Food Manufacturing Africa Q3 2020

AUGUST 2020 • OCTOBER 2020 Vol. 9 • No. 3

Deliver

a great customer experience Consumer trends that tick the right boxes

Botanicals add healthy value

Why cobots are the future

CONTENTS AUG 2020 - OC T 2020

Vo l. 9 • N o. 1

10 Transforming your business “New technologies like cloud computing, artificial intelligence, machine learning and predictive analytics have had a profound impact on the world’s economies and continue to disrupt industries”

5

NEWS

OK certification for Avery Dennison Tate & Lyle celebrates distribution agreement First cannabis extract exported Palsgaard doubles capacity Meet Ishida SA’s new GM Coca-Cola Africa sports new faces Bags that push the wow factor

10

INDUSTRY TALK

It’s time for a digital transformation

New advisory board for plant-based food

13

EVENT

How to reboot the F&B industry

14

SNACKS & CONFECTIONERY

Flexible and agile Iberchem Innovative packing solution for dried fruit

18

BEVERAGE PROCESSING TECHNOLOGY

New positioning targets evolving consumers

Zero-proof your booze

Botanicals add value to drinks

Bottler aims high with new PET line

A new era in CO2-neutral bottling

More performance, less space

23 New positioning target evolving consumer groups Higher demand is transforming sport drinks into mainstream products

26

INSPECTION, CODING & MARKING

How to future-proof SMEs Perfect systems for perfect MAP seals Siemens gives you the edge New production interface for great labels Feel the Veryx difference

ADVERTISERS’ INDEX Bragan Chemicals.........................................9............................www.braganchemicals.co.za Clomark............................................................IBC........................www.clomark.com FUCHS Lubricants South Africa................IFC.........................www.fuchs.com/za Iberchem.........................................................15...........................www.iberchem.co.za Ishida ..............................................................17...........................www.ishidaeurope.com Krones Southern Africa...............................23..........................www.krones.com Omron Electronics .......................................27...........................www.industrial.omron.co.za Polyoak Packaging........................................11...........................www.polyoakpackaging.co.za

Savannah Fine Chemicals..........................19..........................www.beneo.com Shin-I Machinery Works Co. ......................28..........................www.shinican.com Sidel..................................................................25..........................www.sidel.com Siyakha Imperial Printing Co....................30..........................www.labelprint.co.za Sollich KG........................................................7.............................www.sollich.com Syspro .............................................................10..........................www.za.syspro.com TNA Packaging System SA..........................OBC.......................www.tnasolutions.com Vega Controls SA ..........................................22..........................www.vega.com/vegapoint

2020 Quarter 3 | 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: Càndida Giambò-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmedia.co.za

What gives

INTERNATIONAL SALES

consumers joy during lockdown?

D

ATA JUST IN from the US-based National Confectioners Association indicates that sales of snacks & confectionery have increased during the COVID-19 pandemic as people look for ways to add a little bit of joy to what has been a very serious and uncertain time. The report highlighted that consumers felt that these products boosted their mood and lightened perspectives.

Overall sales of chocolate and sweets increased by 3.8% with chocolate (+5.5%) and premium chocolate (+12.5%) outpacing the rest of the categories.

In this edition of Food Manufacturing Africa, our snacks & confectionery feature unpacks the impact of Ishida’s weighing and packaging technology on a dried fruit and vegetable start-up as well as Iberchem’s announcement that the group has consolidated under the name Iberchem Group. Turn to page 14 for the full story.

While some consumers are looking to the sweets aisle for their fix, others focus on health & wellness. On page

20 we investigate Doehler’s range of sustainably-sourced raw materials and find out how botanicals can add healthy value to products. We also unpack ingredient innovations from Beneo. Healthconscious buyers are turning to products with wellbeing properties, but with the blurring of traditional target groups, special ingredients such as slow glycaemic carbohydrates allow for the development of sports drinks into a new position. An interesting read – don’t miss it.

Did you know that since its introduction in industrial manufacturing in the 1960s, robots are now used in all areas of manufacturing? Each year up to 600 000 new robotic systems become operational globally. A particular area of interest for food and beverage manufacturing is the use of cobots – designed specifically to work with humans. Omron (page 26) offers some fascinating insights into this sector.

There is an interesting debate around whether working from home is all it’s cracked up to be. A recent survey found that 86% of South African office workers are ready to return to their places of work.

Similarly, the Wall Street Journal reports that companies are finding that fully remote workforces mean that projects take longer, collaboration is harder, and training a new worker is a struggle. But how to balance that need for structure with the flexibility a post-pandemic world demands? The key lies in reimagining the office in a way that suits both companies and employees. I would love to hear your thoughts on this topic, so please drop me a line at maryke.foulds@ newmedia.co.za or follow our social media pages!

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 felicity.garbers@newmedia.co.za PUBLISHING TEAM General Manager: Dev Naidoo 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: Leone Fouche CEO: MEDIA24: Ishmet Davidson HEAD OFFICE 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 is published by New Media, a division of Media24 (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.

4

Food Manufacturing Africa | 2020 Quarter 3

NEWS

2020 SUBSCRIPTION FORM To ensure you receive a copy of Food Manufacturing Africa each quarter, please complete this subscription form and return it, along with your payment to: NEW MEDIA, a division of Media24 (Pty) Ltd, PO Box 440, Green Point, Cape Town 8051 Email: felicity.garbers@newmedia.co.za

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

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

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

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

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

Tel: (

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

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

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

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

AVERY DENNISON ACHIEVES OK COMPOST CERTIFICATION

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

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

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

Method of payment:

❑

Direct Deposit (email this form together with a copy of

your payment to: felicity.garbers@newmedia.co.za

Payee: Bank:

Acc No:

New Media, a division of Media24 (Pty) Ltd .

Nedbank Seapoint 1069321540

Branch Code: 10-69-09-00

❑

Credit Card (Mastercard & Visa only) Complete the following details and email this form to: felicity.garbers@newmedia.co.za

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

Expiry Date: ................................................................................

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

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

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

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

TAX INVOICE REQUIRED (Please tick) SOUTH AFRICA

❑

(PRICES INCLUDE VAT @ 15%)

FOREIGN

(POSTAGE INCLUDED)

1 YEAR

R360.00 ❑

R443.00 ❑

2 YEAR

R587.00 ❑

N/A

AVERY DENNISON HAS successfully achieved OK Compost certification for a BPA-free and FSC-certified thermal label material combined with the brand-new adhesive SX6030. “Demand for sustainable thermal labels is huge, including compostable labels. The European EN13432 standard imposes extremely strict requirements before OK Compost certification can be awarded by TUV Austria. This new material, under product reference BW099, uses a new facestock/ adhesive combination to ensure a robust and practical material that needs no special storage conditions, and has a normal shelf life. As composting standards are limited, the EN13432 is also to be accepted as compostability standard in many countries outside of Europe,” says Jennifer Bijkerk, development engineer.

The main application for BW099 will be the labelling of compostable food packaging and compostable plastic bags, especially last-minute directly-printed labels for fruit and vegetables that are weighed and packed by consumers in the supermarket. Rapidly-spreading bans on single-use plastics also mean there is a drive towards using compostable carrier bags and other packaging, all of which will require a compostable label. Public opinion on the issue and composting being a potential solution are underlined by the Global Commitment launched by the Ellen MacArthur Foundation and the UN Environment Programme in October 2018. Avery Dennison is one of more than 250 businesses supporting this commitment, working with governments, NGOs, universities, and other organisations to eliminate plastic waste and pollution. “We know how important this product category is to converters and end-users, and we see it as a key contributor to our own wider and highly ambitious sustainability goals. We have been able to use conventional technology to produce this innovation, by creating a unique facestock/adhesive combination, and work is already well underway towards expanding our compostable range with more certified products,” notes Luuk Zonneveld, product manager Select Solutions. •

2020 Quarter 3 | Food Manufacturing Africa

5

NEWS

SA’s cannabis exports Global food ingredient take off Cannabis plant

A

friplex is currently the only licenced GMP cannabis manufacturer in South Africa. The company processed the first exported cannabis from licensed local cultivators. “The first legal extraction of cannabis is a huge achievement for Afriplex and South Africa and the country is poised to become a major player in the international cannabis industry,” says Danie Nel, managing director of Afriplex. “As new markets open, we will be able to export to any

country that is legally allowed to import and sell these products. As demand grows, so will economic development opportunities, especially since South Africa offers a safe and stable business environment in sub-Saharan Africa and is seen as a gateway to the rest of Africa.” Afriplex has a fully-integrated approach to the cannabis market, offering processing services and tools for the manufacturing of cannabisbased finished products. •

suppliers announce distribution agreement

T PACKAGING AND PROCESSING NOW SET FOR 2022 PUTTING CUSTOMERS FIRST is the motivation behind the decision to postpone Ipack-Ima. The event has been rescheduled to take place from 2 to 6 May 2022. “The decision was not easy. After careful evaluation and insight, we preferred to give priority to the needs of our exhibitors and visitors who are engaged in the management of a very tricky period,” Valerio Soli, president of Ipack Ima srl explains. Trade

Ipack-Ima has been postponed

fairs are experiencing a situation that no one could have foreseen. The ability to aggregate projects with high added-value is part of a medium to long-term strategy, which will kick off in May 2021. Meat-Tech – the Ipack Ima trade show specialising in solutions for meat products and the ready meals industry, will take place in conjunction with TuttoFood from 17 to 20 May 2021. •

ATE & LYLE and Solevo have announced their new distribution partnership. Solevo is now the exclusive distributor of Tate & Lyle’s ingredients in West Africa in countries such as Ivory Coast, Senegal and Cameroon.

