Food Manufacturing Africa Q2 2018

MAY - JULY 2018 Vol. 6 • No. 2

SAFETY & HYGIENE: Manage compliance to build consumer trust

Food processing’s latest innovations

Beverage technology designed for the future

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

Visit us in Hall A6 at Booth 320

CONTENTS M AY - J U LY 2 018

Vo l. 6 • N o. 2

06 NEWS

26 Beverage Processing Technology A dairy producer in Italy has doubled its aseptic production of UHT milk in PET bottles. The plant benefits from a simple, safe and sustainable packaging line.

28 Rigid Packaging “HDPE plastic fresh milk containers are typically subjected to tough forces, such as freezing and thawing, flexing and heavy handling during the transport and retail phases of the supply chain”

Sandvik now trades as Ipco

IFF acquires Frutarom

A successful show for Propak East Africa

Coca-Cola celebrates 90 years in Africa

Food delivery embraces blockchain

10

COMPANY FOCUS

CCL Label’s innovative take on packaging

12 INDUSTRY TALK Manage risk with ERP

14 SAFETY & HYGIENE

Manage compliance to build trust

How to ensure a food safe industry

TraQtion introduces cloud-based software

18 FOOD PROCESSING TECHNOLOGY

Specialist equipment for meat

Conveyors move with HACCP regulations

22 COLOURS & FLAVOURS Equipment solutions for fab flavours The ongoing quest for flavour innovation

ADVERTISERS’ INDEX ABB SA..............................................................15.............www.new.abb.com/food-beverage

Ishida................................................................9..............www.ishidaeurope.com

Benison & Co.................................................21.............www.benison.com.tw

Messe Munchen SA......................................6..............www.fdt-africa.com

Berndorf Band...............................................IFC...........www.berndorfband.group.com

Omron..............................................................26............www.industrial.omron.co.za

CCL Label Meerane.......................................OFC.........www.ccllabel.com

Polyoak Packaging........................................29............www.polyoakpackaging.co.za

Chiorino SA.....................................................20............www.chiorino.com

Roha SA............................................................23............www.roha.com

Creative Flavors.............................................24............www.creativeflavors.co.za

Savannah Fine Chemicals..........................25............www.savannah.co.za

Deluxe Chemicals.........................................22............www.deluxe.co.za

Shanghai Dase-Sing Group........................27.............www.dasesing.com

DFS Process Solutions.................................19............www.dfs.za.com

Syspro..............................................................13.............www.za.syspro.com

Fried International Imports.......................8..............www.fii.co.za

Tromp Group..................................................IBC..........www.trompgroup.nl

GEA Africa........................................................OBC.........www.gea.com

2018 Quarter 2 | Food Manufacturing Africa

3

EDITOR’S COMMENT

EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmediapub.co.za Assistant Editor: Aarifah Nosarka +27 (0) 11 877 6209 aarifah.nosarka@newmediapub.co.za Layout & Design: Kirsty Thomas +27 (0)11 877 6168 kirsty.thomas@newmediapub.co.za Contributors Dominique Stucki ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmediapub.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmediapub.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmediapub.co.za INTERNATIONAL SALES

Ongoing threats demand vigilance T HE WORST OF the South African listeria crisis is over, but can consumers trust that food products are not contaminated with harmful bacteria? Food industry sanitation and hygiene experts agree the worst is yet to come if greater governance and enforceable standards are not implemented.

Gareth Lloyd-Jones, chief commercial officer at Ecowize indicates the African continent is still at high risk of further cases of listeria and other foodborne diseases, as the real cause of the initial outbreak must still be addressed. If these situations are approached reactively, it is only a matter of time before another deadly outbreak occurs. Being proactive in the face of safety, hygiene and processing issues is the first line of defence. This edition of Food Manufacturing Africa looks at how plant managers can effectively manage compliance alongside traceability by using suitable operations management and software. Turn to page 14 for the full story. We also investigate TraQtion, powered by global food safety leader NSF International. This cloud-based food safety compliance software for the food and beverage industry (page 17) offers real solutions. Capabilities include advanced specification management and supplier, product and site compliance.

Food processing technology is constantly evolving and turnkey solutions that optimise value recovery, output and quality is at the heart of what drives this sector. On page 18, DFS Process Solution gives a full breakdown of its total turnkey solutions for meat processing, while Chiorino’s HACCP specified conveyor belts are in the spotlight on page 20.

GEA has specified process solutions for flavour manufacturing (page 22). New machine designs, which include control and cleaning elements for production facilities from handling of raw materials to final packaging, can impact on getting perfect flavour to your customer.

Beverage processing technology is also under review. Sidel has allowed an Italian dairy manufacturer to double its aseptic production of UHT milk. Find out how this plant benefits from a simple, safe and sustainable packaging line (page 26). We also bring you the very latest product and technology news in rigid packaging.

All this and more on page 28.

I hope you enjoy this edition of Food Manufacturing Africa. If you have any queries or suggestions for us, please mail me at maryke.foulds@newmediapub.co.za.

Happy reading!

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 CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmediapub.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmediapub.co.za Production Manager: Rae Morrison 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 on behalf of Media24 by New Media Publishing (PTY) Ltd. MANAGING DIRECTOR: Aileen Lamb CHIEF EXECUTIVE OFFICER: Bridget McCarney EXECUTIVE DIRECTOR: John Psillos NON-EXECUTIVE DIRECTOR: Irna van Zyl HEAD OFFICE New Media House, 19 Bree Street, Cape Town 8001 Tel: +27 (0)21 417 1111, Fax: +27 (0)21 417 1112 Email: newmedia@newmediapub.co.za Postal address PO Box 440, Green Point, Cape Town 8051

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 CTP Printers - Cape Town.

Copyright: all rights reserved. ISSN 2309-5334

4

Food Manufacturing Africa | 2018 Quarter 2

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.

2018 DIARY

DIARY 2018

June

od Asia ex-World of Fo 29 May – 2 Thaif d, Bangkok, Thailan doffoodasia.com www.thaifexworl a ee Expo Slovaki 1 – 2 Gluten Fr kia va Trencin, Slo xpo.sk www.glutenfreee

2018 SUBSCRIPTION FORM

5 – 9 Belproduct Minsk, Belarus m/belproduct/ https://eventegg.co

To ensure you receive a copy of Food Manufacturing Africa each quarter, please complete this coupon and return it, together with your payment to:

10 – 13 SAPICS Africa Cape Town, South a www.sapics.org.z

Circulation Department, NEW MEDIA PUBLISHING (Pty) Ltd, PO Box 440, Green Point, Cape Town 8051 Tel +27 21 701 1566. Fax 086 529 6468.

Big 7 24 – 26 Africa’s rica Af uth So , Midrand om www.africabig7.c

ce on Food ional Conferen 28 – 29 Internat 8 01 y 2 chnolog Processing & Te London, UK ies.com logy.conferenceser www.foodtechno n Food Exhibitio a International 28 – 30 IFE Chin Guangzhou, China m www.ifechina.co

Full Name:...........................................................................................

Designation: ........................................................................................

Company: ...........................................................................................

Postal Address:................................................................................... .................................................................Code:.................................

Country: ..............................................................................................

Tel: (

)....................................... Fax: (

) ..................................

E-mail:.................................................................................................

Main activity of company:...................................................................

Approximate number of employees: ..................................................

July

VAT No: ...............................................................................................

12 – 15 Thailand Retail, Foods & Hospitality Se rvices Bangkok, Thailand www.thailandhore ca.com 15 – 18 IFT Food Expo Chicago, USA www.ift.com

Signature:............................................................................................

Method of payment:

❑

Direct Deposit (Fax this form together with a copy of your deposit slip to: +27 086 529 6468 Payee:

Bank:

9 – 22 Coffee an d Chocolate Expo Johannesburg, South Africa www.jamfestivals.co .za

Acc No:

New Media Publishing (Pty) Ltd .

Nedbank Seapoint

1069321540

Branch Code: 10-69-09-00

❑

Name of card: .............................................................................

st Augu e ferenc

on ional C utrition ternat N s 6 – 8 In od Science, obiotic on Fo and Pr ermany G , Berlin rg rence.o ceconfe n ie c s d o o .f w w w o Hortic 17 – 20 ungary H , n e Debrec fairs.com www.to d Seafoo World a 29 – 31 hanghai, Chin S com i. a h g n foodsha orldsea www.w

Credit Card (Mastercard & Visa only) Expiry Date: ................................................................................

Card Number: .............................................................................

CVC Number...............................................................................

Date: ...........................................................................................

