SOUTH AFRICAN
www.foodreview.co.za
Journal for food and beverage manufacturers JULY 2020 Vol. 47 • No. 07
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Creating hope through flavour pioneering
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CONTENTS JULY 2020 | Vol. 47 • No. 07
PAGE
24
PAGE
12 “South Africa is considered one of the world’s top growers of citrus fruits. Symrise, the international flavour and fragrance specialists, can supply customers and consumers with this valuable raw material.”
Robotics – the food industry’s renaissance 6
NEWS
24
ROBOTICS & AUTOMATION
Polyoak Packaging reaches out during COVID-19
Get ready for a robotics revolution!
First locally produced cannabis extract exported
New faces at Coca-Cola Africa and the Middle East
34
METAL DETECTION & INSPECTION
Get inspired with new product inspection technology
Tongaat finalises the sale of Namibian asset
Quality checks with X-ray
Info to be supplied in listeria lawsuit
EnviroServ assists with dough waste solution
37
HYBRID DRINKS
Global food ingredient suppliers announce distribution agreement
Heavy beverage loads just got lighter
A significant milestone for local producer
A first in UHT liquid dairy
10 COVID-19
Food security a major concern
39
END-OF-LINE PACKAGING
Are you getting the most out of your vacuum pump?
11
INDUSTRY TALK
Mono-lidding trays and film – perfect for the meat industry
Time to rethink tough transport height restrictions
Syntegon Technology comes of age
Flexible and agile – the changing face of packaging
A new wave in potato packing
14
COLOURS & FLAVOURS
Total tape-sealing solutions
Botanicals add a healthy kick to new products
Quality and consistency in secondary packaging
Get the edge with plant-based colours
Multivac’s latest packaging lines
Bump up your no-alcohol beverages
Charter commits to sustainable future
20
MATERIALS HANDLING & WAREHOUSING
Get a warm feeling with the right storage support
How to improve your inventory logistics
COVID-19 forces the container industry to adapt
Meat Review All the latest information on meat processing technology and ingredients and how it impacts you in our special supplement!
PAGE
25 July 2020 | 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: Peter Anderson, Maluta Netshaulu
Funding underway for COVID-19 food testing
T
he rapid detection of coronavirus on food processing surfaces is becoming a reality. Five European companies and research institutions have received funding from EIT Food to build a diagnostic platform to improve on-site testing capacity in the food industry, which will deliver results in less than one hour. The joint partnership between SwissDeCode, Microbion, IATA CSIC, University of Helsinki and Eurofins has been awarded €790 000 as part of the COVID-19 Rapid Response Call for Innovation project. In light of the challenges faced by the food industry, monitoring of the virus continues to be a must, even in a post-crisis phase. The platform will allow the industry to minimise the chance of disruption caused by contaminated working environments or food products. The platform is an automated testing device, installed directly at food processing facilities, providing results in less than one hour with no need for complex instrumentation or specialised personnel. The flexibility of this technology allows for the incorporation of a varied group of tests within the food industry, including for other emerging viruses. The development and validation of the device will be ongoing during the next few months and the partners expect that it will be market-ready by the end of the year. This is fantastic news for the food and beverage industry – and a key innovation highlight for the year! Staying with health, did you know that one in every two consumers are concerned about their health? In the Colours & Flavours
feature we bring you the latest in the growing market for botanicals (page 14 and 16), and continuing with the topic of food safety, how to ensure quality and food safety with product inspection technology. Turn to page 34 for the full story. A comprehensive feature on end-of-line packaging round off this edition. Find all the information on page 39. You might have heard official confirmation that SIAL Paris 2020 has been postponed to 2022. The news is not unexpected, but still a big knock for the global community. When the pandemic started, our team took the hard decision to postpone the Food Review/ Symrise New Product Competition to next year, although we are still accepting entries and new products launched throughout this year. Prepare for a bumper event! Please let me know if you have any queries at maryke.foulds@newmedia.co.za. Happy reading and stay safe!
ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmedia.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 càndida.giambò-kruger@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 felicity.garbers@newmedia.co.za PUBLISHING TEAM General Manager: Dev Naidoo 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 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
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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
4
Food Review | July 2020
Managing director of Symrise South Africa; chairman of SAAFFI.
