Food Review 2019

SOUTH AFRICAN

www.foodreview.co.za

Journal for food and beverage manufacturers JULY 2019 Vol. 46 • No. 07

Celebrate

the power of vanilla!

Colours and flavours that push the natural agenda

Smart automation keeps food products safe

End of line packaging that boosts your bottom line

Our Promise is inside Vivit Foods manufactures to the dairy, bakery and catering industry. We supply customised and creative products and packaging solutions

Dairy Industry

Yoghurt fruit pulps & syrups Milkshake syrups

Bakery and Catering Industry

Fruit pie fillings, Toppings, Jam Caramel treat, Lemon curd, Salad dressings, Mayonnaise & Sauces

Sweeten the deal : Bake and freeze/thaw stable Selection of different fruit content Natural & Preservative free product range Standard products with longer shelf life

FSSC 22000 Certified Halaal approved

Celebrate life’s sweet moments!

Phone +27 (0)11 4526730 Email info@vivit.co.za www.vivit.co.za

CONTENTS JULY 2019 | Vol. 46 • No. 07

PAGE

37 Bag closures for all applications

PAGE

14 “Wall's has been working with global charity partner Save the Children, and flavour manufacturing partner Symrise to make a real change for the young people of the country”

07

EVENT

Anuga: your gateway to the latest organic trends

08

NEWS

Palsgaard hits carbon neutral targets ahead of schedule

Distell supports waste management

GEA fast-tracks repair times

Social media makes tea sexy

11

INDUSTRY TALK

Turn waste into natural

food preservatives

The circular economy in action

16

ROBOTICS & AUTOMATION

Laser sorting machines eliminate aflatoxin risk

Smart, connected factories are the future

Lubricants’ essential role in food safety

Sew-Eurodrive launches end-to-end automation solutions

23

COLOURS & FLAVOURS

Green starches for clean labels

Effective bloom retarders keep chocolate at its best

Firmenich drives local flavour production

A growing market for plant-based meat analogues

Use purées to clear the sugar hurdle

High-intensity blues for industrial use

31

MATERIALS HANDLING & WAREHOUSING

Innovative technology is critical for survival

Shipping verification solutions assure 100 per cent accuracy

33

HYBRID DRINKS

Bottle flexibility tackles future production

Stevia offers natural flavour innovation

35

BEVERAGE PROCESSING TECHNOLOGY

Air Products’ upgrade meets increased CO2 requirements

37

END OF LINE PACKAGING

High-speed bagging systems can impact your bottom line

Cama’s latest tech innovations

Complete packaging solutions keeps crisps crunchy

July 2019 | Food Review

3

EDITOR’S COMMENT

EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmedia.co.za Layout & Design: Andipha Nkoloti +27 (0)11 877 6168 andipha.nkoloti@newmedia.co.za Contributors: Deidre Fryer 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

A question of balance

C

lean and clear labelling are well established terms in the food and beverage industry. First coined by Innova Market Insights in its trends listing in 2015, these are now fully entrenched in the sector’s vernacular.

Their mainstream status is illustrated by the fact that nearly 28 per cent of global food and beverage launches recorded in 2018 used one or more of these label claims: natural, organic, no additives/preservatives and GMO-free.

Flavour is still the number one factor influencing purchasing decisions. In recent years, the clean label trend has broadened into a wider movement, focusing on an increasingly mindful consumer trying to make responsible food choices that are not only tasty and healthy, but also sustainable and ethical.

Food Review’s colours and flavours feature kicks off on page 23, where we discuss the changing product portfolios in this dynamic sector. We highlight new clean label texturising starches that can create clean label food and beverage products without impacting light colour, nuanced flavours or luxurious textures.

Meat analogues offer the perfect synergy between meat and colour. Studies indicate that year-on-year sales of plant-based meat alternatives rose by 24 per cent in 2018. This is one category that you would be remiss not to investigate. We also look at the latest innovations in blue powders derived from spirulina (page 30). These products are available in standard or micronised form.

Health experts and governments are looking for new ways to address consumer health and obesity. Stevia leaf ingredients offer a solution and will become an important tool for the industry when formulating products with zero calories. Read all about the evolving story of stevia on page 34.

The food and beverage industry is the largest consumer of CO2. Air Products responded when the market demanded an increase in supply by investing in a R100 million expansion and refurbishment project at its KwaZulu-Natal facility and an upgrade at Natref (page 35).

We end this edition with a look at how manufacturers can benefit from end of line technology. Turn to page 37 for the full story now.

I hope you enjoy this edition of Food Review.

Don’t forget to watch out for our August edition where we will give you a sneak peek at all the Food Review/Symrise New Product Competition entrants and their innovative products!

Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmedia.co.za Sales Executive: Daleen Filbey +27 (0) 83 409 3119 daleen.filbey@newmedia.co.za INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmedia.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmedia.co.za Production Controller: 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

Happy reading,

Published by New Media, a division of Media24 (Pty) Ltd MANAGEMENT TEAM MANAGING DIRECTOR: Aileen Lamb COMMERCIAL DIRECTOR: Maria Tiganis BRAND STRATEGY DIRECTOR: Andrew Nunneley CHIEF FINANCIAL OFFICER: Venette Malone HEAD OF HR: Camillah West

EDITORIAL ADVISORY BOARD Two doctorates in chemistry; leader in the field of palm oil; SAAFoST president 1993-2001 and honorary life member; past president, Society of Cosmetic Chemists SA.

Dr Aubrey Parsons With a PhD in biochemistry, an MBA and a Institute of Brewing and Distilling diploma Heidi also serves on the Innovation Hubs BioPark and UNISA’s Life Science advisory board.

Dr Heidi Grimmer CEO of Stratcom Branding, founding member of the glba (Global Local Branding Alliance)

Gail Angela Macleod

4

Food Review | July 2019

CEO: MEDIA24: Ishmet Davidson

Managing director of Symrise South Africa; chairman of SAAFFI.

Rudy McLean She is a qualified food technologist with an honours in Bachelor of Commerce in Business Management and a PMD at the Gordon Institute of Business Science.

Kerusha Pillay

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

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EVENT

Anuga Organic excellently positioned Growing awareness for health and the environment is boosting the market for organic products.

Transparency is also coupled to strong growth in this sector.

O

rganic foodstuffs are marketed as healthy since they don’t contain artificial colourings, preservatives, aromas and flavourings. They are also grown without the use of pesticides.

Research conducted by Innova Market Insights indicates annual growth of 11 per cent for food with organic labels in the period 2014 to 2108. The percentage of new products that fall under the organic segment grew from 8.8 per cent in 2014 to 10.5 per cent in 2018.

In the same year, 58 per cent of all new introductions with an organic label took place in Europe, while 22 per cent were introduced in North America. The fastest growing category is snacks. This category shows an average annual growth of 18.6 per cent (annual overall growth 2014 to 2018).

Anuga is celebrating its 100th anniversary this year.

Approximately 250 exhibitors from Germany and the rest of the world will be presenting a wide and diversified range of products at Anuga’s Organic Hall. The event will be held from 5 to 9 October in Cologne, Germany.

Exhibitors registered in the Anuga exhibitor database also demonstrate the popularity of these new products.

In 2015, 2 030 exhibitors showcased their products and this has growth to 2 580 companies in 2017. In total, over 63 000 visitors took the opportunity to inform themselves about the worldwide organic market at the last event. •

AMAZING

COLOGNE, 05. – 09.10.2019

Meet old and new friends.

Priceless networking since 1919.

Secure admission tickets at www.anuga.com/tickets

Southern African – German Chamber of Commerce and Industry P.O. Box 87078, Houghton 2041 47, Oxford Road, Forest Town, 2193 Johannesburg, South Africa Tel. +27 (0)11 486 2775 dvanjaarsveldt@germanchamber.co.za

Anuga – www.anuga.com

July 2019 | Food Review Anuga_2019_Anzeige_SA_Food_Review_88x262mm_ZA.indd 1

7

28.05.19 10:04

NEWS

A next level in carbon-neutral production

P

alsgaard has reached its goal of total carbon-neutral production two years ahead of schedule. In 2010, the company set itself a goal of completely carbon-neutral production within ten years.

It has managed to reduce its net carbon emissions from 12 029 tonnes in 2010 to zero in 2018. Over that period, the company achieved CO2 reductions totalling 56 175 tonnes – equivalent to the amount produced by 4 885 European (EU) households in a year.

The company’s six global production sites are now all carbonneutral, mainly through changing sources of energy. Strategies include new heat recovery and insulation techniques; a switch from heavy fuel oil to certified biogas and the use of renewables. At Palsgaard’s main site in Denmark, all electricity is sourced from hydropower and indoor heating is powered by burning home-grown straw rather than oil.

The company’s Dutch factory has over 800 solar panels and has run off renewable energy since the start of 2018. Palsgaard has also partnered with the UN and purchases its official carbon credits to offset emissions.

Jakob Thøisen, CEO of Palsgaard explains, ‘This is a major milestone for the entire ingredients industry. The production of emulsifiers is very energy-intensive. When we decided to eliminate our carbon footprint, many thought it couldn’t be done. We’ve demonstrated that with ambition and innovation, sustainable ingredient production is possible. Achieving CO2 neutral status ahead of schedule has given us extra energy to continue making a difference. We hope other companies will be inspired to go on the same journey.’

Anders Brix, group CEO of the Schou Foundation, which owns Palsgaard says, ‘Throughout Palsgaard’s 100-year history, we’ve been dedicated to meeting challenges and climate change is undoubtedly the greatest challenge facing us now. Carbon neutrality is a rare achievement, but it will soon be the norm. Manufacturers will be forced to reduce their emissions, not just because it’s the right thing to do, but because environmentally conscious consumers demand it.’

As well as being manufactured in CO2 -neutral factories, all Palsgaard’s emulsifiers are vegetable-based and sourced as sustainably as possible.

Where the company uses palm oil ingredients, it relies on RSPO-certified raw materials, enabling it to offer its complete product range as MB or SG certified. •

Sustainable krill oil practices makes waves

DuPont divests natural colours business

T

he company has divested its Natural Colors business, which is part of the DuPont Nutrition & Biosciences (N&B) segment, to DDW, The Color House. DDW is a global privately held company specialising in natural colour solutions for the food and beverage industry.

The divestiture closed on June 28, 2019. DuPont has a defined strategy of active portfolio management to further align the company’s portfolio with high return opportunities, consistent with its disciplined approach to capital allocation.

This includes always evaluating the business and asset mix, and,

8

Food Review | July 2019

pursuing strategic alternatives to optimise value creation. ‘The Natural Colors business offers quality natural colours to a global customer base and is an attractive business with two world-class production sites.

It is however not part of N&B’s strategic focus areas.

'Following a strategic review of the Natural Colors business, we concluded that it would likely deliver greater value as part of a dedicated and leading colours player. We are convinced that the Natural Colors business will thrive under DDW’s ownership,’ said Matthias Heinzel, president, DuPont nutrition & biosciences business. •

F

riend of the Sea, a global certification standard for products and services that respect and protect the marine environment, has certified DailyNutra, a smart nutrition company, for sustainable production of products that contain Krill oil for Omega-3s. With this certification, DailyNutra can display the Friend of the Sea eco-label on its Krill oil products.

‘As the market for nutritional products embraces Omega-3s, we are seeing producers step up and commit to sustainable practices,’ says Paolo Bray, director of Friend of the Sea. ‘This is the right move, as these companies’ success depends on sustainable sources.

'We are very pleased to welcome DailyNutra to this esteemed group of environmentally conscious businesses.’

The company’s fishery source is governed by the Commission for the Conservation of Antarctic Marine Living Resources.

This organisation establishes yearly allowable fishing quotas.

While the quota of 2.7 per cent of Krill is allowed, less than 0.06 per cent of the krill biomass is harvested on an annual basis. Krill fishing is among the most regulated types of seafood production in the world. •

NEWS

Green economy aims to curb waste

D

istell, in partnership with waste beneficiation and implementation partner, Separation at Source (S@S) is launching GreenUp. This progressive community change initiative is focused on a cleaner environment.

It aims to establish and formalise effective value chains of operation in the collection, separation and processing of recyclable postconsumer waste within the western Cape’s Khayelitsha informal settlement.