Signature:....................................................................................

❑

TAX INVOICE REQUIRED

(Please tick) SOUTH AFRICA

(PRICES INCLUDE VAT @ 14%)

FOREIGN

(POSTAGE INCLUDED)

1 YEAR

R315.00 ❑

R392.00 ❑

2 YEAR

R514.00 ❑

N/A

2018 Quarter 2 | Food Manufacturing Africa

5

NEWS

New name and brand for leading steel belt manufacturer IPCO IS THE new name for one of the world’s leading suppliers of steel belts and associated industrial process systems. Previously operating as Sandvik Process Systems, the company is now an independent company within the Wallenberg group and has 600 employees, more than 35 sales and service offices and annual sales in excess of €200 million.

In joining the Wallenberg group, IPCO has gained the stability of being part of a business with approximately 600 000 employees and more than €140 billion in total annual sales of holdings.

The company’s network of regional offices will enable it to continue to provide local, on-the-ground expertise backed up by a service organisation with the ability to support customers in any location around the world.

6

IFF will acquire Frutarom in a cash and stock transaction valued at US$7.1 billion

IFF acquires Frutarom AFTER BEING APPROACHED by several multinationals, Frutarom is set to be acquired

by International Flavors & Fragrances Inc. (IFF). ‘This transaction is a big win and a fantastic outcome for shareholders, customers and employees of both companies,’ says IFF chairman and CEO, Andreas Fibig. ‘Frutarom has an extremely attractive product portfolio, including broad expertise in naturals and diverse adjacencies with capabilities beyond our core taste and scent businesses. It also has significant exposure to complementary and fast-growing small- and mid-sized customers. By combining our deep research and development expertise with Frutarom’s, we can offer our customers a broader range of solutions while accelerating our growth strategy. We believe this combination will lead to faster and more profitable growth, enhanced

Food Manufacturing Africa | 2018 Quarter 2

free cash flow and generate greater returns for our shareholders.’

The two companies have entered a definitive agreement. IFF will acquire Frutarom in a cash and stock transaction valued at US$7.1 billion, including the assumption of Frutarom’s debt.

Following the close of the transaction, Ori Yehudai, president and CEO of Frutarom, will serve as a strategic advisor supporting Fibig.

The transaction is expected to close in six to nine months and is subject to Frutarom shareholders’ approval. IFF will remain at its headquarters in New York City, while maintaining a presence in Israel. ‘Frutarom has had a fascinating journey of accelerated growth, far above our industry benchmarks through our investment in unique technologies and focus on natural products in the growing world of health and taste,’ Yehudai concludes.

NEWS

Propak East Africa focuses on sustainability THE THIRD EDITION of Propak East Africa 2018 was held from 27 February to 1 March at the Kenyatta International Conference Centre in Nairobi, Kenya. The event unwrapped recycling and sustainability in packaging with the hope to provide a focus on sustainability to contribute to changing people’s perception of packaging.

With 4 015 trade attendees, the trade show has cemented itself as the leading industry exhibition for the wider East African region. There were participants from 35 different countries.

During the event, 150 exhibitors met with regional industry buyers to network and discuss future and existing business.

‘We are thrilled that we have run another hugely successful Propak here in Kenya.

Going into the show, we had already grown it massively but the feedback from all participants is the real reward. It is clear exhibitors have done well and are pleased with the show, with many already re-confirmed for next year. We look forward to further improving the trade show,’ says Alexander Angus, Propak East Africa exhibition director.

Ishida, Krones, Bosch East Africa, Thermo Fisher Scientific and USS Pactech were among the exhibitors present at the event.

In August 2017, the Kenyan government followed Rwanda’s example and agreed to pass legislation to ban the use of plastic. This is a step yet to be considered in most western developed societies and firmly demonstrates the country’s commitment to reducing its environmental footprint.

Environmentally sustainable packaging was a key theme presented at Propak East Africa 2018 with packaging brands focused on sustainable and recyclable packaging featured on the show floor. Exhibitors also demonstrated cutting-edge technology and solutions to thousands of stakeholders.

Say no to famine THE AFRICAN DEVELOPMENT Bank’s Deputy director general for East Africa, Nnenna Nwabufo, represented the institution at the launch of the Say No to Famine – Short-Term Regional Emergency Response Project (STRERP) for Somalia. As a response to food security, the Bank has supported the people of Somalia, mobilising approximately US$34 million from both the Transition Support Facility of the African Development Fund and the regional envelope. STRERP aims to provide emergency food assistance, fodder for pastoralists and medical supplies to about 800 000 Somalians, who are most vulnerable to the impact of the drought. It also puts in place preliminary building blocks to strengthen links between production, distribution and consumption hubs of food systems in affected regions, leading to increased system-wide efficiency and longer-term resilience.

STRERP Somalia aims to immediately address the humanitarian needs of those affected by drought and famine.

Coca-Cola Company turns 90 in Africa IN 1928, THE first Coca-Cola was sold on the African continent, in Cape Town, South Africa. With the help of more than 55 bottling partners, the company has expanded into nearly all sub-Saharan African countries through its Coca-Cola export business. It has invested in creating jobs, bringing new technologies to each country and improving distribution networks. It also works to empower communities and contribute to environmental sustainability throughout its markets in Africa.

Throughout the years, the Coca-Cola Company has kept its customers and communities at the centre of its business. This continues under new global CEO, James Quincey, with the business embarking on a journey to become a total beverage company, offering people a variety of beverages that make everyday moments more enjoyable. The company has expanded its consumercentric brand portfolio by launching more than 500 products. This vision Beverages for Life combines the brand-building expertise that has created 21 billiondollar brands with a nimble, test-and-learn approach to launching new products around the world.

The Coca-Cola Company believes creating sustainable communities through shared value not only strengthens its own business, but enables it to build a stronger, more prosperous Africa. That is why job creation and empowerment, particularly women empowerment is integrated into the company’s business model.

The Coca-Cola Company is committed to leading the way when it comes to environmental stewardship.

With water scarcity, a real issue across the continent, the Coca-Cola Foundation and its Replenish Africa Initiative (RAIN), has supported access to clean drinking water to more than 2.8 million people across 2 700 communities in 41 countries in Africa since 2012.

The company is active in exploring new technologies such as desalination for use in manufacturing plants.

The company acknowledges that waste - and plastic waste in particular - poses a serious threat to the environment. Scientists and packaging buyers are working with innovation labs, environmental experts, and mainstream suppliers to develop new, modern packaging that will make its products more sustainable.

In 2018 the company announced it will collect and recycle the equivalent of 100 per cent of the packaging it sells by 2030. It is also accelerating its work to be water neutral – returning all the water used to make its beverages to local communities and the environment by partnering with more than half a dozen aid and development organisations.

Preparing for first delivery

STERP provides emergency food assistance

2018 Quarter 2 | Food Manufacturing Africa

7

NEWS

A successful agrofood &

Mass satisfaction

plastprintpack Ethiopia 2018

after West African expo

THE SECOND EDITION of the event was characterised by the outstanding participation of international market leaders. It hosted more than 60 exhibitors from 17 countries which met with 2 673 trade visitors from across Ethiopia.

Organised by fairtrade, a German exhibition specialist and its Ethiopian partner, Prana Events, the show took place from 3 to 5 May at the Millennium Hall in Addis Ababa.

‘Building on the great results of the first edition in 2017, the quality of exhibitors at the trade fair was set to improve significantly,’ says Martin März, founder and managing partner of fairtrade.

The international exhibitors came from Austria, China, Denmark, Ethiopia, France, Germany, India, Italy, Qatar, South Africa, Spain, Taiwan, Thailand, Tunisia, Turkey, United Kingdom and the US. Agrofood & plastprintpack Ethiopia 2018 received support from the French agrofood association, adepta; the German Society for International Cooperation; Italian Trade Agency and VDMA Food Processing and Packaging Machinery.

Ethiopian State Minister for Industry, Mebrahtu Meles says agro-processing is one of the priority sectors in Ethiopia offering significant investment opportunities for domestic and foreign investors.

‘Owing to its unique and suitable agro climate conditions, Ethiopia produces a wide range of agricultural commodities including coffee, livestock products, oil seeds and more. The government of A ribbon cutting ceremony marked Ethiopia is exerting unreserved efforts to increase the opening of the event the supply and improve the quality of these products. The entire agro sector potential places Ethiopia as a promising country for agroprocessing and related investments.’