Rudy McLean
Food Review is published by New Media Publishing (Pty) Ltd 11 times a year and circulates to executives in the food and beverage industries. Views expressed in this journal, other than where specifically stated, are not necessarily those of the publisher. The editor welcomes for publishing consideration news items, press releases, articles and photographs relating to developments in the food and beverage industries. No responsibility is accepted should contributions be lost.
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Food Review | July 2020
Polyoak Packaging embraces its role during COVID-19
B
efore the lockdown commenced on 26 th March 2020, Polyoak had preventative measures and internal communications in place that exceeded government regulations. Group managing director, Jeremy Mackintosh says, “We salute our customers and suppliers who continue to support us through the lockdown, as well as our dedicated employees working under difficult conditions, to ensure that we don’t let our customers and the nation down. We remain focused.” The company is involved in the following innovations and community initiatives: • New bell bottle range Polyoak launched a range of 28mm neck bell bottles with trigger sprays to facilitate the dispersion of liquids such as cleaning detergents, sanitisers and pesticides. • PET medical spacer Bridged the gap between expensive commercial asthma spacers and the need in low-income communities, by creating a custom blow-mould base with an indentation in the shape of an asthma pump nozzle. • Face shields Ergonomically designed for comfort, being lightweight and spacious enough to accommodate goggles or spectacles to be worn underneath. These fully recyclable face shields provide secure and comfortable personal protection. • Supporting recycling and communities Donated nearly one million Rands to The Waste Pickers organisation to provide electronic food vouchers for around 5 000 registered collectors and partnered with the Umgeni Relief Network to help distribute 10 000 food parcels. Invested over R5 million in community initiatives through the Solidarity Fund, Waste Pickers and Gift of the Givers. Partnered with the Peninsula School Feeding Association and Philisa Abafazi Bethu. Assisted the Peninsula School Feeding Association (PSFA) with the emergency distribution of 13 000 food parcels and in Gauteng partnered with ACFS, a community education and feeding scheme that supports under-resourced townships and communities of Soweto, Alexandra, Thembisa and Tsakane. •
NEWS
Packaging and processing show now set for 2022
P
utting customers first is the motivation behind the decision to postpone Ipack-Ima. The event has been rescheduled to take place from 2 to 6 May 2022. “The decision was not easy. After careful evaluation and insight, we preferred to give priority to the needs of our exhibitors and visitors who are engaged in the management of a very tricky period,” Valerio Soli, president of Ipack Ima srl explains.
Trade fairs are experiencing a situation that no one could have foreseen. The ability to aggregate projects with high added-value is part of a medium to long-term strategy, which will kick off in May 2021. MeatTech – the Ipack Ima trade show specialising in solutions for meat products and the ready meals industry, will take place in conjunction with TuttoFood from 17 to 20 May 2021. •
Ipack-Ima has been postponed
Rockwell Automation hosts second successful VirtualConnect
T
he company ran its second international online technology event on 23 June. VirtualConnect provides the industrial automation sector with the latest news and information on technologies that enable digital transformation in the processing industry. The occasion featured three tracks of video presentations, with live Q & A from the speakers. Jan Van Den Bossche, director of product business units EMEA at Rockwell Automation, says, “Building
on the success of our previous event, we are excited to bring you another virtual experience with new and different technology. We will focus on how technology enables smart manufacturing and we are here to help you on your road to digital transformation. “Successful transformation also relies on the people using the technology. We hope that this event provides you with some inspiration on how to successfully achieve digital transformation in your plant,” he concludes. •
First locally-produced New faces at Coca-Cola Africa cannabis extract exported and Middle East
A
friplex is currently the only licenced GMP cannabis manufacturer in South Africa. The company processed the first exported cannabis from licensed local cultivators. “The first legal extraction of cannabis is a huge achievement for Afriplex and South Africa and the country is poised to become a major player in the international cannabis industry,” says Danie Nel, managing director of Afriplex. “As new markets open, we will be able to export to any country that is legally allowed to import and sell these products. As demand grows, so will economic development opportunities, especially since South Africa offers a safe and stable business environment in subSaharan Africa and is seen as a gateway to the rest of Africa.” Afriplex has a fully-integrated approach to the cannabis market, offering processing services and tools for the manufacturing of cannabis-based finished products. • Cannabis plant