Both entities have a shared ambition to offer innovative solutions to the African continent and provide local consumers with access to high-quality F&B ingredients, including lowcalorie sweeteners and health and wellness ingredients such as soluble fibre, texturants, stabilisers, and acidulants.

“We are proud to have Tate & Lyle as a partner,” enthuses Matthieu Van Bree, head of industrial chemicals, Solevo. “We are expanding our position in the market for speciality food ingredients and solutions we offer to our customers,” he notes. “The long history and experience of Solevo in Africa will be very useful to increase our market presence. The African food industry is growing fast and producers are looking for ingredients and solutions that help them meet growing consumer demand for great-tasting, shelf-stable food and beverages that support healthier diets. With a partner like Solevo we are ready to support these trends,” Dominique Floch, regional sales & technical director, Turkey, Middle East and Africa, Tate & Lyle, points out. •

TONGAAT FINALISES SALE OF NAMIBIAN ASSETS JSE-LISTED SUGAR manufacturer Tongaat Hulett has announced that all conditions precedent to the sale of its entire sugar packaging and distribution business in Namibia have been fulfilled.

The company sold these assets, effective 1 July,

6

to breakfast cereal company Bokomo Namibia for R220m. The last outstanding suspensive conditions to the proposed transaction have been approved by the Namibian Competition Commission. Tongaat Hulett has been disposing of various businesses and assets

Food Manufacturing Africa | 2020 Quarter 3

in an effort to reduce its debt by R8.1bn by March 2021, including an agribusiness in Eswatini, South Africa for R375m and its starch division business for R5.3bn, the sale of which is pending a contractual investigation with the potential buyer, Barloworld. •

GET IN EXCELLENT SHAPE

SOLLFORMAT® KPS www.sollich.com

U N I Q U E FO R YO U R N EEDS

NEWS

PALSGAARD TO DOUBLE CAPACITY AT DANISH FACILITY EMULSIFIER MANUFACTURER PALSGAARD A/S has announced an investment of €100m to double production capacity at its Danish facility by 2024. A new spray cooling tower will add a minimum additional 30 000 tonnes to the company’s spray capacity and will be fully operational by first Quarter 3023. This facility will be supported by the construction of multiple new reaction, distillation, and esterification plants. The expansion adds to the recently installed emulsifier pellet line with a capacity of 10 000 tonnes, which is currently being commissioned.

“This project is another major milestone in our development. By 2024 we will be able to double our current production capacity, which took over a century to reach. It is the result of a decade of significant global growth for our business,” notes Jakob Thøisen, Palsgaard’s CEO. In 2019, Palsgaard was the first global emulsifier producer to achieve CO2-neutral production across its global facilities, leading the way for the food ingredients industry. In line with Palsgaard’s commitment to sustainability, the new production capacity will not compromise the company’s CO2-neutral status.’ •

MEET ISHIDA SA’S NEW GENERAL MANAGER

Melika Seiderer

ISHIDA EUROPE HAS appointed Melika Seiderer as general sales manager of the company’s South African office. Melika has over 15 years’ sales experience in a variety of roles in the metal and materials handling industries where her customer base included many food processing companies, giving her extensive knowledge of this sector.

At Ishida South Africa, she will be responsible for driving the company’s continued expansion throughout the region, helping to support customers’ growth through increased

automation and integrated solutions, and providing comprehensive after-sales service.

“I am delighted to be joining Ishida Europe,” says Seiderer. “The company’s long-established reputation for product and service excellence attracted me to the position. I believe these values are so relevant today, and the wideranging expertise of our team will enable us to establish and maintain long-term partnerships with our customers to provide all the necessary support to stimulate and increase growth within their businesses,” says Seiderer. •

Laminex MaxFlow 4G is efficient in reducing high-molecular-weight β-glucan

New brewing enzyme hits down under MAXFLOW 4G FILTRATION enzyme is an enzyme solution being offered to Australian brewers. The solution forms part of the DuPont brewing enzymes range and allows unprecedented beer flow, especially on barley. For the largescale brewer, it’s all about keeping cost under control while ensuring a high and consistent throughput. Using a special combination of β-glucanase and xylanase, DuPont Laminex MaxFlow 4G is developed with a particular focus on beer filtration and is suitable for use with all conventional types of separation equipment. The enzyme is efficient in reducing high-molecular-weight β-glucan and pentosan levels in all types of wort, making mash separation and beer filtration easier and faster due to the reduction in wort viscosity.

Improving mash separation and beer filtration enables brewers to increase brewhouse yield and reduce energy and water associated with filter cleaning. As a result, brewers can reduce the use of water in the brewhouse and throughout the supply chain. The benefits of using this ingredient include an approximate 0.10% higher brewhouse yield, 0.15% lower beer losses and 17.5% higher throughput at beer filtration.

Jens Eiken, global product manager for Brewing Enzymes in DuPont Nutrition & Biosciences, explains, “If you aim for a production output of several hundreds of thousands of hectolitres of beer, what you need is a solution to keep things flowing. This solution is very favourable for high-gravity brewing.” Using Laminex MaxFlow 4G can minimise the risk of off-flavours in the finished beer compared to other filtration enzymes on the market. The level of ferulic acid is also markedly lower. •

New faces at Coca-Cola Africa and Middle East

T

HE COCA-COLA COMPANY announced the appointment of Matrona Filippou as its business unit president for the Southern and East Africa region. Previous appointee Bruno Pietracci has taken up his position as Africa & Middle East president. “Despite the challenges that COVID-19 presents for businesses at this time, I’m optimistic that new opportunities across the Southern & East Africa region will arise. The Coca-Cola Company remains focused on ensuring

8

Food Manufacturing Africa | 2020 Quarter 3

its products are delivered safely to stores and communities, while taking every precaution to curb the further spread of the virus,” Filippou says.

“While this is an extremely challenging time from a global economic perspective, Africa and the Middle East present exciting opportunities to scale our capabilities and make our business stronger.

These key regions remain an important driver of our overarching growth strategy over the next decade,” Pietracci concurs. •

NEWS

Parties involved in listeriosis lawsuit ordered to provide testing info Listeria monocytogenes, species of pathogenic bacteria that causes listeriosis

J

SE-LISTED PACKAGED goods manufacturer Tiger Brands received a ruling in its favour by the Gauteng Division of the High Court in Johannesburg, compelling third parties to provide information on testing of listeria-causing bacteria. The company has been fighting a class action lawsuit over its alleged role in the world’s largest-ever listeria outbreak in 2018.

The outbreak killed more than 200 people in South Africa and the department of health said it had traced the outbreak back

to a factory run by Tiger Brands’ Enterprise Foods brand in Polokwane, South Africa.

On 3 December 2018, the court granted an order permitting a class action lawsuit to be brought against the company by Richard Spoor Attorneys and LHL Attorneys.

The class action was brought on behalf of those who fell ill as a result of the listeria outbreak and the families of those who lost loved ones.

Tiger Brands previously stated that no specific damages were being claimed and that the first stage of the class action was

concerned with liability and not the cost of damages.

The quantum of damages would be dealt with in the case of a second stage of class action, if the court finds Tiger Brands liable.

The company wanted the third parties to provide information related to testing for, and incidence of, listeria monocytogenes, to which the court now compelled the third parties to provide critical epidemiological information required for the class action, within one month of the date of service of the order. •

MICROWAVEABLE STEAM BAGS PUSH THE WOW FACTOR

U

K-BASED PLANIT PRODUCTS, owner of the Toasta bags brand, has added renewable and compostable NatureFlex NVO film to its portfolio for microwaveable steam bags. NatureFlex NVO was launched by Futamura in October 2019.

It is made from renewable wood pulp sourced from responsibly-managed forestry. It is the first certified compostable, heat-sealable film to market that offers the heat resistance required for conventional and microwave ovens. The film offers a host of

benefits, including heat sealability on both sides, semi-permeability to moisture, a good barrier to oxygen and mineral oils, grease and oil resistance, superb dead-fold, and it is inherently anti-static.

“Our journey to find a compostable product that technically performed began two years ago. We worked closely with Futamura to get the product that we needed and were delighted when the ovenable film was approved for launch in 2019,” says Caroline Kavanagh, managing director of Planit Products. •

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) 31 942 9624

www.braganchemicals.co.za

Port Elizabeth Office Tel. No.: +27 (0) 71 213 9288

Renewable and compostable microwaveable steam bags

Cape Town Office Tel. No.: +27 (0) 21 000 3121

WE DO WHAT IT TAKES 2020 Quarter 3 | Food Manufacturing Africa

9

INDUSTRY TALK

Transforming

your business digitally New technologies like cloud computing, artificial intelligence (AI), machine learning, and predictive analytics, have had a profound impact on the world’s economies and continue to disrupt industries.

R

ECOGNISING THIS POTENTIAL, government strategies emphasise the role of digital in accelerating economic diversification, promoting sustainability and ensuring citizen happiness. Digitalisation has been identified as a pillar that will support the future digital economies on the continent.

By placing new digital and ICT transformation programmes at the heart of their national plans and through collaborations with leaders and entrepreneurs committed to building a better future, governments on the African continent are leading the way in securing a viable future for their citizens. It also raises

its national competitiveness profile at a global level.