Track food delivery DEVERY.IO, A BLOCKCHAIN based startup focused on supply chain tracking, has signed a deal with the Tunisian Ministry of Education to implement a blockchain-based tracking system for its school meals programme. The Tunisian government operates a school meal programme designed to offer one fresh meal a day to underprivileged students.

In seeking to improve the system and to track the quality of meals provided, the Ministry of Education is now exploring the utilisation of blockchain-based tracking. Implementation will involve

EXHIBITORS AT AGROFOOD & plastprintpack Nigeria 2018, which took place from 26 to 28 March, were reportedly satisfied with the show’s outcome. The event was hosted at the Landmark Centre in Lagos, Nigeria. It featured three days of presentations and workshops, which included more than 20 speakers from Nigeria and Europe. The show enabled thousands of B2B meetings between 1 554 professional visitors and 142 exhibitors from 21 countries presenting.

A survey was conducted during the expo.

Based on 124 respondents and a response rate of 88 per cent, the following feedback was received: • 88 per cent of exhibitors indicated they would recommend the event • 92 per cent said they were happy with the service from fairtrade • 85 per cent approved of the quality of the stand construction • 84 per cent were happy with the event as a whole • 75 per cent were pleased with number of visitors • 72 per cent approved of the quality of initiated business contacts • 72 per cent were positive of the business prospects after the fair.

Dieter Rohlf, feed and biofuel technologies area sales manager for Africa at Andritz says the West African market has the best chance to grow produce. ‘We met feed mill owners and developers at the event. On the first day we also met with quality clients.’

Marco Spinger, director of global markets and IT division at the Association of the German Trade Fair Industry says exhibitors on the German Pavilion had an average of 30 contacts over two days.

an initial roll out to a scheme to feed 1 500 primary school kids, with the goal of ultimately rolling out the scheme to all 400 000 Tunisian school children currently receiving food assistance. The programme is managed by the United Nations’ World Food Programme. In achieving these goals, the ability to track the delivery of meals and best utilisation of funds are key measures of success.

Devery.io provides technical advisory and development capability to build, train and utilise a transparent and accountable system of tracking meal deliveries and report any issues with the ministry in real time.

South Africa’s trusted supplier of new European imported plastic pallets HIGH QUALITY

|

COST EFFECTIVE

|

HYGIENIC

072 889 3674

sales@fii.co.za

|

ECO-FRIENDLY

Order yours today!

WE’LL CARRY YOUR LOAD

8

Food Manufacturing Africa | 2018 Quarter 2

www.fii.co.za

Proven to deliver productivity

High speeds are a given with Ishida snacks packaging technology. Our lines are consistently fast, and you’ll experience high levels of operational effectiveness and efficiency too. Delivering only the highest quality packs, in a fraction of the time.

Work in harmony with Ishida.

ishidaeurope.com

COMPANY FOCUS

Maximise sustainable decoration solutions Packaging is one of the most essential components in presenting a brand’s identity. It is the only medium, besides the product itself, that is in direct contact with consumers. It plays a critical role in carrying brand messages to the world.

C

REATING A UNIQUE brand experience is one of the top goals for leading consumer goods companies worldwide. Be it personalisation or never seen before effects and embellishments, the aim goes beyond catching the consumer’s eye: it is to connect and convey a positive feeling and to build or strengthen relationships between brand and consumer.

Packaging pioneer CCL Label helps create the desired brand image by actively supporting global and local companies with latest technologies, innovations and printing capabilities. In the industry for 60 years and an immense network of packaging experts and production sites means it can support companies with high quality products coupled to the latest technologies.

Design optimisations, new-to-market label constructions, functional and promotional solutions have helped create trendsetting brand images. By modernising their brand identity, CCL’s customers see increased sales. This affirms that visual identity is a decisive factor for success at point of sale. Pressure sensitive labels, 360° decorative shrink and stretch sleeves offer original and powerful ways to attract new consumers across all demographic segments.

WELCOME TO THE DIGITAL WORLD Packaging and decoration has stepped into the digital world by integrating tiny antennas and electrical circuits (RFID & NFC) or coming to life through smartphone cameras (augmented reality). Digital printing technology has opened a whole new world of possibilities.

Various collectable designs have been successful, but digital printing took the idea to the next level. Offering each consumer a unique product was once a distant dream. Now it is reality. The list of successful personalisation promotions is impressive. With new possibilities, the list continues to grow.

10

Food Manufacturing Africa | 2018 Quarter 2

Each product can be outfitted with an individual design and variable data easily integrated. Mosaic software allows personalisation of any print run with images, text and designs for maximum impact.

It automatically generates hundreds, thousands and even millions of unique graphics. Thanks to CCL’s digital hybrid technology, varnishes can be integrated.

This allows individually applied special effects.

Fluorescent ink on each label and sleeve is an example.

Digitally printed labels and sleeves feature excellent graphics and are the perfect solution for diverse runs, promotions or seasonal designs. Printing from a digital based image directly onto a substrate reduces the cost for tools and lead times and offers tremendous flexibility. A wide range of substrates can be used.

All kinds of embellishments can be added to achieve outstanding appearances when combining digital with conventional technologies.

A BALANCING ACT

Nestea with EcoStream technology

CCL’s culture of research and development has resulted in several patents and customised solutions some revolutionary to the industry. Industry-leading

COMPANY FOCUS

laboratories not only secure a constant product quality and performance, but develop and advance label constructions that shape the world of packaging.

Sustainability has become a compelling issue. Brand owners are aware of its importance and consumers are on the lookout for greener alternatives when choosing a product from the shelf.

Growing regulations and laws are entrenched and more will follow to support recycling and environmentally-friendly solutions in packaging. The European Commission stated in its European Strategy for Plastics that … “by 2030, all plastics packaging placed on the EU market is either reusable or can be recycled in a cost-effective manner.” To achieve this goal, plastics and products containing plastics must be designed to allow for greater durability, reuse and highquality recycling.

Many companies in the food and beverage industry are looking for fitting solutions to comply with the demands of both politics and consumers. Balancing sustainability and the push for maximum shelf impact play an essential role in the process towards a greener future. For CCL Label, the main goal is to create solutions that offer premium appearance while complying with ecological requirements.

At CCL’s state-of-the-art laboratories engineers develop solutions that fit all packaging requirements.

Proven technologies such as WashOff and EcoStream® are successful, enabling ecological solutions that are sustainable and premium. Global and local beverage brands are increasingly relying on CCL’s sophisticated technologies.

BOTTLE-TO-BOTTLE RECYCLING MADE EASY EcoStream technology continues its extraordinary success story. Many global brands from water, soft drink and ready-to-drink segments rely on groundbreaking solutions that enable true bottle-tobottle recycling.

The decision to go from the current familiar decoration to a whole new construction is not easily made. Consumers recognise and are accustomed to existing packaging. To retain the value of brand awareness, CCL Label develops label solutions that consider all aims and concerns.

The Desperados festival edition for Brau Union Austria was a first step on the path to implement EcoStream technology into the market. Performance and appearance fulfilled all requirements and matched the reliable quality Heineken and Brau Union trust to receive from CCL Label. Recently Nestlé chose EcoStream for the re-launch of their signature

MEET CCL AT FOOD &

DRINK TECHNOLOGY AFRICA IN 2016 CCL Label made its debut at food & drink technology Africa, the third successful offset of Messe Munich’s drinktec. CCL’s sales office in Johannesburg will be augmented by a local production site to facilitate further growth on the African continent. The company will present the latest premium decoration solutions again at the event held from 4 to 6 September at the Gallagher Convention Centre in Johannesburg.

Different types of decoration, a vast range of printing technologies, effects and innovations presented will be under review. Revolutionary technologies such as WashOff and new ecological and recycling-friendly solutions will be the focus for this year. Stop by the CCL booth to look for brand inspiration, learn about the latest technologies and trends; network or discuss current and future projects.

brand in the ready-to-drink tea segment: Nestea hit the market with a refreshed and well-thought-out packaging concept underlining the healthy and conscious positioning of the brand.

FUNCTIONALITY AND DESIGN COMBINED

EcoSolve and EcoSource mock-up

Sophisticated label construction ensures different materials can easily separate during recycling. Inks and adhesives do not pollute PET flakes by staying on the removed label parts. PET can be reused right away.

Even though labels are built to be recyclingfriendly they offer immense creative freedom.

Label constructions with embellishments such as tactile varnish were approved separately

by EPBP and APR as EcoStream+ to verify that functionality is not affected.

ECOLOGICAL TRAILBLAZERS While WashOff and EcoStream focus on the removal and separation of decoration and container, EcoSolve and EcoSource are devoted to the label itself – taking the evolution of labels one step further. To offer a broad range of sustainable decoration CCL Label has developed two options providing solutions for different kinds of ecological challenges.

