


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filling-valve technologies have to be employed. Level-controlled filling is a preferable choice for glass and returnable PET bottles, since these containers, on account of their large volume tolerances, may exhibit substantial fluctuations in fill level, if they are filled in volumetric or gravimetric mode. In level-controlled systems, traditional counterpressure designs are frequently used, where fill level is set using vent tubes. Modern variants of this filling technology already exhibit an abundance of electropneumatic control options. Nevertheless, for each fill level required, a corresponding vent tube has to be used, which entails change-over routines and concomitant downtimes. Moreover, the valve technology involved, with its internals inside the ring bowl, may lead to hygienerelated difficulties. Filling systems featuring electronic control throughout, by contrast, are able to control the fill levels by means of immersed probes. Compared to traditional


counterpressure fillers, these filling systems provide several advantages. They save time when changing over to different products & container formats as it is no longer necessary to replace any vent tubes. In addition, they offer better fill level accuracy, high flexibility regarding fill levels, and optimised cleanability, thanks to reduced internals in hygienic design.

Volumetric filling The currently preferred method for filling containers featuring relatively high dimensional accuracy, like nonreturnable PET bottles or beverage cans, is volumetric filling. The fill quantity concerned is usually monitored using a magnetic-inductive flow meter. The advantages of volumetric filling (particularly in conjunction with neckhandling for the PET bottles) include minimised change-over times, since the filling system and the fill quantity are electronically controlled throughout, and change-over routines are reduced to a minimum. This state-of-theart filling technology, thus, provides maximised flexibility. The hygienic preconditions are likewise substantially better in volumetric filling systems than in their levelcontrolled counterparts. The internals in the parts of the ring bowls and valves coming into contact with the product are reduced to the bare essentials, rendering the fillers optimally suited for effective cleaning and disinfection. This is why some of the companies opt for flow meter technology in the field of aseptic filling, in which still beverages can be filled in non-contact mode, or their carbonated counterparts (like spritzers) in a counterpressure process, with the bottle pressed against the filling valve. Moreover, aseptic PET bottling, hotfill processes in PET bottles are likewise possible, as is can filling, provided the beverage involved possesses a minimum level of electrical conductivity. For products with little or no conductivity, or beverages with a high content of pulps, fibres, fruit chunks

or fat, gravimetric filling can be utilised as an alternative, with the flow meter being replaced by an electronic weighing device.

Monobloc solutions Monobloc solutions for the PET market feature a synchronised stretch blowmoulding machine and a filler. The advantages of this blow-moulder/filler monobloc compared to traditional line concepts include: a substantial reduction in capital investments – savings in terms of bottle conveyors and buffering systems – go handin-hand with stringent savings in operating media and energy. At the same time, the footprint required by monobloc-synchronised machines is significantly smaller, which may be of

Modern-day filling plants frequently operate with cleanrooms, designed to provide protection against microbiological re-contamination of the product during the filling process. crucial importance, particularly in the event of capacity upsizing and severely restrictive space constraints. The close proximity of two reference machines in a line, moreover, enables personnel deployment to be streamlined, with one machine operator sufficing for both the blow-moulder and the filler. The line’s efficiency is improved by the elimination of components susceptible to malfunctions, which leads to reduced downtimes and substantially lower production costs. Monobloc solutions can be used for almost all PET filling jobs. Still products can be handled just as effectively as carbonated beverages or hot-filled drinks. It may be necessary to cool the hot PET bottles arriving from the blowmoulder before they are filled. There

are various options available for this purpose, like using water for cooling. There is also an option for integrating units for bottle sterilisation in the monobloc, which opens up additional possible applications for monoblocs in the fields of enhanced hygienic filling (EHF) and aseptic filling.

Increased demand for hygiene Hygienic, aseptic filling technology is widely being preferred to bottling with cold sterilising agents or hotfill modes. The paramount advantage is the better product quality achieved. But increasing quality awareness among consumers also plays a significant role: they prefer healthy food and beverages without any ‘preservatives’. The growing microbiological risks in filling sensitive beverages have triggered a substantial technological rethink. In line with the individual sensitivity of the products involved, adequate measures must accordingly be taken in the line to ensure optimum production in terms of both technological excellence and maximised cost-efficiency. Hygienic improvements primarily include creating a machine environment that is easy to monitor & clean, and assuring the requisite level of hygiene by means of sophisticated, automated foamcleaning stations and hygiene centres.

Cleanroom technology Modern-day filling plants frequently operate with cleanrooms, designed to provide protection against microbiological re-contamination of the product during the filling process. The ‘large cleanrooms’ surround the entire filler with an enclosure, essentially comprising the machine’s guarding and a cover, which is fitted with High Efficiency Particulate Air (HEPA) filters so as to supply the hygienically critical area with a continuous flow of pure air. In the ‘small cleanrooms’, only the areas of the filler classified as critical (the filler and closer carousels, including infeed & discharge conveyors) are enclosed, and kept under a pure-air overpressure.

April 2011 | Modern Food Processing



A Krones PET-Asept line for aseptic filling of still beverages, featuring isolator technology Courtesy: Krones AG

Both these cleanroom solutions offer sufficient microbiological protection in the case of heavily acidic, carbonated beverages & still waters, for example, and are accordingly the method recommended for EHF and extended shelf-life (ESL) products, eg, dairy products, smoothies, etc. For highly sensitive beverages, like still juice drinks and near-water products without any carbonation, only an aseptic isolator-based design can provide the requisite microbiological safety. Here, all the major areas, from bottle treatment all the way through to the discharge conveyor, are enclosed in a stringently monitored sterile cleanroom atmosphere, the isolator. The isolator’s surfaces are cleaned and sterilised using integrated jetting systems connected to the hygiene centre. To enable operators to intervene manually in the isolator area, gloves are permanently installed in the machine guards, which means the entire area is hermetically sealed off from its surroundings.

Automated cleaning For cleaning and disinfecting the equipment’s surfaces, automated foam cleaning systems are widely used for EHF lines and hygiene centres, particularly in the case of aseptic lines. All the areas to be cleaned are fitted with foam or spray nozzles, designed to perform foam cleaning, plus the


subsequent disinfection routine automatically & dependably during actual production runs. Human error is eliminated almost entirely in this highly critical area. In addition, a modern-day automated hygiene centre supplies the line with the requisite media for packaging material treatment and sterilisation.

