MAY 2019 - JULY 2019 Vol. 7 • No. 2
Improve quality
while reducing operational costs Novel processing technology brings food to the people
Natural advances in colours & flavours
A world of flexible and smart label inspection awaits
CONTENTS M AY 2 019 - J U LY 2 019
Vo l. 7 • N o. 2
6
NEWS Expect big things at this year’s Nigerian Food Event Vanilla farmers have a better future ahead Talbot & Talbot announce partnership with Thesele
8
10 Smarter systems, smarter processes
INDUSTRY TALK Smart solutions for the logistics chain
12
FOOD PROCESSING TECHNOLOGY Sentinel II increases the limits of fresh produce processing
“The increasing cost of manufacturing, raw materials and steeper municipal penalties is driving manufacturing plants to focus on their product losses and effluent overloads at their facilities”
Turnkey solutions in meat processing Steel belts offer unlimited versatility Technology leapfrogs with changing convenience food patterns Equipment that will captivate Africa Angola celebrates its first industrial bread line Snacks with the perfect crunch
24
COLOURS & FLAVOURS Stevia is the natural solution
27
RECYCLABLE PACKAGING Kenya gets serious about PET recycling
16 The unparalleled versatility of steel belts "Ipco forms part of the Swedish-based Wallenberg group. The company is one of the largest suppliers of solid and perforated steel belts to the food processing industry"
29
LABELLING New flexible and smart label inspection solutions A world of different label regulations
ADVERTISERS’ INDEX Afrocet Montgomery (NFE).......................................6 ...........www.nigerianfoodevent.com Afrocet Montgomery (Propak West Africa)..........27..........www.propakwestafrica.com Aspirata...........................................................................OBC......www.nosa.co.za Berndorf Band ..............................................................21..........www.berndorfband-group.com Bragan Chemicals ........................................................12..........www.braganchemicals.co.za Capdan and Allied Equipment.................................20 .........www.capdan.co.za DFS Process Solutions................................................15..........www.dfs.za.com Endress + Hauser ........................................................OFC ......www.za.endress.com GEA Africa .......................................................................IBC .......www.gea.com GNT Group BV................................................................25 .........www.exberry.com IPCO South Africa.........................................................17 ..........www.ipco.com ISW Shrink ......................................................................IFC ........www.iswshrink.co.za
Krones Southern Africa ..............................................7............www.krones.com Omron .............................................................................29 .........www.industrial.omron.co.za Polyoak Packaging .......................................................28 .........www.polyoakpackaging.co.za Renlaw.............................................................................19 .........www.renlaw.com ROHA SA ..........................................................................26 .........www.roha.com Savannah Fine Chemicals .........................................24 .........www.savannah.co.za Sensient Technologies South Africa ....................23 .........www.sensient.com Siyakha Imperial Printing Co....................................30 .........www.labelprint.co.za Sollich KG .......................................................................9 ...........www.sollich.com/world Syspro..............................................................................8 ...........www.za.syspro.com Tomra Sorting NV .........................................................13..........www.tomra.com Vivit Foods .....................................................................11 ..........www.vivit.co.za
2019 Quarter 2 | Food Manufacturing Africa
3
EDITOR’S COMMENT
EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmedia.co.za Layout & Design: Naresh Budraj ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmedia.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmedia.co.za
INTERNATIONAL SALES
Industry must lead
Africa’s growth T
HE CONTINENT’S GENERAL economic performance continues to improve, per a report entitled African Economic Outlook released by the African Development Bank. The area’s gross domestic product (GDP) reached an estimated 3.5 per cent in 2018, about the same as in 2017 and up from 2.1 per cent in 2016. Africa’s GDP growth is projected to accelerate to 4.0 per cent this year and 4.1 per cent in 2020. This is still not good enough to generate decent jobs. The 2019 Outlook shows that macroeconomic and employment outcomes are better when the industry leads growth. Research indicates that five trade policy actions could bring Africa’s total gains to 4.5 per cent of its GDP or US$134 billion per year. First it should eliminate all applied bilateral tariffs in Africa. Secondly, it should keep the rules of origin simple, flexible and transparent. Third in line is removing all non-tariff barriers on goods and services trade on a most-favourednation basis. Implementing the World Trade Organization’s Trade Facilitation Agreement to reduce the time it takes to cross borders and transaction costs tied to nontariff measures is the fourth policy. Lastly, negotiate with other developing countries to halve their tariffs and nontariff barriers on a most-favoured-nation basis. On this challenging but positive note, this edition of Food Manufacturing Africa looks at systems that can ensure processing facilities run optimally. We start with an editorial on how to detect product loss through the management of industrial wastewater. Turn to page 10 now to read all about Endress + Hauser’s Netilion Smart Systems that make intelligent monitoring as easy as checking your smartphone app. Mecatherm has completed its launch of Angola's first industrial bread line (page
4
Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com
Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk
22). The system includes a fully automated production line with customised support in project management. We also bring you information on how stevia can offer natural flavour innovation to product developers seeking to increase flavour but reduce sugar in new products. On page 24 we discuss the ingredient's sweetening properties and flavour modification compounds that assist in bitter masking, sweetness onset and other flavour enhancements. Kenya's current recycling rate of five per cent is set to get a boost with the formation of a Kenyan version of PETCO. The organisation will coordinate initiatives to collect, sort and recycle plastic bottles – this question is gaining a lot of traction in the face of the country's ban on the use of plastic bottles after April this year! Turn to page 28 for the full story. I hope you enjoy this edition of Food Manufacturing Africa. If you have any comments, suggestions or news from your corner of Africa, please don’t hesitate to contact me at maryke.foulds@newmedia.co.za.
CIRCULATION
Happy reading, Maryke
New Media House, 19 Bree Street, Cape Town 8001 PO Box 440, Green Point, Cape Town 8051 Tel: +27 (0)21 417 1111, Fax: +27 (0)21 417 1112 www.newmedia.co.za
Food Manufacturing Africa | 2019 Quarter 2
Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmedia.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmedia.co.za Production Manager: Mandy Ackerman Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park 2092 Tel: +27 (0)11 877 6111 Fax: +27 (0)11 877 6198 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published by New Media a division of Media24 (Pty) Ltd MANAGEMENT TEAM MANAGING DIRECTOR: Aileen Lamb COMMERCIAL DIRECTOR: Maria Tiganis BRAND STRATEGY DIRECTOR: Andrew Nunneley CHIEF FINANCIAL OFFICER: Venette Malone HEAD OF HR: Camillah West CEO: MEDIA24: Ishmet Davidson HEAD OFFICE
Food Manufacturing Africa is published by New Media Publishing (Pty) Ltd quarterly and circulates to executives in the food and beverage industries. Views expressed in this journal, other than where specifically stated, are not necessarily those of the publisher. The editor welcomes for publishing consideration news items, press releases, articles and photographs relating to developments in the food and beverage industries. No responsibility is accepted should contributions be lost. Food Manufacturing Africa is printed and bound by Novus Print Solutions - Cape Town. Copyright: all rights reserved. ISSN 2309-5334
Readers are prohibited from using the contact details displayed in any advertisement or editorial within the pages of this publication to generate and/or distribute unsolicited bulk emails or other forms of mass marketing correspondence.
DIARY
2019 DIARY June
fex28 May – 1 Thai ia As od Fo of World
d Pak Kret, Thailan m rldoffoodasia.co wo ex aif th w. ww
2019 SUBSCRIPTION FORM
9 – 12 Sapics
h Africa Cape Town, Sout a o.z s.c pic sa w. ww
To ensure you receive a copy of Food Manufacturing Africa each quarter, please complete this coupon and return it, together with your payment to:
g7 23 – 25 Africa’s Bi
Africa Midrand, South .com ig7 ab ric af w. ww
NEW MEDIA a division of Media24 (Pty) Ltd, PO Box 440, Green Point, Cape Town 8051 Tel +27 21 701 1566. Fax 086 529 6468.