EcoSource labels consist of components with up to 94 per cent biological share. They enable the use of raw materials made from renewable resources such as a rapeseed oil-based adhesive. Chosen bioplastics and bio-based adhesives do not fall short compared to other variants. Processability and clarity guarantees secure performance and premium appearance.

EcoSolve labels are biodegradable and compostable. They are the ideal solution for ecological containers such as bottles made of PLA. Ecological composition is suitable for conventional printing techniques and meets all the requirements of OK Compost certificate standards. •

CCL Label – www.ccllabel.com

2018 Quarter 2 | Food Manufacturing Africa

11

INDUSTRY TALK

Invest for

MANAGING RISK

success with ERP Working across multiple spreadsheets where each department runs in isolation can mean constantly averting one crisis after another. Integration in a business is critical when trying to work efficiently.

D

ealing with large batches of sophisticated products can come with a new set of challenges. One tiny mistake such as not ordering enough stock and overpromising can end up costing you time, your reputation and money.

Many industries require refrigeration and heating products to keep their business running, so they become an integral part of the business. Every restaurant or kitchen has a different environment with its own set of unique needs. It is the responsibility of the manufacturer to understand these needs and serve bespoke products that will please customers.

FULFIL THE DEMAND AND AVOID THE KNOCK ON EFFECT Components used to produce a processing plant’s fridge or heating system can differ greatly. Ordering stock on a large scale can also affect business. With many projects on the go, visibility across the board is needed so you can understand the probability of success in completing a product.

Problems in maintenance, repairing or delivery of this piece of product can have a

12

knock on effect for many other areas of the business. It is important to remove all silos and integrate parts of the business to make everything seamless.

An ERP system adds value by giving you an overall view of all that is required including stock and capacity. It answers questions such as: Do we have enough time, resources and capacity based on the demand to fulfil orders? What are the production timelines, and are we capable of meeting our deadlines without being sleep deprived?

ERP systems also provide insight on the typical lifespan and other behaviours in different environments where product is placed. This allows the manufacturer to advise its customers on the warranty period, how long it will last and how often servicing should happen.

“Without using an integrated system that shows you what is happening on the project or procurement side, you risk the chance of overspending”

Food Manufacturing Africa | 2018 Quarter 2

Without using an integrated system that shows you what is happening on the project or procurement side, you risk overspending.

If the finance team is not kept in the loop on what is happening until it is too late, they will likely have to figure out a way to fit stock purchases into the cash flow. The finance team will have to keep juggling balls to make sure payments are satisfied so they don’t receive bad ratings from suppliers.

If a stock shortage is not visible, business needs to remedy the situation. Otherwise you will work at a crisis point where you are managing risks and trying to ensure all projects can be delivered on time. You end up sourcing product from anywhere and could possibly get low quality products or risk overspending because you don’t have time to get the right suppliers or negotiate the right price.

ERP systems assist in providing visibility across the organisation, allowing for improved planning and collaborations lowering potential of risky situations.

With the growth of AI across different industries, Syspro is developing artificial and IOT capabilities into its ERP system, along with the right tools and methodology.

This will go a long way to help customers to optimally use technology. By leveraging ERP in the refrigeration industry, customers are guided through the process of asking the right question to ensure they fully use all capabilities of their ERP systems.

By utilising an ERP system across the organisation, a business can begin to move from crisis management into strategy management. •

Syspro – za.syspro.com

SAFETY & HYGIENE

How to manage compliance

in food production With the growing number of food recalls in recent years, the food industry is in a precarious situation. Dominique Stucki explains how plant managers can work towards rebuilding consumer trust.

Data is only worthwhile when managed

T

HERE WAS WIDESPREAD panic across Europe in mid-2017 when millions of eggs were recalled due to contamination with Fipronil — a highly toxic insecticide that is banned in the EU. Eggs were found to contain high levels of the toxin, which led to products being removed from shelves in Belgium, Germany and the Netherlands.

This of course only addressed part of the problem. Since eggs are a staple ingredient in many delicacies and dishes prepared and sold through supermarkets, the extent of the contamination is still unknown. This is only the latest in a long line of blows to consumer trust of food manufacturers in the twentyfirst century.

While the use of banned insecticides is indefensible, particularly in this incident, the recall does highlight a persistent issue in the international food chain. Fipronil, while outlawed in the EU, is legal for sale and use in the US agricultural sector. There are similar inconsistencies in product and practice legality in the food industry. This underlines the importance of best practice when managing compliance.

If we consider best practice as being the most effective means of businesses achieving compliance, it is important that food plant managers also effectively manage the requirements of the regulations their products are subject to.

For smaller businesses that source, manufacture and sell products entirely within one country, this is not too challenging. The difficulty arises in exported products, which

14

“MOM and MES systems unite disparate equipment and systems in a plant and collate process data into one central location in a clearly presented way” require businesses to produce several recipes for products that meet the specific needs of each territory exported to.

An example of this is alcohol manufacturer Sazerac, which had its Fireball whiskey temporarily removed from sale in Finland, Norway and Sweden in 2014. This was because the product contained amounts of propylene glycol in excess of EU limits of one gramme per kilogram of product — yet that amount met US market requirements. In a statement, Sazerac regarded this as a ‘small recipe-related compliance issue.’

Fortunately, plant managers can effectively manage compliance alongside things such as traceability by using suitable food manufacturing operations management (MOM) systems or manufacturing execution software (MES). MOM and MES systems unite disparate equipment and systems in a plant and collate process data into one central location in a clearly presented way.

This means plant managers can use these systems to create a strong digital footprint for every product, which can validate raw materials, trace ingredient origins and provide a clear overview of production recipes

Food Manufacturing Africa | 2018 Quarter 2

— including ratios of ingredients against regulatory limits.

Management of processes is an area of food production where many plant managers often fail to realise best practice, yet it will become increasingly critical to operations.

Recent years have seen a significant rise in the uptake of internet of things (IoT) technologies in the food sector, and a growing number of initiatives prompting businesses to invest in it.

This makes effective data management and food manufacturing IT a necessity.

The EU has been funding the Internet of Food and Farm 2020 (IoF2020) since the start of 2017. The initiative aims to increase the largescale uptake of IoT systems in the agricultural, farming and food processing sectors by the end of 2020. If successful, this will make the modern food plant highly connected, featuring hundreds of points of data collection.

Data is only worthwhile if it is managed effectively. Plant managers using MES systems can not only collect and review performance data quickly, but also set quality parameters for those systems to ensure all products meet quality standards.

This is key to not only delivering peace of mind to consumers, but also to ensuring long-lasting regulatory compliance. Society is becoming data-driven and there is a rising expectancy for information pertaining to the history of products, whether for hygienic or ethical reasons.

It’s realistic that conscientious consumers will soon be able to use smartphones in stores to view data on product history and ingredients. Plant managers can already use that same data in a MES to ensure that, before any product leaves the plant, it is safe for consumption and regulatory compliant.

Regulations change frequently, so managing compliance is about more than understanding multiple market standards. It’s about having the ability to flexibly react to changes in regulation without downtime or reduced output. Plant managers using MES have the organisational agility to respond to these adjustments quickly and effectively, without risking releasing an unsuitable product to market. •

ABB – www.new.abb.com/food-beverage

DOMINIQUE STUCKI

is the head of operations for manufacturing execution systems at ABB’s control technology business unit.

— ABB’s food & beverage solutions Plant-wide solutions to optimize productivity, efficiency and uptime ABB’s broad digital portfolio enables Increased control and visibility to better optimize productivity with less energy and water, realize improved food safety and traceability, and minimize waste. ABB can help you build the flexible, costeffective production systems needed to manage your risks and gain the most from today’s trends. new.abb.com/food-beverage

SAFETY & HYGIENE

Food safety regulations will impact growth R

E-ESTABLISHING TRUST IN the food safety industry, manufacturers and regulators is necessary. With a consistent approach to quality standards across geographies and a genuine concern for developing a safety-centric culture for consumers this is possible.

Food safety related outbreaks can have farreaching consequences for all parties concerned across the supply chain. Singular events of foodborne disease outbreak can have devastating consequences for consumers including loss of life and notable reputational and economic losses for business. Some examples of direct and indirect economic losses include, but are not limited to cost of recall, product destruction, share price impact and time loss due to operational shut down.