Packaging material sterilisation In most cases, chemical processes are used for sterilising the packaging materials. The chemicals employed for this purpose are either peracetic acid for wet-chemical sterilisation or hydrogen peroxide for dry sterilisation. The appropriate process will depend on several factors. Peracetic acid treatment, for example, consumes large quantities of water, whereas the hydrogen-peroxide method, as a dry process, is more energy-intensive, since the sterilising agent has to be evaporated. Certain sterilisation tasks, however, can be performed only with the dry method, like treating sportscaps or other multi-part closures.

Secondary packaging For reasons of cost, material and weight reductions are essential for secondary packaging as well. Clients frequently demand a processing capability for ultra-thin films, some of them as little as

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25 micrometre thick. Maximising a line’s flexibility, while reducing operating costs involved, is no less important than modularised expandability, given the necessity of coping with the rapidly increasing diversity of both containers and packs. Secondary packages have assumed the task of presenting the product in a ‘shelf-friendly’ form, as strikingly demonstrated by the steep rise in the number of display packages. The job profiles for modern-day packers and palletisers are automatically entailed by these requirements: the machines must be able to handle the increasingly lightweight, and thus mechanically-sensitive packaging materials & packs encountered, without causing any damage or line downtimes. Efficient distribution systems for lightweight packs are accordingly a basic precondition for assuring troublefree handling. The machines also have to cope with a wide range of different packaging concepts (eg shrink-only, shrink-tray and shrink-tray-pad) on a single machine. Moreover, a high degree of modularised expandability is required, so that space-saving monobloc solutions are no longer a rarity for the dry end as well.

New-age filling The dramatically shortened product life-cycles demand maximised flexibility with regard to beverage diversity and packaging material concepts. In order to minimise the capital investment involved, there is an increased demand for modularised, expandable machinery and line concepts, enabling clients to respond swiftly to new trends. Thomas Schuhbeck is heading the Test Centre at the Filling and Closing Technology Division, Krones AG. Prior to being assigned this responsibility, he was the Product Specialist at the Filling and Closing Technology Division, Krones AG, Neutraubling, Germany. Email:


Dairy industry

Skimming impurities to stay ahead Referred to as the ‘oyster’ of the global market, the Indian dairy industry has established itself as the highest milk producer in the world. The country has not only prudently managed the natural resources to enhance milk production, but has also upgraded milk processing capacity by utilising innovative technologies, over the years.

Shushmul Maheshwari


he Indian dairy industry has come a long way to hold the numero uno position in terms of milk production globally. Given the highest milch bovine population in the world, India presents stupendous potential to further boost its position in the world dairy market. At present, the dairy sector in the country is worth $ 70 billion, with about 80 per cent engaged in the unorganised sector. Statistics reveal that India has one of the largest stocks of cattle and buffaloes, accounting for more than 50 per cent of the world’s buffaloes and 20 per cent of cattle. The dairy industry contributes a large share to India’s agricultural GDP and has remained a major source of inexpensive and nutritious food to millions of people in the country. Additionally, dairy production has been an important direct and supplementary source of income for around 75 million rural families accounting for 98 per cent of total milk production. Rising income level and urbanisation coupled with population growth are fuelling the consumption of milk, which is anticipated to remain so in the coming years as well, thereby creating an absolute livestock revolution in near future. Hence, the dairy industry is poised for incessant growth in the future.


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Production scenario Milk production in the country has escalated from 17 million tonne in 1951 to 110 million tonne in 2009. The per capita availability has also increased and reached the highest mark of 271 gm/day during 2009. A study indicates that the Indian dairy production is growing at a rate of about 4 per cent annually, while consumer demand is increasing at approximately double that rate. However, the major impetus for this growth came from the successful implementation of ‘Operation Flood’ and other dairy development programmes by the Central and state governments. Region-wise, Uttar Pradesh, Rajasthan, Punjab, Andhra Pradesh, Gujarat, Maharashtra, Madhya Pradesh, Bihar, Tamil Nadu and Haryana account for over 80 per cent of India’s total milk production. India also tops the chart in terms of milk consumption. This is evident from the fact that India consumed 51.5 billion litre of milk and other livestock, dairy & poultry (LDP) products in 2008 – with a Compounded Annual Growth Rate (CAGR) of 2.7 per cent during the period 2004-2008. Rural households consume almost 50 per cent of India’s total milk production, while the urban market accounts for the rest. Of the total share of milk sold in the domestic market, almost 50 per cent


is used as fluid milk, around 35 per cent as traditional products (yoghurt, paneer, cheese and milkbased sweets), and above 15 per cent is used for the production of butter, milk powder, ghee and other processed dairy items including baby foods, ice cream, casein, whey powder and milk albumin. Of the total milk production in India, the organised sector constitutes 15 per cent share (butter, cheese, milk powder and liquid milk). Despite being the world’s largest milk producer, India’s share in the world dairy trade is almost negligible. However, India is a net exporter of dairy products, equating to over 70,790 tonne in various categories of milk products. Of these, baby food and milk powder exports constitute around 50 per cent of the total dairy exports, followed by butter & other fats, casein, milk & cream, cheese, whey powder and other processed dairy products. Geographically, India exports over 50 per cent of its total dairy products to the US, Bangladesh, the UAE, China, Egypt and Singapore.

Key players In terms of products, the packaged milk segment is dominated by dairy co-operatives, such as Gujarat Co-operative Milk Marketing Federation (GCMMF), Gokul, Warana (Maharashtra), Saras (Rajasthan), Verka (Punjab), Vijaya (Andhra Pradesh), Aavin (Tamil Nadu), etc. Other private players include J K Dairy, Heritage Foods, Indiana Dairy, Dairy Specialties, etc. There are numerous other products that are sold in the Indian dairy sector. For instance, the consumption of ghee is the highest in medium-sized towns at 37.2 per cent compared to 31.7 per cent in urban areas and 21.3 per cent in rural areas. In relative terms, ghee holds higher marketshare in north and west, which are milk surplus regions. Northern region accounts for an estimated 47 per cent of ghee consumption and western

region accounts for an estimated 29 per cent. Southern & eastern regions collectively account for the rest 24 per cent (estimated). Other products, like butter/margarine have a share of only 4 per cent, largely represented by urban areas. Further, consumption of cheese is almost nil in rural areas and negligible in the urban areas. Milk powder and condensed milk have not been able to garner any significant consumer acceptance in India as indicated by a low 4.7 per cent penetration rate. However, flavoured milk is increasingly becoming popular in certain markets as consumers are becoming more health-conscious. It constitutes a good substitute for carbonated soft beverages. GCMMF – that owns and markets Amul dairy products – is the leader in the segment, with 60 per cent marketshare. On the competitive front, Indian dairy sector is poised for rapid expansion and higher efficiency with the entry of big players. Major players including Reliance, ITC, DCM, Bharti, Coca-Cola, and PepsiCo are already creating a competitive environment for future growth. New players, like Yakult-Danone have made their debut and, with the recent acquisition of Cadbury by Kraft, the Indian dairy market can expect to scale new heights. The sector represents huge opportunities for multinational brands as well as input suppliers and will enable them to increase their exports, facilitate technology shift, sign new joint ventures, and create valuable investments in India. Moreover, a research on the dairy industry indicates that milk prices in the domestic market are growing at 20 per cent annually, and the demand for milk is growing at 7 per cent. Besides, issues like adulteration needs to be looked at by the dairy sector as there is huge demand for good quality milk. This is encouraging various firms to invest in this domain and focus on quality issues.