Within South Africa, The National Development Plan 2030 (NDP) published in 2012 emphasises how ICT will underpin the development of connected information society and a vibrant knowledge economy that is more inclusive and prosperous.

Similarly, the Moroccan government introduced the Morocco Digital 2020 strategy, a set of policies and reforms which promote the effective use of and access to technology in various sectors to position the country as a digital economy. Nigeria has also taken significant steps to drive economic transformation,

sustainability and future skills development through technology.

BUSINESSES REAPING THE BENEFITS OF 4IR Digitisation spurs the development of new industries as in the case of e-commerce, mobile financial services, IoT, and cloud computing. These contribute to national GDP in multiple ways while promoting the growth of allied industries such as logistics, infrastructure, and payments. These opportunities are not only limited to the ICT industry, but also disrupts traditional industries to unlock speed, lower costs, and ensure higher quality.

While many businesses are fuelled by

Digital Transformation - Where do you start?

SYSPRO Webinar series; 2 Sep, 16 Sep & 30 Sep Learn more at https://za.syspro.com/product/business-digitization/dx-webinar-series/ or contact us on 011 461 1000.

721117 OSFF

SYSPRO AFRICA

10

@SYSPRO_Africa

Copyright Š 2020 SYSPRO (Pty) Ltd. All rights reserved. All brand and product names are trademarks or registered trademarks of their respective holders.

Food Manufacturing Africa | 2020 Quarter 3

INDUSTRY TALK competition and adopting new and disrupted forms of technology, many organisations are still using legacy IT and have shied away from digital transformation. Digital transformation essentially involves a fundamental change in how an enterprise uses its technology, its workforce and business processes to improve its performance and value to customers.

While businesses can gain massive value opportunities in these areas, companies undertaking these efforts quickly learn that the technology in digital transformation is often the easiest part of the change. Development gains from digital transformation are not automatic and can result in new divides and widen inequalities.

BUILDING INTERNET INFRASTRUCTURE AND DIGITAL SKILLS A major obstacle to the development of internet infrastructure within Africa is a lack of experienced network engineers.

Without these engineers, national internet investment, policy and regulatory decisions may lack the technical foundation that will ensure an open, affordable, scalable internet. If South Africa had the required mass of network engineers who can shape the future of network infrastructure at

both a local and national level, businesses and organisations would be able to unlock their full potential and fully utilise Fourth Industrial Revolution (4IR) technologies, like the Internet of Things (IoT), artificial intelligence, blockchain technology and big data.

“A major obstacle to the development of internet infrastructure within Africa is a lack of experienced network engineers”

KNOWLEDGE BUILDING AND FUTURE-READY CURRICULA Apart from access to affordable connectivity and devices, there is also a need to digitally upskill people to operate or work with the advanced and/or emerging technology in 4IR. Investments in human development and digital skills are necessary to build a pipeline of future talent that can embrace this dynamic and increasingly digitised

environment. This will require a massive educational overhaul that addresses basic education backlogs at all levels, from basic to tertiary education.

The World Economic Forum has highlighted the importance of African educators to design future-ready curricula that accelerate the acquisition of digital and STEM skills to match the way people will work. African governments, with the help of private sector stakeholders, have an opportunity to develop tailored approaches to understanding the region’s evolving skills base and emerging jobs scenarios.

The need for schooling and re-tooling of the African labour force to find occupations less susceptible to automation needs more recognition To take advantage of what 4IR has to offer business, governments must be able to develop, attract and retain the skills and capabilities. Ministries of Education need to re-think how skills can be obtained.

Governments and communities need to take a fresh look at how they develop emerging technology skills and knowledge. •

Syspro – www.za.syspro.co..za

2020 Quarter 3 | Food Manufacturing Africa

11

EVENTS TALK INDUSTRY

Formation of stellar advisory board announced

Infinite Foods, Africa’s highly regarded go-to-market platform for leading plant-based food brands, announced the formation of its inaugural advisory board.

T

HE BOARD WILL accelerate its mission to make nutritious and environmentally sustainable plantbased meat and dairy alternative products accessible in sub-Saharan Africa.

Within 18 months of launch, the supplier has brought the biggest plant-based food brands to Africa, including Beyond Meat, Miyoko’s Creamery, Nature et Moi and Oatly.

These products are now offered through more than 800 retail, and foodservice outlets, including Woolworths, Famous Brands and Spur Group.

As Infinite Foods has expanded operations to South Africa, Mauritius, Botswana and soon opening in Kenya, there has been incredible growth and excitement among consumers choosing a plant-forward lifestyle. Consumers are embracing efforts to improve their health and environmental footprint through their food choices whether it is meat-free one day a week, flexitarian or 100% plant-based (vegan).

In response to growing consumer demand for plant-based food options, Infinite Foods has assembled a group of leading advisors to grow its reach, expand local manufacturing and incubate opportunities for plant-based protein agricultural inputs in Africa. The board includes agricultural policy experts, best-selling plant-based nutrition authors and investors: • Ada Osakwe – entrepreneur and founder of Nuli, fresh-food and beverage company • Marco Borges – New York Times Bestselling author and founder of 22 Days Nutrition • Lindiwe Sibanda – Globally recognised food security and agricultural policy expert • Nil Zacharias – Entrepreneur, Author, and host of leading food podcast “Eat For The Planet” • Johnny Ream – a venture investor Stray Dog Capital, a VC fund that partners with early stage companies across the food, beverage, and biotechnology sectors • Leozette Roode – author of The South African Vegan Cookbook • George Sibtoshiwe - entrepreneur and cofounder of South African delivery company, Sendr.

Announcing the advisory board launch, Michelle Adelman, founder and CEO of

12

World-renowned agricultural policy experts, food entrepreneurs and investors join forces to catalyse sub-Saharan Africa’s plant-based food economy.

“Infinite Foods has assembled a group of leading advisors to grow its reach, expand local manufacturing and incubate opportunities for plant-based protein agricultural inputs in Africa”

Infinite Foods, said, “We are passionate about catalysing a sustainable plant-based food sector in Africa. We are honoured to work with our advisors to improve the accessibility, affordability and convenience of great tasting, locally relevant and nutritious plant-based products.” The board is chaired by Mayur Patel, an experienced entrepreneur and founding member of Infinite Foods.

“Changing what we eat is the most powerful tool we have to improve health and

Food Manufacturing Africa | 2020 Quarter 3

environmental sustainability,” Patel explains.

Plant-based foods are scientifically proven to be healthier than animal-based protein, reducing emerging lifestyle diseases such as diabetes, heart disease and some cancers.

The guidance from leading public health institutions, including the American Heart Association is clear: “eating less meat or giving it up entirely [leads to] less risk of disease and improved health and wellbeing”. As a result of the recent COVID-19 crisis, consumers will be increasingly focused on food safety, health and how to build up immunity through improved nutrition, which will likely lead to an increased adoption of accessible plantbased foods on the continent. Infinite Foods is committed to providing consumers with delicious plant-based food options from both local and international brands and creating more opportunities for the plant-based industry to grow in sub-Saharan Africa. •

Infinite Foods – www.infinitefoods.com

EVENTS

Innovation and collaboration

needed to reboot industry South Africa’s liquor industry, particularly craft distillers and brewers, have been hard hit by the protracted lockdown and ban on the sale of alcohol, with fears that many may not be able to survive.

Hard-hit craft brewers and distillers brace themselves for a rocky business restart

E

XPECTING TO TAKE years to recover, the sector hopes that it may survive by collaborating and innovating. This emerged during an online panel discussion hosted by Messe Muenchen South Africa, the organisers of the food & drink technology (fdt) Africa trade fair, held in July.

Moderated by Clive Belcher, chairperson of the Institute of Brewing & Distilling (IBD) Africa sector and MD of Global Beverage Solutions, the panel included Craft Beer Association South Africa (CBASA) chairperson Wendy Pienaar, brewmaster and founder of Brewsters Craft Apiwe Nxusani-Mawela, and Southern African Craft Distilling Institute (SACDI) secretary Pro Tem, Hendré Barnard, amongst others.

Panellists noted that the sudden lockdown left brewers with beer still in tanks; it dried up key contracts and cash flow, and negatively impacted supply chains. This means that most would be unable to pick up production immediately when the ban is lifted again.

Nxusani-Mawela said, “Brewing beer is a process. It takes three weeks, so restarting won’t happen overnight. Cash flow is also a problem, so buying raw materials and packaging will be a tight squeeze – if we can source these at all. It won’t be easy.”

Pienaar added, “There are operational issues to consider – like getting staff safely to work, and making the brewery safe for customers and staff. Even if the ban is lifted,

it won’t be the end of the challenges we face.”

Brewers and distillers might face challenges in obtaining yeast, hops, botanicals and bottles and producers would likely find that neutral spirits would be diverted to making sanitiser. “If producers are able to access alcohol, they might be able to get production up and running in around a week after the ban is lifted, but distillers and brewers will take a lot longer,” Barnard pointed out.

SURVIVAL STRATEGIES Noting that craft brewers and distillers had been achieving slow growth even before the ban, the panellists said there would be tough times ahead for the entire sector. However, craft brewers and distillers could survive by innovating and collaborating.

Barnard noted that the market would become more price sensitive, and that brewers and distillers would have to prepare for this. “There is a real possibility that the market is going to change. We are in a recession and the first thing to suffer will be luxury goods. Some things will become more expensive to produce and certain raw materials and bottles will be more expensive.

If you are spending R50 on packaging, you need to consider rebranding, using cheaper packaging, and passing the savings on to consumers.”