The World Trade Organization and its predecessor, The General Agreement of Tariff and Trade have helped create a successful international trading system, facilitating exceptional global economic growth over the last 60 years. A globalised food trade, extensive production and complex supply chains are factors that contribute towards an increased number of microbiological food safety outbreaks. With the anticipated doubling of global demand for food and international trade within the next few decades, it is expected this will drive an increase in foodborne disease incidence. A factor contributing to the expected increase in foodborne disease, but not always considered, is that of ageing and growing populations. The young and elderly are higher risk consumers as well as pregnant women and the infirm.

Recently we have experienced an alarmingly high number of food safety related incidences, in South Africa and globally.

DID YOU KNOW? Mintel’s 2018 report specifies that consumers are mistrustful of food safety in general.

to policy, technology and operations. Such a multitude of challenges can only be addressed by an international and multi-disciplinary community of researchers, public health practitioners and other stakeholders.

Roy Kirby, director of global microbiology and food safety at Mondelēz International notes, ‘Often, the relationship between the regulator and industry is one between stakeholders with opposing objectives. Recent meetings between industry and regulators held under the umbrella of the Global Food Safety Initiative have confirmed this is not the case.’

Some elements of successful food safety system implementation include technical robustness, food safety-centric culture, horizon scanning and management commitment. In the manufacturing industry, implementation of robust food safety systems and compliance to standards is critical to ensuring business success and fostering international trade. ‘Public access to a safe food supply chain is seen by governments from around the world as a key element of ensuring public health. Governments and industry have a role to play in maintaining public trust in the safety of food. Maintaining that trust is key to ensure the public have access to a healthy and balanced diet,’ Kirby concludes. •

“A globalised food trade, extensive production and complex supply chains are factors that contribute towards an increased number of microbiological food safety outbreaks” In addition to increasing demand, one of the global megatrends that impact the food industry is consumer empowerment. Technology has made access to information easier for consumers. As they become more knowledgeable, their demands raise the bar for manufacturers.

Mintel’s 2018 report specifies a general mistrust of food safety throughout manufacturing and supply chains by consumers. Advances in analytical and omics technologies are set to improve food safety by making great strides in surveillance.

The harmonisation of applications in the global market present multiple challenges, with regards

16

Food Manufacturing Africa | 2018 Quarter 2

Mondelēz focuses on proactive, preventative programmes to ensure the highest possible confidence for consumers

SAFETY & HYGIENE

Restore consumer faith in food TraQtion, powered by global food safety leader NSF International, is a cloud-based food safety compliance software for the food and beverage industry.

A

S THE FOOD industry works to regain consumer trust and prevent future foodborne illness outbreaks, a cloud-based food safety and supply chain quality compliance system is now available. TraQtion, a wholly-owned subsidiary of NSF International, uses a cloud-based platform to comprehensively manage all aspects of food industry supply chains – including products, suppliers and site compliance.

While TraQtion is new to South Africa, the cloudbased software’s quality and compliance tools are being used by thousands of food industry professionals in 90 countries.

‘In light of current events, there is no doubt the food industry has been dealt a massive public health and reputational blow,’ says Ulli Gerntholtz, NSF International Africa’s consulting and technical services manager. ‘I believe TraQtion will become an essential tool as we work to regain control of food industry’s processes, rebuild consumer confidence, protect public health and quell confusion facing industry today.’

TraQtion was designed by food safety and technology experts at NSF International, a global organisation with more than 70 years of public health expertise.

TAKE RISK IN HAND FOOD AND BEVERAGE industry supply chains are complex. Products are perishable which requires supplies to be delivered to end users as fresh as possible. The Allianz Risk Barometer 2018 ranks business interruption from supply chain disruption as a top risk in the industry.

Catia Folgore, liability expert at AGCS Africa explains, ‘The recent listeriosis outbreak in South Africa led to a recall of many meat products from the country’s supermarkets. This confronted implicated firms with reputational risks and brand disassociation. As certain food brands are condemned by health authorities, consumers reduce their purchase of products. Companies try to regain consumer confidence by adhering to food and safety regulations through intense PR campaigns, but usually consumers will have moved to other brands.’

Consumers are asking for food that can be carefully vetted and handled as food safety risks increase. Quality deficiencies, serial defects and product recall are significant risks in the food and beverage sector. Serial defects in food products consequently lead to losses for businesses operating in the food and beverage sector.

The use of nanotechnology in food production is also a concern. As public awareness and scientific evidence around the risks and benefits of nanoparticles increases, more regulation from health authorities is likely. Nanotechnology presents risks, especially in the product recall sector and for the food and beverage industry, as personal injury exposures are most imminent.

TraQtion’s capabilities include: •A dvanced specification management – Helps bring speed to market in new product development and ensures central, validated ingredient specifications and finished product information. The module can be stand alone or combined with the full suite of services to scan, evaluate and interpret data across the supply chain.

•S upplier compliance – Provides control and visibility into supply chain food safety information and supplier communications. Its proprietary compliance engine runs 24/7, checking against requirements and generating automatic alerts for appropriate actions. This solution can help companies acquire better document management to meet numerous governmental standards.

•P roduct compliance – Delivers assurance that products received meet specifications and enables more informed product orders. Product information is in one place allowing for full compliance. It can permit the immediate pull of products and identification of alternate suppliers when needed.

•S ite compliance – Offers necessary tools at site level while enabling centralised compliance tracking. The central dashboard for facilities provides at-a-glance performance ratings identified by the TraQtion compliance engine. This supports quick actions and streamlined communications.

‘I challenge every leader in the food industry – from CEOs to quality assurance and operational directors to talk with us about TraQtion, a solution specifically designed to simplify complexity and restore peace of mind,’ Gerntholtz exclaims. ‘The system can help ensure compliance – from raw ingredients to enduser consumer packaging – simply and effectively.’ •

TraQtion – www.traqtion.com

2018 Quarter 2 | Food Manufacturing Africa

17

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 on offer.

T

HE PORTFOLIO INCLUDES turnkey solutions for primary processing through to further processing, including rendering and wastewater treatment throughout southern Africa.

PRIMARY PROCESSING •B aader 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 choice of manual, semi-automatic and fully automated plant operation based on requirements. It also features a range of technically advanced processing equipment, which caters for capacities of 500 birds to 13 500 birds per hour.

•M arel Meat (previously MPS) is a global provider of automated slaughter lines for pigs, cattle and sheep, CO 2 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 integrated Butina systems for livestock handling, CO 2 stunning, blood collection and blood processing in slaughter houses. Cutting and deboning systems include turnkey solutions for primal cutting, classification and sorting, deboning and trimming, packing, palletising, internal transportation and storage. Integrated system solutions for conveyance, materials handling, order picking, labelling and automatic storage and retrieval completes its portfolio.

• F reund Maschinenfabrik designs and manufactures hand tools for red meat abattoir processing. The company is a world leader in slaughtering and cutting technology.

in the meat, pet food, fish oil, environmental protection and biofuel industries. It is also active in protein recovery systems and byproducts 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 a specialist in the field of advanced water treatment equipment and techniques. The company offers products like flotation units, and 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 Maschinenbau manufactures injectors and massagers. Technology may be used to add brine mixes, flavours and colour to meat products. New generation Imax injectors, Brimax mixing systems and Max massagers are equipped with intelligent

technology, which provide live process monitoring and traceability.

• Steen F.P.M. International offers skinning machines for most applications. Mid-wing tulip processor has specially been developed to create unique and trendy tulip wing snacks.

The spare-rib cutter optimises revenue of thigh production by transforming thighs into value added snacks.

• Food Technology Thielemann 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.

• Marelec Portio combines state of the art technology for creating high precision yet economic portion cutting machines. 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 Marlen and Carruthers, products have long set the standard for quality and performance in vacuum stuffing and pumping, portioning, size reduction and food handling • Unitherm Food Systems develops unique thermal processes for various product markets including frying, cooking (spiral ovens), grilling (flame grill and tunnel of fire). It also offers 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. Econoline was developed to make the automated process of pre-dusting, batter coating, crumbing and frying, accessible to small and large volume producers. The Formatic range guarantees accurate forming and portioning.

It is suited to a variety of mixtures of numerous textures and consistencies. •

DFS Process Solutions – www.dfs.za.com

BY-PRODUCTS RENDERING •H aarslev Industries manufactures processing equipment for customers

18

Food Manufacturing Africa | 2018 Quarter 2

Baader Linco’s Compact Plant 396 includes slaughtering and manual evisceration of up to 1 200 birds per hour depending on scalding requirements

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.