49% 33%

Fluid milk Traditional products (paneer, cheese, yoghurt, etc) Butter, milk powder and other processed products Source: RNCOS Estimation

Figure 1: Share of milk sold in the domestic market (2010)


47% 29%



South & East

Source: RNCOS Estimation

Figure 2: Region-wise consumption of ghee (2010)

The regulator’s stance Various measures have been adopted by the government to sustain the growth of the dairy industry. Recently, the government has initiated various plans to maintain the strides in the sector. For instance, the government is planning to launch a National Mission for Protein Supplements, and the Accelerated Fodder Development Programme to provide the much-needed support to the Indian dairy industry. Additionally, the government has decided to support cold chain infrastructure to boost the dairy industry. Some of the schemes that have been implemented by the Central and state governments for the development of the dairy sector in the country are as follows: R Intensive Dairy Development Scheme R National Programme for Cattle and Buffalo Breeding R Dairy Venture Capital Fund Scheme R Assistance to Co-operative Scheme

April 2011 | Modern Food Processing




Delhi Milk Scheme Strengthening Infrastructure and Clean Milk Production Scheme R Central Fodder Scheme R National Dairy Plan R Budgetary allocation to different dairy schemes under Department of Animal Husbandry and Dairying R

Shortfalls and way ahead Indian dairy industry has been facing various challenges that need to be properly addressed, if it has to maintain the growth pace. Despite the fact that India possesses one of the largest livestock wealth in the world, lack of financial resources to purchase the inputs for dairy sector, inadequate technical skills, and insufficient landholding for proper farming are hampering the growth of the industry. In addition, inadequate feeding of animals and frequent incidences of diseases are still at their peak in India. To put it simply, although small holders and marginal farmers constitute the foundation of Indian dairy industry, deficient labour, land and capital are still the major issues to be addressed. Too many intermediaries are involved throughout the value chain at the collection level, which remains a major constraint for the industry. Due to the large number of intermediaries, the quality of milk deteriorates. It also increases the variations in the volume of milk, with higher chances of milk getting prone to microbial


contamination before reaching the bulk coolers and collection centres. Likewise, adulteration and food safety are the most important aspects of milk production, which often cannot be guaranteed by milk producers. This is not all. The absence of a proper screening system and adulteration of milk by producers act as bottlenecks, impacting the growth of the industry. At the processing level, lack of quality standards and trained & skilled workers limits the progress of the dairy industry in the country. Further, inadequate cold storage facilities coupled with gap in the cold chain and transport facilities also needs to be taken care of, if the sector vies for further growth. Last but not the least, the bulk of the dairy industry in the country is still unorganised. Moreover, lack of transparent milk pricing system poses an important impediment for the industry regulators. Further, there is no technological interference in the dairy industry to ensure proper record of milk collected from milk producers. On the infrastructure front, huge amount of milk goes waste due to shortage of bulk coolers and chilling plants. In order to strengthen the position of India in the global dairy industry, the industry regulators need to consider certain suggestive measures that are discussed below. Each level of value chain of dairy sector should be assessed to judge the financial support requirement. The concept of micro-financing and customised financial products with specific schemes should be executed to provide ample support across the milk value chain. Further, a liberal credit policy should be adopted to provide the much required impetus to the dairy sector. However, it is imperative that dairy farmers should be made aware of these financing schemes, which can be supplemented by awareness campaigns. The sector holds immense opportunities as new business models in partnership with private players can be more fruitful. Training and capacity-

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building programmes will be decisive for the development of dairy industry, which can effectively be executed by public-private partnership (PPP) model. India’s dairy co-operative structure and milk zones can be properly utilised through the PPP model. In addition, establishment of vocational training institutes for imparting education on dairy processing technologies will facilitate the sector’s growth. The government can provide subsidies to these institutes for running various courses and building the infrastructure. Procurement and processing functions can be improved by co-ordinating with private players. The entire supply chain should be scrutinised for seeking strategic locations for milk collection and building & designing the entire collection network. Assistance in R&D and export of dairy products is also critical for the development of this sector.

On the hygienic route There is a wide disparity in India’s dairy segment when it comes to the volume of milk produced and that of milk processed. The gap in support logistics and infrastructure is possibly the most indispensable cause for the small share of hygienic milk in India. The venture of private players into this key area can change the picture with support in the form of operational and logistics backup for maintaining the quality of milk through a channel of processing plants and cold chains. Shushmul Maheshwari is the Chief Executive of RNCOS E-Services Pvt Ltd, a market research & information analysis company with global presence. He has spent more than 15 years working in the senior management teams of both, Indian and multinational companies. He has gained expertise in research & analysis field and actively participated in various national and international conferences & discussions organised by business & trade-related associations. Email:


Ice cream processing

Getting the right safety mix

Ice cream is relished by one and all, irrespective of the age factor. However, what goes into the making of it and the safety measures practised during the manufacturing process hold immense significance. Read on to know the recipe of safety while producing ice cream.

Subhash Vaidya


he ice cream market in India is estimated at ` 3,000 crore per annum, of which about 30 per cent is manufactured by organised sectors. This segment is emerging as the fastest growing dairy favourites. In Western and developed countries, the per capita consumption of ice cream is over 15 litre per annum as against India’s 0.5 to 1 litre per annum. Taking into consideration the rising population, changing lifestyles and increasing urbanisation in India, there is a tremendous Conduct hazard analysis

Establish documentations for all procedures

potential for production and consumption of ice creams. The main ingredients used for making ice cream include milk, cream, butter, skim milk powder, sugar, stabiliser and emulsifier, among others.

Safety measures during production process At the manufacturing level, food safety can be achieved through the adoption of Hazard Analysis Critical Control Point (HACCP) principles. HACCP is a management tool for assessing various hazards – be it biological, chemical

Determine critical control point

Establish procedure to verify

Establish corrective action

Figure 1: Steps involved in HACCP


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Establish critical limits

Establish procedure to monitor


or physical – and identifying critical control points to either eliminate those or maintain them at acceptable levels.