T
he Coca-Cola Company announced the appointment of Matrona Filippou as its business unit president for the Southern and East Africa region. Previous appointee Bruno Pietracci has taken up his position as Africa & Middle East president. “Despite the challenges that COVID-19 presents for businesses at this time, I’m optimistic that new opportunities across the Southern & East Africa region will arise. “The Coca-Cola Company remains focused on ensuring its products are delivered safely to stores and communities, while taking every precaution to curb the further spread of the virus,” Filippou says. “While this is an extremely challenging time from a global economic perspective, Africa and the Middle East present exciting opportunities to scale our capabilities and make our business stronger. These key
regions remain an important driver of our overarching growth strategy over the next decade,” Pietracci concurs. •
July 2020 | Food Review
7
NEWS
Tongaat finalises sale of Namibian assets
J
SE-listed sugar manufacturer Tongaat Hulett has announced that all conditions precedent to the sale of its entire sugar packaging and distribution business in Namibia have been fulfilled. The company sold these assets, effective 1 July, to breakfast cereal company Bokomo Namibia for R220m. The last outstanding suspensive
conditions to the proposed transaction have been approved by the Namibian Competition Commission. Tongaat Hulett has been disposing of various businesses and assets in an effort to reduce its debt by R8.1bn by March 2021, including an agribusiness in Eswatini for R375m and its starch division business for R5.3bn, the sale of which is pending a contractual investigation with the potential buyer, Barloworld. •
Parties involved in listeriosis lawsuit ordered to provide testing info
J
SE-listed packaged goods manufacturer Tiger Brands received a ruling in its favour by the Gauteng Division of the High Court in Johannesburg, compelling third parties to provide information on testing of listeria-causing bacteria. The company has been fighting a class action lawsuit over its alleged role in the world’s largest-ever listeria outbreak in 2018. The outbreak killed more than 200 people in South Africa and the department of health said it had traced the outbreak back to a factory run by Tiger Brands’ Enterprise Foods brand in Polokwane. On 3 December 2018, the court granted an order permitting a class action lawsuit to be brought against the company by Richard Spoor Attorneys and LHL Attorneys.
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Food Review | July 2020
The class action was brought on behalf of those who fell ill as a result of the listeria outbreak and the families of those who lost loved ones. Tiger Brands previously stated that no specific damages were being claimed and that the first stage of the class action was concerned with liability and not the cost of damages. The quantum of damages would be dealt with in the case of a second stage of class action, if the court finds Tiger Brands liable. The company wanted the third parties to provide information related to testing for, and incidence of, listeria monocytogenes, to which the court now compelled the third parties to provide critical epidemiological information required for the class action, within one month of the date of service of the order. •
NEWS
EnviroServ assists with dough waste solution
I
n the food industry, waste can be the difference between profit and loss. Bakery waste, which includes excess or discarded dough left over from the baking process, can be used to make livestock feed, which reduces disposal costs and alleviates environmental issues. EnviroServ Waste Management works with enterprising farmers in KwaZulu-Natal, Gauteng and the Western Cape to offer a raw dough disposal service to industrial bakeries. “Bakeries no longer have to bear a transport and disposal fee, but receive a rebate,” explains Yolandi Kruger, EnviroServ project manager for recycling and on-site. The company has won business from various large bakeries in SA. EnviroServ staff are responsible for managing the client’s waste, separating it
into general waste, recyclables and dough waste. They are also responsible for housekeeping and making bookings for collections when bins are full. “Bakeries usually discard the first batch of dough; remaining dough when swapping between one recipe and another, and batches when something has gone wrong. We offer our customers a collection service for their raw dough and transport it to the facility where it is treated and combined with other organic waste stream ingredients that have a nutritional value,” Kruger concludes. •
Global food ingredient suppliers announce distribution agreement
T