TEL +27 (0)87 238 1873 | EMAIL sales@dfs.za.com | www.dfs.za.com

FOOD PROCESSING TECHNOLOGY

Your partner in food safety conveyor belts Chiorino manufactures conveyor and process belts that fully comply with the latest European and international food regulations. These products are particularly recommended for HACCP systems.

T

HE VALUE OF a company is represented not only by its size but also by the goals it sets for itself. This is the viewpoint of Malcolm Turner, managing director of Chiorino South Africa. ’The product range is customised to suit each individual customer’s needs. Confronting new challenges and hitting increasingly ambitious targets, requires synergy and collaboration between company departments, customers and suppliers.

Chiorino’s philosophy is to enhance the

KEY FEATURES OF CHIORINO BELTS: • E xcellent resistance to cuts and abrasions • Superior resistance to most aggressive fats and oils • No edge fray • High flexibility • Resistance to high temperatures.

valued contribution of all stakeholders,’ Turner enthuses.

HP belts offer increased resistance to high temperatures compared to traditional polyurethane belts. They maintain characteristics even at lower temperatures.

They also offer excellent resistance to chemical agents, fats and aggressive oils, including palm and coconut oil.

RESISTANCE TO ABRASIVE CLEANING SYSTEMS Thanks to its high resistance to hydrolysis, HP belts don’t deteriorate. Users can benefit from long service life and significant cost reduction.

Compared to modular belts, HP belts offer considerable water, time and energy savings.

High hygiene levels are assured since most food scraps are easily removed during cleaning and sanitisation.

‘We offer a comprehensive range of high performance food belts, HP belts and HP

compact drive, for processing of meat, fish and poultry throughout the production chain.

Careful selection of raw materials; constant adjustment by research and development department to legislative developments in food safety, and strict controls throughout the production process (good manufacturing practices) guarantee total food compliance of Chiorino belts,’ Turner notes.

Declarations of compliance as prescribed by law are available for every Chiorino food belt.

‘Our aspiration is to be a dynamic company that is constantly evolving. We also aim to be a reliable partner whose mission is total customer satisfaction. We pride ourselves on innovative prospects, winning entrepreneurial choices and a top level production division,’ Turner concludes. •

Chiorino – www.chiorino.com

Conveyor and process belts for meat, poultry and seafood

You partner for food safety

Chiorino manufactures conveyor and process belts that full comply with the latest European and International Food Regulations, and are particularly recommended for HACCP systems with Certified Food Compliance.

Key features: Excellent resistance to cut and abrasion Superior resistance to most aggressive fats and oils No edge tray Very high flexibility Extraordinary Resistance to Cleaning Systems Thanks to the high resistance to hydrolysis, HP belts and HP ‘Compact Drive’ belts do not undergo deterioration due to the “Clean-In Place” washing and sanitization processes with warm water, steam, foam and aggressive detergents.

The user can benefit from the belt’s long service life and significant costs reduction.

Chiorino HP belts are at the forefront of hygiene and food safety with total compliance of the HACCP system.

®

Johannesburg | T: +27 (0)11 397 1268 | met@chiorino.co.za Cape Town | T: +27 (0)21 510 1361 | wh@chiorino.co.za Durban | T: +27 (0)31 792 5500 | rfz@chiorino.co.za www.chiorino.com

20

Food Manufacturing Africa | 2018 Quarter 2

FOOD PROCESSING TECHNOLOGY

Technology supports snacks’

success and growth

A snacks producer is benefitting from an integrated packing line solution sourced through Ishida Europe. The technology enables the company to meet growing global demand for its unique range of organic and allergen-free snacks.

T

O MEET HIGH production rates of approximately 4 800kg per day – it installed two Ishida iTPS (integrated total packing systems), multihead weigher and bagmaker combinations. In conjunction with an IX-GA-4075 x-ray inspection system and DACS-G checkweigher, the systems deliver the highest quality control and inspection procedures.

Speed and accuracy are important. The Ishida line handles pack sizes of 15g to 90g for extruded snacks and 23g to 125g for baked products, with accuracy to within 0.1g of target weight. Top speeds for each system are up to 140 packs per minute - limited only by the lightness of most of the products, which means they take a little more time to transfer through the iTPS. For the smallest pack sizes, the two snack packing systems work

in tandem to deliver around 240 packs per minute to match the capacity of the extruder.

A wide variety of brands and private label products are manufactured each day.

Changeovers can take place two or three times per shift. The manufacturer reports that these are easy to implement, with all details saved in the system’s remote control unit.

Cleaning is equally easy. The hygienic design of the weighers and easy-to-remove parts mean many cleaning processes can be completed within 30 minutes. Machines are in operation 24 hours a day for five or six days per week.

The IX-GA x-ray inspection system can spot foreign bodies such as metal, dense plastics and rubber as small as 0.6mm and below as part of enhanced quality checks at the company. Although current BRC food safety

regulations only specify metal detectors for quality assurance purposes, the producer believes in being able to demonstrate ultrahigh quality standards to its global customer base and ensure it is ahead and ready for any changes that might occur in these regulations in the future.

As packs of snacks are very light, they would not be able to pass through the normal protective tungsten curtains on the Ishida X-ray system. Ishida therefore designed and installed special covers that sit over the infeed and outfeed conveyors.

The DACS-G checkweigher provides a final weight check in line with e-weight regulations, ensuring all packs leaving the factory comply with relevant legislation. •

Ishida – www.ishida.com

2018 Quarter 2 | Food Manufacturing Africa

21

COLOURS & FLAVOURS

Optimise that flavour Technology group GEA has specified its process solutions for flavour manufacturing. New machine designs include control and cleaning elements for production facilities - from handling of raw materials through to final packaging.

W

ITH THIS, GEA helps flavour manufacturers to ensure the taste, consistency and repeatability of products. The goal is to create a flavour that mimics the real thing. It’s not just the combination of raw materials that contribute to the taste result - the manufacturing process is equally crucial.

Any variation in method can cause variations in a product. GEA uses its 50 years of experience in the production of mixing, pumping, homogenisation, drying and handling equipment to develop and bring them together, and provide consistent quality of flavours.

TECHNOLOGY KNOW-HOW ENSURES CONSISTENCY When producing flavours, there are lots of opportunities for things to go wrong.

An ingredient added too quickly into a mixing vessel, inconsistent temperature, insufficient mixing or incomplete homogenisation can have an effect further downstream that affects the outcome.

Variations in oil droplet size, shearing or drying parameters all have an effect that in some subtle way can alter the product.

These parameters are critical to producing a consistent product. The process becomes more complex when 300 to 400 different flavours are produced on the same machinery. Control and automation should rule out deviations.

GEA's new integrated line, controls all individual unit operations precisely. In doing so, it controls the output. Repeatability is not just a question of adjusting a computerised control system. Achieving a consistent product also requires very precise engineering to allow the component parts of the line to work together in harmony. Feed systems must be calibrated specifically to match the capabilities of mixers. The size of the mixer must be scaled precisely with the size of the dryer to ensure compatibility.

CLEANING REMOVES RESIDUES AND ODOURS To comply with hygiene regulations, every production plant must be cleaned effectively.

As every flavour manufacturer knows, that’s not the whole story. Flavours and aromas can linger in equipment even after they have been cleaned to the most scrupulous hygiene standards. Residue of previous flavour can easily taint the next product, destroying allimportant consistency. To prevent this, GEA has done much more than provide an efficient rotating-ball cleaning system.

GETTING THE DESIGN RIGHT GEA has eliminated sharp edges or dead zones in the machines, pipework and valve systems, which even the smallest quantity of product could become trapped. Special materials have been carefully chosen to provide smooth internal surfaces to which product cannot

adhere. The size of cleaning fluid tanks is calculated to ensure they hold precisely the right volume of medium to clean the whole system efficiently in less than four hours.

Even gasket materials have been chosen to ensure they do not harbour traces of product.

These elements combine to ensure the efficiency of the cleaning in place system.

It is efficient and enables fast product changeover, reduced downtime, minimal waste and low use of water and detergents.