Eric Leong Son, Distell’s sustainability manager and GreenUp project sponsor says, ‘The broad aim of this project is to align its operational activities with its sustainability objectives. We have made significant strides in the past few years in fine-tuning our business to be sensitive and responsive to our environmental impact. By working with S@S in formalising networks or value chains in waste management in Khayelitsha, we also help combat socio-economic challenges and empower individuals within this expansive and fast-growing community.’

Kathryn Warner of S@S says, ‘The waste industry in South Africa consists of waste collection and landfilling, with as little as 10 per cent recycling. It is estimated that 65 per cent of waste - approximately 38 million tonnes is recyclable and could subsequently be diverted from landfill and recovered to be reprocessed or repurposed.’

Son says Distell is embarking on this project because of the focus area’s proximity to its operations in Stellenbosch.

‘We recognise that in order to make good on our sustainability commitment, we need to tap into a number of opportunities within our value chain, which may not be a traditional fit, but enable us to make a greater impact within society.

'This initiative helps to support the waste management efforts in lower-income communities such as Khayelitsha that serves as our project target area, by empowerment through mentorship and skills transfer. It also plays an important role in the collection of qualitative and quantitative data to better aid our understanding and efforts as we continue rolling out the project,’ he concludes. •

Demand for dilutables decreases

T

he category is known to perform well when the economy is strained due to affordability and the value it offers. A report from BMi Research shows that for the past two years this has not been the case and the substantial increase in the average industry selling price across the different subcategories is believed to be associated with the reduced demand for dilutables.

The dilutable dairy juice blends subcategory continued to hold the largest share of packaged and reconstituted volume.

This subcategory is cheaper on a rand per litre basis and has a high reconstitution factor compared to other subcategories. In an economy where consumers are looking for ways to stretch their budgets on products that offer value for money, this becomes an attractive option. Dilutable sports drink/ dilutable iced tea subcategory contributed the lowest share in packaged and reconstituted volume.

This subcategory holds the highest average industry selling price and has a niche target market. The category has limited players that have established themselves as market leaders in this subcategory. It is believed that this may

be making it difficult for new players to penetrate the subcategory.

The outlook on dilutables is positive as players are confident that their proposed marketing strategies and innovations will positively impact the performance of the category. Cleide Tinga from BMi Research comments that due to the sugar tax, RTD vegetable juice is becoming popular and questions whether there could be an increase in vegetable concentrate juice provided there is a market for it. ‘If so, will it pose a threat to the fruit juice concentrate market?’ she asks.

The other concern is the PET backlash.

As one of the major pack types in dilutables, Tinga questions whether players in this category will shift to other pack types or will PET continue to dominate the category. •

Limit switch box for quarter turn valves

V

alve specialist Gemü is launching electrical position indicators for manually and pneumatically operated quarter turn valves. To automate process plants, the Gemü LSC (LSC) limit switch box detects the valve position of manually and pneumatically operated quarter turn valves.

This is signalled by an optical indication and transmitted to the plant control system. The LSC position indicator can be fitted to all quarter turn valves, such as butterfly valves or ball valves, with a VDI/VDE 3845 standard interface.

The company offers solutions preinstalled on butterfly valves or ball valves, but retrofitting is also possible. Up to four position feedback messages can be sent.

In addition to simple microswitches, the LSC limit switch is also available with two or three wire proximity switches. It has the protection class IP 67 and is suitable for explosion-proof areas to ATEX and IECEX. The LSC limit switch box has also been checked to ensure the reliability of safety functions and has SIL approval. A 3D optical position indicator or Open/Closed LED display is optionally available. It comes with a variety of electrical connections, such as an M20 cable gland, an M12 plug or an NPT threaded connection.

Besides the existing LSF inductive dual sensor, the company is expanding its range of electrical position indicators for quarter turn valves with the addition of the LSC limit switch box, therefore enabling quarter turn valves to be integrated and controlled in automated plants. •

Gemü 481 Victoria butterfly valve with Gemü LSC electrical position indicator fitted

July 2019 | Food Review

9

NEWS

CVC Capital Partners and Bosch reach an agreement Packaging technology and pharma and food units to remain intact

B GEA now offers a faster inspection and repair service

New Fast Lane Service for GEA separators significantly shortens repair times

F

ollowing a series of optimisation measures at its Center of Excellence (COE) in Germany, GEA has significantly reduced the general repair times of its separators.

Infrastructure and organisational improvements, and the appointment of an assessment coordinator have resulted in inspection and repair times being reduced by up to 40 per cent globally. For particularly urgent cases, GEA now offers a Fast Lane Service. This enables affected separators to be repaired in less than 10 days, depending on the requirements.

Even the short-term breakdown of a separator can halt production. Such situations require quick analysis and repair.

In most instances, the separator must be transported to a certified GEA workshop to ensure authorised repair by the original manufacturer, which includes the necessary safety tests. Shipment, reporting, repair, inspection and return requires a certain time frame.

While this cannot be bridged via bowl rentals or spare parts it is not the optimal solution for customers.

GEA developed a Fast Lane

10

Food Review | July 2019

Service for particularly urgent repairs, which are handled by a dedicated team who take care of these prioritised requests. These employees work alongside regular diagnostic and repair service teams but have the advantage of being able to exclusively handle prioritised cases more quickly.

The Fast Lane Service is offered for separators in all application areas with a surcharge based on bowl diameter.

The Fast Lane offer is currently limited due to capacity and time considerations. A small steering team will decide on the urgency of each repair based on diverse criteria. Once a repair is prioritised, the operational team takes over the order, managing the entire process. This includes cooperating with the specialist departments as well as arranging for the dispatch of parts and repaired machines – reducing overall lead times by up to 80 per cent. With its considerable reduction in repair times and optional Fast Lane offer, GEA has achieved an important improvement in its service which is a clear plus for customer satisfaction. •

osch plans to sell its packaging machinery business to a newly incorporated entity managed by CVC Capital Partners (CVC).

The company and its pharma and food units will remain intact. Based in Luxemburg, CVC is a leading private equity and investment advisory firm with 24 offices in Europe, Asia and the US. It currently manages more than US$75 billion of assets.

The parties signed an agreement on July 11, 2019 effecting the transfer of the entire packaging technology business and its 6 100 associates in 15 countries.

It has been agreed that the purchase price and other details of the purchase agreement will not be disclosed. Completion of the sale is subject to approval of various bodies, including antitrust authorities and is expected to close at the turn of the year. •

Tea is the beverage industry’s sexiest new offering

S

ocial media has revolutionised the way we think and talk about what we eat and drink.

An Innova Market Insights consumer study indicates that one in ten consumers in the US, Canada, Mexico, Spain, the Netherlands and Australia are influenced by social media in their food and beverage purchases. That number increases to a whopping one in five in China and India.

In South Africa, the case is bound to be similar with more than 23 million users spending almost three hours on average a day on social media. It’s a phenomenon that is having a big impact on tea consumption worldwide, says Adele du Toit, spokesperson for the SA Rooibos Council. ‘Before the social media boom, coffee was king, but these day’s tea

is catching up. Tea has been hash-tagged in over 29 million Instagram posts alone – turning one of history’s oldest drinks into what may be the beverage industry’s sexiest new offering,’ she notes.

The tea drinking demographic is also widening and many consumers are tending towards caffeine-free drinks with natural plantbased ingredients.

This opens the door for botanical and herbal teas.

According to industry experts, consumers have maxed out on other beverages and enjoy the variety of flavour combinations that teas offer them. Beverage giants have responded by launching teainfused waters, soft drinks and energy drinks. Ready-todrink, tea-flavoured alcohol options are also proving popular. •

I N D U S T RY TA L K

Could citrus and grape by-products serve as food preservatives?

Large amounts of citrus and grape by-products, normally treated as waste and generally disposed of in landfills, could potentially be used in the production of natural food preservatives.

T

his is one of the main findings of an interdisciplinary study at Stellenbosch University (SU). ‘Our research has shown that the use of bioactive-rich citrus and winery by-products could provide an efficient, inexpensive, easily available and environmentally friendly platform to produce natural and sustainable food preservatives,’ says Dr Cletos Mapiye from the Department of Animal Sciences at SU. He conducted research with colleagues from the Department of Food Science and the Postharvest Technology Research Laboratory in the Department of Horticultural Sciences.

The study was published recently in the open access journal Sustainability.

For the successful adoption of fruit byproduct-based natural preservatives in sustainable food systems, it is important to know the following: the phytochemical (biologically active compounds in plants) composition, antioxidant and antimicrobial efficacy, and safety and stability of these byproducts during food processing.

‘Bioactive phytochemicals play an important role in preserving food quality by retaining flavour, colour, texture and nutrients while reducing the chance of contracting a foodborne illness and potentially contributing to the prevention of chronic diseases due to their antioxidant properties,’ Mapiye says.

Mapiye and fellow researchers analysed the phytochemical composition, and the antioxidant and antimicrobial properties of extracts from grape pomace, grape seeds and Clementine mandarin orange peel and pulp grown in South Africa. After collection, samples were washed, oven dried and ground into fine powders before extracting the phytochemicals for analysis.

Researchers found that grape extracts contained the largest amounts of condensed tannins while mandarin peel extracts had the greatest content of ascorbic acid (Vitamin C).

‘Overall, grape seed extracts had the most antioxidant activity of all the tested extracts.

Grape pomace, grape seeds and Clementine mandarin orange peel and pulp could be a viable alternative to Antimicrobial activity was synthetic preservatives highest in mandarin orange peel and pulp extracts industry and contribute immensely towards followed by grape seed and sustainable food systems given the amount grape pomace extracts. of food being wasted every year.

‘Grape seed and mandarin orange peel and Food spoilage is an important contributor pulp extracts can be considered for potential to wastage with about 1.6 billion tonnes of application in food - either individually or in food being lost or wasted annually. In South combination as an excellent antioxidant and Africa, annual postharvest food losses antimicrobial sources.’ and waste amounts to 10 million tonnes, Grape pomace, grape seeds and with about 95 per cent of the food wastage Clementine mandarin orange peel and pulp occurring along the value chains prior to could be a viable alternative to synthetic reaching the consumer.’ preservatives. These ingredients are Mapiye points out at least 40 per cent of commonly used to inhibit and or delay the the one million tonnes of mandarin produced processes that cause food spoilage and annually in the country are channelled to enhance the quality, safety and shelf stability juice production. Waste accounts for of food.

50 to 70 per cent of the fresh weight ‘Due to its antimicrobial properties, comprising of peels, pulp and seeds.

Clementine mandarin orange peel and pulp ‘In addition, 1.5 million tonnes of grapes could be a viable alternative to sulphites, are produced for wine production with thereby reducing the risk of allergies posed pomace making up 20 to 25 per cent of the using the synthetic preservative,’ Mapiye pressed grapes on a dry matter basis. Grape points out. pomace is made up of stalks, seeds, skin Consumer health concerns have led and pulp.’ to fear and avoidance of food containing Given the lack of systematic research in synthetic preservatives. The valorisation South Africa on the preservative capabilities of fruit by-products as natural food of extracts from local grape and citrus preservatives has the potential to unlock by-products, it is important to establish new value chains for the fruit processing the bioactivity and real benefits of these extracts for functional food applications.

Consumer health concerns have ‘Further studies to validate the safety and led to the fear and avoidance of food containing synthetic efficacy of such products for use in food are preservatives warranted,’ he concludes. • *(Source - Pfukwa, TM et al 2019. Food Preservative Capabilities of Grape (Vitis vinifera) and Clementine Mandarin (Citrus reticulata) By-products Extracts in South Africa. Sustainability Vol 11 (6).)

July 2019 | Food Review

11

I N D U S T RY TA L K

Circular economy is saving the planet and boosting profits Shoes made from ocean plastics, packaging material made from mushrooms, and a green partnership between Ford and Heinz to build car parts from tomato fibre are examples of the circular economy in action.

I

n a traditional linear economy, materials flow in a line. They are taken from the earth, made into an item in an affordable way and waste goes into landfills when we are finished using the product.

The circular economy has been inaccurately referred to as “recycling on steroids”. It was shown to be much more than that in an impactful presentation

by US-based supply chain specialist Deborah Dull, at the recent Sapics Conference held in Cape Town.

She contends supply chain management, and the circular economy, can save the planet. In her current role as principal supply chain management at General Electric subsidiary, GE Digital, Dull works across the supply chain community to accelerate the transition to a circular economy. Her goal is to progress past a linear “take-makewaste” approach to one in which supply chains around the world are supporting a “make-reuse circular approach to dramatically lengthen the lifecycle of the items around us”.