Pienaar said collaboration could help

the industry survive. “We need to think about buying as a consortium, working together, becoming more creative in using what is available. We also need to do market research to make sure that we are producing what the market wants and will move quickly.”

Now is the time for brewers and distillers to work on industry collaborations, market awareness and innovative new ways to go to market. Facilities should also be preparing to reopen production by sourcing the safety equipment and personal protective equipment their factories and staff would need once the ban on alcohol production is lifted.

“Food & drink technology Africa has always been a hub of local and international industry collaboration and innovation. As the world adapts in this new environment, we are committed to working with stakeholders to help them overcome challenges,” said Dain Richardson, senior exhibition manager of food & drink technology Africa.

The spotlight will be on the challenges, solutions and emerging trends in the craft brewing and distilling sector at food & drink technology (fdt) Africa, the biennial trade fair for the pan-African food & drink sector next year. The fourth edition of this exhibition will be held from 13 to 15 July 2021 at the Gallagher Convention Centre in Johannesburg. •

2020 Quarter 3 | Food Manufacturing Africa

13

SNACKS & CONFECTIONERY

Growth and agility underpins activity in Africa

Iberchem has announced that it will expand its presence on the South African market through the the joining of Iberchem, Scentium and Versachem under a new name: Iberchem South Africa.

Maryke Foulds looks at what this venture will bring to the industry.

DID YOU KNOW? Iberchem’s technical laboratory in South Africa has developed a library of flavours, specific for the African market.

Ishida was contracted to provide a complete packing solution

T

HE ANNOUNCEMENT COMES two years after the group acquired 70% of Versachem, a company specialising in food colourants and seasonings. The group recently bought the remaining 30%, thereby fully integrating Versachem’s activity into the group’s portfolio. All three divisions will be temporarily accommodated in Versachem’s current offices in Pretoria, north of Johannesburg, South Africa until a new location is found.

Scentium creates bespoke flavours for beverages as well as for sweet and savoury products while Versachem specialises in the production of food seasonings, dustings and colourants. With all three expertise combined, the group is well-positioned to service not only locally but also the export market, creating work opportunities and earning foreign exchange for South Africa.

Iberchem South Africa is managed by Quentin Questiaux, who joined the company in May this year. Questiaux is well-known on the African market, with a proven track record in the flavour and fragrance industry.

In the coming months, Iberchem South Africa

14

will gradually welcome new members to both Iberchem and Scentium. “We are looking to expand our equipment to be even more autonomous and agile with shorter delivery times of the projects. Our biggest strength would be the laboratory that was developed to perfectly respond to the needs of our local clients,” he enthuses.

A key focus for the company this year is the expansion of its sensory library. It is an ongoing process as taste trends evolve and change. “We rely on thousands of fragrance and flavour references, all made available to our clients. If what we have is not exactly what they're looking for, our teams of specialists are at their disposal to fine-tune the selected reference until we find the exact profile they were looking for. In my opinion, having an extensive library is essential, but the technical support that goes with it is even more important.”

One of the biggest trends and areas of growth Questiaux predicts is that of reduced sugar products with a clean label – especially in beverages. “The sugar backlash continues to put pressure on the food and beverage

Food Manufacturing Africa | 2020 Quarter 3

market to reformulate with low and nosugar variants and meet consumer health demands without compromising on taste. This situation is expected to keep Quentin Questiaux going even more as the result of the COVID-19 pandemic.

“Botanical ingredients like herbs and spices are innovative, and also feature certain health benefits, combined with less sugar claims and vitamin and fibre additions.

This can help brands to capitalise on growing consumer interest in natural and better-foryou products,” he notes.

The experience-seeking consumer is also looking for unique and quirky flavours, such as banana & chocolate or coffee & caramel.

These flavours take you into a sensory journey that can intrigue consumers in-store and encourage impulse purchase.“Substitute products must be equally qualified in taste for not losing the consumer's attention.

Working in artificial sweeteners or natural flavours is a challenge for the sector.”

Concerning growth on the African continent, he is optimistic. “Iberchem South Africa is the result of substantial investments that fall into an even larger expansion plan by the Iberchem Group on the African continent. Overall, it confirms the tremendous growth potential we see on the market. We wish to support and be part of this growth offering speed to development, production, supply, affordability, and the ability to supply both small and large volumes to service a broad spectrum of customers. I am confident that this news is only the beginning and that shortly we will be making more announcements,” he concludes. •

Iberchem – www.iberchem.co.za

PACKAGING

Complete packing solution

for dried fruit snacks A complete packing line solution from Ishida Europe has enabled an entrepreneurial French company to automate and bring in-house the packing of its dehydrated fruit and vegetable snacks, with the ability to increase throughput six-fold.

I

l Était Un Fruit , based in Montpellier, was founded in 2014 by Laure Vidal, who wanted to ensure her children were able to eat the required five portions of fruit and vegetables each day. She devised a means of drying seasonal fruits from the region, such as apples, pears, strawberries and apricots.

In 2016, the company raised €1.2m to support its commercial development, including investment in equipment to industrialise the process. Further investment is planned for 2020. In addition, in 2019 the product offering was diversified with the introduction of dried sliced vegetables, including a special Apéritif range.

Ishida was contracted to provide a complete packing solution

Il Était Un Fruit ’s products are sold in a variety of bag sizes for the retail sector – 10, 15, 30, 50 and 80g – as well as 1 and 2kg bags for specialist retail companies. With the many different fruit and vegetable varieties, this equates to around 40 different product lines, requiring a fast and flexible weighing and bagging solution.

Initially the company contracted out its packing operation but when the decision was made to take it in-house, Ishida was selected for its ability to provide a complete solution for which it had total responsibility, as well as the company’s reputation for accurate weighing and reliable after-sales service.

The Ishida designed line comprises a 14 head CCW-RV multihead weigher mounted directly over an Astro 103S vertical bagmaker, which provides a compact and space-efficient combination, together with a

16

DACS-GN-SE-012 checkweigher with integrated CEIA metal detector.

The RV-214 weigher incorporates a special C4 coating which prevents product sticking to the contact parts. This ensures a consistent flow of the dried fruit and vegetables throughout the weigher. Thirteen of the weighing heads are dedicated to the main ingredient, such as apple, while a small quantity of a second, high value item, for example fig, is manually fed into the fourteenth head and weighed. Once this individual ingredient has been weighed, the weigher combines it with the main product, delivering accuracy to within 0.02g of the target weight.

The intermittent motion Astro bagmaker features servo motors and software controlled variable seal time, jaw temperature and pressure to ensure a high level of precision. Stripping plates clear the seal area before sealing which ensures good pack quality and servo driven and vacuum assisted pull down belts enable accurate and consistent bag lengths to maximise film use and optimise pack presentation.

Nitrogen gas flushing is used to support the preservation and freshness of products that are naturally susceptible to air (oxygen) degrading the product, giving an ambient shelf life of around six to ten months depending on the product.

The weigher and bagmaker combination is currently running at 30 bags per minute on a 30g pack, well within its top speed of 70 packs per minute.

The DACS checkweigher and integrated metal detector provides a final quality and weight check. Rejected packs are directed into two separate containers, depending on whether they are non-compliant in terms of weight or contain foreign bodies.

The checkweigher features an intuitive and robust display with an easy to learn menu structure that ensures quick and easy set up and is fully compliant with the European directive on measuring instruments.

The checkweigher’s open frame design ensures easy cleaning and maintenance, including a complete washdown of the line every week.

Food Manufacturing Africa | 2020 Quarter 3

The RV-214 weigher

“We are pleased with our investment,” comments Nicolas Rey, industrial director at Il Était Un Fruit . “The various machines have all lived up to their expectation, while Ishida’s after-sales service is quick to react if there is a problem. We are currently producing one million bags a year but are confident we can continue to grow because the line can cope with up to six million bags a year.”

IL ÉTAIT UN FRUIT Il Était Un Fruit has developed a special technique for the drying of fruit and vegetables with no added sugar, additives or preservatives. The fruit is sourced from eco-responsible orchards and organic fruit and vegetables are Ecocert certified. 95% of the fruit and vegetables are supplied by local growers in the Occitanie region.

The products are washed in water, disinfected, peeled, diced and then dried using a patented drying method developed in partnership with the CIRAD (French Agricultural Research Centre for International Development).

The new Apéritif range has been developed in association with leading French chef Gérard Cabiron, recipient of the prestigious Meilleur Ouvrier de France. •

Ishida – www.ishida.com

READY-TO-DRINK

New positioning target

evolving consumer groups Beverage aisles are packed with an enormous selection of classic juices, waters, near-water drinks, energy drinks, sports and wellness products and/or superfood fusions with Matcha and other plant extracts.

H

EALTH-CONSCIOUS BUYERS are turning to products with well-being properties, but the boundaries between traditional target groups are blurred. Special ingredients such as the low-glycemic carbohydrate, Palatinose allow the development of sports drinks with new positionings.

To effectively reach these new target groups, it is important to understand their objectives. Whereas professional athletes need to prepare their bodies for extreme stress situations with special foods that are tailored to their needs, or quickly replenish their energy and mineral stores during and after training with isotonic drinks, hobby athletes are generally more interested in getting their bodies in better shape with a

moderate level of activity. At the same time, those who hope to get more and long-lasting energy for their everyday lives are turning to fitness drinks.