Production line The various activities involved in the manufacturing process are as follows: Purchase & selection of ingredients: While the ingredients get delivered at the factory, such as milk & milk products, sugar, etc, these must be checked for any sort of contamination. Chemical hazards need to be detected that include finding chemical traces in raw materials. It is therefore, necessary to follow control measures such as sourcing ingredients from approved suppliers and as per the given specifications. Any type of contamination seen in ingredients can result in bacteriological hazards, thus making heat treatment of ingredients a necessity. In some cases, filtration is also necessary to control foreign particles. The contamination that occurs during handling and storage of ingredients can be identified by conducting hazard analysis. Figuring and making the mix: As per the recipe, all ingredients are mixed in the specified proportion – including the desired percentage of fat, total solids, sugar, emulsifiers and stabilisers. Contamination may occur if personal hygiene is not followed. Hence, hygiene is a crucial aspect. Moreover, it needs to be ensured that dust, rubbish, broken ceiling particles, etc, do not get mixed with the ingredients. Pasteurisation of mix: The mix is pasteurised at 680C for 30 minutes. If the desired temperature is not obtained, there are chances of survival of pathogenic organisms. Temperature monitoring as well as maintaining the records of the same are essential tools to control and prevent hazards. Heat treatment may also be used to activate stabilisers. In order to overcome chemical and physical hazards, the ice cream mix must be properly filtered before pasteurisation. It is essential

to check the filter every day to ensure effective filtration process. Homogenisation: Use of accurate pressure during homogenisation is necessary to produce stable and uniform-sized fat globules. If this is not achieved, it will harm the quality of the end-product. Cooling: The mix should be cooled at a temperature of 40C, within one-and-a-half hours of heat treatment (after pasteurisation and homogenisation) to enhance quality of the liquid mix during storage. In order to prevent dust particles, stones and other contaminants in the mix, the vats need to be cleaned properly. Ageing: After the mix is cooled to a temperature of 40C, this temperature should be maintained till it is taken for freezing (16 hours). For checking and monitoring the temperature, the vat should be fitted with accurate temperature-indicating instruments. The temperature should be maintained during ageing period. Ageing is done mainly for hydration of protein. Colour addition: The mix is shifted from the ageing vat to flavouring vat. As per the concerned company’s recipe, colour & flavour are added proportionately. It should be ensured that the measuring cylinder used for adding colour is properly cleaned. Unclean apparatus may cause contamination of product, as there is no control measure to destroy pathogenic organism. Freezing the mix: The freezing process of ice cream mix may be carried out according to the type of product to be manufactured and available equipment for the same. All precautions should be taken to prevent contamination of product during different operations. The air is incorporated into the mix and the mix is whipped to increase its volume, and then it is put into the freezer. The incorporation of air is done to give a tempting appearance to ice cream and a smooth texture. On the flip side, this air may contaminate the product,

Selection of ingredients

r Figuring the mix

r Making the mix

r Pasteurising the mix (680C) for 30 minutes

r Homogenising the mix


Cooking and ageing of mix (0-40C)


Freezing the mix (-40C to -50C)

r Packing of ice cream

r Hardening & storage of ice cream (-230C) Figure 2: Flow diagram depicting ice cream manufacturing process

and hence, it should be ensured that good quality air is incorporated, and air-borne organisms must be inhibited from contaminating the product, on account of undesirable environmental conditions. Packing: Ice cream packs come in different sizes and types – family pack, party pack, bulk pack – depending upon customer requirements. Every precaution should be taken to prevent contamination of product during packing. The control measures that can prevent, eliminate, or reduce food-related hazards to acceptable levels include effective cleaning and proper handling of packing equipment, adherence to hygiene by staff members, etc. The most important aspect is that the frozen state of the ice cream should be maintained. In some cases, fruits, dry fruits, chocolate chips are added at the time of filling in the packing units. This is

April 2011 | Modern Food Processing



a critical step. Care should be taken that these ingredients are treated with heat so as to prevent bacteriological contamination. Hardening & storage of ice cream: The packed ice cream – either in bulk or in containers or packages – should be stored in cold room or deep freezer cum hardener at a temperature below -200C. It may pose some hazards, in some cases, if the package gets damaged. The control measures should ensure that the frozen state should be maintained during storage and the product handling takes place with care. Dispatching: All vehicles used for transportation of ice cream should be so built and operated as to protect their contents from exposure to sunlight, dust and contamination. Suitable arrangements should be made to keep ice cream at a temperature not exceeding -200C till it reaches the destination.


Safety tips in a nutshell To ensure food safety, effective systems need to be implemented not only during production, but also for other activities involved till it reaches the end-consumer. Establishment should be away from polluted areas. All the internal structure and fittings should be made of impervious material. It should not have toxic effect on food that is being handled. Equipment should be properly cleaned with liquid detergent and disinfected. It should be maintained in such a way that it does not result in food contamination. Potable water use should be ensured. Water tanks should be cleaned regularly at planned intervals and records should be maintained. There should be sufficient water supply to clean utensils and equipment. Septic tank and drainage lines should be cleaned frequently. Wire mesh covering on drainage outlets in the premises should be provided.

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It is necessary to maintain the quality of air to minimise air-borne contamination, control odours and humidity. Storage facilities for raw materials, finished products should facilitate maintenance, cleaning and protection from contamination. It is recommended to establish the specification for incoming raw materials, packaging materials and finished goods. It should be documented, verified and inspected at all stages. Thus, by enforcing various pre-requisite programmes and following the best practices, the food safety objectives in the ice cream industry can be achieved to meet the quality standards demanded by customers. Subhash Vaidya is a Senior Consultant for food, HACCP & ISO 22000 food safety management system. He is also a Consultant for the dairy industry. Email:


Quick service restaurants

Catering to changing eating habits In today’s fast-paced life, most people do not find enough time to cook. They prefer eating out or getting food delivered at home. This has led to a surge in the demand for quick service restaurants or fast food joints, which provide sumptuous food at affordable prices and also pay heed to the time pressures faced by consumers. Courtesy: Green House and Hestsoft Foods


uick service restaurant (QSR) is one of the world’s fastest growing segments in the food industry. It now accounts for roughly half of all revenues earned by restaurants in developed countries and continues to expand significantly in several other industrialised nations. But the developing world is witnessing the most rapid growth in this area, where this industry is influencing the eating habits of people to a great extent. People generally opt for fast food because it is affordable, less time-consuming and can be eaten while on the move. Double-income families and larger disposable incomes in India have generated a demand for different types of food services, which the quick service format has been able to address. Over the years, the quick service market has grown at about 20 per cent per annum. Currently, nearly 300 million upper-class and middle-class consumers of processed & packaged food exist in the country, and another 200 million are expected to opt for this service in the near future. A major reason for the growth of this segment of the food service industry in India is the introduction of a variety of cuisines from various countries. For instance, pizza joints, which are largely popular among the youth, constitute 4-5 per cent of the entire fast food segment in the country. A number of restaurants worldwide have combined the right ingredients


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and years of successful experience to create a growth-oriented business operation.