SEQUENCED PRODUCTION There is also another key factor in maintaining repeatability. When producing multiple products on the same line it is critical that products are processed in the correct sequence to help prevent any tainting from one to the next. Purer flavours such as melon or strawberry, instantly recognised by consumers and often consumed on their own, take precedence. Stronger flavours such as orange, garlic, chilli, curry that are usually mixed with dishes, come later. The control system on the GEA line is capable of not only managing the recipe for each product, but sequencing the production for maximum efficiency ensuring that after each operation the line is cleaned sufficiently. Deep cleaning can be performed at the end of the sequence before the programme begins again. This also helps to minimise the use of chemicals and water and reduces plant downtime. •

GEA – www.gea.com

MANUFACTURER AND SUPPLIER OF CLEANING AND DISINFECTING PRODUCTS SUITED FOR EVERY INDUSTRY

: 2015

INDUSTRIES

SABS 1828: 2016 and SABS 1853: 2017 Seeking Agents to further expand Registered products to kill Listeria Monocytogenes Currently operating in Namibia, Botswana, Zimbabwe, Mozambique, Malawi and Zambia

Food and Beverage Laundry Hospitality Contract Cleaning Sanitation Pharmaceutical Mining

5 Kelly Road, Boksburg, South Africa

22

Food Manufacturing Africa | 2018 Quarter 2

|| Tel: (+27)11 397 3299

www.deluxe.co.za

COLOURS & FLAVOURS

Ongoing quest for

FLAVOUR INNOVATION In the hot beverages sector, the quest for innovative and intense flavour is leading the way in the development of new flavour carriers.

T

HE ART OF development and innovation requires a great deal of technical know-how and creativity.

Claudia Caetano, product manager for FREY&LAU at Savannah Fine Chemicals, distributor of the range explains, ‘Frey&Lau has launched a new range of products, which incorporate Capso technology.

This is a highly innovative process for encapsulating flavours. Product ranges are distinguished by authentic profiles, and retention of high end notes. Granules also feature outstanding mechanical stability and low hygroscopicity.’

Because of their long shelf life, and a water soluble matrix, Capso flavour granules are suitable for flavouring tea. Products have a three-year shelf life, including the oxidation of sensitive products such as citrus flavours.

Creative Flavors International

offers the National and International market with

quality flavours and emulsions

Designed to add various degrees of cloudiness and flavour to beverages, our emulsions form the foundation for efficient beverage manufacturing. We offer consistent high quality products with a perfect balance of cloudiness, flavour and colour stability. We offer flavours for all beverage applications e.g. alcoholic beverages, fruit juices and soft drinks.

All of our flavours are Kosher- and Halaal suitable and manufactured under strict hygienic conditions with the necessary Good Manufacturing Practices in place. We are also ISO 22000 certified.

CONFECTIONERY

BEVERAGES

BAKERY

EMULSIONS

DAIRY

Tel: +27 11 760 1830 • Fax: +27 11 760 1829 • www.creativeflavors.co.za

Creative Flavors.indd 1

24

Food Manufacturing Africa | 2018 Quarter 2

2018/05/22 9:05 AM

COLOURS & FLAVOURS

FAST FACT GLOBALLY, TEA CONSUMPTION markets continue to grow. Leading trends include added options for premium leaf teas and unique and diverse flavour combinations. The latest products to hit the shelves combine the indulgence of dessert, without the calories or guilt. Unusual options include condensed milk and chocolate praline, while flavoured green and rooibos tea hits the perfect sweet and sour note with Marula and strawberry.

THE RANGE CAPSOPEARL® – These flavour granules are produced in the form of high quality pearls and activate when they get in contact with water. Due to their extremely long shelf life, and high solubility in hot and cold liquids, these granules are very well suited to flavoured fine-cut tea, tea blends, coffee and instant beverages. Granules are distinguished by high mechanical stability and excellent flowing properties. Flavours include bergamot, spearmint, natural pear and wild berry.

CAPSOSTICK® – Due to their size and shape, this ingredient cannot be differentiated from the tea blend itself. The dyed flavour granules are available in most colours. It does not change the colour of the tea bag, making it an ideal solution for rooibos tea.

CAPSOFLAKE® – Ideally suited for flavouring fruit and herbal teas. This ingredient applies to medium and large cut blends. Due to its green, blue-violet and brown colours, the flavour flakes in the tea blend are not visible, making it well suited to tea blends in pyramid bags.

CAPSOLEAF® – The largest of the flavour granules, this product has been recreated in the shape of a tea leaf.

It is perfect for flavouring FREY&LAU is known black, fruit and green for its creative edge and as a leader in teas – both coarse and continuous flavour medium cut. Despite its development for large surface, it has a shelf hot beverages. life of at least three years.

The product is available in most colours customers require. •

DID YOU KNOW?

Savannah Fine Chemicals – www.savannah.co.za

2018 Quarter 2 | Food Manufacturing Africa

25

BEVERAGE PROCESSING TECHNOLOGY

A first for UHT MILK Centrale del Latte di Brescia in Italy has doubled its aseptic production of UHT milk in PET bottles. The plant benefits from a simple, safe and sustainable packaging line.

T

HE DAIRY PRODUCER invested in a complete aseptic PET line equipped with standalone equipment. It switched UHT milk production from carton to PET bottles, a ground-breaking development, which received positive response from consumers.

Building on the increasing consumption of UHT milk in PET in Italy, Centrale del Latte di Brescia needed to enlarge its production capacity. The company wanted to ensure its products were of the highest quality, while reducing its reliance on chemicals.

BRAND DIFFERENTIATION AND MARKETING OPPORTUNITIES

SENSITIVE PRODUCT SAFETY ENHANCED BY PET BARRIER BOTTLES

By investing in the Sidel aseptic Combi Predis, the company took advantage of integrated blow-fill-cap solution to leverage practical and marketing benefits offered by PET. The square shape of the bottle allows an optimal palletisation pattern, with more containers per pallet. The unique design of the PET bottles for fresh and UHT milk also ensures the dairy and retailers’ brands stand out compared to other products on shelf. The producer plays with the shape and the large surface area the bottle offers for decoration, dressing products with roll-fed or sleeve labels, completed with a tamper evident seal around the cap.

Product safety and integrity are important in ensuring the success of packaging fresh and UHT milk in PET bottles.

Few quality issues are caused by microorganism growth or alterations caused by light, oxygen and temperature. PET packaging solutions offers dairy products the possibility to retain fresh taste, vitamin content, texture and colour from production to storage, including shipment and distribution. Opaque barrier PET combined with a dry preform decontamination process offers product safety.

COMPACT FOOTPRINT WITH PRODUCTION DOUBLED At the dairy, the small floor space available was challenging.

An industrial configuration like the first aseptic line based on a standalone equipment approach could not fit within the limited floor area. The company had to implement a compact configuration. This justified the decision to turn to an integrated blow-fill-cap solution. The low-output aseptic Sidel Combi Predis specifically accommodates the need for an ultra-reduced footprint, making it ideally suited to the space constraints faced in a plant. It is perfectly sized for production needs of up to 16 000 bottles per hour.

Achieve flexible production with integrated robotics solutions

AN IMPORTANT STEP FORWARD

Delta Parallel robot Quattro and Hornet

Articulated robot Viper

SCARA robot eCobra

Choice of equipment was an important step forward in terms of food safety and sustainable production. It also impacts cost-saving. Sidel dry preform decontamination technology use no water and only minimal amounts of chemicals. The blower oven activates the sterilising effect of hydrogen peroxide vapour, without the need for additional heating of preforms.

The same technology is employed for cap decontamination with Sidel’s Capdis™.

By integrating preform decontamination, blowing and filling functions with cap decontamination in a single enclosure, Sidel's Combi Predis ensures an aseptically filled and capped PET bottle, without consuming water. The solution benefits in terms of food safety, top production quality and reliability, costeffective and environmentally friendly production. Compared with PET lines equipped with a stand-alone blower and aseptic filler with wet bottle decontamination, it is also easier to operate and maintain. The result is reliable, simple aseptic beverage production in PET bottles, while continuously monitoring critical parameters to bring contamination risk to zero. •

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

Sidel – www.sidel.co.za

26

robot_88,5x130_food_manufacturing_africa_ad_enza_01.indd Food Manufacturing Africa | 12018

Quarter 2

20-07-17 12:55

BEVERAGE PROCESSING TECHNOLOGY

Increase flexibility without compromising quality

I

S IT POSSIBLE to increase production capacity and response times while simultaneously improving hygiene standards?

Matcon’s latest range of beverage processing technology might just be the answer.

In January 2018, beverage processor Wetra decided to renovate an old factory to produce its 35 beverage mix products.

Retrofitting had to accommodate its contract manufacturing business. The newly installed system provides excellent product quality coupled with manufacturing flexibility; fast response times; low levels of inventory and dust containment.

Wetra did not have its own engineering support to assist in designing the new facility. The company looked to Matcon to conduct an engineering study for installing an IBC system for immediate production. It also took future expansion plans into account and layout was perfected to optimise future efficiencies. State-of-the-art software employed by Matcon produced a virtual reality factory layout to see how the system would be arranged.