‘The circular economy is already well underway around the world and goes beyond sustainability agendas,’ Dull informed delegates in her presentation at the annual Sapics Conference. This year, the event attracted some 800 supply chain professionals representing 28 countries.

‘The circular economy builds on industrial symbiosis where the idea is that a series of factories are set up next to each other. The bi-product or residual product of one factory process

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Food Review | July 2019

“The circular economy builds industrial symbiosis where the idea is that a series of factories are set up next to each other. The bi-product or residual product of one factory process is used as a resource by another” is used as a resource by another.

Through local collaboration, public and private enterprises buy and sell residual products from one another, both making money and saving the environment.

With new Industry 4.0 technologies, the concepts beyond the industrial symbiosis can be stretched across digital supply networks, allowing for materials and byproduct exchanges to happen at scale.

She also highlighted that organisations and governments are investing in these initiatives because of the capabilities of the circular economy.

Challenging the misconception that saving the planet always comes at a cost, Dull reported the circular economy is on track to add US$4.5 trillion to the global economy by 2030 and create hundreds of thousands of new jobs.

‘I argue that the true focus of circular is first on the economy part – that of expanding profits,’ she stated.

Sports brand Adidas, is embracing circular economy principles in its partnership with Parley for the Oceans, an environmental organisation fighting environmental threats posed by ocean plastic pollution. ‘In 2017, Adidas sold one million pairs of its Parley brand shoes made with ocean plastic. In 2018, five million pairs were sold. Adidas has announced it will make 11 million pairs in 2019. These are not inexpensive shoes, but they are in demand,’ Dull said.

Proctor & Gamble is making bottles from recycled plastic and ocean plastic. As part of their Ambition 2030 Initiative, they have taken nearly all of their manufacturing facilities past zero waste towards circular models and have saved over two billion dollars. There is a growing emphasis on designing products for the circular

Biodegradable Mushroom packaging

I N D U S T RY TA L K Timberland Flyroam Go Stohl Oxford ReBOTL yellow shoes for men made with six recycled plastic bottles

economy. EcoCradle is one such product. Designed to replace Styrofoam, it is a mushroom-based packaging material that is now being used by furniture giant IKEA. ‘It grows relatively quickly, is cost-effective and it decomposes in 30 to 90 days,’ Dull explained. The global market for sustainable packaging is expected to reach more than US$140 billion in the coming years.

The circular economy highlights the importance of extending the useful life of an item for as long as possible.

This has increased product-as-a-service offerings across the market, such as Uber, US-based Rent the Runway clothing rental, and for an industrial example – “time on wing� for aeroplane engines.

Dull explained that GE Aviation offers this service through an Outcome as a Service offering to airlines, making GE Aviation responsible for predictive and preventative maintenance. ‘This is important because assets are smart. Machines are intelligent. The Industrial Internet of Things and Industry 4.0 are bringing together sensors, advanced analytics and machine learning. This combination means that the engine tells us when it needs to be serviced. As you can imagine, this is very powerful and a key enabler of the circular economy.’ Dull finished her presentation by Deborah Dull exploring the impacts of the circular economy on the supply chain, asking delegates to imagine waste as something of value that will be exchanged among supply chains as input to products and processing.

With material exchanges starting to emerge across the world, Dull showcased early examples of parts passports, which record an asset’s details and history, including market analysis for valuation, and pair up potential buyers and sellers. ‘We need to start thinking about waste as inventory. Consider how much of the circular challenge could be solved if everyone switched to using recovered materials and no longer used new, virgin materials,’ she challenged.

A circular economy forums around the world, supply chain professionals are missing from the conversation.

Dull concluded, ‘Invite yourselves to the discussions.

Supply chain teams find solutions to impossible challenges across the world. Now is the time to come together as a global community and create supply chains that can support circular business models.’ •

Sapics – www.sapics.org

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5/28/2019 12:40:52 PM July 2019 | Food Review

C O M PA N Y F O C U S

Celebrate the power of vanilla!

Unilever UK and Ireland’s leading ice cream brand Wall’s has partnered with Save the Children, Symrise and ME to WE. The initiative will allow consumers to see the real change Wall’s is making in the lives of young people in vanilla farming communities and at home.

Unilever and Save the Children are working together. Their aim is to give young people a chance of a better future and improve the lives of families involved in vanilla production in the Sava region of Madagascar

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all’s ice cream announced the financial education and youth training launch of Vanilla for Change. opportunities. The region is responsible The campaign is set to reinforce for 80 per cent of the world’s global the company’s assistance to global vanilla supply, one of the world’s most vanilla farmers and youngsters in farming desired spices. communities in Madagascar. It is also To build on the journey, Wall’s is aimed at supporting young changemakers also partnering with ME to WE, a social across the UK through the power enterprise that enables people to do of education. good through everyday consumer choices.

Wall's has been working with During the Vanilla for Change global charity partner Save programme, the purchase the Children, and flavour of popular Wall’s ice cream DID manufacturing partner products (Cornetto YOU KNOW? Symrise to make a real Strawberry, Cornetto change for the young Classico, Calippo Bourbon vanilla beans from Madagascar are superior, with people of the country.

Combo Vanilla flavour and aromatic qualities that The collaboration Strawberry and make Madagascar vanilla beans between the Solero Exotic) will the most popular and sought after three partners support ME to WE’s vanilla variety. Bourbon vanilla is has been in place charitable partner’s rich, dark and creamy with an for over three years. active citizenship overwhelming sweet, To date, it has programme called buttery aroma. positively impacted WE Schools. more than 40 000 people in The programme provides 76 villages in Madagascar free educational resources with lifesaving health insurance, for teachers and a range of learning

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Food Review | July 2019

THE PROGRAMME HAS DELIVERED: • Over 9 000 households and 38 000

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community members are covered by lifesaving health insurance An estimated 114 Village Savings and Loans associations are active across the region, providing communities with access to fair credit and savings More than 2 700 people (33 per cent women) have been trained in the Farmer Business School Financial assistance for 73 parents’ associations of primary schools (with 17 200 students) Close to 40 000 people received Essential Package training, which encourages improved family health, nutrition and parenting behaviours 2 400 young people now have access to education services, such as numeracy and literacy catch up classes.

C O M PA N Y F O C U S

Marinette is a peer educator for Save the Children in her community. She started vanilla farming about two years ago and hopes to be able to sell her crop for a decent price in the coming years Credit: Charlie Forgham-Bailey | Save the Children

Bolo has his own small vanilla plantation and loves to sing and compose songs in his spare time Credit: Charlie Forgham-Bailey | Save the Children

opportunities for students. Thanks to this extended partnership, Wall’s and ME to WE will be supporting 100 000 young people with educational resources through the WE Schools programme in the UK. During the Vanilla for Change programme, customers who purchase the select Wall’s ice cream products will be able to see how Wall’s is making a difference through ‘Track Your Impact’.

This unique tool empowers customers to track and learn where and how the products they purchase can have a positive impact on society.

With the Track Your Impact code, ice cream fans will be able to see how Wall’s is making a difference in schools across the UK and in farming communities in Madagascar. ‘We can make a real difference through our Vanilla for Change programme. Not only in the communities in Madagascar who farm our vanilla, but also amongst young people in the UK. We are hugely passionate about both.

‘Having successfully supported vanilla farming communities for many years, everyone who enjoys a Wall's ice cream can now track a Madagascan farmer who is directly benefiting from our programme. In addition, our WE Schools partnership aims to inspire young people to improve their education. It is hoped this will positively affect their lives in the UK and Ireland. These are two causes we are really committed to,’ says Sebastian Munden, general manager Unilever UK and Ireland.

‘Vanilla for Change is the first step in demonstrating our commitment to fairness across our supply chain,’ adds Ian Maskell, Global VP Wall’s. ‘It’s a beautiful chapter of the journey we embarked on. As a brand, we believe in making a difference to the lives of the communities we serve. Our purpose is building a happier, more inclusive world - one street at a time.’

“Vanilla for Change is the first step in demonstrating our commitment to fairness across our supply chain” Wall’s also works closely with sustainable vanilla pioneer, Symrise.

The company is the only fully integrated flavour manufacturer in Madagascar.

‘Symrise and Wall’s are committed to a supply chain that creates shared value for everyone involved. Employees who live and work with us are the friends and neighbours of smallholder farmers, so we are passionate about developing these communities. We’re delighted that we can now share our work with the world via Track Your Impact, so more people can get involved,’ says Heinrich Schaper, president flavour division at Symrise.

‘We’ve been doing great work with Wall’s to improve the lives of these farmers to help stabilise incomes, improve education and enhance infrastructure. By combining Save the Children’s global expertise in understanding and meeting the needs of vulnerable children and their families, and the experience of our partners working in the vanilla supply chain, we contribute towards building a sustainable supply of vanilla for the future. The process will also improve the livelihoods of some of the most impoverished children in Madagascar,’ says Gemma Sherrington, executive director of fundraising and Marketing at Save the Children UK. ‘ME to WE is committed to supporting young people with the resources they need to change the world. Last year, over 4 000 UK schools and groups involved in WE Schools, volunteered over 860 000 hours and collected more than 115 000 kilogrammes of food for local food banks. Through Wall’s Vanilla for Change programme, even more youth from across the UK will be supported to create change in their communities. Together we're empowering the next generation of engaged citizens,’ concludes chief development officer, Erin Barton. •

Symrise – www.symrise.com

July 2019 | Food Review

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R O B O T I C S & AU T O M AT I O N

Addressing aflatoxin risk Aflatoxins in food and milk can seriously harm humans, animals, and corporate reputations. Nestlé Group in China and the longest-serving peanut-shelling plant in the US are both showing how laser sorting machines can eliminate the risk.

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ood contamination by aflatoxins, which can cause cancer, is worrying scientists and regulators. New concerns about these naturally-occurring poisons, voiced earlier this year by scientific advisors, have provided a stark reminder of the health risk to consumers and the commercial risk to food businesses.

Aflatoxins are a problem most commonly encountered with plants grown or food stored in parts of Asia, Africa and the US. This is because the toxins originate in two species of fungus, which favour hot and humid climates. Aflatoxins are 68 times more lethal than arsenic and capable of seriously damaging human and animal livers. Aflatoxins can cause fever, malaise and anorexia, followed by abdominal pain, vomiting, and hepatitis. Worse still, chronic toxicity from aflatoxins can reduce immune efficiency and trigger cancer, which is why they are classified by the World Health Organization as a Group 1 Carcinogen.

Exposure to aflatoxin-contaminated food is known to have caused hundreds of deaths in India and Kenya and many more fatalities have probably gone unreported.

Even in Europe, where there are strict rules about food safety, several nations reported widespread aflatoxin-contamination of milk in 2013.

The most poisonous type of aflatoxin, B1, occurs naturally in a wide range of food.

This fungus infects cereal crops including wheat, plus walnut, corn, cotton, peanuts and tree nuts. Aflatoxin B1 also infects spices, crude vegetable oils, figs, other dried fruits, cocoa beans, and rice. Another type of aflatoxin, M1, can be present in milk taken from animals, which have eaten feed contaminated by aflatoxin B1.

Pasteurisation of the milk does not protect against aflatoxin infection.

Aflatoxins are not harmful to humans or animals if consumed in small doses, but aflatoxin-intake from food and milk does have to be kept low. This is why, in many parts of

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Food Review | July 2019

the world, maximum permissible levels of aflatoxins in food are defined by law.

If regulators find these levels exceeded, the business responsible pays a heavy price.

In addition to the expensive disruption of a product-recall, there is the likelihood of costly and possibly fatal brand damage.

All of these dangers are made worse by the fact that aflatoxins are invisible to the naked eye.

WHY GOOD SAMPLES CAN LEAD TO BAD NEWS Some food businesses check for aflatoxins by testing samples of their products. This might seem like a responsible precaution, but unfortunately, it is not dependable.

Taking samples does not provide statistically-adequate proof the product is wholly safe. To visualise why, imagine peanuts filling a huge silo. That’s a lot of peanuts. The problem is that dangerously high levels of aflatoxins can be present in the silo but only in small clusters of nuts.

This means there is a correspondingly small chance of those contaminated nuts being picked for a test sample - and a very high chance they will reach a customer and would fail a regulator’s test.