Why QSR? The demand for processed foods and beverages in India is constantly on the rise. In the past few years, average monthly income of people has increased by almost 43 per cent. Further, the disposable income of individuals has increased to nearly 45 per cent. This growth in income will give a further boost to India’s processed food industry. The changing scenario of Indian retail industry, such as opening up of new supermarkets/hypermarkets, shopping malls and fast food outlets, coupled with favourable industry trends, is about to bring a radical shift in the Indian food & drink industry. Despite food production in the country expected to double by 2020, not much attention has been given to the growth of this vital industry. Rapid transformation in Indian lifestyle, particularly among the urban populace has resulted in a dramatic increase in the demand for fast food. According to a research report – ‘Indian fast food market analysis’ – India has one of the rapidly growing fast food markets in the world. The Indian fast food market is growing at an annual growth rate of 30-35 per cent. Almost all big fast food joints of the world have succeeded in gaining a foothold in the


country, with a majority registering a substantial growth. Most of these joints offer the highest quality products and in several varieties, without compromising on the taste of the food products.

Factors leading to the shift People nowadays regard home delivery as a necessary attribute for restaurants and fast food joints. Players in the market are well aware of this fact and provide this service to customers, thus generating 20 per cent of their revenue through home delivery. The strength of major pizza joints depends on home delivery through which they generate 80 per cent of business. Besides, about 70 per cent of the population prefers to visit restaurants or fast food joints within 2-5 km range. A recent research states that taste and quality are two major factors that people look for in a restaurant, followed by food quality, service and ambience. Another major factor leading to this shift is the spending habit of consumers. The spending habit of people is fast catching up, with almost 48.5 per cent spending ` 100-200 on fast food items. The figure shows the changing trend in eating habits of people, mostly the youth, who prefer to buy food at these joints, instead of regular meals. This trend is welcoming for the fast food joints, as it will spur the consumer spending on fast foods.

The star attraction As good quality food and excellent ambience play an important role in the demand for restaurants, the upscale pizza joints cater to this demand. They not only provide good ambience, but also give consumers the best price range, without compromising on product quality. Moreover, to have an edge over competitors, these service providers ensure that the consumer is served only the best-in-class products.

Road ahead The future of QSR appears bright. Most of the popular fast food chains have chalked out massive plans for expanding their business and presence throughout the country. For instance, restaurants, such as Slice of Italy, plan to increase the number of their outlets to 50 by the end of 2011. Domino’s Pizza has plans to open about 60-65 outlets annually, during the next few years. Moreover, Yum Brands, Inc, is preparing for a massive expansion across the country, with plans to open about 1,000 fast food outlets by 2015. The emergence of various factors fuelling the demand for QSR and the initiatives taken by this category of restaurants indicate that it is here to stay. Courtesy: Green House and Hestsoft Foods Pvt Ltd is the owner of Slice of Italy pizza joint. For details contact on email:

April 2011 | Modern Food Processing



National AHMEDABAD PUNE Gujarat Maharashtra Oct 14-17, 2011 Nov 18-21, 2011 Gujarat University Auto Cluster Exhibition Hall Exhibition Centre

CHENNAI Tamil Nadu Dec 2011 Chennai Trade Centre, Nandambakkam

INDORE Madhya Pradesh Jan 6-9, 2012 Poddar Plaza, Nr Gandhi Hall

India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumatics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.

For details contact: Nexgen Exhibitions Pvt Ltd 1201/1206 Pragati Tower 26, Rajendra Place New Delhi 110 008 Tel: 011-4008 1051/1000 Fax: 011-4008 1099 Email:

For details Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. T: +91-22-30034651 F: +91-22-30034499 E: W:

FF&B 2011 The second annual Functional Food & Beverages (FF&B) India show for health and wellness products; June 28-30, 2011; at ITC Maratha, Mumbai For details contact: Oby George Programme Manager - Fi Conferences UBM India Pvt Ltd 611-617, Sagar Tech Plaza - A Saki Naka, Andheri-Kurla Road Andheri (East), Mumbai 400 072 Tel: 022-6612 2600 Fax: 022-6612 2626 Email:

PackPlus South 2011 The event will focus on latest trends in food packaging and emerging opportunities in the fast industrialising markets of South India; July 1-4, 2011; at HITEX, Hyderabad For details contact: Pvt Ltd International Infotech Park Vashi, Navi Mumbai 400 705 Tel: 022-2781 2093, Fax: 022-2781 2578 Email:

Food & Technology Expo 2011 An international exhibition focussing on food processing & packaging machines & technologies; July 29-31, 2011; at Pragati Maidan, New Delhi For details contact: Anil Rana NNS Events & Exhibitions Pvt Ltd Meri Delhi House 25/10, East Punjabi Bagh New Delhi 110 026 Mob: 098102 13597 Email:

India Foodex 2011 An exhibition on food processing & packaging technology, and food & beverage products to be held


concurrently with DairyTech India, GrainTech and AgriTech India; September 09-11, 2011; at Gayathri Vihar, Palace Ground, Bengaluru For details contact: Media Today Group (Exhibition Div) T-30, 1st Floor, Khirki Extension Malviya Nagar, New Delhi 110 017 Tel: 011-6565 6553/2668 2045 Fax: 011-2668 1671 Email:

Fi India 2011 An event featuring new and innovative food ingredients from India and abroad; October 3-4, 2011; at Bombay Exhibition Centre, Mumbai For details contact: Bipin Sinha UBM India Pvt Ltd 611-617, Sagar Tech Plaza - A Saki Naka, Andheri-Kurla Road Andheri (East), Mumbai 400 072 Tel: 022-6612 2600 Fax: 022-6612 2626 Email:

Annapoorna - World of Food India 2011 An international exhibition and conference for the food and beverage industry; November 16-18, 2011; at Bombay Exhibition Centre, Mumbai For details contact: Trade Fair Secretariat FICCI Federation House, Tansen Marg New Delhi 110 001 Tel: 011-2373 8760-70 Fax: 011-3091 0411 Email:

SUGARASIA 2011 An event dedicated to sugar processing, co-generation, ethanol and cane harvesting; November 21-25, 2011; in New Delhi

Modern Food Processing | April 2011

Poultry India 2011 Exhibition for livestock and poultry industries; November 23-25, 2011; at HITEX, Hyderabad For details contact: Indian Poultry Equipment Manufacturers’ Association (IPEMA) E-36, ‘D’ Road, MIDC, Satpur Nashik 422 007 Mob: 098220 94653 Email:

IFDE India 2011 A food & drink international exhibition; December 01-03, 2011; at Pragati Maidan, New Delhi For details contact: Tarsus Group Plc Metro Building, 1 Butterwick London, W6 8DL, The UK Tel: +44 (0) 20 8846 2700 Fax: +44 (0) 20 8846 2801 Email:

India Packaging Show 2011 The show aims to bring together the worldwide manufacturers and providers of machinery, materials and services for food, pharma and packaging industry from India and neighbouring countries; December 0710, 2011; at NSIC Exhibition Centre, Okhla Industrial Estate, Delhi For details contact: Pvt Ltd International Infotech Park Vashi, Navi Mumbai 400 705 Tel: 022-2781 2093, Fax: 022-2781 2578 Email:

VIV India 2012 International trade fair for intensive animal production and processing; February 22-24, 2012; Bangalore International Exhibition Centre (BIEC) For details contact: VNU Exhibitions Europe Jaarbeursplein 6 NL- 3521 AL Utrecht The Netherlands Tel: +31 (0)30 - 295 2700 Fax: +31 (0)30 - 295 2701 Email:


International Interfood Sweden 2011

IFIA Japan 2011

DISF 2011

A food industry exhibition & congress; April 14-16, 2011; at Swedish Exhibition & Congress Centre

Exhibition and conference for food ingredients and additives sector; May 18-20, 2011; at Tokyo International Exhibition Center, Japan

The Dubai International Seafood Expo (DISF) 2011; September 27-29, 2011; at Jumeirah International, Dubai

For details contact: Svenska Mässan Box 5222, 40224 Gothenburg, Sweden Tel: +46 31 708 80 00 Fax: +46 31 16 03 30 Email:

Oil China 2011 An international exhibition of olive oil and edible oil; April 18-20, 2011; at Shanghai Everbright Convention & Exhibition Center, China For details contact: Beijing Regalland Convention & Exhibition Co Ltd Room No 438 Jin Ou Building Chaoyang District Beijing 100029, China Tel: +86 10-64416542 Fax: +86 10-64412631 Email:

IBEXPO 2011 Exhibition showcasing latest from bakery, additives, ice cream, chocolate, coffee and patisserie equipment & accessories; May 05-08, 2011; at Tüyap Fair Convention and Congress Center, Istanbul, Turkey For details contact: Hannover - Messe International Istanbul Büyükdere Caddesi C.E.M. Ýþ Merkezi No: 23 Kat: 3 Þiþli – Ýstanbul Turkey Tel: +90 (212) 334 69 48 Fax: +90 (212) 334 69 34 / 230 04 80 Email:

Interpack 2011 An exhibition for processing and packaging technology offering innovative solutions to meet the challenges of the markets; May 12-18, 2011; at Duesseldorf, Germany For details contact: Rajesh Nath VDMA Liaison Office GC 34, Sector III, Salt Lake Kolkata 700 106 Tel: 033-2321 9522/7391 Fax: 033-2321 7073 Email:

For details contact: Orange Fairs & Events P O Box 111164, Dubai UAE Tel: +971 4 2988144 Fax: +971 4 2987886 Email:

For details contact: E J Krause & Associates Inc 6550 Rock Spring Drive Suite 500 Bethesda, MD 20817, The US Tel: +1 (301) 493-5500, Fax: +1 (301) 493-5705 Email:

ANUGA 2011

PROPAK ASIA 2011 A trade show for food processing and packaging technology; June 15-18, 2011; at BITEC, Bangkok, Thailand

One of the leading exhibitions for processed foods and technology; October 08-12, 2011; at Exhibition Centre Cologne, Germany For details contact: Koelnmesse GmbH Messeplatz 1 50679 Köln Germany Tel: +49 221 821-0, Fax: +49 221 821-2574 Email:

For details contact: Bangkok Exhibition Services Ltd 62 Rama VI Soi 30 Rama VI Road, Samsennai Phiyathai, Bangkok 10400 Thailand Tel: +66 (02) 617 1475 Fax: +66 (02) 617 1406 Email:

China Foodtech 2011

FI ASIA-CHINA 2011 An international food ingredients exhibition; June 21-23, 2011; at Shanghai New International Expo Centre, China For details contact: CMP Information P O Box 200, 3600 AE Maarssen The Netherlands Tel: +31 346 559444 Fax: +31 346 573811

FOODPRO 2011 A trade fair showcasing latest trend and technology in food manufacturing; July 10-13, 2011; at Sydney Convention & Exhibition Centre, Australia For details contact: Dmg World Media (UK) Ltd Westgate House 120/130 Station Road Redhill, Surrey RH1 1ET The UK Tel: +44 (0)1737 855000 Fax: +44 (0)1737 855475 Email: Email:

Exhibition for the food processing and packaging machinery; November 02-04, 2011; at China International Exhibition Centre (CIEC), Beijing For details contact: CIEC 6 East Beisanhuan Road Chaoyang District Beijing, 100028, China Tel: +86 10 8460 0335 Fax: +86 10 8460 0325 Email:

SIFSE 2011 The Shanghai International Fisheries & Seafood Expo (SIFSE) for fish processing industry; December 08-10, 2011; at Shanghai Everbright Convention & Exhibition Center, China For details contact: Shanghai Gehua Exhibition Service Rm.1206-1208 Xin’an Building No. 99 Tianzhou Rd Shanghai, 200233, China Tel: +86-21-54451166 Fax: +86-21-54451968 Email:

The information published in this section is as per the details furnished by the respective organiser. In any case, it does not represent the views of Modern Food Processing