Full Name:........................................................................................... Designation: ........................................................................................
International 26 – 28 Malaysia ir Fa ge Food & Bevera ia
Africa’s Big 7
Kuala Lumpur, www.mifb.com
Malays
Company: ........................................................................................... Postal Address:................................................................................... .................................................................Code:................................. Country: .............................................................................................. Tel: (
)....................................... Fax: (
) ..................................
E-mail:................................................................................................. Main activity of company:................................................................... Approximate number of employees: .................................................. VAT No: ............................................................................................... Signature:............................................................................................ Method of payment:
❑
Direct Deposit (Fax this form together with a copy of your deposit slip to: +27 086 529 6468 Payee: Bank:
Acc No:
New Media, a division of Media24 (Pty) Ltd .
Nedbank Seapoint
July 4 -4 5 -Global Dairy Congres s s 5 Global Dairy Congres Africa
Abuja, Nigeria www.szwgroup.com
9 – 11 fdt Africa 2019
Midrand, South Africa www.fdt.co.za
30 – 31 PMA Fresh Connection Conference
Cape Town, South Africa www. pma.com
airy Global DAfrica s Congres
1069321540
Branch Code: 10-69-09-00
❑
Credit Card (Mastercard & Visa only) Name of card: ............................................................................. Expiry Date: ................................................................................ Card Number: .............................................................................
August
CVC Number...............................................................................
7 – 10 Vietfood & Beverage Ho Chi Min City, Vietnam www.foodexvietnam.com
Date: ........................................................................................... Signature:....................................................................................
❑
7 – 10 WorldFood Expo
TAX INVOICE REQUIRED
Pasay, Phillipines www.wofex.com
(Please tick) SOUTH AFRICA
(PRICES INCLUDE VAT @ 14%)
FOREIGN
29 – 31 Anufood India
(POSTAGE INCLUDED)
1 YEAR
R315.00 ❑
R392.00 ❑
2 YEAR
R514.00 ❑
N/A
Mumbai, India Mumbai, India www.wo rldoffoodindia.com www.worldoffoodindia.com
ge
Vietfood & Bevera
2019 Quarter 2 | Food Manufacturing Africa
5
NEWS
Nigerian Food Event 2019 continues to grow As a new show to the international trade calendar, the event is gaining traction amongst global manufacturers, suppliers and buyers from the food, beverage and hospitality sectors. TO FACILITATE EASY navigation at the trade fair, organisers introduced dedicated pavilions to group together relevant products and regions. Some of the key pavilions announced will be country pavilions. Top suppliers and manufacturers from these selected regions will offer a coherent overview of the region’s primary exports. Current country pavilions include China, Korea, Norway and Turkey. The Nigerian Enterprise Zone is another innovation. Specifically designed for SMEs, the pavilion will provide a great opportunity for companies looking to expand or enhance their existing reach in the West African region from the local market. This year’s exhibition includes dynamic features such as Drink Lagos as part of the colocated Nigerian Drink Event. This is a premier pavilion for those that source, buy or serve drinks from sommeliers to bartenders. Chef
Skillery will invite leading chefs into a live kitchen demonstration area to provide exclusive tips and tricks from trending ingredient combinations to innovation
techniques. The inaugural edition of the Nigerian Food Event will be taking place from the 22 to 24 of October 2019 at the Landmark Centre in Lagos, Nigeria. •
Co-located with:
nd
The Nigerian
drink event F O O D • B E V E R A G E • H O S P I TA L I T Y
22 - 24 OCTOBER 2 0 1 9
The Nigerian hospitality event
LANDMARK CENTRE, LAGOS, NIGERIA
nh
FOOD • BEVERAGE • HOSPITALITY
22 - 24 OCTOBER 2019 LANDMARK CENTRE, LAGOS, NIGERIA
Book your stand!
6
Food Manufacturing Africa | 2019 Quarter 2
NEWS
A brighter future with vanilla WALL’S HAS BEEN working with global charity partner Save the Children and fl avour manufacturing partner Symrise to make a real change for the young people of Madagascar. The collaboration between the three partners has been in place for over three years and has already positively impacted more than 40 000 people in 76 villages in Madagascar with lifesaving health insurance, financial education and training opportunities for youth. Madagascar is responsible for 80 per cent of the world’s global vanilla supply. To build on the journey, Wall’s is also partnering with ME to WE, a social enterprise that enables people to do good through their everyday choices. During the Vanilla for Change programme, the purchase of popular Wall’s ice cream products (Cornetto Strawberry, Cornetto Classico, Calippo Combo Vanilla Strawberry and Solero Exotic) will support ME to WE’s charitable partner’s active citizenship programme, WE Schools. The WE Schools programme provides free educational resources for teachers and a range of learning opportunities for students. Thanks to this extended partnership, Wall’s and ME to WE will be supporting 100 000 young people with educational resources through the WE Schools programme in the UK. ‘Symrise and Wall’s are committed to a supply chain that creates shared value for everyone involved. Employees who live and work with us are the friends and neighbours of the smallholder farmers, so we are passionate about developing these communities. We’re delighted that we can now share our work with the world via Track Your Impact, so more people can get involved,’ says Heinrich Schaper, president fl avour division at Symrise. •
Strategic partnership announced SOUTH AFRICAN WATER and wastewater solutions provider, Talbot & Talbot and Thesele Group (Thesele), a 100 per cent black-owned investment holding company, have concluded a substantial equity transaction. Thesele has acquired a 35 per cent stake in the business and its entry into the water industry represents a strategic addition to Foodportfolio, Manufacturing Africa, x 200 mm, Hydronomic, CC-en34-AZ231 05/19 ‘Our its diverse which includes major132 interests in financial services, industrials, transport and logistics. partners bring with them a broad network, valuable strategic input and access to capital to fuel the growth of the business,’ says Talbot & Talbot chief executive officer Carl Haycock. ‘Thesele shares every aspect of our vision and is completely in alignment with our future growth objectives, both within and outside South Africa’s borders,’ he adds. ‘Thesele identified water infrastructure as a strategic investment theme and were drawn by Talbot & Talbot’s comprehensive water and wastewater management solutions implemented at numerous facilities across the continent,’ concludes Thesele group executive director, Oliver Petersen.
Hydronomic #GermanBlingBling #Hydronomic
We do more.
2019 Quarter 2 | Food Manufacturing Africa CC-en34-AZ231_05-19.indd 1
06.05.2019 14:00:08
7
INDUSTRY TALK
Keep products cool
and avoid a broken cold chain Temperature control is an integral part of a logistics provider’s overall products and services. When applied to the cold chain, it becomes even more complex and requires smarter solutions.
F
OOD WHETHER FRESH, canned, dry or vacuum packed has a shelf life. The longer it takes to distribute these products to retailers, the less time and probability exists to sell and consume them. There are two important lead times at play. The first is the time from factory to shelf or distribution lead time. The second is from shelf to consumer. This is referred to as consumption lead time. Effective logistics planning must manage the following: • Storage and movement of food to deliver best customer service • Deliver a brand promise in line with consumer expectation. Lead time contains both these elements. Activities must be planned and coordinated to prevent eating up usable shelf life. This is not as easy as it sounds.
CONTROL AND MEASURE Let’s look at a manufacturer of yoghurt-based desserts. The processor can control the time a manufacturer holds raw materials and manufactures, packs, stores and cross-docks to vehicles. Software can also control the environment by ensuring temperatures stay constant at four degrees Celcius or lower if required. Truck temperature can be monitored when offloading to retailers in temperature controlled receiving areas. It is then up to merchandisers to pack cold shelves quickly in an ambient environment. What about difficult to reach mall-located or garage forecourt retailers though? It’s challenging to monitor broken cold chain activities such as slow
offloading. Even if these second-tier outlets are efficient at logistics, planning and coordination could be problematic. A broken cold chain is often the result of having to wait to fi ll shelves. This could result in additional cost to check systems to maintain the cold chain. It can also reduce available lead time.