First phase of factory installation: • S ack tipping for filling the IBCs • IBC blending • Feeding to a single high-speed packing line • A single IBC discharge station feeding to two packing machines • IBC Washing via a simple wash lance • 1 500ℓ stainless steel IBC. Factory design can accommodate a further filling and blending area, with at least three more packing line stations. Matcon’s modular design makes the integration of additional capacity straightforward and blending takes places within the IBC. This means there is no need to clean between recipe changes as there are no contact parts. The blender is immediately ready to accept the next IBC, regardless of whether it is a different recipe.

Any recipe can be mixed at any time, resulting in full flexibility for orders on demand. There is no longer any need to keep vast stocks of inventory to meet an order. This saves capital and prevents a potentially wasted product.

Matcon’s discharge station gives an automated and controlled discharge of powder. It is designed to deliver a constant supply of product to packing lines, enabling equipment to operate effectively. Unique Cone Valve technology protects the blended powder against segregation ensuring the final product is of consistent high quality.

Matcon’s system is always closed, even during discharge and there is no dust released into the production area. This is reassuring in minimising cross-contamination, for worker safety and also significantly reduces housekeeping required around the facility. •

Matcon – www.matconibc.com

Filling and blending area

2018 Quarter 2 | Food Manufacturing Africa

27

RIGID PACKAGING

INNOVATIONS in rigid technologies and packs The correct mix of rigid containers and wrappers can help achieve the best protection on packaging.

Trendy technologies in bottle production keep manufacturers competitive in the food and beverage industry.

H

G MOLENAAR’S PACKAGING Equipment division is offering Gernep labellers the opportunity to reliably wrap high density polyethylene (HDPE) fresh milk containers in normal polypropylene labels. These are usually associated with carbonated soft drinks (CSD). This departure from low density polyethylene stretch sleeves typically used for fresh milk containers provides enormous cost advantages without detrimental effects usually associated with glued labels on milk packaging.

‘HDPE plastic fresh milk containers are typically subjected to tough forces, such as freezing and thawing, flexing and heavy handling during the transport and retail phases of the supply chain,’ says Reinhard Watermeyer, business manager at HG Molenaar.

Stretch sleeves adequately handle different pressures, but the low volumes associated with the limited application focused on the dairy industry increases the unit cost of labels. ‘Before now, there was no reliable alternative.’

“HDPE plastic fresh milk containers are typically subjected to tough forces, such as freezing and thawing, flexing, and heavy handling during the transport and retail phases of the supply chain” Normal PP labels are, by contrast, widely used in the CSD industry in high volumes.

While the ability to apply these labels to milk containers is not entirely new, this is the first time it has been made possible using standard, un-modified equipment, boosting peace of mind on line uptime and production availability.

Gernep’s closed loop glue method, with its unique spray system, allows the same labels that wrap CSD products to be applied to milk containers.

‘There is significant market interest in this capability and equipment available from Gernep,’ Watermeyer says.

28

Food Manufacturing Africa | 2018 Quarter 2

German engineers have tested and developed the equipment on fresh milk HDPE packaging over the past few years. Gernep’s unique glue spray system gives producers and packagers precise control over where glue is applied. This ensures the label adheres perfectly to all panels of the rectangular or square profile containers.

RIGID FORMING TECHNOLOGIES

Reliable wrapping on rigid containers

With 30 years’ experience in PET containers solutions, Sipa has acquired considerable expertise bottle manufacturing and filling technologies. This ranges from preforms to finished products for the food and beverage sectors, amongst others.

Its product range includes equipment for the production of preforms, single stage injection stretch blow moulding systems and stretch blow moulding equipment, both rotary and linear. The company supplies a complete range of PET preform and container production systems.

Sipa works alongside customers to select the production scenario that best meets their needs.

It takes into account factors such as bottle cost, energy saving, space and flexibility. The company’s offering comprises various families of machines for preform production. These are the XFORM 350-500 GEN3 and XTREME injection compression equipment. Each bottle production technology has its own unique system. These are single stage systems with high and low productivity. The ECS FX-HS integrated system features high output, whilst the ECS SP integrated system is aimed at medium to low output.

There are also two stage systems, which include high performance linear and rotary blow moulders.

Sipa’s filling lines for PET bottles are usually filled with mineral water, soft drinks, juices, sensitive products, milk and dairy products, amongst others. There is a full range of lines combining diverse complementary skills.

These provide a 360° view of the packaging.

Martina Bottarel, Sipa’s communications manager, says the company is the only supplier on the market capable of providing specific know-how on the entire bottling process.

‘This is from the design and production of preforms and containers all the way to the creation of turnkey production lines. We provide solutions for

RIGID PACKAGING

extremely flexible, high efficiency and highly customised bottling lines. By means of engineering activities we can design solutions to satisfy our customers’ most diverse manufacturing requirements,’ she explains.

The company provides sales and aftersales service to the sub-Saharan region in Africa from its South African branch.

NEW POT ON THE BLOCK RPC Superfos’ SuperLock container is providing supermarket shoppers an interactive and novel shopping experience by allowing them to mix their own selections of nuts. The container is ideal for both point of sale allure and on the go convenience. Shoppers are presented with an inviting supermarket display where they can choose between two sizes. These are 300 and 450g. The container is an attractive self-service SuperLock container. It is embellished with inmould labelling. The concept is an original one devised by Ranobo, a Belgian wholesaler of nuts, tropical fruit and rice crackers established more than 20 years ago.

‘Ranobo has installed pick and mix displays at a few supermarkets and we are reaching the

Sipa's horizontal injection moulding machine

The SuperLock container

expected sales figures,’ explains founding member, Gilles Jeuris.

He says the container’s strength, attractiveness and practicality help to convey brand values.

An advantage of the pot is its shape and size. It fits perfectly into car cup holders and reflects the fact that nuts are an excellent healthy snack for people who spend long periods driving. Further convenience is provided by the easy re-closure of the screw lid, which makes an audible click sound when closed correctly. The rigid pack’s screw lid preserves the quality of the product it houses.

Astrapak is the supplier of RPC’s products in and around Africa. •

Astrapak – www.rpc-astrapak.com HG Molenaar – www.hgmolenaar.co.za Sipa – www.sipasolutions.com

DEMANDS AND FORECASTS THE DEMAND FOR global rigid plastic food containers is expected to grow at 4.2 per cent annually to 2022 with sales predicted to increase to US$7.7 billion. These gains will be faster than those in the paperboard, metal and glass container categories and will continue to take share from other products. The need for rigid plastics will be driven by the lightweight, low cost, crush and shatter resistance, design flexibility and graphic capabilities of this type of packaging. Additional gains will be limited by competition from flexible packaging, particularly pouches, which offer convenience advantages.

According to the Freedonia Group, dairy products remain the largest market in the food and beverage industry for rigid plastics. This is owing to the suitability of plastic for all sizes of yoghurt bottles, which includes bottles for drinkable yoghurt. These products benefit from increased awareness of protein and probiotics, boosting demand for plastic packaging. They are also widely used to package sour cream, butter and some cheese products.

30

Food Manufacturing Africa | 2018 Quarter 2

Meet us at: - IBA - Gulfood

Delicious!

INTEGRATED SOLUTIONS

SHEETED BREADS PASTRY & LAMINATED DOUGHS PIZZAS, BAKED & TOPPED CAKES & MUFFINS WAFFLES & FUNCAKES PIES

WWW.TROMPGROUP.NL Texmate Bakery Solutions • 185 Beyers Naude Drive, 2195 Northcliff, South Africa • info@texmate.co.za • Tel. 031 764 03 53 • Tel. 011 888 86 67

Co-products take centre stage with GEA technologies Once a waste stream, whey and its derivatives are now

together with our unequalled experience in the field

considered highly valued co-products. Healthy, wholesome

of whey processing, means we are able to implement

and rich in protein, these co-products are meeting the

complete and fully integrated solutions to whey

ever-changing market demands of the food, dairy and

processing plant design. We continuously invests in

nutritional supplement industries. GEA’s technological

technological advancements, both evolutionary and

expertise allows for precise extraction of these prized

revolutionary, for improved manufacturing

ingredients, maintaining nutritional and functional

efficiency. GEA work closely with our customers to

integrity without compromising quality and yield.

perfect their processes and bring their products to market quickly and profitably.

GEA is the leading supplier of whey processing technology to the dairy industry world wide. Our vast

For more information contact GEA Africa (Pty) Ltd

range of dairy process technologies and components,

at 011 392 7114 or info-sea@gea.com.