Sports drinks must also deliver in terms of taste. Protein beverages are a good example: when they were still a niche product in training halls and fitness studios, the powdery mouthfeel and typical off-taste were mostly considered to be “necessary evils.” Today, with protein-enriched drinks readily available, expectations are rising and manufacturers are looking for new ways to compensate for the sensory disadvantages of protein enrichment with masking ingredients.

Manufacturers of sports drinks for general consumer use also have to keep

an eye on carbohydrates, and on sugars in particular. Whereas athletes primarily see the functional properties of carbs and sugars as sources of energy, conventional sugar is one of the ingredients that many healthconscious consumers are wary of. For many, conventional sugar is seen as a fattening and disease-causing agent and a precursor to obesity, cardiovascular disease, type 2 diabetes or tooth decay. At the same time, sugars are also key energy sources our bodies need to function, which is why making the right choice is important.

Especially for amateur fitness enthusiasts who go to the gym to get their body in better shape or lose weight, for the employee under duress or the student taking exams, strong

Range of premium extracts for low or no alcohol drinks

Kerry, the Taste & Nutrition company has released the Botanicals Collection Zero, an extensive range of high-quality, authentic botanical extracts that contains 0% ethanol. The range is designed specifically for the low- and no-alcohol beverage markets.

T

HE PORTFOLIO CURRENTLY includes 15 standard products including juniper, rosebud, elderflower, cocoa, turmeric, cinnamon with investigations ongoing to add more exciting tastes producers and consumers will love.

Beverage producers can now create sophisticated low-alcohol spirits and no-alcohol options with the taste of gin, rum, cocoa, ginger, etc., all while meeting emerging clean-label and quality requirements.

Amid a growing global trend to moderate and control alcohol intake that looks set to continue for the foreseeable future, consumers are seeking authentic-tasting drink taste options beyond simply soft drinks. This makes low-alcohol spirits or no-alcohol beverages a growth market, with trade sales in the area expected to record a 41% increase over the period 2015 to 2021.

With botanical extracts in alcohol beverages already a $500 million business and growing

18

The Botanicals Collection ZERO range of distillate from botanical sources enables the creation of greattasting low- or no-alcohol beverages

by 9% per annum, producers that can offer tasty and healthier upscale beverage choices will see a significant and growing market opportunity in the years to come.

The range offers many advantages: it’s fully traceable, clean-label, certified to Halaal-certified, kosher-suitable and, most important, ethanol-free and also free of any alternative solvent.

It allows manufacturers to maintain a low (or zero) alcohol content and permits a “0.0%” claim. In comparison to other ethanol-free technologies, the Collection ZERO range is more stable, with no haze, no sedimentation, and a fresher botanical taste and mouthfeel. Kerry’s extensive expertise and experience in natural extraction fosters innovative “fusion distillates” that are based on a proprietary capability to blend natural botanicals (leaves, flowers, seeds, etc.) and then magnify taste by running a distillate following a period of slow maturation. This allows for tailored extracts or blends that

Food Manufacturing Africa | 2020 Quarter 3

can be made to order to suit specific local and regional tastes and requirements.

The range contains more than 45 single distillate profiles and five fusions distillates that can be blended and tailored to suit specific markets and create unique winning tastes. Some of the available botanical taste sources include juniper, ginger, rose bud, chamomile, lemon, mint, orange, dandelion, cola nut, rhubarb, burdock, elderflower, black tea, cocoa, cumin, fennel, turmeric, and cinnamon, among others. •

Kerry – www.kerry.com

READY-TO-DRINK Overweight people could benefit from products that promote fat burning and support weight management with innovative ingredients during moderate training

that of conventional sugar (sucrose). As well, sensorial trials have shown that this alternative sugar has a beneficial effect on the taste of a drink; it improves both the body and mouthfeel.

fluctuations in blood sugar levels are not ideal. If the sugar level rises sharply, the body releases more insulin to transport this sugar into its cells. Consequently, the blood sugar level then drops just as rapidly. As a result, performance suffers and the body demands a replenishment — the well-known “boost and crash” effect.

LONG-TERM ENERGY TRUMPS SHORT-TERM PERFORMANCE Although sports drinks have become more popular, many still contain classic energy sources, high-glycaemic carbohydrates such as maltodextrin, sucrose or glucose syrup.

High-glycaemic ingredients are broken down shortly after entering the small intestine and cause the glucose level in the blood to rise rapidly after consumption. This can be useful, for example, as an "instant" energy

boost during a sprint event or intense training sessions, but by contrast, low-glycemic carbohydrates with a more constant energy release rate such as Palatinose, are much better suited for endurance sports, moderate training or during everyday stress situations as they ensure a long-term balanced blood sugar level.

Although energy from conventional sugar is available to the body very quickly, the blood sugar level falls again soon after. As a novel form of sugar, Beneo’s Palatinose, by contrast, is metabolised much more evenly: this balanced supply of carbohydrate energy has an overall positive effect on blood sugar and insulin levels, as confirmed by the European Food Safety Authority (EFSA).

Palatinose is extracted from sugar beet and occurs naturally in honey. With a 50% sweetness profile, its taste resembles

SPORTS DRINKS FOR IMPROVED FAT METABOLISM High glucose levels and elevated insulin concentrations have another disadvantage: they inhibit the body's ability to burn fat.

Studies have shown that carbohydrate-based sports drinks with Palatinose instead of conventional sugars and/or other rapidly available carbohydrates increase the fat burning rate and performance of endurance athletes. This makes sports drinks with Palatinose interesting for a new target group: overweight people could benefit from products that promote fat burning and support weight management with innovative ingredients during moderate training.

Beneo products are supplied through Savannah Fine Chemicals. •

Give green light to better food choices.

Build consumer trust with BENEO’s ingredients.

Where consumers in general aim for a healthy lifestyle with matching nutritional habits, now more than ever, they look for balance and moderation. When in the past a “diet” label on the Front-Of-Pack would be enough, today’s buyer takes a more holistic approach of health and wellness. People look for simple solutions and focus on familiar ingredients and inherent goodness. Brands can gain consumers’ loyalty by being open about their ingredients. Improve your product’s nutritional content with the naturally sourced, functional ingredients from BENEO.

Follow us on:

Savannah Fine Chemicals – www.savannah.com

Our Sales Network Partner in South Africa:

sfc-info@savannah.co.za

www.beneo.com

2020 Quarter 3 | Food Manufacturing Africa

19

READY-TO-DRINK

Botanicals add healthy value to products

One in every two consumers are concerned about their health and look for naturalness in the products they consume. Food Manufacturing Africa looks at some of the latest trends predicted by global ingredient supplier Doehler.

T

HE GLOBAL FACT BOX MARKET for Doehler offers technology-driven natural botanical extracts ingredients, ingredient systems and integrated is expected to reach solutions for the F&B industry. The company’s $5 833.4m by 2022 and is product portfolio ranges from natural colours driven by strong health and flavours, health ingredients, pulses and and wellness trends. cereal ingredients to dairy, plant-based, fermented, fruit and vegetable ingredients to Nutrition that supports full ingredient systems. wellbeing and immunity is of particular interest and consumers are actively seeking out products that are SUSTAINABLY-SOURCED organic, sustainably sourced, produced and RAW MATERIALS AS A processed. Substances obtained from plants BASIS FOR SUCCESS offer a significant boost to products.

The African Cape region is botanically Many superfoods are known as health diverse and renowned for an abundance enhancing. Aloe vera leads the field, followed of plants known to have a positive impact by extracts such as olive leaf, moringa and on consumer health and wellbeing. African baobab. Consumers associate a positive botanical extracts are very popular. Plant emotional benefit with plant extracts, which extracts such as baobab for gut health or is also increased by demand for more plantimmunity, or rooibos for stress relief are onbased nutrition. trend and used in various inspirational and Doehler’s range of high-quality innovative concepts. products include minimally processed fullDoehler offers a broad product portfolio spectrum powders, which contain the full of botanical extracts, which they produce load of healthiness from the raw material; at the place of origin by using gentle to high-end standardised botanical extracts. technologies. The use of hydro-alcoholic These products guarantee amounts of extraction, water-based extraction, batch certain naturally occurring healthy actives, distillation and spray-drying, to name just a like antioxidants. few innovative technologies, enables them These valuable botanicals are paving to capture the multi-sensory and healthy the way for inspirational natural food properties of the plants in their entirety. and beverage applications with a healthy positioning. Alongside plant extracts, HEMP MEETING IMPORTANT infusions, distillates, essences and natural CONSUMER TRENDS flavours allow consumers to choose an In our fast and digital life, nutrition must individual flavour. stand out from the mainstream to have

Globally, one in three consumer perceive hemp to have a positive impact on health

20

Food Manufacturing Africa | 2020 Quarter 3

a serious impact.

Consumers value experiences over possessions and are therefore searching for unusual ingredients.

Cannabis experienced a first peak in popularity in 2019 and is still on the rise: It is the ultimate “natural” health and wellness “super-ingredient”.

Healthy and digital lifestyle drives novel and botanical flavours

It addresses the requirement for sustainablysourced products, since it can grow on arid land and uses up to 1/14th less water than cotton.

Hemp, a species of cannabis, is also trending. It is grown industrially, and applications range from food oil to biocomposites in car parts. The hemp trend can mainly be observed in beverages: Consumers accept hemp as a functional ingredient, slowly expanding into other product categories.

Globally, one in three consumers perceive hemp to have a positive impact on health.

In non-alcoholic beverages, hemp-flavoured sparkling and functional water, juices and CSDs are winning examples of natural and innovative refreshment with functionality and a healthy positioning. Increasingly, spirits, beer mixes and flavoured beers are proving popular.