TECHNOLOGY CAN HELP Lateral thinking and technology may come to the rescue through innovations such as temperature sensitive strips on food packaging. These items discolour when the cold chain is broken, allowing merchandisers or category managers to backtrack and analyse where the breakdown occurred. RFID tags on pallet covers or boxes can record the logistics activity, route planning and temperature. This can facilitate a call to action when needed to
optimise shelf life and measure and select LSPs and outlets for yoghurt-based desserts. ‘Syspro provides enterprise resource planning systems to plan manufacturing and distribution better by collecting RFID tag or other IoT device data. We can feed built-in artificial intelligence which, over time and multiple data cycles, is boosted by machine learning,’ explains Doug Hunter of Syspro Africa. This continuously improves the prediction of which LSPs routes, activities, products or customers likely to be affected by cold chain problems before they happen. •
Syspro – https://za.syspro.com/
Grow Your Business with SYSPRO ERP Software for Food Manufacturing. For more information or to arrange an appointment, please contact us on 011 461 1000 or info@za.syspro.com. Copyright © 2019 SYSPRO (Pty) Ltd. All rights reserved. All brand and product names are trademarks or registered trademarks of their respective holders.
8
Food Manufacturing Africa | 2019 Quarter 2
P3RF3C T
3NR0B1N6 ENROMAT ® T H E K E Y T O “PERFECT ENROBING”
www.sollich.com/world
COMPANY FOCUS
Smarter systems, smarter processes
Experts estimate approximately two to three per cent of total milk purchased by manufacturing facilities in the dairy industry is lost during processing. The good news is that a significant portion of this water can be saved.
P
RODUCTION LOSSES ARE further exacerbated when you consider the impact of an organisation’s effluent footprint. Effluent overloads have a significant societal and financial impact, which can result in large penalties and damage to a company’s corporate image. The traditional approach to managing product losses and effluent overloads is to rely on grabbed samples with laboratory analysis. This will determine the degree of waste from specific production areas and the success or failure of the water treatment facility. This is a challenging area for the food and beverage industry. Resources available to manage an analytical programme in this traditional format are often only focused on quality parameters of the processed products. Manufacturing plants have, in the past, viewed the production and industrial wastewater plant as two separate entities. The increasing cost of manufacturing, raw materials and steeper municipal penalties is driving manufacturing plants to focus on their product losses and effluent overloads at their facilities.
systems ineffective as you do not know when probes have drifted. This impacts the reliability of the measurement and actions taken when related to the incorrect measurement. Triple redundant pH measurement ensures reliable and accurate results as drifting probes can be easily identified. If your company is struggling to identify the source of product losses or the cause of high effluent loads, Endress+Hauser has a solution. Its Water Quality Smart System with complete Cloud integration and monitoring allows for readily available data to correlate to periods where high product load in effluent occurs.
“.… resources available to manage an analytical program in this traditional format is often focused on quality parameters of the processed products”
WHY IS EFFLUENT MONITORING IMPORTANT? Chemical Oxygen Demand (COD) is an indicative measure of the amount of oxygen that can be consumed by reactions in a solution. A COD test can be used to easily quantify the degree of organics in water. A growing number of companies are facing municipal penalties due to regulatory compliance for the monitoring of effluent. Fines are associated with high COD loads and pH spikes in wastewater effluent. Compliance with these regulations requires a multifaceted management system.
THE MOST COMMON CAUSE OF EFFLUENT NON-COMPLIANCE Incorrect measurement plays a big part in non-compliance. The drifting of pH measurement equipment makes existing
10
Food Manufacturing Africa | 2019
HOW CAN THE WATER QUALITY SMART SYSTEM HELP YOU? Smart systems are packages composed of connectivity product with or without sensors. These provide data to an application that the user can consume. It’s not all about using data, it’s about understanding what data is available and making it available when and where you need it to help you optimise and react quickly to your processes.
QUALITY SMART SYSTEM OFFERS: • One package containing everything needed, from instrumentation to connectivity devices. • Mobile access to water quality parameters via a smartphone app, from anywhere and at any time. Alarms and notifications allow quick reactions to limit deviations and changed sensor status. • Endress+Hauser’s Netilion Smart Systems are packages of smart sensors that can communicate with your smartphone. When the Smart Systems App is installed on your Endress+Hauser magazine smartphone, you can check and manage the information wherever you are. In case of triggered events you directly receive a notification on your smartphone. You can set up Netilion Smart System on your
Water quality smart system
Liquiline CM444 (Modbus TCP) with e.g. • •/LTXLOLQH &0 0RGEXV 7&3 ZLWK H J • pH S+ • Conductivity &RQGXFWLYLW\ • Dissolved 'LVVROYHG 2[\JHQ Oxygen • •0RGEXV (GJH 'HYLFH Modbus Edge Device • •6PDUW 6\VWHPV DSS Smart Systmes app • •8QSDFN ² Unpack –FRPPLVVLRQ commission - XVH use
7KH :DWHU 4XDOLW\ 6PDUW 6\VWHP R̟HUV • One package containing everything Quarter 2 needed, from instrumentation to connectivity devices. • Mobile access to water quality parameters via a smartphone app, from anywhere and at any time. $ODUPV DQG QRWLÀFDWLRQV DOORZ
“It’s not about using all the data – it’s about understanding what data is available when and where you need it to help you optimise
9
resources available to manage an analytical program LQ WKLV WUDGLWLRQDO IRUPDW DUH R͉HQ IRFXVHG RQ TXDOLW\ parameters of the processed products. 0DQXIDFWXULQJ SODQWV KDYH R͉HQ YLHZHG WKH SURGXFWLRQ plant and the industrial wastewater plant as two separate entities. The increasing cost of manufacturing, raw materials and steeper municipal penalties drives
FRPSOLDQFH WR UHJXODWLRQV 'UL͉LQJ RI S+ PHDVXUHPHQWV PDNH H[LVWLQJ V\VWHPV LQHĚ&#x;HFWLYH DV \RX GR QRW NQRZ ZKHQ WKH SUREHV KDYH GUL͉HG 7KLV LPSDFWV WKH UHOLDELOLW\ of the measurement and the actions that are taken related to the incorrect measurement. Triple redundant pH measurement ensures reliableCOMPANY and accurate results as FOCUS GUL͉LQJ SUREHV FDQ EH HDVLO\ LGHQWLĂ€HG
+RZ WULSOH UHGXQGDQF\ ZRUNV How triple redundancy works
Output = Average of the closest 2 Alarm = Any probe drifts more than 1pH
SMS Message to E+H Service Technician
Remote access to system to diagnose issue
Math is done in CM44R
Corrective action needed to can be taken
7ULSOH UHGXQGDQF\ HQVXUHV DFFXUDF\ DQG UHOLDELOLW\ LQ H̢XHQFH WHVWLQJ own and start your intelligent monitoring right away. Checking your measuring data with your smartphone app is as simple as checking your messages and you can choose a package of smart sensors to measure relevant parameters. Sensors are connected to your smartphone by using specific connectivity solutions. This allows you to visualise and manage equipment and measurement data wherever and whenever you need it. Setup alarms and notifications can also be customised to your specific requirements. •
Endress + Hauser https://iiot.endress.com/smart-systems
Don't face municipal penalties, rather monitor effluent
A COD test can be used to easily quantify the degree of organics in water
We offer creative and innovative solutions through in-house research, customised products and packaging
Our Promise is inside
Phone - +27 (0)11 4526730 Email - info@vivit.co.za Web - www.vivit.co.za
Manufacturer of cake pie fillings, toppings, yoghurt fruit pulps,caramel treat, milkshake syrups, salad dressings,mayonnaise and sauces.