One alternative to taking samples is to blanch the peanuts, passing them through a low-temperature heat treatment to loosen and then remove the seed coat. This process is unpopular with food producers because it can shorten the product’s shelf-life and adds considerably to costs.

The other solution, and by far the safest, is to rely on detection by sorting machines.

SORTING MACHINES RECOGNISE AND DISPOSE OF AFLATOXINS The best method for aflatoxin detection is to employ sensor-based sorting machines.

Equipment supplier Tomra’s machines employ near infra-red (NIR) spectroscopy, fluorescent lighting and state-of-the-art lasers to analyse the surface structure and

Concerns about aflatoxins can be addressed with new technologies

elemental composition of objects passing along a food production line.

The special optical design of the Detox laser makes it possible to identify the extremely low intensity of light reflected by aflatoxin mould and fungus in a variety of food types. This enables the detection of aflatoxin contamination.

In addition to this extraordinary capability, Tomra’s sorting machines also employ unique biometric signature identification (BSI) technology. BSI works by detecting the biometric characteristics of the food items it scans - for example, nuts and raisins. It then compares these to features stored in the machine’s database to determine whether the items should be accepted or rejected. This detects and removes smaller defects than would be possible with conventional spectral technology. Detection accuracy is so good that false-rejection rates are exceptionally low and yields exceptionally high.

A good example of this technology can be seen in action at Nestlé Group’s processing line in Dongguan, China, run by sub-brand Hsufuchi Foods. Quality and safety are one of the ten corporate principles at Nestlé.

The company chose Tomra as its strategic partner in fighting aflatoxin contamination in peanut products. Since September 2016, Hsufuchi Foods has operated two Helius free-fall sorting machines to achieve Nestlé’s global quality standards, which are more stringent than China’s domestic food safety regulations.

In addition to supplying sorters to fight aflatoxins, Tomra also provides comprehensive support in setting up and optimising machines. To validate Nestlé’s Helius sorters with detox technology, the company’s application support teams conducted a six-month test on the Dongguan processing line, adjusting sorting

R O B O T I C S & AU T O M AT I O N

parameters with more than 500 tonnes of in the US. This is the oldest operational peanuts of different varieties. Tomra also peanut-shelling plant in the country and has worked with Nestlé on quality inspection been relying on Tomra machines since 2002. and invited a third-party inspection agency The result is high-quality peanuts, supplied to define validation protocols. This would to many well-known food brands in Europe, ensure the validation process and results Japan and the US. were sufficient.

Bryan Willis, president of Zhang Ahfung, deputy general Damascus, explains, ‘Aflatoxin manager in charge of production is an expensive problem for a at Dongguan explains, ‘Technical peanut processor. Before we support was very efficient and installed the technology, the quick in response, both in the only way to deal with aflatoxin test phase and after machine was to blanch. Compared installation. We are now assured to blanching, using a laser Bjorn Thumas that the Helius sorter can is much less expensive and effectively control the level of our machines have paid for aflatoxin in peanuts. This puts my mind at themselves many times over. They do a ease because I do not have to worry about great job of detecting and removing foreign our products’ quality. We are considering material. This is the reason we originally the implementation of a Detox-technologypurchased them before discovering they can based sorter in all facilities where aflatoxin sort something humans cannot see. problems arise.’

‘Initially, we were sceptical about the machine detecting aflatoxin. We began to US SUPPLIER LOVES THE RESULTS understand that the toxin is structurally Smaller, family-owned businesses also different from the meat of the peanut. The benefit from Tomra’s technologies. Three laser sorter looks at the toxin no different of the company’s Nimbus free-fall sorting than it would a piece of glass, metal, or any machine, each equipped with the laser organic material that is not peanut. It was module required to detect aflatoxin, are very hard for the industry to understand this used by the Damascus Peanut Company at first because it was such an advancement

“Taking samples does not provide statisticallyadequate proof the product is wholly safe” over existing technology. I’m still astounded, but the proof is in the results, and the aflatoxin problem has been solved.’

Tomra Food´s VP business development, product management food sorting Bjorn Thumas explains, ‘What our machine does is equivalent to inspecting every single kernel.

The system also simultaneously performs other important sorting functions, taking out foreign material and removing allergens from the line.

‘When handling corn, the laser can also differentiate between GMO- and non-GMO seeds. Our machines increase productivity and improve yields at the same time as providing protection against one of the biggest dangers facing the food industry.

Aflatoxins are a potential killer, of humans and of businesses, but we can keep them under control,’ he concludes. •

Tomra – www.tomra.com

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July 2019 | Food Review

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R O B O T I C S & AU T O M AT I O N

Robotics-enabled factory of the future ABB enables companies and enterprises of any size to be as flexible as possible, while increasing productivity, enhance operational efficiency and improve safety and security.

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he Fourth Industrial Revolution is shaping the factory of the future by processing ever-growing volumes of data generated from smart automation and producing analytics that drive performance.

Smart, connected factories are the future of manufacturing. Just as over a century ago when it was at the forefront of electrifying cities and railways, ABB leads the way with its suite of ABB Ability digital solutions.

ABB’s factory of the future features industry-leading digital twin technology, which makes it possible to amend and optimise manufacturing without interrupting the production process.

A key feature of the factory of the future is the sensor, which collects and feeds information about the production process into the industrial internet.

ABB has developed a compact ABB Ability Smart Sensor that can be easily attached to the frame of a low-voltage

"The Fourth Industrial Revolution is shaping the factory of the future by processing evergrowing volumes of data generated from smart automation and producing analytics that drive performance" induction motor, mounted bearings and pumps to measure key parameters, such as vibration and temperature. Using onboard algorithms, based on ABB's decades of expertise in electric motors, the ABB Ability Smart Sensor gathers information about the equipment’s condition and sends the data via a wireless Bluetooth connection to a secure server, from which it can be accessed through a smartphone or tablet.

ABB is making mass customisation a reality and its flexible, efficient digital manufacturing eco-system makes it all possible.

YuMi collaborative robots perform

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Food Review | July 2019

ABB Ability Connected Services and YuMir collaborative robot

precision assembly operations; the SuperTrak flexible transport system orchestrates the timely movement of parts from station to station and ABB Ability Connected Services monitor health and performance.

As the factory of the future develops, people and collaborative robots like YuMi will work side by side. Robots will deliver repeatable quality by taking on repetitive tasks, which are often dirty, dangerous and dull and they'll handle computer-controlled decision-making duties. Increasingly computer-controlled decision-making, based on industrial artificial intelligence will support man and machine.

In 2018, ABB and The Economist published The Automation Readiness Index, which states the countries with the highest adoption rates of robots and intelligent automation namely South Korea, Germany and Singapore also have among the lowest unemployment rates in the world.

Robots, as well as autonomous systems, will be crucial in augmenting the workforce in the near future. This will, in turn, create opportunities for people to develop new work opportunities that are more inspiring, intuitive and interesting.

The single arm YuMi robot ABB's lightest and most agile collaborative robot

For example, people can offer process knowledge, as well as the insight and improvisation required to identify new efficiencies and devise production improvements.

Augmenting human potential with technology, in a responsible way, while providing ongoing education and training, is an opportunity to drive prosperity and growth. Lifelong educational ecosystems will emerge from efforts like ABB's support for practical vocational training for the jobs of the future. •

ABB – www.abb.com

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R O B O T I C S & AU T O M AT I O N

Why food-grade lubricants are essential

Statistics South Africa’s 2018 manufacturing production and sales report notes manufacturing is South Africa’s fourth largest industry. It also contributes 14 per cent of the country’s gross domestic product.

Synthetic H1 lubricants have a much higher viscosity than mineral types

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he food and beverages division is the biggest portion of the industry, contributing 25 per cent of total manufacturing activity 1. This high economic value means this sector needs to be especially vigilant about using high-quality products for the running and maintenance of equipment.

One of the ways to keep a food production environment safe is to use food-grade lubricants on machinery that could have incidental contact with food.

Lubrication experts Lubrication Engineers (LE) South Africa has a range of synthetic H1 lubricants for machinery that could come into incidental contact with food. Lubricants used in the food industry are classified as either H1, H2 or H3.

Managing director Colin Ford explains that H1 lubricants are for incidental contact with food; H2 are common industrial lubricants and H3 lubricants are used in applications where there is constant contact with food. ‘If non-H1 lubricants are used above the food line and the lubricant drops into the production, it can cause the entire batch to be scrapped. This can be due to

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Food Review | July 2019

colouration (such as a dark oil drop into a white bread dough) or toxicity.’ Any piece of machinery that is above a food processing line and requires a lubricant should be lubricated with an H1 lubricant.

Synthetic H1 lubricants usually have a much higher viscosity index than mineral lubricants. This allows them to operate in a wider temperature range. By using synthetic H1 lubricants in a food processing plant, safety is assured even in instances of incidental food contact.

“By using synthetic H1 lubricants in a food processing plant, safety is assured even in instances of incidental food contact” It also means that gearboxes can still be properly lubricated in extremely cold or extremely hot conditions, such as refrigerators or ovens.

H1 products must be non-toxic and either clear, white or a light beige in colour. These products must

also withstand the usual demands of lubrication in a plant, as well as lots of washing.

‘LE’s H1 products are able to do this, due to our exclusive Quinplex additive. This tacifier keeps the lubricant in place, even during high-pressure steam cleaning,' Ford notes.

All food grade lubricants should have a National Sanitation Foundation (NSF) International certification. LE has identified the importance of catering to a range of requirements for South Africa’s food industry, and the range of lubricants also have Halaal and Kosher certification.

‘In addition to certifications, clients should be asking about the technical performance of a lubricant, such as its water, temperature and wear resistance.

It’s no use using an H1 lubricant just because it is H1 if it does not do the job well,’ Ford concludes. • 1. Stats SA 2018 Manufacturing: Production and sales http://www.statssa.gov.za/?p=11890

Lubrication Engineers – www.lelubricants.com

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R O B O T I C S & AU T O M AT I O N

A taste of the future of automation Sew-Eurodrive gave Food Review a glimpse of its newly launched Movi-C modular automation system at the Africa Automation Fair 2019. These units are readymade for the requirements of Industry 4.0.

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he system consists of a Maxo-RPST-RRRRR0-10-1300-01, including a stand and polycarbonate guard, CMP motors, Move-C Modular; Movi-C Controller, a human machine interface (DOP) and Movikit Robotics software.

The system provides for an end-to-end automation solution, from planning to commissioning, operation and diagnostics software, electronic control and monitoring devices, mechanical drives and gearmotors.

It also features an open communications topology from Profibus and Industrial Ethernet to Modbus.

While the Movidrive B Drive Inverter and Moviaxis Multi-Axis Servo Inverter have been available for some time, the Movi-C modular automation system sets the company on a path to embrace Industry 4.0.

“This technology is making inroads into the food and beverage industry due to its ease of use and quick installation” 'This requires products that are both open and flexible,’ national sales and marketing manager Norman Maleka stresses. ‘Our focus is to provide our customers with a fully modular and customisable solution.’

The unit on display was a high-speed pick-andplace solution, including a tracking function, applicable to a range of industries.

‘We focus on energyNorman efficiency,’ Maleka notes.

Maleka ‘Three segment conveyors about one to 1.5m in length featured IE2, IE3, and IE4 motors, with the different energy consumption were displayed onscreen. Apart from its motor range, the Movigear mechatronic drive system was also showcased. This technology is making inroads into the food and beverage industry due to its ease of use and quick installation.

It is also easy to clean and meets strict

hygiene standards, for which an optional smooth surface is available.

Other energy-efficient products on display included Variable Speed Drives and the LTP-B Eco HVAC drive. Features include an advanced ‘sleep’ and ‘wake’ function that maximises energy efficiency by only switching on a pump, for example, when it is required.

‘Our aim is not only to stay ahead of the technology curve, but to be able to ensure our customers always have access to the latest complete solutions that are flexible, adaptable, and cost-effective,’ Maleka concludes. •

Sew-Eurodrive – www.sew.co.za

Metal & X-Ray Detectable Products & Stationary

Johannesburg, South Africa Email : jeremy@jelatech.co.za Phone: +27 (0)11 465 1528 Cell : +27 (0)82 412 0076 Web : www.jelatech.co.za

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Food Review | July 2019

Protect your reputation and avoid a costly product recall!