Doehler’s range offers natural hemp, cannabis, hop-hemp flavours and a hemp leaf infusion. Neither the natural flavours nor the hemp infusion carry any active components nor any functional properties.

Instead, the company provides the entire spectrum of flavours, from the characteristic herbaceous, resinous and flowery taste profile of hemp to a wide selection of other hemp nuances.

Doehler supports their customers worldwide in formulating new recipes based on premium raw material and in bringing their smart and innovative product ideas to life. •

Doehler – www.doehler.com

READY-TO-DRINK

Ugandan bottler climbs

high with new PET line

Uganda’s Rwenzori water brand has a 65% market share in Africa

With the help of KHS technology, the sale of packaged water in Uganda is climbing to new heights. Denise Schneider-Walimohamed of KHS East Africa talks to Food Manufacturing Africa about how new technology can impact operations.

A

T JUST OVER 5 000m above sea level, Margherita Peak in the Rwenzori Mountains in northwestern Uganda is Africa’s third-highest summit.

For many mountaineers, the massif is considered an attractive alternative to Kilimanjaro. Despite its location on the equator, surrounding peaks are still glaciated.

WATER AS GROWTH PRODUCT One of Uganda’s best and largest mineral water brands, Rwenzori, depicts the mountain range on its logo. The product is bottled nearly 300km from Margherita Peak in Namanve in the greater Kampala region.

When the Rwenzori Bottling Company began operations in 1993, it faced the challenge that bottled water was still a relatively new and unknown product for many people. This has changed: the sale of bottled water has skyrocketed throughout Uganda, especially in urban centres. Annual growth rates clock in at a steady 10% precipitated by a growing awareness that the product is safer to drink than tap water, better in quality and a brand with a long tradition.

EXPLORING POTENTIAL In 2014, the Rwenzori Bottling Company was acquired by Coca-Cola Beverages Africa (CCBA), which operates in South and East Africa. Part of the new strategy is to locally integrate well-known mineral water brands into their group to develop them further.

Targeted marketing measures can effectively exploit growth potential – in addition to Uganda, this is already happening in Kenya, Ghana and Ethiopia.

Rwenzori has plans for further growth of its water brand, which has gained an approximate 65% share of the Ugandan market, but it remains a challenge. There’s no space available for a new production line at the main plant where three smaller bottling lines are in operation. Instead, operations are to be expanded on the site belonging to

CCBA subsidiary Century Bottling Company, just a few hundred meters away. The group is investing a total of $10m – about two-thirds of Uganda’s planned budget for 2018.

COMPELLING TECHNOLOGY KHS was awarded the contract for the new PET line. In addition to an Innoket Neo labeller, the package includes an InnoPET BloFill stretch blow moulder/filler block with a capacity of up to 25 000, 500ml bottles per hour.

“This is the second water bottling line that CCBA will be receiving from us within a very short space of time,” enthuses Denise Schneider-Walimohamed, managing director of KHS East Africa. “Last year we installed an almost identical line at Voltic in Ghana.

Until now, many customers in the region have associated KHS with higher-capacity machines outputting up to 80 000 bottles per hour. With these two projects, we’ve been able to prove that KHS offers excellent water bottling systems in the low-capacity range.”

All capacity levels are now in demand in Africa and most water bottling systems are sold in the KHS Middle East/Africa Market Zone managed by executive vice president Markus Auinger.

The company was particularly impressed by the Innofill PET NV water filler – the first machine designed for still water acquired

by Coca-Cola Beverages Africa in Uganda.

The German systems supplier has chalked up points with other projects KHS has also implemented for CCBA in Uganda, including a PET line for carbonated Coca-Cola soft drinks installed in Mbarara in 2015. “Our experience with KHS has been very good.

We know that we can rely on short delivery times, fast installation and commissioning and the expert support and flexibility of the KHS team,” explains Edward Ojede, project manager at CCBA in Uganda.

EXPERTISE IN BOTTLES Particularly noteworthy is the support provided by the KHS experts in the company’s Bottles & Shapes programme

who contribute their expertise in the development and optimisation of bottles.

The consultancy service produces PET bottles which have been optimised in terms of ecology and economy and boast 100% line suitability and compliance with the customer’s design concepts.

Although the line was officially commissioned in May 2019 by the president of Uganda, represented by the minister of trade, industry and cooperatives, production has been running since the beginning of that year – and very smoothly at that. The performance figures of the new system have even exceeded CCBA’s high expectations.

“We’re achieving a line efficiency of 98%,” says Conrad van Niekerk, managing director of CCBA Uganda, happily. “Rwenzori’s water bottling line operates around the clock, seven days a week. The performance figures of this line and those from Mbarara are the best in the entire group.”

Even though the expanded capacity is already reaching its limits, the key factor in CCBA’s output is the availability of water, which is a limited and therefore precious resource in Uganda.

In addition to efficiency, the subject of sustainability is important not only for beverage producers in Uganda but for the rest of Africa as well.

CCBA can score here, too: under the motto of ‘a world without waste’, CCBA wants to help ensure that by 2030, 100% of all PET bottles sold are collected and recycled. Plastic Recycling Industries, a recycling initiative owned by CCBA and founded specifically for this purpose, buys collected PET bottles from consumers and then reintroduces them to the recovered materials cycle. If many more companies follow this example and are thus able to stem climate change, the glaciers of the Rwenzori Mountains will retain their beauty for a long time to come. •

KHS – www.khs.com

2020 Quarter 3 | Food Manufacturing Africa

21

READY-TO-DRINK

Innocent’s new CO2-neutral bottling plant in the Port of Rotterdam in Holland is equipped with four complete Krones PET bottling lines and the corresponding IT landscape

CO -neutral bottling 2

plant makes waves

Following years of contract-bottling, the smoothie and juice producer innocent has decided to build its own bottling plant.

K

RONES WON THE order for four complete PET bottling lines and the corresponding IT landscape. The paramount consideration for “the blender”, as innocent has christened its greenfield project, was sustainability: the aim is to build an entirely CO2-neutral factory.

“We’re also keen to reduce water consumption to a minimum, since we want to treat and re-use as much of it as possible,” explains Sam Woollett, engineering and facilities lead. Each of the four identical PET lines handles up to 32 000 containers an hour. The new plant has been tasked with filling about 400 million bottles of chilled

drinks a year. In all, innocent has invested approximately $250 million in this project.

FOUR COMPLETE PET BOTTLING LINES FROM KRONES The Contipure AseptBloc DA blow-moulder/ filler block consists of a Contiform 3 Pro stretch blow-moulding machine and a Modulfill Asept aseptic filler. For the Contipure D preform sterilisation module, innocent opted for a particularly sustainable version. This ensures a reduced total cost of ownership (TCO), thanks to lower consumption of hydrogen peroxide, steam and energy, plus shorter preparation times.

256 colours Individually selectable: Measurement in progress Sensor switching Process malfunction

R2 870.00 VEGAPOINT 21 G½"

www.vega.com/vegapoint

22

Food Manufacturing Africa | 2020 Quarter 3

"The group’s digitalisation expert Syskron has developed a turnkey MES concept"

After being filled, all containers are fitted with a tamper-evident seal, and depending on the format involved, dressed in a wrap-

We bring colour into view!

Compact capacitive level switches with 360° custom-colour status display

READY-TO-DRINK

DID YOU KNOW? Every day, millions of glass bottles, cans and PET containers run through a Krones line. As a supplier for complete systems, Krones designs and implements complete lines for beverages and food, which cover each individual production process step – starting from product and container production, filling and packaging all the way up to material flow and container recycling.

South African Food Review , 132 x 200 mm, MetaPure, CC-en53-AZ036 07/20 around or pressure-sensitive label. The modularised Topmodul labeller is block-synchronised directly with the Variopac Pro FS packer.

SYSKRON IS DIGITALISING ALL THE FACTORY’S PROCESSES As the group’s digitalisation specialist, the Krones subsidiary Syskron has developed a turnkey MES concept for innocent that integrates through appropriate interfaces also integrates the ERP system, the process control and warehouse management systems in the new plant. This concept includes various solutions from the SitePilot IT family brand, not least the production planning system, the Line Management order and administration system, plus Line Diagnostics for production data acquisition and analysis. From the category of Share2Act services, innocent will in future be using Connect: this enables all information, such as shift schedules, to be made available to all staff in digital form.

Chief blender Andy Joynson explains, “Innocent is aiming to build the earth’s favourite little healthy drinks factory, the blender. It’s location in the Port of Rotterdam is no accident: We will minimise the distance between the place where the fruits arrive from overseas and the actual production facility. This enables us to reduce the company’s CO2 footprint by about 10%. We are delighted that we will be able to bottle our healthy drinks in our own plant, but more pleased that we will ensure that the production operation and the buildings comply with our sustainable standards.” •

Krones – www.krones.com

2020 Quarter 3 | Food Manufacturing Africa

23

READY-TO-DRINK 2

1, 2, 3: Sidel’s EvoFill HS Still guarantees a faster performance than some traditional units

1

“The new filler with proportional filling valves, controlled by electro-magnetic actuators, guarantees a 30% faster filling with total control and accuracy when it comes to dosing liquid into its designated container”

Super Combi Compact

allows more performance using less space Two years ago, Sidel introduced the Super Combi for compact line solutions. This year sees a bolder, next-generation solution Super Combi Compact that, as indicated in its name, is even more condensed.