FSSC 22000 Certified
2019 Quarter 2 | Food Manufacturing Africa
11
FOOD PROCESSING TECHNOLOGY
Maximise volume and quality Tomra Food, a manufacturer of sensor-based sorting machines has been selected to partner with Ardo, a supplier to the fresh-frozen vegetable sector. The company installed two Tomra Sentinel II optical sorting machines at its processing plant in Belgium.
A
RDO HAS AN annual turnover of one billion Euro and employs 3 800 people at 21 production, packing and distribution sites. It exports products to more than 100 countries. Vegetables, herbs and fruit are sourced from 3 500 growers and the facility processes 860 000 tonnes annually. One-quarter of all frozen vegetables in Europe come from Ardo, primarily for use in soups, ready-to-eat meals and baby food. Ardo’s group marketing and communication director, Heidi Goovaerts comments, ‘We are an innovative company and investments in our factory is just one way that we are different from our competitors. We also differentiate ourselves through sustainability and focus on minimising food waste. The technology will help us minimise waste and maximise productivity while delivering a high quality product.’ The Sentinel II has a flexible design configurable for many different types of food sorting. It is most often used for tomato, peach and potato processing. The latest illumination and detection technology (with double-sided or single-sided off-belt inspection of product flow) ensures unmatched sorting accuracy, capacity and durability. The Sentinel II is available in three different sizes, and its
The Sentinel II optical sorting machine
throughput-to-width ratio is among the highest in the industry. The heart of Sentinel II's sorting ability is pulsed LED/sensor arrays technology for illuminating and detecting impurities. Combining this technology with an easy-touse control screen enables users to remove a broad range of defects, discolouration, damage and undersized product, in addition
to removing foreign materials. The Sentinel II's patented rejection system offers low, medium or high-speed modes and has a wide capacity range of 40 to 200 tonnes per hour. This makes the machine ideal for seasonal and year-round processors seeking perfect product quality. Bjorn Thumas, business development director at Tomra Food says, ‘Ardo is one of the food industry’s success stories, not only because of the company’s dedication to innovation and quality. Ardo bought a Tomra colour sorter about 15 years ago. The company knows first-hand how effective and durable our machines are. By investing in newer technology, Ardo is wellpositioned to stay ahead of the game.’ •
Heidi Goovaerts - Ardo’s group marketing and communication director
Tomra Food - www.tomra.com
Johannesburg Head Office Seven Warehouse Complex 3 Bernie Street, Unit 3, Kya Sands Tel. No.: +27 (0) 11 708-0007
Durban Office Tel. No.: +27 (0) 83 252 4826
www.braganchemicals.co.za
Port Elizabeth Office Tel. No.: +27 (0) 71 213 9288
Cape Town Office Tel. No.: +27 (0) 78 780 9976
WE DO WHAT IT TAKES 12
Food Manufacturing Africa | 2019 Quarter 2
SORTING & PEELING SOLUTIONS FOR THE FOOD INDUSTRY TOMRA Food has become the preferred sensor based sorting and peeling solutions supplier for the food industry. We provide the most suitable, cost-effective, and advanced sorting solution for the efficient removal of defects from any product stream, in whole or processed condition. FOOD@TOMRA.COM WWW.TOMRA.COM/FOOD
FOOD PROCESSING TECHNOLOGY
Turnkey solutions for total meat processing
DFS Process Solutions supplies, installs and services specialist food processing equipment for the poultry, red meat and fish processing industries. To keep up with customer expectations, the company has expanded its offering. Food Manufacturing Africa looks at what is available.
T
HE PORTFOLIO COMPRISES turnkey solutions for primary processing through to further processing, including rendering and wastewater treatment throughout southern Africa.
PRIMARY PROCESSING Baader Linco offers wall-to-wall poultry processing solutions - from live bird handling to final product dispatch. Solutions are based on a total value chain concept to ensure optimal benefit and value of each bird throughout the complete process. Committed to quality in all phases of the process, the supplier offers the potential of advanced technology and the choice of manual, semi-automatic and fully automated plant operation based on your requirements. It also features a range of technically advanced processing equipment which caters for capacities of 500 birds to 13 500 birds per hour. Marel Meat (previously MPS) is the global provider of automated slaughter lines for pigs, cattle and sheep, CO2 stunning systems, cutting and deboning lines and intra logistic systems for the food industry. Red meat slaughter lines include pig slaughter lines with capacities from 10 to 1 400 pigs per hour and cattle slaughter lines with capacities from 10 to 150 cattle per hour. It also offers the integrated Butina systems for livestock handling, CO2 stunning, blood collection and blood processing in slaughter houses. Freund Maschinenfabrik designs and manufactures hand tools for red meat abattoir processing. The company is a world leader in slaughtering and cutting technology. Innovative Water Concepts (IWC) in the Netherlands has launched its revolutionary, water-saving cleaning technique for the food industry. The Undine technique is used to effectively clean food (chicken, vegetables, fruits, potatoes), conveyor belts, bottles, tins, crates, sieves and more. With its unique capacity for mixing water and air under pressure, it guarantees a significantly cleaner result and allows customers to save up to 70 per cent on water consumption.
14
Undine frequently leads to a lower energy consumption, seeing that the (process) water often must be heated or cooled.
BY-PRODUCTS RENDERING Haarslev manufactures processing equipment for customers in the meat, pet food, fish oil, environmental protection and biofuel industries. It is also active in protein recovery systems and by-products rendering. Animal by-products, such as carcasses, which are not intended for human consumption, are transformed into valuable proteins, minerals and oils. From simple batch cookers to continuous wet and dry rendering systems, a wide range of process equipment can be employed to suit almost all raw material conditions and final product standards. Energy saving process technologies are an important feature of the product range, as are specialist processes for pet food, high protein meal, fat recovery and blood processing. Odour control systems are an integral part of modern by-product rendering processing.
WASTE WATER TREATMENT Redox water technology has been a global supplier of water and wastewater treatment systems for more than thirty years and is a specialist in the field of advanced water treatment equipment and techniques. The company offers products like DAF units, a wide range of screens and biological wastewater treatment systems. Redox installations are suitable for primary, secondary (biological) and tertiary wastewater treatment.
FURTHER PROCESSING Schröder is a leading manufacturer of injectors and massagers. Technology may be used to add brine mixes, flavours and colour to meat products. The new generation Imax injectors, Brimax mixing systems and max massagers are equipped with intelligent technology, which provide live process monitoring and traceability.
Food Manufacturing Africa | 2019 Quarter 2
Steen offers skinning machines for most applications. The mid-wing tulip processor has specially been developed to create unique and trendy tulip wing snacks. The spare-rib cutter optimises the revenue of thigh production by transforming thighs into value-added snacks. Thielemann Food Technology is an innovative machine manufacturer for poultry breast slicing machines. It offers tailored solutions for poultry fillet processing and portioning. Marelec Food Technologies designs and manufactures high technology portioning systems for the poultry, red meat and fish industries, to optimise manufacturing efficiency. Marelec Portio combines state of the art technology for creating a high precision yet economic portion cutting machine. It is suited for fresh products such as fish fillets, whole fish, meat and poultry products. Marlen International designs and builds equipment to process meat, poultry, fish and many other products. Sold under the brand names of Marlen and Carruthers, their products have long set the standard for quality and performance in vacuum stuffing and pumping, portioning, size reduction and food handling Unitherm has developed unique thermal processes for various product markets including frying, cooking (spiral ovens), grilling (flame grill and tunnel of fire) and product enhancement technologies such as bar-marking and infrared smoking and browning. Unitherm Spiral Cookers can be used to bake, roast, steam or combination cook. The Econoline was developed to make the automated process of pre-dusting, batter coating, crumbing and frying, accessible to small and large volume producers. Formatic Range guarantees accurate forming and portioning and is suited to a variety of mixtures of numerous textures and consistencies. •
DFS Process Solutions – www.dfs.za.com
C
M
Y
CM
MY
CY
CMY
K
6666_GENERIC ADVERT.pdf
1
14/05/2019
14:16
C
M
Y
CM
MY
CY
CMY
K
LEADERS IN PROCESSING EQUIPMENT
BAADER LINCO Poultry Abattoir Equipment | PLUMATECH Plucking Fingers | MAREL MEAT Pork and Red Meat Abattoir Equipment | FREUND Hand Tools for Red Meat Abattoir Processing | SCHRÖDER Injectors and Massagers | HAARSLEV By-products and Rendering Equipment | REDOX Waste Water Treatment Technology | STEEN Deboning, Skinning and Value-Added Processing Equipment THIELEMANN Slicing Equipment and Meat Flattening Machines | LIMA High Pressure Meat-Bone Separators | MARELEC Intelligent Portioning Systems | UNITHERM Cooking, Searing, Smoking, Flame Grilling and Coat and Fry Systems | MARLEN INTERNATIONAL Vacuum Stuffers, Shredders, Dicers and Slicers | IWC Innovative Water Concepts.