April 2011 | Modern Food Processing



Hot-ink roller Process Instrumentation & Controls (PIC) offers hot-ink rollers for various dry-contact coders of Markem & Stacking Coder machines. These rollers do not require adding or charging of conventional inks. It is solid at room temperature and does not smudge. It is non-toxic, gives sharp impressions & contains solvent free ink and therefore there are no hazards possible, as in conventional ink. These rollers are used in various industries such as food (snack foods, nuts, chips, and confectioneries), pharmaceuticals, cosmetics, dairy, frozen food etc. These are designed to be used in high speed date coding and lot number marking printers, which use stamps affixed to a rotating drum that contacts a heated urethane roll impregnated with an ink/paraffin formulation. Once the print head is covered with hot-ink, the rotating drum deposits the ink mixture on the label or packaging substrate. Once deposited on the substrate, the ink dries almost instantly and creates a mark that is permanent & visually readable. The result is a visually readable date code, which is simple and extremely cost-effective. Process Instrumentation & Controls Vadodara - Gujarat Tel: 0265-235 7228, Fax: 0265-235 5429, Mob: 098251 39846 Email:

Mixing battery Feliz Biotech Industries offers the wash down station (mixing battery). It is designed to provide instantaneous hot water economically by mixing steam and potable water to the required temperature. Mixing battery provides food, beverage, pharma and cosmetics industry with economical hot water for cleaning applications wherever steam is available. It incorporates hydraulic fail safe device, so that when correctly installed and maintained, no steam, regardless of its pressure, can enter the mixing chamber until the water flows to raise the steam valve of its seat. When turned off at the outlet, there is immediate and positive shut-off. A temperature indicating gauge is provided to know the temperature of the emerging hot water. The outlet hose can be connected to a water saver nozzle for external cleaning or to a spray ball for internal cleaning of process equipment. The unit can be provided with self-rewinding hose reel. Using heavy duty internal spring, the reel quickly & easily rewinds the hose. The ratchet assembly locks the reel when the desired length of the hose is pulled out. All hose reels are preset with enough force to fully retract the hose. Feliz Biotech Industries Mumbai - Maharashtra Tel: 022- 2685 9440, Mob: 098922 73314 Email:


Modern Food Processing | April 2011


Vacuum packing machine Monarch Appliances offers vacuum packing machine, which is used to pack food products. The key advantage of this machine is that it increases the shelf-life of the products. It vacuums the product through machine. The advantage of chamber machine is that even the space surrounding the product outside the package also vacuums. Vacuum chamber machines can also be used to package products with a modified atmosphere. Very low residual oxygen figures can be obtained by first pulling a vacuum before the injection of gas. The vacuum machine is used for packing cheese, meat, fish, flower bulbs, coffee beans, pillows, PCBs, food products, khakhara, roti, groundnuts, namkeen, spices, instant food, bakery products, chemicals, electric components, pharmaceuticals, dairy products, dry fruits, seafood, etc. Monarch Appliances Rajkot - Gujarat Tel: 0281-2461 826, 301 7420 Fax: 0281-301 9788 Mob: 098252 15733 , 093767 77277 Email:

April 2011 | Modern Food Processing



Raw chapatti making machine Jas enterprises offer a mesmerising range of raw chapatti making machines. This provides relief to those involved in the preparation of meals in various institutes, hospitals, school & college hostels, industrial canteens and railway & defence establishments. Dough just needs to be fed into the hopper and at the outlet one gets raw chapatti. Apart from this, no oil is required. Thus, this machine offers oil-free chapattis at economical prices. This is presented with one horsepower silicon controlled rectifier rated DC motor with base speed 300 to 3000 rpm electric motor along with variable speed DC drive which converts incoming single-phase AC volts to DC volts. During this conversion process, DC drives can regulate speed, torque, voltage and current conditions of the DC motor, dusting arrangements and one number of die roll. This machine is able to produce 500 to 1,200 chapattis per hour & 1000 to 2,400 pooris per hour and requires little space, 98 inches x 43 inches x 20 inches. Jas Enterprises Ahmedabad - Gujarat Tel: 079-2274 3454, Fax: 079-2274 5062 Email:

April 2011 | Modern Food Processing



Multi-spring balanced seal Hi-Fab Engineers manufactures and offers multi-spring balanced seals (type HBN) that are nonclogging seals with protected springs. These seals are bidirectional and fit on any ANSI, ISO and DIN pumps. The seals find application in viscous and arduous duties, food & beverages, dye liquor applications, moderate slurries, crystallising & solidifying media, etc. Also offered are mechanical seals with a wide product range of pump seals, agitator/mixer seals, universal cartridge seals, metal bellow seals and seals for special process equipment. Hi-Fab Engineers Pvt Ltd Mumbai - Maharashtra Tel: 022-4076 6555 Fax: 022-4076 6556 Email: The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any case, it does not represent the views of

Modern Food Processing

Business Insights •Technologies•Opportunities

Dear Reader, ‘Modern Food Processing’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the food processing industry. You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 3000 words, while that of a product write-up should not exceed 200 words. The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format. The final decision regarding the selection and publication of the articles shall rest solely with ‘Modern Food Processing’. Authors whose articles are published will receive a

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ll... e w s a i t e t h a t r e wa r d s

complimentary copy of that particular issue and an honorarium cheque. Published by Infomedia 18 Limited, ‘Modern Food Processing’ is the leading monthly magazine exclusively meant for producers and user fraternities of the food processing industry. Well supported by a national readership of over 80,000 and our strong network of 26 branch offices across India, this magazine reaches out to key decision makers among the Indian manufacturers of food processing products, machinery and allied sectors. Brought out in association with Hong Kong-based Ringier Trade Publishing Ltd (one of the world’s largest

trade publishing houses with more than 200 special interest titles and offices in every major country), it ensures that advertisers are able to promote their products and services across the globe at no extra cost. So get going and rush your articles, write-ups, etc… Thanking you, Yours sincerely,

Manas R Bastia Editor Infomedia 18 Limited ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W) Mumbai 400 028 India


Modern Food Processing | April 2011

D +91 22 3003 4669 T +91 22 3024 5000 F +91 22 3003 4499 E W



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Pg. No.

Sl. No.


Pg. No.