W

ith a 30% footprint reduction compared to the previous model, the solution features efficiency enhancement with new filling technology embedded in the Sidel EvoFILL HS Still. The technology guarantees a 30% faster performance.

Customers globally are seeking possibilities to optimise resources and space required for production. Sidel has developed a ready-made solution to fit any production site footprint. Line integration and planning are important drivers at the centre of Sidel’s technological advancement. Super Combi Compact is an innovative product designed and engineered to deliver low total costs of ownership (TCO) and production costs per square foot.

GROWING DEMAND FOR PACKAGED WATER The water category is seeing an unprecedented growth fuelled by a worldwide increase in demand. “Rising health consciousness paired with the trend of better-for-you drinks, the packaged water category has remained at the forefront of consumer purchasing decisions since 2018,” explains Stefano Baini, product manager filling and Super Combi at Sidel. This is just one of the reasons why the company has invested in the development of a compact line solution for still water production.

24

2

This green trajectory throughout the water category was globally influenced by a large hike in tourism along with extremely warm weather not only in warm climate countries but in parts of Western Europe too.

The overall higher level of efficiency of the solution is achieved by providing maximum uptime and consistent production output at medium to high speed. Maximum productivity of the line is reached

Food Manufacturing Africa | 2020 Quarter 3

particularly due to improvements at the blowing, filling and labelling stages.

To highlight some of the most important improvements, the blower can produce up to 2 700bph per mould. A robotic arm solution for automatic mould changeover is available to drastically reduce changeover time and improve safety conditions by not requiring any human intervention.

READY-TO-DRINK ENHANCED PERFORMANCE AND PRODUCTIVITY Similarly, to its predecessor, Super Combi Compact is integrating five process steps – preform feeder, blower, labeller, filler/ capper and cap feeder into an all-in-one, smart system. What describes the new solution the best is the continuous toplevel performance it provides up to 54 000 bottles per hour (bph) in a reduced space. Ergonomic design and the latest technologies supports easy access, operation and maintenance while ensuring high end-product quality.

“Labelling is assured by a single-aggregate labe lling systems, ensuring reliable production and fast and easy label-reel auto splicing”

Labelling is assured by a single-aggregate labelling system, ensuring reliable production and fast and easy label-reel auto

splicing. Super Combi Compact’s labeller technology features faster changeovers and easy replacement of parts and an automatic label vacuum extractor for maximised uptime. The labeller can accommodate different labels and technologies (roll-fed and PSL).

SIDEL EVOFILL HS STILL FILLING TECHNOLOGY The new filler with proportional filling valves, controlled by electro-magnetic actuators, guarantees a 30% faster filling with total control and accuracy when it comes to dosing liquid into its designated container. The improved and completely dynamic filling technology allows for highest precision in modulating the beverage flow, as the plunger inside the filling valve can individually be moved to an infinite number of positions, resulting in maximum freedom in terms of different beverage types to be filled, and different optimum filling speeds and levels. Furthermore, the new hygienic valve design with no beverage membrane assures beverage quality with no flavour carry-over.

EvoFILL HS Still is a simplified solution characterised by fewer components and

functions, resulting in fewer maintenance costs, and a highly reduced filler footprint with less filling valves. Additionally, filler features and onboard beverage tanks further contribute to minimising the required floor space. It could also be equipped with an Integrated Cleaning System (ICS), cutting down on water and chemical consumption for internal cleaning and rendering the need for an external cleaning-in-Place system and additional tanks unnecessary.

With savings of up to 30% floor space, a boost in production efficiency of 30%, and the delivery of maximum speeds of up to 54 000bph, the new Super Combi Compact is a perfect fit for producers of PET bottled water. Baini concludes, “Its new, compact design and innovative filling technology makes it an ideal solution for maximising production and increasing line efficiency at the best TCO per square foot – allowing producers to make the most of their existing space or new greenfield projects." •

Sidel - www.sidel.com/supercombicompact

2020 Quarter 3 | Food Manufacturing Africa

25

INSPECTION, CODING & MARKING

Cobot and flexible production - future-proofing SMEs Many countries the EMEA region are likely to experience serious labour shortages over the coming decade, especially in relation to technical specialists. At the same time, product lifecycles are becoming shorter.

ABOUT INNOVATIVE-AUTOMATION As a leader in industrial automation, Omron has extensive lines of control components and equipment, ranging from vision sensors and other input devices to various controllers and output devices such as servomotors, as well as a range of safety devices and industrial robots.

By combining these devices via software, the company has developed a variety of unique and highly effective automation solutions for manufacturers globally. Based on its reservoir of advanced technologies and comprehensive range of devices, it can set forth a strategic concept called innovative-Automation consisting of three innovations or "i's": integrated (control evolution), intelligent (development of intelligence by ICT) and interactive (new harmonisation between people and machines). Omron is now committed to bringing innovation to manufacturing sites by materialising this concept.

D

ESPITE THIS, SMALL and mediumsized enterprises (SMEs) might be reluctant to invest in additional automation due to the cost factor.

Collaborative robots (cobots) are easy to set up and offer a quick and cost-effective solution, for example the Omron TM series of collaborative robots. They can increase the flexibility, quality and speed of production and enable companies to respond rapidly to changing market conditions.

The question is however, how will robots future- proof these enterprises?

Robots are not new to the industrial world and were first used in industrial manufacturing in the 1960s and since then, their number has increased inexorably. Some 500 000 to 600 000 new robot systems are

26

now becoming operational throughout the world each year, although the increase is particularly noticeable in the Asian market, as reported in ‘World Robotics 2019’ by the International Federation of Robotics (IFR) and Fraunhofer IPA. If small and medium-sized production companies in the EMEA region want to keep up with constant economic growth internationally, they need to invest more in automation for cost reasons alone.

Due to technical skills shortages, greater automation is needed to counteract this decline.

COBOTS PROVIDE GREATER FLEXIBILITY Classical industrial robotics might not be the solution in all applications. Traditional production lines are designed for manufacturing large numbers of products.

In today’s world, product lifecycles are getting shorter for example, in the 1970s, the average product lifecycle of a vehicle was eight years. Today, car models often get their first modifications or facelifts after just two to three years. Production and automation must adapt to the shorter lifecycles of products, and cobots can help with this.

Cobots were first introduced in 2008 and represent a relatively new category of industrial robots. In contrast to traditional robots, which must be shielded from the human workspace by a security fence, cobots were developed to work safely with people. Users also need less time and money to program an application with these “helper robots.”

In addition, cobots can easily be moved from one location to another to work on different tasks, whereas conventional industrial robots have to stay in one location and can normally only be used for a specific task within the robot cell. Cobots therefore

Food Manufacturing Africa | 2020 Quarter 3

“In contrast to traditional robots, which must be shielded from the human workspace by a security fence, cobots were developed to work safely with people”

provide greater flexibility to the user.

The diverse tasks they can handle vary from simple pick-and-place applications for parts handling, sorting, and palletising, right through to machine assembly, order picking, packaging, and testing. They can help to apply adhesive and sealants, assemble or disassemble parts, measure, test, check and take over screwing operations.

The result is seen in significant benefits for the employees, who no longer have to carry out monotonous, physically demanding or even dangerous work, but will receive support with precision work and can concentrate on their core abilities.

COBOTS ARE USER-FRIENDLY AND VERSATILE Omron’s TM series of cobots illustrate how versatile and straightforward cobots are in today’s world. The different versions are suitable for practically any environment, such as the automotive, semiconductor, food, packaging, and cosmetics sectors. Due to the flowchart-based programming, an intuitive HMI user interface and simple, hand-guided teaching functions, almost no previous knowledge of programming is required. Just like with a PowerPoint presentation, the user can assemble complete function blocks

INSPECTION, CODING & MARKING

Cobots were first introduced in 2008 and represent a relatively new category of industrial robots

and fill the predefined attributes with the desired parameters. The cobots have options that include an integrated camera, vision and a lighting system which enable them to precisely handle and trace items.

Many core functions (such as pattern, barcode and colour recognition) enable detection, inspection, measurement and sorting applications to be implemented easily and, if necessary, adapted to other requirements. With the help of Omron’s Landmark positioning recognition facility, the cobot knows where it is and can be aligned with another machine, for example,

without much effort or recalibration. It can even move autonomously and work wherever it’s needed, because cobots can be combined with Omron’s LD series of mobile robots.

FROM NEEDS ANALYSIS TO SUPPORT Additional components (such as extra axes, grippers, force sensors, communication devices or screwdrivers) can be easily used by the cobots via plug-and-play system.

Omron has set up a partner network that offers a range of suitable components. The company’s automation experts also provide

support with any queries about the use of cobots. This starts with the analysis of the production task and the environment; the selection of the appropriate cobots and grippers or additional components; and also includes risk analysis and assessment, commissioning, training and technical support. All of this makes it easier for SMEs to gain a foothold in the flexible manufacturing industry of the future. •

Omron - www.industrial.omron.co.za

Superior image sensing speed and precision FH Series

• High-precision object detection • Ultra-high-speed searching • Flexible functionalities to provide high compatibility with manufacturing machines

Would you like to know more? +27 (0)11 579 2600 info_sa@omron.com industrial.omron.co.za fh_series_177x65_ad_enza_02_d01.indd 1

09-06-20 10:22

2020 Quarter 3 | Food Manufacturing Africa

27

INSPECTION, CODING & MARKING

New measurement system for perfectly sealed MAP packaging LeakCheck is GEA’s new in-line measurement system capable of the contactless checking of seal and package integrity on all forms of modified atmosphere packs (MAP). This guarantees the protective function of the seal and assures consumers about the quality of the products and food packaging.