TEL +27 (0)87 238 1873 | EMAIL sales@dfs.za.com | www.dfs.za.com
FOOD PROCESSING TECHNOLOGY
A close-up of a bake-oven belt
The unparalleled versatility of steel belts
Ipco forms part of the Swedish-based Wallenberg group. The company is one of the largest suppliers of solid and perforated steel belts to the food processing industry.
"The excellent thermal conductivity of the belt delivers fast, controlled solidification and pastilles are discharged cleanly at the end of the system"
V
ERSATILE ENOUGH TO be used at temperatures from minus 80°C to +750°C, steel belts are a remarkable processing medium. Initially seen as an unpretentious but durable conveyor material, they have developed into an engineered process tool with hundreds of different applications, particularly cooling, solidification and freezing systems. Cooling is an area in which Ipco has endto-end process expertise, working with machine manufacturers to ensure optimum productivity and return on investment. These systems are widely used for cooling and solidifying, with applications including chocolate, sugar mass, caramel, gelatine, hard melt candy, nougat and nut brittle. Steel belts are also used in zoned conditioning systems for slab and bar casting applications such as caramel and sugar mass. This process expertise extends to complete cooling lines: the most widely used is the Rotoform. This is an efficient, steel belt-based granulator used for the pastillation of a range of food products including chocolate chips, emulsifiers and fats. Molten product is fed into the Rotoform unit and deposited onto a continuously running stainless belt in the form of droplets. The heat of the melt is transferred to cooling air blown onto the product belt. (Another method, suitable for compounds not sensitive to humidity, is to spray cool water onto the underside of the belt.) The excellent
16
Steel belts can be used at temperatures between -80°C to +750°C
thermal conductivity of the belt delivers fast, controlled solidification and pastilles are discharged cleanly at the end of the system. The excellent thermal quality steel belts mean they are also suitable for freezing processes. Among the most common applications in this area is the freezing of coffee slurry as part of the production process for instant coffee granules, but any product that requires freezing can be processed on a stainless-steel belt. As with cooling lines, the company can work with OEMs or supply complete systems for the production and distribution of chilled air (evaporators, impingement boxes and ammonia group valves), which are designed and manufactured on advanced thermodynamic calculations.
The hard, flat, smooth surface of a steel belt ensures easy product release at the end of the freezer. It is also easy and economical to clean, enabling the highest standards of hygiene to be maintained. Far more resistant to damage by corrosion, abrasion or impact than any other belt type, a stainless steel conveyor provides the ideal long term solution for a whole range of potentially aggressive applications. Ipco steel belts are manufactured in a range of thicknesses, widths and lengths to suit different applications. Products undergo extensive levelling and straightening processes to ensure optimum flatness and reliable operation. •
IPCO – www.ipco.com
Food Manufacturing Africa | 2019 Quarter 2
IPCO_
Solid and perforated steel belt conveyors for the food industry IPCO is a world leader in the manufacture and supply of solid/perforated steel belts and associated process systems for the food industry, with application-specific expertise that extends across baking, cooling, forming, freezing, drying, casting, meat cutting, conveying and more. Our belts and systems are used to handle literally hundreds of different food types, from cookies, chocolate and coffee to strawberries, sugar and seafood. And in every area they offer efficient, reliable and durable operation together with fast, easy cleaning for maximum hygiene. Whatever your requirement – belt-only, process support or system solution – our global coverage and technical expertise means we deliver the level of service that’s right for your business, whatever its size or location. • W orld leading steel belt technology: solid/perforated, carbon/stainless, wide belts, choice of grades. • Process solutions including our proven Rotoform FD pastillation system. • G lobal service and spare parts support, new installations, upgrades, planned maintenance, belt replacements. • Experienced engineers offer consultancy on all aspects of process design.
ipco.com
IPCO_Food_Manufacturing_Africa_ad_210x297.indd 1
07/05/2019 14:28
FOOD PROCESSING TECHNOLOGY Cube, strip and slice blades
The convenience trend effect
Toothed packaging punches
The consumption of ready-to-eat meals is showing sustained growth. Globally, pre-prepared meals are flying off shelves at an unprecedented rate. This trend is set to continue in the future. We chat to Mikko Brunner of Renlaw on how this development is affecting consumption patterns in convenience food.
R
ESEARCHERS AT THE South African Journal of Science indicate the last two decades saw a steady decline in the consumption of cereals that require home cooking. Sub-Saharan Africa is seeing greater demand for other convenience food, with an increase in all other prepared meal categories. The increase in these products has driven demand for a range of associated products and industries. Food processing and packaging industries are seeing a corresponding surge in business. Brunner maintains that an important factor in the growth in convenience food consumption can be attributed to the changing financial climate. ‘Money is definitely a little tighter and the average South African works longer hours than in previous generations. Far more families rely on the income from both parents to make ends meet. This means less time available to spend in the kitchen. We are becoming very reliant on prepared or partially-prepared food.’ Pre-cut vegetables for stir-frying or baking, pre-grated cheese and pre-cut fruit salad cups are very popular. Renlaw is constantly
18
“…another noticeable trend is juicing. The average South African consumed 63.6 per cent more fruit and/or vegetable juice in 2017 than in 1999” expanding its product line to keep up with the evolving needs of manufacturers and international trends. ‘We’ve had a surge in orders for fruit and vegetable slicing, dicing and cubing blades, cheese slicing blades and other tools used in the processing of convenience food. It has also influenced the packaging side of our business, with greater demand for packaging blades and knives, punches and dies and converting tooling. It’s an exciting time to be in the industry,’ he enthuses. Brunner explains another noticeable trend is juicing. The average South African
Food Manufacturing Africa | 2019 Quarter 2
consumed 63.6 per cent more fruit and/or vegetable juice in 2017 than in 1999. Increasing awareness of healthy eating habits has contributed to the popularity of pure fruit and vegetable juices, with the younger generation driving the popularity of these drinks. ‘This is a positive trend. People are trying to make healthier diet choices, but don’t have hours to spend slaving away in the kitchen. Veggie juices tick all the right boxes,’ he enthuses. Renlaw’s research and development teams are working around the clock to ensure its production and packaging technologies are in line to meet this need. ‘Our research and development teams are working hard to offer South African companies innovative solutions. Our quality control measures our industrial machine knives and makes sure other tooling meet OEM standards for corrosion resistance and durability,’ Brunner concludes. •
Renlaw – www.renlaw.co.za
Renlaw CUTTING-EDGE TECHNOLOGY
Africa’s leading supplier of industrial cutting tools
CAPE TOWN BRANCH:
JOHANNESBURG BRANCH:
+27 (0)21 701 7917
+27 (0)79 155 7358
sales@renlaw.com
sales2@renlaw.com
www.renlaw.com
FOOD PROCESSING TECHNOLOGY
Processing equipment to captivate Africa Capdan and Allied Equipment (Capdan) can design, manufacture and supply custom built steam jacketed kettles and processing equipment to meet its growing customer base on the African continent and abroad.