C O L O U R S & FL AVO U R S

Colours and flavours shine with green label starches Ingredion has launched three new clean label texturising starches. These products enable manufacturers to create clean label food and beverages without impacting light colours, nuanced flavours or luxurious textures.

FAST FACTS Novation starches are ideal for delicate applications

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ovation Lumina’s range of functional native starches can support manufacturers in making ‘natural’ claims. It enables them to formulate clean label products with consumer-winning sensory qualities and excellent shelf life and freeze/ thaw stability.

“Consumers are shopping for clean and simple labels. Globally, allnatural claims are the most influential factor in consumer purchasing decisions” Texturising starches are ideal for use in pale-coloured or delicately flavoured applications. Their neutral profiles allow flavours and colours to be delivered with increased intensity. This offers manufacturers the ability to maintain the most appealing qualities of their products - even in the most delicate of applications.

Delivering viscosity and gel strength comparable to that of modified

starches, three new natural * ingredients were designed to perform across the full range of processing conditions.

From the low-to-moderate conditions required for applications such as bakery cream fillings and fruit preparations to the challenging processing conditions of sauces, dressings, alternative dairy and UHT products.

‘Novation Lumina functional native starches can assist customers in meeting consumer demand for natural, clean label products while delivering optimal flavour, colour, texture and performance,’ explains Constantin Drapatz, senior marketing manager, clean and simple food ingredients, EMEA. Novation Lumina functional native starches are produced using Ingredion’s proprietary innovative technology. They can be labelled simply as corn starch or corn flour, non-GM and are naturally * gluten-free.

Ingredion proprietary research shows that flours and starches rank in the top 10 of the most consumeraccepted ingredients 1. Consumers are shopping for clean and simple labels globally and all-natural claims are the

Demand for starch-based texturising agents is increasing daily. These ingredients can add or modify the texture of food products. The primary starch-based texturising agents are emulsifiers, stabilisers, phosphates, dough conditioners - each with its own unique functions.

Apart from improving the texture of food, other applications include the dispersion of oil and food flavours; preventing the evaporation of volatile flavour oil and enhancing the waterholding capacity of food components.

Owing to its numerous applications, this market is likely to expand at a significant rate. most influential factor in consumer purchasing decisions 2 . • *Manufacturers should consult regulations specific to all target markets. Of the countries that have provisions in place to regulate the term 'natural' in food labelling to date, Novation Lumina functional native starches and Homecraft flours meet the criteria for a natural ingredient in the UK, France, Ireland, and associated EU legislation, and the global ISO technical specification on definitions and technical criteria for food ingredients to be considered as natural (ISO/TS 19657).

Ingredion proprietary research, Dragon Rouge, 2017.

2 Ingredion proprietary research, Global Clean Label Consumer Study, 2017.

Ingredion – www.ingredion.com

July 2019 | Food Review

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C O L O U R S & FL AVO U R S

Blooming good chocolate Cobao Pure is a new cocoa butter from AAK that delivers significantly improved bloomretarding effects in all kinds of applications. The list includes milk and dark chocolate tablets, coated and filled products and dark chocolate with nuts.

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t delays migration and heat-related bloom, extending the shelf life with between 50 and 400 per cent depending on the recipe, processing techniques and storage conditions.

It is anticipated that the new ingredient will be particularly beneficial in the premium chocolate segment. Sales of premium chocolate are growing three times faster than standard chocolate, presenting an excellent market opportunity.

Consumers pay more for high-end chocolate and expect the product to reach them in perfect condition.1 This means avoiding blooming and maintaining an attractive appearance for longer is essential.

“Blooming, a common problem in chocolate, is a whitening that can occur over the shelf life of a product, especially if it is stored at varying temperatures. This is something that is difficult for chocolate manufacturers to control once the product has left the factory” Milk fat is commonly-used as a bloom retarder but presents several challenges that Cobao Pure helps to solve. Unlike milk fat, this ingredient will not change the sensory qualities of the product or cause excessive softening. It is especially suitable for dark chocolate applications. It is also free from

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Food Review | July 2019

lactose and other allergens, but tests show this can fall to providing an excellent as low as one to three option for the growing months when storage free-from category. With temperatures rise by 19 per cent of free-from just two to three Sales of premium consumers saying they degrees Celsius. chocolate are growing avoid lactose or dairy The addition of three times faster than products, this offers Cobao Pure in the standard chocolate. significant potential.2 recommended range Cobao Pure is a fully of eight to 12 per cent deodorised 100 per cent of the used cocoa butter cocoa butter that is compatible retards blooming, extends with other cocoa butter and needs shelf life and significantly only to replace an amount of the existing reduces a product’s sensitivity to higher cocoa butter in a recipe. storage temperatures.

On-pack, it should be labelled ‘cocoa Marco Oomen, AAK’s global business butter', in contrast to milk fat and other antidirector for chocolate and confectionery blooming agents like cocoa butter equivalents fats says, ‘Consumers expect products and emulsifiers, which require a separate to look as good as they taste so declaration on the ingredients list. blooming poses a risk to revenue and More than two-thirds of consumers brand perception.

(69 per cent) say reading labels have 'As a product moves down the supply an impact on their purchase decisions, chain, storage temperatures can fluctuate highlighting the importance of using so an effective bloom retarder is a natural ingredients that will not disrupt a must. This ingredient delivers excellent clean label. 3 bloom-retarding capabilities without the Blooming, a common problem in formulation and labelling drawbacks of chocolate, is a whitening that can occur some other ingredients. over the shelf life of a product, especially 'It’s an exciting new solution that is set if it is stored at varying temperatures. This to make a real, positive difference in the is something that is difficult for chocolate chocolate category.’ • manufacturers to control once the 1Euromonitor product has left the factory. While it is not 2Mintel, 2017 dangerous, blooming is unsightly and may 3C+R Research. Your guide to the clean label be unappetising for consumers. It also has revolution (2017) a negative impact on the overall sensory quality of the chocolate.

The shelf life of standard dark chocolate AAK – www.aak.com is usually set at around 10 to 12 months,

DID YOU KNOW?

DISCOVER THE WORLD

OF NATURAL COLORS with plant based coloring solutions

Sensient Technologies South Africa Ltd. Email: sfc-zaf@sensient.com Tel: +27 11 053 5200 Discover colorful insights at www.sensientfoodcolors.com

C O L O U R S & FL AVO U R S

Reinventing the world of taste and smell Firmenich, the Swiss flavour-powerhouse is focusing on the African market with the opening of its new plant in Johannesburg. Food Review met with Amith Sheopershad to discuss the new facility and some notable achievements for the company this year. sites run on renewable energy by 2020, and the South African site is planned to make the transition in 2020.

Q: WHAT IS THE EXACT NATURE OF THE BUSINESS? A: We develop fragrance and flavours and partner with customers to transform their product ambitions into reality. We invest heavily into research and development, and have strategic partnerships with key academic institutes and research centre. This places us at the forefront of innovation and technology, enabling us to deliver value through our innovative range of products and solutions.

Q: WHAT IS YOUR SECRET? A: Our success is anchored by our business fundamentals: • Mutual success with our customers • Our passionate, talented and committed people are the heart of our company • Creativity is our essence • Our integrity and sense of individual and collective responsibility ensure our longterm success • Our independence gives us the freedom to control our destiny.

Q: WHAT IS YOUR TECHNICAL CAPABILITY? A: In South Africa, the business can offer application work across beverages (alcoholic and non-alcoholic), sweet goods, and savoury.

Our labs are well staffed, with 15 technical staff in total. At our newly upgraded plant in Midrand, we can produce flavours locally, warehouse these items and also offer blending capabilities to our customers.

accolades I am very proud to share is the announcement earlier this year of Firmenich been ranked by CDP as a world leader in environmental management, one of only two companies this year to achieve CDP triple “A” status for climate change, water security and forests.

This world-class distinction is testament to Firmenich’s commitment to conducting its business responsibly, with ambitious sustainability goals embedded in its strategy.

In 2015, Firmenich announced its vision to become a carbon neutral company as well as its ambitious Environmental Goals for 2020.

One of only 160 companies worldwide to have approved science-based targets, the Swiss company committed to operating with 100 per cent renewable electricity or offsets,

distributor, Flavourome in December 2017 was strategic. As mentioned, the facility has been upgraded and opened in March 2019.

The inauguration was attended by our CEO, Gilbert Ghostine, as well as customers, staff and media.

The facility’s manufacturing capabilities include: • Flavours • Flavouring compounds • Emulsions • Juice-based compounds • Snack seasonings.

Part of our overall business goal is to have our

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Group turnover is 3.7 billion Swiss Francs Average growth per year is seven per cent Number one privately owned perfume and taste company • Present in 64 countries and over 100 markets

DID YOU KNOW? In 2018, Firmenich removed 150 metric tonnes of sugar in products - thereby removing up to 600 billion calories.

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Q: ANY ADDITIONAL INFORMATION YOU WOULD LIKE TO SHARE WITH OUR READERS? A: One of the many achievements and

Q: GIVE US A LOWDOWN ON THE NEW PREMISES A: Firmenich acquisition of the, then

FACT BOX:

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30 Manufacturing sites and four R&D centres 3 800 patents currently in force Eight acquisitions in two years, with the most notable being: o Campus (US) o Flavourome (SA) o Natural Flavours (US) o Senomyx (US)

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1: Vessels were manufactured by local supplier Henry S. Komar 2: The state-of-the-art laboratory 3: Totally geared for the business of flavour creation

along with a 20 per cent reduction in absolute CO2 emissions and a 25 per cent decrease of water use in water stressed areas.

On track to deliver these goals, the perfume and taste company currently operates with 100 per cent renewable electricity across all of its US and European manufacturing sites. •

Firmenich – www.firmenich.co.za

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Food Review | July 2019

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2019 Firmenich Flavor of the Year: Hibiscus Overview 

The “Instagramable” nature of Hibiscus flowers, along with their floral and slightly tangy taste has helped propel them onto the mainstage.

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As with many popular ingredients today, hibiscus has numerous health benefits, from treating heart disease to reducing cold symptoms, making it an increasingly common supplement in teas and healthy beverages.

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Most commonly used in the form of infusions in beverages, Firmenich sees broader potential and exciting opportunities in savory applications.

Growing Appeal

Hibiscus Flavor

Health Benefits

Consumers continue to seek out new and authentic experiences in this fast-moving digital world. Hibiscus meets the need for consumers’ desire to be connected with new unique experiences, yet not straying too far from their comfort zones.

Hibiscus is more than just a flower extract. It has a strong floral aroma with a woody-astringent character, but at the same time there are subtle and delicate fruity undertones, even a hint of green, like freshly cut mint leaves. Incredibly versatile, Hibiscus is used all around the world in many cultures, from the simple street beverages up to sophisticated culinary sauces.

Consumers are acutely aware of sugar content - in particular in their beverages and their desire to replace sweetness with other flavors that help deliver sensorial impact and provide novel experiences has led to the rise of hibiscus as a flavor and active ingredient in food & beverages.

Hibiscus is… unusual yet approachable; vibrant, yet mellow, cool but not elusive.

In addition to being a sugar alternative, recent studies show promise for both the tea and the hibiscus plant extract to lower blood pressure and cholesterol levels.* *https://www.uofmhealth.org/health-library/hn-4373005

firmenich.com © Firmenich SA 2019

C O L O U R S & FL AVO U R S

A perfect synergy of meat and colour

Meat analogues are thriving. In the US, figures issued by the Plant Based Foods Association show that year-on-year sales of plant-based meat alternatives rose by 24 per cent in 20182 . Using plant-based colours will ensure vegan and vegetarian consumers find meat analogues appetising. suitable for applications where the addition of flavour is undesirable.

The other option is additive colourants, which many consumers are not interested in.

Global research commissioned

by GNT indicates that 60 per cent of respondents said they wanted products to be made without artificial colours 3 .

A third option growing in popularity is colouring food.

These are colours made from fruits and vegetables using only gentle, physical processes such as pressing, chopping, filtering and concentrating. Consequently, they are not classed as additives, but food with colouring properties.

These products qualify for cleaner and clearer labelling declarations than other colourants.