Accelerated ageing test .................... 57


Flexible transparent PVC strip door......... 63


Plastic pellets............................................ 9


Air breathing apparatus ......................... 63


Floor automation ................................... 37


Plate heat exchanger ................................ 6


Air cooled sealers ................................... 17


Flour milling ............................................. 9


Plug valve................................................. 6


Air cooler ............................................... 27


Food processing lines ............................. 65


Pneumatic valve ....................................... 6


Ammonia liquid chillers............................ 6


Forced convection unit air cooler ........... 27


Polymer characterisation......................... 57


Animal feed technology ........................... 9


Fruits/vegetables processing machine ..... 65


Process tanks............................................ 6


Automatic scrubber dryers ..................... 35


Fuel........................................................ 57


Programmable logic controllers ..............FIC


Banking services................................ 65


Gantry automation ........................... 37


Programmable terminals ........................FIC


Battery charger....................................... 51


Gases ..................................................... 57


Proximity sensors....................................FIC


Biodiesel................................................. 57


Gear oils................................................. 57


PVC strip door........................................ 63


Brewing.................................................... 9


Grain handling ......................................... 9


Rail tankers.......................................... 6


Bulk milk cooler ....................................... 6


Grill magnet ........................................... 63


Railway products .................................... 51


Butterfly valve........................................... 6


Grinding & dispersion .............................. 9


Rare earth tubes..................................... 63


Carpet cleaning machines ................ 35


Gyratory screen ...................................... 63


Raw chapatti making machine .............. 65


Chemical dosing pump .......................... 63


Heat resistant door ........................... 63


Refrigerant pumps.................................... 6


Chlorination plant .................................. 63


Heater controller .................................... 51


Refrigeration ............................................ 6


Chlorine cylinder/tonner emergency repair kit .. 63


High capacity bag palletiser ................... 15


RFID .......................................................FIC


Chlorine gas cylinder .............................. 63


High pressure cleaners ........................... 35


Rice milling equipment............................. 9


Chlorine gas mask.................................. 63


Hopper magnet...................................... 63


Robotic automation ............................... 37


Chloroscope ........................................... 63


Hot-ink roller.......................................... 60


Safety door........................................ 63


Chocolate/cocoa machine......................... 9


Induction sealing .............................. 17


Safety light curtains ...............................FIC


Cleaning section equipment ..................... 9


Industrial control & sensing devices........FIC


Screw compressor .................................... 6


Colour masterbatches............................. 54


Industrial door ....................................... 63


Sealers.................................................... 17


Colour sorting machine ............................ 9


Industrial type unit air cooler ................. 27


Self-adhesive tapes ................................ 60


Compositional & trace metal analysis ..... 57


Ink adhesion .......................................... 17


Shrink film packaging machines ............. 15


Inverter/variable frequency drives............FIC


Single disc machines .............................. 35


Inverters ................................................. 51


SME car loan.......................................... 55


Label adhesion .................................. 17


SME finance ..................................... 55, 65


Level controllers .....................................FIC


SME loan ............................................... 47


Lubes (engine oils) ................................. 57


Stretch film packaging machines............ 15


Magnetic equipment......................... 63


Stretch wrapping machines .................... 15


Magnetic plate ....................................... 63


Surface treatment .................................. 17


Magnetic traps....................................... 63


Sweepers................................................ 35


Material identification ............................ 57


Switching relays .....................................FIC


Measuring & monitoring relay................FIC


Tanks & silos ....................................... 6


Metallography ........................................ 57


Temperature controllers..........................FIC


Mixing battery........................................ 60


Testing ................................................... 57


Mixing machine ..................................... 65


Thermal processes .................................... 9


Motion controls .....................................FIC


Timers ....................................................FIC


Multi-spring balanced seal ..................... 66


TPU masterbatches................................. 54

Engineering Expo exhibition ................... 61


Oil milling............................................ 9


Transmission fluids ................................. 57

Evaporating units for cold rooms ........... 27


Online B2B marketplace ................... 23, 67


Turbidity meter....................................... 63

Packplus South-2011 exhibition ....... 64


Universal type unit air cooler ........... 27


Conveying systems ................................. 65


Counters & power supplies ....................FIC


Cutters/slicers ......................................... 65


Dairy machinery .................................. 6


Dehydration equipment.......................... 65


Diesel fuel .............................................. 57


Doors ..................................................... 63


Drawer magnet ...................................... 63


Drives ............................................... 31, 61


Drives & automation .............................. 51


Dust control door................................... 63


Eco flux corrugated tube heat exchangers... 5

38 39 40 41 42 43

Electromagnetic feeder........................... 63 Embedded systems................................. 51 Encoders ................................................FIC Energy saving products ......................... BIC

Exhibitions..................................61, 62, 64



Extruded products .................................... 9


Palletising robots.................................... 15


UPS system ............................................ 51


Failure analysis .................................. 57


Pasta making machine ............................. 9


Utility support equipment ...................... 51


FI India-2011 exhibition ......................... 62


Peeling machine ..................................... 65


Vacuum cleaners ............................... 35


Filler compositional analysis.................... 57


Petrol & fuel oils .................................... 57


Vacuum packing machine ...................... 63


Filteration/separation solutions .............. BIC


pH meter ............................................... 63


Ventilators ............................................ 60


Filters .................................................... BIC


Photoelectric sensors ..............................FIC


Vibration motor ..................................... 63


Financial services .................................... 65


Piston pumps ........................................... 5


Vision sensors ........................................FIC


BC - Back Cover, BIC - Back Inside Cover, FIC - Front Inside Cover

April 2011 | Modern Food Processing



Advertiser’s Name & Contact Details

Alok Masterbatches Ltd

Pg No


Advertiser’s Name & Contact Details

Giantwell Machinery Co., Ltd.

Pg No


Advertiser’s Name & Contact Details

Plast World


T: +91-11-41612244

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Aqua Services




T: +91-265-2331748

Gudel India Pvt Ltd

Pg No


Print Packaging.Com Pvt Ltd


T: +91-22-27812093

T: +91-20-25459531


E: E:




BEUMER Group GmbH & Co. KG 15

Shiva Analyticals (India) Limited Hi-Rel Electronics Pvt Ltd

T: +49-2521-240


T: +91-80-27971322


T: +91-79-23827180



E: contact@hirel,net



Siemens Ltd

Bonfiglioli Transmissions (Pvt) Ltd


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HRS Process Systems Ltd


T: +91-20-66047894



Buhler (India) Pvt Ltd



5 W:

Siemens AG I DT MC MS T: +9131-98-3630


IDMC Limited


E: T: +91-2692-225399 E:



Spirax Marshall Pvt Ltd




India Mart Intermesh Ltd


T: +1800-200-4444

Sreelakshmi Traders


T: +91-44-24343343

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Jaykrishna Magnetics Pvt Ltd

Enercon Asia Pacific Iss Pvt Ltd 17

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Omron Automation Pvt Ltd 61

T: +91-9920401226


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Pall India Pvt Ltd





State Bank Of India T: +1800 11 22 11





UBM India Private Limited

T: +91-22-67995550

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Standard Chartered Bank


FX Multitech Pvt Ltd




Engineering Expo


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Diversey India Pvt Ltd



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Our consistent advertisers


Modern Food Processing | April 2011

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Modern Food Processing - April 2011  

‘MODERN FOOD PROCESSING’ is the leading monthly business magazine in India exclusively for the food processing industry.