T
HE COMPANY’S HEAD office is situated in Johannesburg, South Africa. All steam kettles are manufactured in the western Cape to the highest quality standards and designed to meet stringent SANS 347 and PD5500 regulations. Capdan kettles are used extensively in the food manufacturing industry. It is primarily used to produce soups, jams, sauces, pie fillings, general bulk food production, various confectionery products amongst others. ‘From small scale to large scale production, we are proud of our capacity to design and manufacture high-end products to meet our client's bespoke needs. Capdan’s capabilities are evident through continued support from
2 000 litre soup pot with hoist
DID YOU KNOW?
our prestigious client base. Our growing strength in the market bodes well for our brand moving forward,’Capdan director Jolene Venter concludes. •
Capdan has over 40 years’ experience in the food processing and catering equipment industry.
CAPDAN SUPPLIES: • Preparation equipment Vegetable, meat, general preparation, trolleys and hot holding equipment. Brands include Hallde vegetable processing machines and Spar planetary food mixers. • Cooking equipment A wide range of Capdan steam jacketed cooking pots and general cooking equipment (not limited to combination ovens and tilt frying pans).
• Specialised products Mayonnaise plants, wine and beverage equipment, sauce/jam plants, holding tanks, transfer vessels and vacuum cookers.
Capdan and Allied Equipment is a South African manufacturer, designer and supplier of bespoke processing and industrial kitchen equipment to the food, beverage and pharmaceutical industries. We engineer our products to meet your specific requirements.
Our extensive portfolio includes but is not limited to, Steam Jacketed Kettles, Sauce/Jam/Soup/Mayonnaise Plants, Bulk Cookers, Confectionary Cookers, Ovens, Bulk Fryers, Transfer Vessels, Vacuum Kettles. www.capdan.co.za | sales@capdan.co.za | +27 (0) 11 969 3407 | +27 (0) 21 862 6110
20
Food Manufacturing Africa | 2019 Quarter 2
Capdan – www.capdan.co.za
St
Steel belts for the food industry
Perfect belt geometry Excellent conductibility of temperatures Effortless cleaning in compliance with strictest sanitary standards
Berndorf Band GmbH E: band@berndorf.co.at T: +43 2672 800 0 www.berndorfband-group.com Steel Belts | Belt Systems | Service
FOOD PROCESSING TECHNOLOGY
Angola celebrates
its first industrial bread line A year after launching The Baguette Factory, Mecatherm announced its completed project in Luanda, Angola. Dimassaba - Le Comptoir d'Export Group has launched the country’s first industrial bread production line at the DimaPao facility.
T
HE BAGUETTE FACTORY is a complete solution. The system includes a fully automated production line with customised support in project management. The range of services includes finding financial partners and conducting technical studies, to setting up the factory, recruitment, personnel training and technical support. This approach allows investors in growing countries to move into the industrial bakery sector, regardless of their level of familiarity with the industry or with managing largescale projects. Originally, flour importer Dimassaba, wanted to diversify its business by producing finished products on an industrial scale. The project aims to offer bread of a consistent quality that meets high, international standards in terms of food health and safety. Hussein Bourji, president of Dimassaba says, ‘Mecatherm supported us through all stages in the
project, from defining our requirements to starting up and launching the production line. ‘Once the outline of the project was agreed, we moved to the site setup phase. We tested different recipes in laboratories at Mecatherm’s demo centre, using the same raw materials as those imported into Angola. The testing facility can reproduce the production conditions of the planned factory.’ The industrial bakery unit will start a business with a production capacity of 150 000, 95g round rolls per day. This is equivalent to just over 6 000 bread rolls an hour. The opening of this site has generated 80 direct and more than 150 indirect jobs related to bread sales. Bourji plans to ensure production can meet the needs of the entire region of Luanda. He aims to develop the business in other towns in the country. The group is interested in producing derivative products such as brioches,
The inauguration of the DimaPao site in Viana, Luanda in Angola. With Sylvain Itté, the French Ambassador of Angola, Hussein Bourji, president of Dimassaba - Le Comptoir d'Export, Olivier Sergent, president of Mecatherm and Bernarda Martins, Angola's minister of industry
milk rolls and sandwich bread or buns products not yet industrialised, despite very high market demand. •
Mecatherm – www.mecatherm.com
Crumb-coated snacks
DID YOU KNOW?
for a perfect crunch
Crisp Sensation has developed snack coatings that promise perfect, crispy results. With its latest innovation, the company will soon enable manufacturers to develop microwaveable crumb-coated snacks.
T
HE TECHNICAL BREAKTHROUGH comes down to moisture control: Even if the product is kept in a freezer for up to six months, it will still retain a crispy coating and succulent core when cooked in the microwave. Products are also suitable for other preparation methods such as oven, airfryer, Merrychef and Turbochef. Addressing fast-paced consumers who are always on the go and demand quick and tasty snack options, products with Crisp Sensation coatings fit the bill. The
22
coating system is suitable for a large variety of products that can be crumb coated, including chicken, cheese and even sweet fillings. The company has filed a patent for the coating system, which guarantees that even products that have been kept in a freezer for months will still taste great, and remain crispy on the outside. Supported by new intellectual property on improved moisture control, Crisp Sensation will soon enable manufacturers to develop a completely new generation of crumb-coated snacks. The company has a long history
Food Manufacturing Africa | 2019 Quarter 2
Crisp Sensation has launched ZeroFry, an innovation that enables manufacturers to produce crispy crumb coated snacks for oven or airfryer without the need for pre-frying or deep-frying. The ZeroFry coatings allow for a fat reduction of 50 per cent and a considerable reduction in calories.
of filing patents on coating systems, with multiple patents already granted. Some of the most important developments have been innovative moisture barriers and water binding technologies. For creating diversity and tailored products, crumbs with specific characteristics and designs are available for all applications and requirements. These patented functional crumbs display special porosities, thickness and crumb shapes.
www.crispsensation.com
W
Your secret recipe calls for our natural ingredients‌ Spice up your life with variety, purity and consistency and bring extraordinary flavour and colour to your table with Sensient’s innovative product range.
t e f We bring li
s t ! c u d o r p o
www.sensient.com
1
COLOURS & FLAVOURS
Stevia offers
natural flavour innovation The food and beverage industry has seen a rapid increase in demand for natural ingredients including flavours and sweeteners. Consumers are becoming nutritionally aware and are seeking out simpler labels and natural solutions.
H
EALTH EXPERTS and governments are also looking for new ways to address growing health concerns related to obesity and diabetes. Regulatory pressures, in the form of taxes and levies, are driving the need for natural sweeteners. These will see further adoption by global brands. Stevia leaf ingredients offer a solution and are primed to become an important tool for food and beverage companies. Stevia plants contain natural, non-GMO, zero calorie ingredients, which work well in a wide range of reduced sugar food and beverage applications. As innovators in the production
24
of stevia leaf ingredients, PureCircle has developed a range of sweeteners and flavour modifiers to assist formulators in achieving this goal. The company has mapped the entire stevia leaf genome to better understand what exists within the stevia plant. This enables the company to isolate specific compounds for flavour modification and other technical functions, including sweetening properties. It has also optimised flavour modification compounds in the stevia plant to create tools with various functions like bitter masking, sweetness onset and other flavour enhancement.