As they are plant-based, they offer a perfect DID synergy with meat YOU KNOW? lant-based meat analogues, enabling Innova Market Insights analogues are no reveals that meat alternatives manufacturers to longer niche. Sales accounted for 14 per cent of ensure products are driven by an increasing global meat-product launches have clean number of vegans and in the first nine months label credentials vegetarians, but also by of 2018, compared with without compromising six per cent in 20131 a new wave of flexitarians. on appearance or These are people looking to performance. They are reduce their overall also vegan-friendly, which meat consumption. is an important consideration in Mainstreaming of the category has the South African market, where the brought greater competition between veganism trend is on the rise 4 . brands, resulting in added pressure on There are over 400 products in the Exberry Coloring Foods range

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companies to ensure their products have strong visual appeal.

THE IMPORTANCE OF COLOUR In the past, manufacturers used one of two solutions for colouring meat analogues. One was spices - added primarily for flavour, but often delivering colour as a secondary function. Spices only provide a limited range of colour shades and are not

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Food Review | July 2019

TECHNICAL CONSIDERATIONS Colouring food is the perfect option to ensure meat analogue products look great in-store and appetising on the plate.

Solutions based on safflower, turmeric, carrot, paprika, beetroot and radish will impart a meaty colour to applications that consumers will find appealing. They are perfect clean-label alternatives to additive colourants often used in the

meat industry, such as carmine, paprika oleoresin and various carotenoids.

As with any colouring ingredient, there are several technical factors to bear in mind. When selecting shades, the original colour of the meat analogue base should be considered, since this can impact the result.

It is also advisable to focus on achieving the desired colour in the cooked product rather than the raw premix, as the application of heat will affect the final shade. If manufacturers are looking to achieve a similar effect both before and after heating, a solution would be to use colouring food rich in anthocyanins such as radish. These offer good resistance to high temperatures.

MORE THAN 400 SHADES The Exberry range comprises more than 400 shades, all obtained from fruits, vegetables and edible plants. GNT controls its entire supply chain, with cultivation and harvesting monitored by the company’s expert agronomists for a true farm-to-fork operation. This guarantees availability and ensures only high-quality raw materials are used.

GNT offers customers full technical assistance through its modern application development centres. For manufacturers of meat analogues, this level of support will ensure that their product looks good throughout its journey to the consumer’s plate. GNT’s Exberry range of products are supplied locally by Carst & Walker. • 1Green, Elizabeth ‘New meat categories? Meatless targets “hybrid” meat protein platforms’ Food Ingredients First 31 October 2018 2Nielsen, ‘U.S. Retail Sales Data for Plant-Based Foods’ https://plantbasedfoods.org/consumer-access/nielsendata-release-2018 3What Natural Really Means to Consumers (2017), GNT Group/TNS 4https://chefspencil.com/veganism-surging-in-southafrica/

Carst & Walker - www.carst.co.za

C O L O U R S & FL AVO U R S

Purées an effective option to clear the sugar hurdle Fruit purées are emerging as a viable solution for food companies as they work towards complying with challenging new rules on the labelling of sugar.

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n the US, the FDA introduced new labelling regulations in 2016 and the compliance date of 1 January 2020 is looming. The soon-to-be-implemented rules will mean that manufacturers and brands will be required to declare ‘added sugar’ in addition to the standard total sugars on nutrition facts panels – even if some of those sugars are added by way of fruit juice powders or concentrates1.

The change is forcing businesses to rethink how they formulate their products, to avoid the negative perception associated with added sugar.

A simple solution is at hand, in the form of fruit purées, says Welch’s Global Ingredients Group. Purées are not included in the

definition of added sugar and the fruit sugars naturally present in purees only need to be included in the total sugars declaration.

‘Purées deliver natural sweetness, but their sugar content isn’t considered to be added sugar by FDA,’ said Kevin Kilcoyne, vice president at Welch’s Global Ingredients Group. ‘This means they offer a good option for food companies who prefer not to see added sugar on their nutrition facts panels or wish to minimise the amount of added sugars they are obliged to declare.’

Manufacturers will still be able to use fruit juice concentrates or powders. They will need to declare some of the sugar contributed by these ingredients like

added sugar, depending on the final application. FDA regulations stipulate that the portion of sugar above what would normally be found in an equivalent volume of 100 per cent juice must be labelled as added sugar. Calculations involved in establishing this often need to be carried out manually – a cumbersome and costly process.

Using purées and purée concentrates means companies can avoid this extra burden. • 1 https://www.fda.gov/Food/GuidanceRegulation/ GuidanceDocumentsRegulatoryInformation/ ucm535371.htm

Welch’s Global Ingredients Group www.welchsgig.com.

South Africa

Within the Food Ingredients division we have developed sustainable partnerships worldwide, and offer specialised solutions from expertly qualified and trained staff.

Our suppliers are carefully selected to offer top quality products that deliver top quality results.

Johannesburg T + 27 (0) 11 489 3600

Durban T + 27 (0) 31 313 8500

Cape Town T + 27 (0) 21 506 4598

Port Elizabeth T + 27 (0) 41 399 9529

Email: info@carst.co.za Website: www.carst.co.za

July 2019 | Food Review

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C O L O U R S & FL AVO U R S

New powders deliver naturally intense blue colours to delicate food and beverages

It’s a spirulina blue breakthrough

Coloring food with food

Colouring food supplier GNT Group has developed a range of blue powders derived from spirulina, which offers a significantly higher colour intensity. These products are available in standard and micronised powder form.

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Say it with color, deliver it with EXBERRY® EXBERRY® Coloring Foods harnesses nature’s gifts to deliver colors that will breathe life into your food & beverage products. Produced only from carefullyselected fruits, vegetables and edible plants.

All premium quality products are sourced through our highly sustainable farm-to-fork supply chain and backed by our promise of optimum performance and year-round availability. Aim high with EXBERRY® for colors that really are as good as they look.

Visit EXBERRY.COM to learn more about plant-based colors

he company’s range of Exberry High Intensity Blues offers a choice of carriers, including maltodextrin or sugar. They are guaranteed to be trehalose-free, ensuring good levels of consumer acceptance.

Food and beverage manufacturers can use the powders to formulate products with high-intensity blues from a natural and traceable source - at reduced doses. These ingredients offer superior solubility and stability in several applications and are suitable for use in instant beverages, hard-panned products, fondant, white chocolate and pressed tablets.

Sonja Scheffler, product manager at GNT explains, ‘The challenge of achieving vibrant blue colours in food using only ingredients from a natural origin is well understood. Naturalness is what consumers are demanding so there is pressure on manufacturers to deliver. Our new high-intensity blue powders from spirulina will make it significantly easier to do so at lower doses without compromising on important product performance factors such as solubility and stability.’

GNT produces colouring food from spirulina in its dedicated facility in Mierlo, Netherlands. In a recent investment programme, the company doubled its spirulina processing capacity, consolidating Exberry as one of the leaders in blue colouring food.

This sector is notoriously difficult to produce. Spirulina is bluegreen algae, valued for its colouring and nutritional properties and is widely and safely consumed globally.

Exberry’s range, Coloring Foods, are colouring ingredients obtained from fruits, vegetables and edible plants using gentle, physical processes such as pressing, chopping, filtering and concentrating. Products retain characteristic properties of the source material and concentrate are not selectively extracted.

Consequently, within the EU they are not classed as food additives, but food with colouring properties and qualify for cleaner and clearer labelling declarations. Made with GNT’s own innovative processes, they can impart almost any colour shade to foods and beverages and are ideally suited for industrial use.

To ensure the highest level of quality and year-round availability, GNT controls the entire supply chain, with cultivation and harvesting monitored by GNT’s agricultural engineers. •

GNT Group – www.gnt-group.com

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Food Review | July 2019

M AT E R I A L S H A N D L I N G & WA R E H O U S I N G

Technology is critical for survival

The food and beverage industry faces a myriad of challenges, such as regulatory compliance, traceability and quality assurance. By Deirdre Fryer

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ood and beverage companies operate in a very different environment to a few years ago. This is a direct result of changing consumer demands and trends.

With increased regulations around quality and traceability, innovation is critical for survival.

Let’s look at the recent listeriosis outbreak in South Africa. Contaminated processed meats led to fatalities and brand damage, which is hard to bounce back from. Regaining consumer confidence is a mammoth task, and endless campaigns may not salvage a brand once it has been tarnished.

This outbreak highlighted the need for better quality products, enhanced traceability and stricter adherence to regulations. It’s also a clear example of how having preventative measures in place is far easier than recalling products and doing damage control. Long term, it’s more cost-effective too.

The American entrepreneur and farmer, Ezra Taft Benson summed it up perfectly, ‘It is better to prepare and prevent than it is to repair and repent.’

The demand for innovation couldn’t come at a better time. With advancements in technology, a company can keep tabs on the entire process, thereby avoiding recalls and public prosecution.

REDUCE PRODUCT RECALLS These have risen significantly over the past decade. Increased regulations and harsher penalties, growing consumer awareness and the uptake of social media are just some of the contributing factors.

A report by Allianz Global Corporate & Speciality reveals that the food and beverage industry is the second most

impacted sector in terms of product recalls. It accounts for 16 per cent of analysed losses, with the average cost of a major recall claim nearing US$9.5 million or roughly R134 million.

Using technology, a company can reduce the likelihood of product recalls as every step of the process is monitored. If errors do occur, the business is better equipped to pinpoint exactly what went wrong.

QUALITY ASSURANCE Ensuring the quality of raw materials, such as ingredients, processing aids and packaging is essential in the manufacture of most finished food products. The ability to monitor and track all these components allows a company to meet its specifications and regulatory requirements.

This process is not as simple as it used to be. Increased access to complex materials, global sourcing, handling methods, customer locations, plus regulations requires a team of experts.

With the help of technology, a company can overcome such hurdles.

IMPROVE TIME TO MARKET Constant innovation is a key factor if businesses want to remain competitive.

Ongoing research and development into

new and improved products are integral to the industry. Shorter product life cycles mean the speed that companies deliver these innovations to the market is critical if they want to stay ahead of the game and remain profitable.

ENHANCE TRACEABILITY To meet the stringent requirements of the Food Safety Modernisation Act and the Safe Quality Food Standards, companies can harness technology to identify and trace every ingredient consumed in the manufacturing process. This works from receipt through processing, packaging and shipping to customer location. Whether used for compliance or as an analysis tool for continuous improvement strategy, traceability is vital for companies. •

Syspro – https://za.syspro.com/

Grow Your Business with SYSPRO ERP Software for Food Manufacturing.

For more information or to arrange an appointment, please contact us on 011 461 1000 or info@za.syspro.com.

Copyright © 2019 SYSPRO (Pty) Ltd. All rights reserved. All brand and product names are trademarks or registered trademarks of their respective holders.

July 2019 | Food Review

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M AT E R I A L S H A N D L I N G & C O N V E Y I N G S YS T E M S

Accuracy and efficiency through real time visibility Zetes has installed a state of the art shipping verification solution for a company specialising in the production of coleslaw, wet and side salads, soups, sauces and mayonnaise to retail and food service customers. The system will enable 100 per cent shipping accuracy, efficiency and real-time supply chain visibility.

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s a supplier to M&S, Irish-based Avondale Foods were faced with the challenge of overhauling its outbound shipping systems to comply with the retailer’s new requirements for improved inbound logistics visibility.

Delivery lead times are very short with orders typically received at 6 AM for shipping accuracy for despatch the same day. Speed and the absolute elimination of shipping errors is paramount to efficiency and on-time service commitments. Previously, Avondale used RFID as a means of verifying shipping contents prior to transportation. This is no longer suitable for increased speed and accuracy required.

FASTER SHIPPING WITH 100 PER CENT EVIDENCE BASED ACCURACY In consultation with Zetes, who had also provided M&S with their real-time visibility platform for their food supplier network, Avondale opted to implement an automated image based data capture solution for their Advance Shipping Notification (ASN) process. Incorporating

Lockers

Zetes’ unique camera based ImageID technology, the solution dramatically reduces the entire shipping verification process time, with 100 per cent accuracy and no human errors or additional tag costs.

It achieves this through capturing a full view of the loaded totes, rapidly detecting and decoding their multiple barcodes simultaneously, with 100 per cent accuracy. Instantaneously, it compares barcode data to shipping orders providing operators with real-time visual alerts about any discrepancy while pinpointing missing or unreadable labels. Digital images are stored for visual evidence.