C

ONSUMERS WANT FRESH, hygienically packaged food, while retailers want long-lasting products that look attractive.

Positioned at the start of the supply chain, food manufacturers must provide solutions that meet all hygiene and quality standards.

Meeting these demands while boosting productivity calls for end-toend process monitoring automation.

First in line was GEA’s tried-and-trusted OxyCheck quality control system. This contactless, non-invasive oxygen content measuring system has been verifying every MAP since 2017. Based on that system, the GEA LeakCheck now uses an in-line process on the GEA thermoformer to test the seal and package integrity on each package.

The test procedure comprises three steps. Firstly, the residual oxygen content in each package is measured with a fluorescent sensor spot printed on the inside of the top film. Optical sensors mounted on the thermoformer project light onto the sensor spot, gauging the wavelength of the light emitted by the dye to accurately determine the oxygen content.

“Optical sensors mounted on the thermoformer project light onto the sensor spot, gauging the wavelength of the light emitted by the dye to accurately determine the oxygen content”

GEA LeakCheck sensors measure the oxygen content of the MAP packs

GEA LeackCheck

Volker Sassmannshausen

This step alone significantly reduces the risk of defective packaging with excessively high residual oxygen levels. Next, packages are subjected to overpressure and under pressure in a stress unit before a second contactless measurement is taken. If the new result differs from the first, the package seal is broken.

Using the GEA CombiPick, for instance, the leaky package is automatically detected and accurately removed on exiting the packaging machine. This method ensures that even the smallest leaks are detected.

To boost food processing productivity, the industry is increasingly focusing on automation. The aim is to achieve a consistent or even enhanced product quality.

Thanks to GEA LeakCheck, the two key factors for ensuring food safety – residual oxygen content and seal integrity – can now be continuously recorded and monitored on an end-to-end basis.

Process errors are rapidly detected and the delivery of faulty packaging is virtually zero.

In summary, Volker Sassmannshausen, senior product manager, thermoforming packaging systems at GEA, emphasises, “With the GEA LeakCheck, all units leaving the packaging machine are tested non-invasively. Since the measuring techniques are non-invasive, neither the packaging material nor the contents are wasted.

Besides efficiency and sustainability, the upshot is that practically no defective packaging reaches the market.” •

GEA – www.gea.com

28

Food Manufacturing Africa | 2020 Quarter 3

INSPECTION, CODING & MARKING

Automation and digitalisation offers significant advantages

COVID-19 is creating major challenges for industrial companies. Food Manufacturing Africa looks at how digitalised and highly automated production can react to current and future challenges with the required degree of flexibility.

A

S PART OF Siemens’ Digital Enterprise Virtual Summit, respresentatives from numerous companies from the discrete and process industries discussed strategies and technologies for future success under these new conditions.

The focus was on topics such as the horizontal and vertical integration of the value chain with simulation and optimisation from product creation through to servicing and from field level to the cloud. Other topics included online and remote solutions as well as edge and cloud computing, additive manufacturing, industrial 5G and artificial intelligence.

The Digital Enterprise Virtual Summit had around 12 000 registrations from customers and partners with 6 300 live attendees on the

day. The summit is now also available to be viewed on-demand at http://www.siemens. com/digital-enterprise-summit.

“Digital and automation solutions proved its worth during this crisis. Companies already invested in digitalisation were better equipped to handle new requirements, such as scaling back or ramping up production.

These technologies will ensure that companies can react particularly effectively to crises and changing market requirements because they can adjust their products quickly and flexibly," explains Klaus Helmrich, member of the board of Siemens AG and CEO Digital Industries. “This flexibility is also the next step toward autonomous production processes.”

Siemens is integrating future technologies

such as artificial intelligence, edge computing and cloud technologies, additive manufacturing or industrial 5G into its digital enterprise portfolio and helping industrial companies to work under these new conditions and to meet the requirements of today and tomorrow. Klaus Helmrich concludes, “No company can meet the current challenges on their own. It's all the more important that industrial companies act in ecosystems. Stakeholders - developers, users, partners and integrators - can bring their strengths and thus increase the value of these ecosystems. •

Siemens – www.siemens.co.za

Production interface

minimises case and pallet labelling downtime Markem-Imaje’s 2200 Production Interface reduces the risk of rework and recalls by minimising the scope for operator error.

D

OWNTIME IS REDUCED by the ability to preview and adjust labels digitally.

It is also improved by a large intuitive touchscreen, which helps operators work more quickly.

With downtime, rework and recalls eating into profits, manufacturers must minimise these elements. The 2200 Series Print & Apply (P&A) labelling system for cases and pallets can save up to six days of downtime per year.

Traditionally, labels have been created and stored away from the production line.

Untrained or distracted operators can make mistakes by picking the wrong product label and/or inputting the wrong data from the remote location (e.g. in an office or separate line PC). With no label preview function at printer level, mistakes can only be spotted after printing has started, resulting in

production stops and rework.

The Production Interface minimises scope for such mistakes and accelerates changeovers. It also makes case and pallet labelling less resource-intensive to manage, freeing up operators to do other, higher priority activities.

The improved storage capacity means labels are effectively stored en masse at printer level with limited image editing capabilities, protecting layout and data integrity, while increasing speed. Enhanced connectivity also makes it easier for label formats and data to be retrieved, on demand, from a remote location directly to the printer via the CoLOS information management system.

Incorrect label selection by operators can also be eliminated by enabling keyboardfree label selection and variable data

updating through a connection to a handheld barcode reader - linked to a production manifest. The Production Interface’s large touchscreen shows exactly how variable content will appear on the eventually printed label. If needed, operators can easily make six types of minor adjustments, such as label position and print contrast, digitally via the interface. In other labellers such setting changes can be so difficult to access that operators commonly resort to manually moving the printer product sensor which can result in equipment damage and personal injury. Available in 261mm or 396mm touchscreens, colour-coded printer statuses are more visible at a distance so problems can be spotted and addressed without delay. •

Markem Imaje – www.markem-image.com

2020 Quarter 3 | Food Manufacturing Africa

29

INSPECTION, CODING & MARKING

Potato processing

line feels the Veryx difference Key Technology has teamed up with Bem Brasil, the largest potato processor in Brazil, to add a new state-of-the-art potato strip processing line to its facility.

T

HIS MULTIMILLION-DOLLAR purchase includes six Veryx digital sorters, an ADR Exos automatic defect removal system, three Sliver Sizer Removers and 57 Iso-Flo vibratory conveyors on a line designed to process 30 metric tonnes of frozen French fries per hour. Bem chose to partner with Key to maximise food safety and consistently meet final product quality specifications while improving operating efficiencies and increasing yield.

“We selected Key for two primary reasons – their leadership in our industry and our trust in the company and their solutions,” Walter Takano, foreign trade manager at Bem Brasil points out. “Our confidence is based, in part, on years of experience with their Iso-Flo shakers on our other lines.

To learn more about their Veryx sorters and ADR systems, we visited Key and then travelled to see the equipment operating at major potato processing facilities in North America and Europe. Overall, Key's expertise and the reliability of their technology impressed us."

Key will equip Bem’s Veryx sorters with its full suite of sorter intelligence tools as well as top- and bottom-mounted sensors to achieve full-surface inspection. The sorters immediately before packaging will also feature Key's patented Pixel Fusion technology to find and remove even the most difficult-to-detect FM and defects immediately before packaging. Images of FM will be time-stamped and archived for

30

retrieval utilising Key’s FMAlert feature.

Veryx combines all camera views into one all-surface analysed object, which enables the sorters’ patented Sort-to-Grade (STG) software to automatically maintain final product specifications for both defect and/or length profile without operator intervention to increase yields and eliminate mechanical length grading. The sorters’ Information Analytics software exports real-time individual object data, allowing Bem to collect, analyse and share big data across the enterprise to reveal patterns, trends and associations, which can help optimise processes.

“Bem is a prominent potato processor in Brazil, committed to becoming a global leader by investing in state-of-the-art technology as they grow. We are honoured that they have decided to partner with us,” said Bret Larreau, director of InterCon

Food Manufacturing Africa | 2020 Quarter 3

Sales - Latin America and Asia Pacific at Key Technology. “Before they selected their suppliers, they took a close look at what other world-class French fry facilities are doing. The real-world examples of yield increases, food safety practices and process optimisation achieved using tools such as our STG, FMAlert and Information Analytics, plus the reliability and consistency of our VERYX platform made a compelling impression that led to securing this business.

Takano concluded, “For us, the single most important thing is taking good care of our consumers. Working with Key, we’ll ensure we produce the ideal final product quality. At the same time, we expect to increase yield and reduce operating costs.” •

Key Technology – www.key.net

SUPERCHARGE YOUR BRAND WITH

quotes@clomark.com

+27 (11)-314 5444

www.clomark.com

CLOMARK’S DIVERSE PACKAGING RANGE

Supplier of packaging for essential products during the Covid-19 crisis

7 Bushbuck Close, Corporate Park South, Randjespark, Midrand, Johannesburg, South Africa

Materials Handling

Performance

Flexibility

Simplicity

Controls & AI

Project Management

Processing

End of Line

Coating & Seasoning

Packaging Cooling & Freezing

We put a lot into

Distribution

this one perfect fry.

Scan me for more details