Food Manufacturing Africa | 2019 Quarter 2
COLOURS & FLAVOURS
“Our global stevia production capability allows us to bring new ingredients to food and beverage companies at prices competitive to other plant-based flavours in the marketplace” – Aymeric De Gantes, VP business development
Stevia leaf flavours can significantly boost specific flavours like vanilla, cocoa and citrus amongst others. These stevia leaf flavours are labelled as flavours and not as sweeteners on product ingredient label. This allows food and beverage companies to modulate flavours and optimise usage levels of such flavours like cocoa and vanilla. These new products will allow developers to reduce the amounts of cocoa, vanilla, etc. alongside sugar - without compromising taste. In addition to boosting and improving flavours, stevia leaf ingredients add complexity and subtlety to the overall flavour. This assists with flavour management and improvement, including the ability to mask the aftertaste of plant proteins or other ingredients. There is strong demand for these ingredients and their availability in emerging applications (e.g. savoury). The story of stevia is evolving rapidly. Not long ago, it was viewed as a plant-based, zero-calorie, single-ingredient sweetener, which worked well in some product applications. Pure Circle now offers a range of stevia leaf ingredients, including flavour modifiers and sweeteners like Reb M, which have great taste and zero calories.
THE RAPID RISE OF STEVIA In 2018, the number of new products using the ingredient grew approximately 31 per cent. That compares to an 11 per cent increase in 2017. That means the growth rate last year nearly tripled. In looking separately at product launches with stevia last year, the increase was 36 per cent for beverages and 27 per cent for food, according to figures released by the Mintel Group*. Stevia is the next generation solution for natural flavour modification and sweetness. PureCircle collaborates with companies to make formulating with stevia simpler and offers tailored stevia solutions designed to work optimally in different consumer product categories. PureCircle is supplied locally through Savannah Fine Chemicals. *The data reflects new product launches from January-December 2018 compared to January-December 2017 and was extracted from the Mintel Global New Products Database in April 2019. •
Savannah Fine Chemicals – www.savannah.co.za
2019 Quarter 2 | Food Manufacturing Africa
25
RECYCLABLE PACKAGING
Committed to
PET recycling Polyoak Packaging (Polyoak) is intensifying its commitment to extended producer responsibility and partnering with customers to optimise packaging recyclability.
T
HE COMPANY has been a contributing member of PETCO, the PET industry’s recycling body, since its inception in 2004. It actively participates on the PETCO board. In 2018, PETCO and member companies who pay the voluntary levy facilitated the collection and recycling of 103 tonnes of postconsumer PET bottles in South Africa.
LIGHTWEIGHTING Polyoak’s national executive for its specialist PET division, Polypet, maintains that PET has significant advantages as a packaging material because of its strength, thermostability and clarity. It’s shatterproof, safe, hygienic, portable, resealable, lightweight, easy to recycle and cost-effective. According to PETCO, the weight of PET packaging has
reduced by more than 30 per cent over the last decade. Polyoak’s Wessel Oelofse agrees, ‘Over the last ten years, Polypet has reduced the weight of its four and five litre PET bottles by an average of 30 per cent, while maximising robustness and improving top load strength. Smart design has improved performance, whilst utilising significantly fewer resources to deliver a greener footprint.’ Stronger, lighter packaging is especially important in Africa, where packs often need to travel vast distances over rugged terrain, and cost is a vitally importance aspect.
RECYCLABILITY OF PET Another major advantage of PET is recyclability. According to PETCO, 66 per cent
BOOK YOUR STAND NOW
GO
The Largest Packaging, Plastics, Food Processing, Labelling and Print Exhibition in West Africa
Propak has raised the bar in marketing and creating an enabling environment for packaging solutions providers to showcase their technologies
3
Heidelberg
Get in touch to book now:
DAYS
Ben Dale International Sales Manager Ben.Dale@montex.co.uk T: +44 (0)20 7886 3048
5000 VISITORS
www.propakwestafrica.com
Polyoak’s specialist PET division, Polypet, promotes clear PET to optimise the recyclability of its bottles
200+ EXHIBITORS
propakwa
propakwa
2019 Quarter 2 | Food Manufacturing Africa
27
RECYCLABLE PACKAGING of all PET purchased in South Africa during 2018 was recycled. That’s significantly up from 52 per cent just three years earlier. Of all the bottles recycled, only 38 per cent were reprocessed into bottle-2-food grade products, such as new PET bottles. ‘There is still headroom, especially as demand for food-grade recycled PET (rPET) continues to grow, and brand owners and retailers respond to consumers' demand for packaging containing recycled material,’ Oelofse notes. The challenge is that only natural (clear) and light blue PET bottles can be reprocessed into food-grade rPET. It is essential for more trusted brands to switch from coloured to clear PET, to increase the production and availability of recycled material, for inclusion in their packaging. Retailers, brand owners and consumers will sleep better at night, whilst they enjoy the related economic and environmental benefits. Other countries in Africa, such as Kenya only have a PET recycling rate of five per cent (of what is consumed), and recycling organisations are a new trend. In 2018 manufacturers in Kenya teamed up for the first time to form a Kenyan version of PETCO, that will coordinate initiatives to collect, sort and recycle plastic bottles. This will become more important, following 1.pdf
1
2018/05/10
16:49
Kenya’s ban on the use of plastic bottles post April 2019. From a regulatory perspective, if African countries follow UK and EU legislation, it is likely packaging that is not easily recyclable or does not contain recycled material, may incur penalties. There is clearly an early mover advantage for brands to embrace sustainable packaging. Furthermore, convertors need to self-regulate fast to the satisfaction of their government, before blanket bans are placed on plastic, like those in Kenya.
MIGRATION TO PET Countries such as France are experiencing a growing preference for PET over other packaging materials. This is due to the economic, technical and aesthetic advantages of PET as cost-effective and the fact it provides a good oxygen barrier. This move is prevalent in categories such as detergents, hygiene, personal care and value-added dairy products.
OPAQUE PET IS NOT RECYCLED Opaque and fluorescent PET bottles are not readily recycled, because there are no enduse markets, according to Extrupet’s Chandru Wadhwani. They cause blockages to the die heads on the fibre plant due to the types of
masterbatches used. Opaque PET bottles also have zero value to collectors as recyclers don’t want them. They are likely destined for landfill or the ocean, and from a recycling and brand equity perspective are best avoided.
PET IS PROBLEMATIC Coloured or highly pigmented PET bottles comprise only about 15 per cent of all the PET bottles collected by recyclers in South Africa currently, according to Extrupet. Coloured PET can only be used in the production of fibre, geotextiles and strapping. Surplus coloured PET can no longer be exported to China, given their ban on recycled plastics. As a result, collectors in South Africa earn up to 40 per cent less for coloured PET than clear PET. This disincentivises the collection of coloured PET bottles, which risk ending up as litter or as plastic waste in the ocean. Oelofse concludes, ‘There is a significant opportunity for more categories to transition to clear PET bottles, including CSD’s (ginger beer and crème soda), lemon juice, sauces and dairy products. Polyoak invites brand owners to partner with us to create recycling-friendly packaging that will help gain the respect and loyalty of their consumers.’ • Polyoak Packaging – www.polyoakpackaging.co.za
C
M
Y
CM
MY
CY
CMY
K
Polyoak’s specialist PET division, Polypet, promotes clear PET to optimise the recyclability of its bottles.
28
Food Manufacturing Africa | 2019 Quarter 2
Polyoak Packaging – www.polyoakpackaging.co.za
LABELLING
A new world of flexible
and smart label inspection
The ability to catch a defective product before shipping to retail customers can offer significant savings in time and money. It can also prevent expensive product recalls, wasted production and expensive legal costs.