Upon confirmation that an order is correct, ASN data is captured in Avondale’s host system and M&S’s visibility platform simultaneously. John Ferguson, head of supply chain at Avondale explains, ‘We initially set out to solve one challenge that had caused our existing RFID solution to be no longer fit for purpose. In speaking with Zetes it became apparent that by implementing their ZetesMedea shipping verification solution we would not only realise complete compliance with our customer’s updated ASN requirements, but also benefit from increased accuracy through automated processes and greater visibility.’

Alain Wirtz, CEO, Zetes adds, ‘We are delighted to be working with Avondale Foods and pleased that ZetesMedea will be used to help improve operations across the business and allow them to respond effectively and efficiently to new market challenges. The introduction of a single system will not only ensure compliance with a key customer but it will also allow them to reduce complexity and build a solid foundation for other potential visibility and traceability projects in the future.’ •

Zetes – www.zetes.com

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Food Review | July 2019

HYBRID DRINKS

Efficient and optimised bottling line increases profits Caribbean Bottling Company invested in a Sidel PET complete line to cater to the increased demand for water and juice. The new line gives the Haitian bottler the flexibility to tackle future production requirements and the possibility to develop an optimised packaging solution.

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aribbean Bottling Company (CBC) products are subject to rigorous testing for hygiene and quality and meet stringent legal requirements, including those of the International Bottled Water Association. CBC also produces and distributes a wide portfolio of juice and teas.

Gaetan Barrau, CBC CEO explains, ‘Delivering a safe and high-quality product with consumer and pricefriendly packaging is challenging. Sidel offers longstanding expertise in PET packaging design and equipment.’

SAVING SPACE AND RESOURCES The partnership between the two companies started a few years ago when the Haitian bottler installed a Sidel standalone blower. This was intended to serve a complete line of mineral water.

Due to the positive growth in the local beverage market, the company needed to increase its production capacity. It decided to install a new PET complete line. ‘We thought about enlarging our plant and building an additional area to accommodate the new line. Partnering with Sidel, we could leverage a very compact layout and locate the new line in an existing area of the factory,’ Gaetan enthuses.

The PET complete line handles lightweight bottles in various formats while optimising energy consumption.

‘The support we received from Sidel

proved instrumental to understanding the specific conditions experienced by our bottles throughout the value chain from production to distribution. Thanks to this partnership, CBC shifted from just making a bottle, to efficiently and effectively making a bottle.

ANTICIPATING FUTURE NEEDS Installation of the new PET line started at the end of 2018 and was completed in March this year. Processing juice drinks and iced tea, the line features a Sidel Matrix Combi. The system can deliver a 30 per cent less maintenance downtime and up to 12 per cent reduction in the total cost of operation. This is complemented by a Sidel RollQuattro Evo labeller plus an end-of-line solution, including shrink-wrapping and palletising systems.

The Combi installed at the facility features Sidel’s BlendFILL system. By combining the mixer and filler in a single system, it allows for quality beverages while reducing floor space and the environmental footprint of the company.

By choosing this configuration, CBC is gaining flexibility and anticipating future production requirements.

The entire line’s efficiency will be tracked and optimised with Sidel’s Efficiency Improvement Tool (EIT) system. This assists in enhancing productivity through real-time access to relevant and actionable information on Sidel equipment is focused on energy and raw material savings

performance, quality, efficiency, losses and other production-related possible failures.

PACKAGING DESIGN FOR EFFICIENCY AND STABILITY A key requirement for CBC was developing a bottle that can withstand challenging distribution conditions. It must also protect the product, improve the consumer experience and secure an affordable price – the latter is a key requirement for CBC. Gaetan highlights, ‘Typically, those drinks are sold frozen along the streets by local retailers. The bottle is intended to resist below zero temperatures without compromising on stability and attractiveness.’ This is where the proven Sidel RightWeight bottle concept comes into play.

‘At Sidel, we are concentrating our innovation efforts around the RightWeight approach, making sure the packaging is fit for purpose. This means ensuring the bottle is robust enough to withstand transportation and distribution challenges and delivers performance - from the onset of production to the moment it reaches the consumer. The way we branded this concept is quite powerful. It clearly reflects the need to match a great performance level while reducing total cost of ownership.’ he concludes•

Sidel – www.sidel.com

The PET complete line handles lightweight bottles in various formats

July 2019 | Food Review

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HYBRID DRINKS

Stevia offers natural flavour innovation The food and beverage industry has seen a rapid increase in demand for natural ingredients including flavours and sweeteners. Consumers are becoming nutritionally aware and are seeking out simpler labels and natural solutions.

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ealth experts and governments are also looking for new ways to address growing health concerns related to obesity and diabetes. Regulatory pressures, in the form of taxes and levies, are driving the need for natural sweeteners. These will see further adoption by global brands.

Stevia leaf ingredients offer a solution and are primed to become an important tool for food and beverage companies.

Stevia plants contain natural, non-GMO, zero calorie ingredients, which work well in a wide range of reduced sugar food and beverage applications. As innovators in the production of stevia leaf ingredients, PureCircle has developed a range of sweeteners and flavour modifiers to assist formulators in achieving this goal.

The company has mapped the entire stevia leaf genome to better understand what exists within the stevia plant. This enables the company to isolate specific

Stevia offers formulators reduced calorie options when developing new products

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Food Review | July 2019

compounds for flavour modification and other technical functions, including sweetening properties. It has also optimised flavour modification compounds in the stevia plant to create tools with various functions like bitter masking, sweetness onset and other flavour enhancement.

Stevia leaf flavours can significantly boost specific flavours like vanilla, cocoa and citrus amongst others.

These stevia leaf flavours can be labelled as ‘natural’ on product ingredient labels.

This allows food and beverage companies to modulate flavours and optimise usage levels of such flavours like cocoa and vanilla. These new products will allow developers to reduce the amounts of cocoa, vanilla, etc. alongside sugar - without compromising taste.

In addition to boosting and improving flavours, stevia leaf ingredients add complexity and subtlety to the overall flavour. This assists with flavour management and improvement, including the ability to mask the aftertaste of plant proteins or other ingredients. There is strong demand for these ingredients and their availability in emerging applications (e.g. savoury).

The story of stevia is evolving rapidly. Not long ago, it was viewed as a plant-based, zero-calorie, single-ingredient sweetener, which worked well in some product applications. Pure Circle now offers a range of stevia leaf ingredients, including flavour modifiers and sweeteners like Reb M, which have great taste and zero calories.

PureCircle has isolated specific stevia compounds for flavour modification

THE RAPID RISE OF STEVIA In 2018, the number of new products using the ingredient grew approximately 31 per cent. That compares to an 11 per cent increase in 2017. That means the growth rate last year nearly tripled. In looking separately at product launches with stevia last year, the increase was 36 per cent for beverages and 27 per cent for food, according to figures released by the Mintel Group*.

Stevia is the next generation solution for natural flavour modification and sweetness.

PureCircle collaborates with companies to make formulating with stevia simpler and offers tailored stevia solutions designed to work optimally in different consumer product categories. PureCircle is supplied locally through Savannah Fine Chemicals. • *The data reflects new product launches from January-December 2018 compared to JanuaryDecember 2017 and was extracted from the Mintel Global New Products Database in April 2019.

Savannah Fine Chemicals – www.savannah.co.za

B E V E R AG E P R O C E S S I N G T E C H N O L O GY

Strategic focus and market demands an extensive upgrade Air Products was well-poised to respond when the market demanded an increase in the supply of carbon dioxide (CO2). The company invested R100 million in a CO2 expansion and refurbishment project at its KwaZulu-Natal facility and an upgrade at Natref in Sasolburg.

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he food and beverage industry is the largest consumer of CO 2 . It has been identified as a target market in line with the long-term strategic vision for the CO 2 business at Air Products.

Air Products’ gaseous CO 2 facility in Newcastle has the capacity to produce and recover large quantities of carbon dioxide from blast furnace off-gas. The facility’s capacity to liquefy gas was extremely limited.

The bulk business was awarded a large tender to supply one of South Africa’s largest beverage manufacturers. This resulted in a definite need to invest in a new liquefier to complement the existing liquefaction plant and utilise the excess gaseous CO 2 production capacity available at the Newcastle facility.

Charles Dos Santos, general manager on sites, explains what the project entailed, ‘The scope of the CO 2 expansion and refurbishment project started early in 2017 and was quite extensive.’ The project was executed in three parallel streams, which required the installation of a new liquefier; the addition of two

liquid storages and the refurbishment of the existing gaseous CO 2 production facility.

‘The refurbishment part of the project was extremely challenging as work had to be done on a facility that was operational. This allowed the refurbishment team limited opportunities to undertake the necessary refurbishment, upgrades and tie-ins as the operations allowed.

As the existing plant was completed in 1998, and its full capacity had not been used since 2013, the condition of the equipment and scope of work could not be assessed until the equipment could be dismantled and inspected internally,’ Dos Santos explains.

The project also included improvements with regards to water utilisation and energy efficiency.

Even though there was an extremely tight deadline, the project was completed on time and exceeded its design performance.

Air Products is fortunate to have highly skilled employees with various skills sets required to execute a project

“The overall investment in the project has enabled Air Products to costeffectively and optimally utilise its assets to expand rapidly to meet the market’s increased CO2 requirements” of this complexity. ‘The key role players in the project consisted of a multidisciplinary on-sites projects team based at the Vanderbijlpark and Newcastle facilities. As with most projects of this nature, you encounter challenges. The team adapted and managed challenges exceptionally well. We are focused on maintaining high safety standards, and this remained a key priority. Besides the on-sites teams, the supply chain and quality teams were also instrumental in the process,’ Dos Santos enthuses.

Quality is an important aspect of Air Products’ operations and depending on

Air Products’ bulk tanker, ready to load from two new carbon dioxide storage tanks at the Newcastle facility

July 2019 | Food Review

35

B E V E R AG E P R O C E S S I N G T E C H N O L O GY

the application there are varying specifications required by customers.

CO 2 is produced for Air Products from two different sources – the Newcastle facility and the Natref refinery in Sasolburg.

CO 2 is produced at these sources per the International Society of Beverage Technologists (ISBT) specifications as a minimum quality specification and is used for food and beverage applications. The CO 2 used for the food and beverage customer applications is required to be tested and supplied with a certificate of analysis (COA).

The COA is issued to the customer upon delivery of the product.

Abdul Shaik, operational risk manager explains, ‘Prior to the upgrade project, the CO 2 produced at the Natref Facility had to be transported by tanker to the Air Products Vanderbijlpark facility where it was tested and a COA was issued by the Vanderbijlpark Quality Control (QC) Laboratory. This caused inefficiencies in our road tanker fleet and unnecessary time delays, ultimately impacting on the overall service delivery to the customer. With the upgrade, a laboratory and analyser were installed at Natref enabling on-site testing. Laboratories located at both the Natref and Newcastle facilities ensure the quality is verified at source - leading to an improvement in customer service.’

“Laboratories located at the Natref and Newcastle facilities ensure the quality is verified at source. This leads to an improvement in customer service”

The overall investment in the project has enabled Air Products to cost-effectively and optimally utilise its assets to expand rapidly to meet the market’s increased CO 2 requirements. The upgrade project resulted in a substantial increase in the liquid CO 2 production capacity as well as the diversity of supply to customers.

The upgrade project had a huge impact on Air Products’ supply chain business. It is now fully geared to confidently offer a secure supply of CO 2 to support the market growth and growing its footprint in the food and beverage market.

Seelan Gounden, general manager supply chain, explains that supplying larger volumes of CO 2 is perceived as challenging to most companies. ‘Air Products has been extremely cautious. We did all the necessary forecasts and projections to ensure our decision is responsible and will benefit the organisation in the long term.’

Dos Santos and Gounden agree the completion of this project is a noteworthy achievement for Air Products in many ways. Utilising existing assets and improved efficiencies address the continuous strive towards improvement and innovation. Gounden concludes, ‘Air Products' entire value chain has been impacted by this upgrade and we are pleased with the increased diversity of production sites and storage capacity. We are also ensuring we optimise our modern fleet by doing fewer trips and reducing our carbon footprint. We are looking forward to providing a secure supply of CO 2 to our existing customers as well as to grow the CO 2 market.’ •

Air Products – www.airproducts.co.za

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Food Review | July 2019

E N D O F L I N E PAC K AG I N G

Bag closures for all applications Buckle Packaging offers solutions for closing bags of different materials neatly and securely.

T

he company has 40 years’ experience and knowledge in supplying the right equipment for different product packs - either by heat sealing or stitching. Buckle Packaging operates from company-owned premises in City Deep, Johannesburg.

‘Our location allows us to deliver to the Johannesburg Fresh Produce Market daily, servicing our farming clientele with their packaging needs,’ explains managing director Anthony Mason. ‘Our products include the Fischbein range of industrial bag stitching machines, suitable to close any open mouth bag filled with a range of products from maize, flour, pecan nuts, macadamia nuts, sunflower seeds, potatoes, sugar, fertiliser and other non-agricultural products.’

The equipment range varies from portable handheld stitchers through to automated heavy duty in-line stitchers capable of highspeed bagging. Fischbein technology can be adapted successfully to most packing lines.

‘We have many farmers throughout South Africa and neighbouring countries using Fischbein stitchers in their pack houses, sewing thousands of bags daily.

The result is a neat closure, easy handling, rapid closing times and no tampering of the product,’ Mason continues. ‘The same applies to macadamia and pecan nuts that are either transported around the country or exported to other parts of the world. The bags best suited to stitching are paper, woven polypropylene, laminated, BOPP, bag netting and hessian/jute bags.’

If the product is packed into LDPE plastic bags or clear polypropylene bags, Buckle Packaging offers the Saxon range of hot air or band sealers as a solution. The FischbeinSaxon machines are a new generation of continuous sealer that represents advanced bag sealing technology. It features the latest innovation in PID temperature-control, innovative direct drive and enhanced airflow

design. This guarantees a high-efficiency transfer system that seals thicker bags with ease.

The machine is ideal for sealing bags from 100g to larger bags of 50kg and is

“The equipment range varies from portable handheld stitchers through to automated heavy duty in-line stitchers capable of highspeed bagging” proven to be a reliable, low maintenance unit. Buckle Packaging has been selling the Saxon sealers to the dried fruit, nut, sugar, vegetable, fruit, poultry and meat industries for many years.

‘In conjunction with the equipment we sell, we offer a full range of consumables

Fischbein range of industrial bag stitching machines

such as back up spares on all the equipment.

We have a range of bag closing thread in various colours and sizes, mainly used for identification purposes. This massive investment in stock holding shows our commitment to growing the business and forming partnerships with our clients for years to come,’ Mason adds.

‘We have a team of knowledgeable sales staff and technical support available to offer you a solution to your packaging needs.

40 years in the industry has allowed us to show our commitment to offering the best machinery and consumables at affordable prices,’ Mason concludes. •

Buckle Packaging – www.bucklepack.co.za

Saxon SB1000 continuous hot air sealer

July 2019 | Food Review

37

E N D O F L I N E PAC K AG I N G

Ultra-automated packaging line boosts productivity and turnover An Italian based biscuit company sources and uses ingredients with no artificial flavours, colours, preservatives or dehydrated products. The use of high-quality ingredients constitutes a significant proportion of the cost of production.

T

he company decided to take certain steps to remain competitive.

It developed a strategy based around investment in the best possible manufacturing practices and equipment.

‘We believe that these investments are the best way to ensure the development of the company,’ explains Stefano Cabrioni, president of Cabrioni. ‘We’ve invested heavily in infrastructure and automation, selecting highly qualified suppliers with established strategic partnerships. This approach has allowed us to obtain a positive return on investment in a relatively short time.’

‘At the production level, our philosophy is to invest in quality high-tech machinery to optimise the packaging process and minimise waste and machine downtime for repairs,’ Cabrioni notes.

Over the last 20 or so years, the company has gradually expanded its space-optimised production area, which today extends over an area of 15 000m2. This expansion has gone hand in hand with major investments in the automation of the manufacturing line. This includes two lines dedicated to the production of wafers. The manufacturer replaced manual packaging processes, which could only handle 50 per cent of the oven’s

The IF318 Monoblock line was commissioned in 2019

production, with a new fully robotised Cama packaging line.

The packaging line was engineered and installed in 2018 by Cama. It comprises an IF318 Monoblock fully robotised twoaxis loading system with integrated box forming/loading/closing units, and an FW748 wraparound case packer.

The robotic monoblock system and the wrap-around case packer are part of the Break-Through Generation (BTG) range from Cama, which incorporates the latest technological innovations.

These include higher sanitary standards, open profiles, improved integrated cable system routing, flexible and compact

BUCKLE PACKAGING (PTY) LTD Bag Closing Technology

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Food Review | July 2019

“The manufacturer replaced manual packaging processes, which could only handle 50 per cent of the oven’s production, with a new fully robotised Cama packaging line”

configuration, enhanced ergonomics, user-friendly controls, energy-saving engineering and easy format-change thanks to RFID technology.

In the loading unit, format changeover is achieved by initiating a recipe change

E N D O F L I N E PAC K AG I N G

in the HMI, followed by the replacement of some mechanical parts. These are determined by blank sizes. In the wraparound machine, the changeover is performed exclusively by interactions with the HMI. The line is capable of packing 330 cartons per minute, with 22 per wraparound case. In operation, flow-wrapped wafers are packed by vacuum-cup-equipped robots into boxes that have been formed from blanks in a parallel module. These boxes are then glued and closed before being conveyed to the case packer, where they are loaded into pre-formed wraparound shipping or shelf-ready cases.

These display cases are then closed and sent to a palletiser.

The machine is also equipped with a special photocell device for quality control. It can identify issues such as non-glued flaps, where cases can be rejected onto a free roller conveyor at the machine’s outfeed.

Electrical cabinets have been integrated into the machine structure to gain space, while the "easy entry" solution guarantees safe and ease of access for maintenance and cleaning. The magazine has been positioned at 800mm height for improved operator ergonomics.

Hit all your inspection targets

The line is capable of packing 330 cartons per minute, with 22 per wraparound case

Cabrioni owns three Cama packaging lines. The renewed confidence in the Italian machine builder was backed up by the new line’s short return on investment coupled to increased production efficiency and significant labour savings. ‘We appreciate the solution proposed by Cama for the simplicity of the process and the reliability of the system that guarantees an efficiency rate over 95 per cent,’ Angelo Cabrioni points out.

The company also invested in its logistics structure, which includes a fully automated warehouse managed by Automated Guided Vehicles. These units collect the pallets at the end of the line and place them on the special vertical racks in a preestablished order, before loading onto trucks.

Thanks to this continual investment in modern infrastructure, Cabrioni has a turnover that has increased at a rate of five per cent per year since 2012. The company is also aiming to increase its domestic and export sales volume, especially in areas where it is less established.

This will be achieved with the expansion of its product range, from prepared cakes through to ready-to-cook ingredients. A new 3 000 m2 factory expansion, adjacent to the main plant, will also be ready by the end of this year. •

Cama – www.camagroup.com

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5/28/2019 12:37:42 PM July 2019 | Food Review

E N D O F L I N E PAC K AG I N G

Inspection systems ensure immaculate snack packaging A German potato chip brand is maintaining excellent quality control on its upgraded high-capacity packing lines. The company produces 12 different pack formats with fill weights ranging from 20 to 200g.

W

hen the company’s end-of-line packaging systems were automated in 2018 it resulted in the upgrade of quality control facilities. Employees previously checked the density of sealed packets by hand and weight monitoring was a matter of spot checks.

Ishida’s range of sealtesters and checkweighers delivers a seamless, reliable quality control solution. It can operate at speeds of up to 85 packs per minute for a 115g bag, with only the upstream systems preventing them from achieving even higher speeds. ‘Ishida was the only supplier to offer sealtesters and checkweighers in one package,’ explains André Wurz, technical manager at the snacks producer.

Ishida TSC-RS sealtesters form part of a fully automatic inline system that can detect Ishida’s DACS-G The range of Ishida leaks with diameters of just three checkweighers TSC-RS sealtesters millimetres at speeds up to 150bpm. ensure that all As packs are full of fragile crisps, finished packs careful handling from the sealtesters is a comply with relevant particularly useful feature. Crisps wedged at regulations, rejecting any that fail to angles inside the packets can often create meet specifications. Checkweighers bulges, especially in smaller bags. Special further minimise product giveaway due brushes smooth out these lumps and bumps to overfilling. The machines’ high-speed before the packets are inspected. loadcell delivers accuracy to within 0.2g, Packs are delivered to the sealtester's while a special system compensates for inspection head in the most effective way floor vibrations. possible, enabling it to test the seal integrity Operators can switch between two of every pack inline automatically. A servosettings at the touch of a button, which driven pressure head allows the system to means the checkweighers can be used for exert ideal pressure without damaging the a larger product range. In conjunction with packaging or its contents. quick changeovers, this makes the Ishida TSC-RS sealtesters can detect a wide DACS-G models ideal for the processor’s range of defects. Packing material or product snack requirements. The robust design residue burnt onto the sealing jaws of the also features a dislocating force limiter bagmakers can sometimes result in pinholes function. This disconnects the highly in the heat seal. Bits of product often find sensitive weighing sensor from the their way into the bottom seals of the crisp belt before it can suffer any permanent bags during filling. This could prevent the damage from external impacts. It then packs from sealing correctly. immediately resumes operation.

The system will also identify packs Checkweighers incorporate Ishida’s Data with holes in the seal areas. Packaging Capture System (IDCS II) web-based software. that has not been sealed correctly and This system collects data about every single has open seals, or those sealed but the pack. This provides valuable information that pack thickness is outside the set limits can help snack producers boost productivity. will be rejected by the sealtester during IDCS can carry out real-time analyses an inspection. The machine can identify based on product batches, shifts, operators, faulty bags caused by problems in the products, machines or lines. Graphic displays upstream bagmakers. and reports are user-defined and can be

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Food Review | July 2019

The snack producer produces 12 different pack formats in weights from 20 to 200g

customised. Parameters can be accessed online during production and direct process adjustments can be made. Ishida software is compatible with systems such as SAP or SCADA and data transfers can be carried out to programmes such as Microsoft Word, Excel and Adobe PDF. The combination of checkweighers and data analysis is a control function the manufacturer considers very useful from a business management point of view. If figures produced do not match the targets, the operator can immediately make the appropriate adjustments.

‘IDCS II tells us what we need to know about line output,’ Wurz confirms, adding that the software is also very interesting for his colleagues in quality assurance. ‘With IDCS II, we can log every packet of crisps and then pass these logs onto our customers.

They can then use the system on a mobile device even when away from the factory.’

The Ishida systems work faultlessly in three-shift mode. Operators can carry out product changeovers, which usually take place twice daily, very quickly by calling up pre-sets. ‘We have maintained full and exceptionally reliable quality assurance while saving on expensive manual labour at the same time,’ Wurz concludes. •

Ishida – www.ishida.com

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ADVERTISERS’ INDEX JULY 2019 ABB South Africa................................19......www.new.abb.com Azo Group.............................................36......www.azo.com Buckle Packaging................................38......www.bucklepack.co.za Carst & Walker.....................................29......www.carst.co.za Crest Chemicals .................................34......www.crestchem.co.za Dexion Storage Solutions ..................32......www.dexionrackingandshelving.co.za Eptech Products .................................42......www.eptech.co.za Firmenich..............................................27......www.firmenich.com GNT Group ..........................................30......www.exberry.com Hahn & Hahn Inc..................................5......www.hahn.co.za

Hanna Instruments........................ OBC......www.hanna.co.za Heat & Control SA ................. 13, 21, 39......www.heatandcontrol.com Jelatech ................................................22......www.jelatech.co.za Koelnmesse GmbH...............................7......www.anuga.com Sensient.................................................25......www.sensientfoodcolors.com Symrise SA ......................................OFC......www.symrise.com Syspro ...................................................31......www.za.syspro.com Tomra Sorting .....................................17......www.tomra.com Vivit Foods......................................... IFC......www.vivit.co.za

July 2019 | Food Review

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Anita Raath

Sales executive +27 (0)82 976 6541

Carla Melless

Sales executive +27 (0)83 260 6060

Candida Giambo-Kruger Sales executive +27 (0)71 438 1918

Daleen Filbey

Sales executive +27 (0)83 409 3119

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METROHM SOUTH AFRICA Metrohm SA is a subsidiary of Metrohm AG, a leading Swiss company. We are a regional support centre for all sub-Saharan countries, including Mauritius and Madagascar.

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