Q
UALITY INSPECTION of packaging is critical for perishable products. An unreadable barcode or an incorrect expiry date could result in perfectly good products being recalled and discarded. As production lines become more automated, so must inspection and quality control. These systems can improve a line’s effectiveness, by performing tasks quickly and accurately. The real benefits only materialise when smart automation is implemented. When applied to vision inspection systems, defects can be spotted and dealt with swiftly with minimal impact to the line. A smart vision inspection system can make a production line efficient and less wasteful. All production lines face challenges regarding inspection and quality control. Governments want to protect their citizens and are enforcing tighter restrictions on package markings, especially in the food and pharma sector.
control, safety and robotics in a single management system, such as Omron’s Sysmac Studio, production lines can accommodate short production runs and adapt to market demands. Line set-ups can be changed quickly for new production runs and the recognition pattern for quality inspection can be updated easily in the software. This ensures different variants or even different products are produced and packaged correctly. The system is also future-proofed as it can easily adapt to accommodate changes to regulations. All that is required is to roll out a new firmware update for the existing solution. • www.industrial.omron.co.za
ALL PRESENT AND CORRECT Omron systems cover all parts of the production line, including quality inspection. Whether a complete system solution or a partial upgrade to an existing system, each component is geared towards ensuring the highest quality control. Omron’s very compact visual inspection units monitor production in real time and respond instantly to any defect. Data sent from the vision system is processed locally and sent via the cloud for powerful analysis that allows the system to take appropriate actions. The system is totally interlinked, with the improved connection between machines in a manufacturing line delivering accurate quality control and higher efficiency. If any error is detected, the system can often compensate automatically, allowing production to continue unaffected. Omron's smart automation solutions are very fast and possess lots of processing power, yet they are easy to use. This combination of speed, intelligence and user-friendliness deliver effective inspection and transparent quality control.
Achieve flexible production with integrated robotics solutions
FOLLOW THE RULES For an inspection system to make smart decisions, it needs to collect data from a sensor, such as a vision camera. Vision cameras can be set up to monitor different aspects of the product; check for imperfections or labels for misprints or missing information. Powerful processing then analyses this data to monitor the process, comparing actual results with expected results. If any problems are found, the system follows programmed rules on how to respond to changes. It may even be able to deal with the matter automatically. An operator will always be informed for correct process management or additional action that might be required.
FUTURE FLEXIBILITY A further advantage of an effective inspection and process management system is flexibility. Combining vision, motion,
Delta Parallel robot Quattro and Hornet
Articulated robot Viper
SCARA robot eCobra
Mobile robot LD Series
The new Omron Robotic Automation enhances the most demanding manufacturing lines. Realize faster line start-up & change-over, implement easier to use technology & vertical line integration, and facilitate faster data capture & analysis to increase your in-line efficiency. Our industrial robotics range from articulated, SCARA, and DELTA to collaborative (mobile) robots that optimize the handling of varying lot sizes and diverse products, formats and qualities. Achieve flexible production with integrated robotics solutions that give you a competitive edge! Discover how to improve your flexible production, contact us: +27 (0)11 579 2600 info.sa@eu.omron.com industrial.omron.co.za
29
2019 Quarter 2 | Food Manufacturing Africa 20-07-17
robot_88,5x130_food_manufacturing_africa_ad_enza_01.indd 1
12:55
LABELLING
A mixed bag of regional regulations The debate about food safety policies is unlikely to end soon. While the obvious objective of setting food standards is for consumer protection, it is interesting the world cannot agree on common regulations.
F
OOD SAFETY POLICY refers to structures that ensure food is handled, prepared and stored in a way that minimises contamination risk. It is a pertinent global issue. Food hygiene regulations are aimed at preventing food poisoning cases. They involve equipment and surface sanitising; high personal hygiene levels; effective pest control and proper storage and heating. While there are general guidelines applied across the global divide, some aspects set apart regional regulations in different locations.
FOOD SAFETY IN AFRICA Most African countries rely on subsistence farming and widespread food vending in urban spaces. As a continent of contrasts, it also has some first-world farms and developed food processing facilities. As African countries embrace international trade, they are paying a lot more attention to food safety and there are plans to create a common guideline framework for countries. The African Union has formulated a promising project in this regard. It is bringing together willing participants from different regions to work toward a common food standards framework. This has encouraged meaningful participation and helped inspire confidence from other countries. The project is still in the early stages, focusing on
minimising public health risks and getting consumers to trust local food systems. Food safety-related problems still account for almost 2 000 fatalities on the continent daily. Contamination, diarrhoea and foodborne illness outbreaks are very high. Dangerous food additives still make their way into soft drinks and snacks without warnings on food labels. On the upside, governments are giving higher priority to these issues.
AFRICAN FOOD LABELS There is no common authority on African food labels and requirements differ from country to country. South Africa offers a suitable example in this regard with a few basic traits characterising most food labels: • Company name • Net weight • Year of manufacture • The expiry or best-by date • Hazards warnings.
GMO REGULATION IN AFRICA On the African continent, only Algeria, Rwanda and Madagascar have bans in place for GM crops. Considering the common food production constraints experienced, GM technology offers a welcome reprieve. It has boosted agricultural output and food security in many sub-Saharan countries.
Research has shown positive economic results from these crops. There are initiatives aimed at relaxing policies in the sector to reduce product prices. The public has not been as enthusiastic with environmental and agricultural bodies warning of adverse health effects. Regulations in most countries are gradually becoming more flexible particularly in the face of drought and famine.
UNDERSTANDING DIFFERENT FOOD MARKET REGULATIONS It is evident that within the African continent food-related regulations are far from uniform. While certain products are considered risky in one market, they are a staple in another. The same applies to the US and EU markets where different rules apply for distinct food products. To succeed in international trade, you would need to have these regulations on your fingertips. This will help you avoid losses that would result from consignment rejection due to quality issues. • *This is an edited version of an original article by Nic Pantucci entitled “Food-Related Regulations in Africa compared to the EU and US”.
Waystocap – www.waystocap.com
Trim size – 65mm (H) x 177mm (W) Type area – 50mm (H) x 168mm (W)
Experts in Pressure Sensitive Labels , Wrap Around Labels & Shrink Sleeves
For further information on how we can help build your brand contact our Project Developement team on Tel 031 502 5050 T: 031 502 5050 E: info@labelprint.co.za www.labelprint.co.za Label Experts.
30
Food Manufacturing Africa | 2019 Quarter 2
beverages
dairy farming
dairy processing
utilities
transport
food
core technologies
Milking & Cooling
Seperators
Decanters
Homogenisers
Valves
Spray Drying
Aseptic Filling
Brewery & Dairy
Compressors
Packages & Skids
Ice Machines
Freezers
GEA Southern & Eastern Africa 48 Reedbuck Crescent, Corporate Park South, Midrand 1682, RSA Tel. + 27(0)11 392 7114, Fax. +27(0)11 392 7000 info-sea@gea.com
www.gea.com
engineering for a better world
Are you compliant with Regula�on 638?
If you prepare, transport, handle or sell food, you must comply with Regula�on 638 (R638) to meet the minimum hygiene requirements. What is Regula�on 638? This is the regula�on that replaced R962 on 22 June 2018, and it is the duty of the person in charge to be trained in its principles and prac�ces, and the training must be accredited. What is more, if you are not already compliant, your training will need to be complete by 22 June 2019. NOSA provides accredited training in R638 NOSA has developed a training course to cover the broad spectrum of food safety. We are accredited with the FoodBev SETA and the South African Auditor and Training Cer�fica�on Authority (SAATCA). Ensure full compliance with the R638 Good Manufacturing Prac�ces course from NOSA, which includes Food Safety and Food Quality; Food Safety Hazards, and Good Manufacturing Prac�ces. To discuss your training regarding R638, please contact: Jolanie Kleynhans (Na�onal Internal Audi�ng Manager) Email: jolanie.kleynhans@nosa.co.za Tel: 082 413 5927 Keshav Beachen (Na�onal Sales Manager) Email: keshav.beachen@nosa.co.za Tel: 071 442 9418