ate & Lyle and Solevo have announced their new distribution partnership. Solevo is now the exclusive distributor of Tate & Lyle’s ingredients in West Africa in countries such as Ivory Coast, Senegal and Cameroon. Both entities have a shared ambition to offer innovative solutions to the African continent and provide local consumers with access to high-quality F&B ingredients, including low-calorie sweeteners and health and wellness ingredients such as soluble fibre, texturants, stabilisers, and acidulants. “We are proud to have Tate & Lyle as a partner,” enthuses Matthieu Van Bree, head of industrial chemicals, Solevo. “We are expanding our position in the market for speciality food ingredients and solutions we offer to our customers,” he notes. “The long history and experience of Solevo in Africa will be very useful to increase our market presence. “The African food industry is growing fast and producers are looking for ingredients and solutions that help them meet growing consumer demand for great-tasting, shelf-stable food and beverages that support healthier diets. With a partner like Solevo we are ready to support these trends,” Dominique Floch, regional sales & technical director, Turkey, Middle East and Africa, Tate & Lyle, points out. •
Food industry specialist ventures into ventilator production
D
ale Automation has developed a prototype emergency ventilator to assist with the treatment of COVID-19 and other respiratory diseases. The company is based in Johannesburg and active in the poultry and baking industries. The ventilator uses invasive (ambu-bag-type) and non-invasive (constant positive airway pressure, or CPAP) control. The unit is named respirare – Latin for breath. “The unit was designed around simplicity, yet offers the safety features of highend mechanical ventilators,” explains operations director Adam Sweeting. It is suitable for mobile or fixed applications. It has a custom-made walker trolley that can be fitted with
various accessories as required. “After a bit of research our MD thought that as an engineering company we could design our own system. We pulled the team together via video conference [during Alert Level 5 lockdown] and started to discuss various methods of mechanical ventilation, which led to our idea of the Respirare device,” Sweeting explains. The plan was to build a simple yet cost-effective machine designed for Africa, in answer to the urgent demand for ventilators. The device will not replace ventilators, but provide emergency ventilation when required. It also allows paramedics, nurses or others to free their hands to focus on other needs, depending on the situation. • Jakob Thøisen
Palsgaard to double capacity at Danish facility
E
mulsifier manufacturer Palsgaard A/S has announced an investment of €100m to double production capacity at its Danish facility by 2024. A new spray cooling tower will add a minimum additional 30 000 tonnes to the company’s spray capacity and will be fully operational by first quarter 2023. This facility will be supported by the construction of multiple new reaction, distillation, and esterification plants. The expansion adds to the recently installed emulsifier pellet line with a capacity of 10 000 tonnes, which is currently being commissioned.
“This project is another major milestone in our development. By 2024 we will be able to double our current production capacity, which took over a century to reach. It is the result of a decade of significant global growth for our business,” notes Jakob Thøisen, Palsgaard’s CEO. In 2019, Palsgaard was the first global emulsifier producer to achieve CO2neutral production across its global facilities, leading the way for the food ingredients industry. In line with Palsgaard’s commitment to sustainability, the new production capacity will not compromise the company’s CO2-neutral status.•
July 2020 | Food Review
9
C OV I D -19
Food security a major concern Businesses are struggling to get to grips with the COVID-19 pandemic. As the country eases lockdown regulations, the ability of South Africa and the continent to look after its people remains high on the agenda, writes Maluta Netshaulu.
A
ccording to the fourth annual Global Report on Food Crises (GRFC 2020), Africa has the largest
numbers of acutely food-insecure people in need of assistance in countries badly affected by weather events–particularly in the Horn of Africa and southern Africa. Food insecurity refers to the lack of secure access to sufficient amounts of safe and nutritious food for normal human growth and development and an active and healthy life. According to the United Nations Sustainable Development Goals (SDGs), the second out of 17 challenges, is Ending Hunger. In sub-Saharan Africa. The number of undernourished people increased from 195 million in 2014 to 237 million in 2017. This report was done before the impact of COVID-19 was established. Agriculture is no stranger to adverse external factors presenting risk to the point of business continuity being
through the provision of temporary
threatened. Climate change, pests,
short-term overdrafts or the extension of
diseases, and a volatile currency are
import facilities.
some of the external factors that this
This was also the message delivered
sector has to face year in, and year
by both Professor Ferdi Meyer, managing
out, with the added pressure of
director of the Bureau for Food and
nations depending on this sector for
Agricultural Policy (BFAP) and Dr John
food security.
Purchase, chief executive officer of the
Fears about the potential disruptions
Agricultural Business Chamber (Agbiz)
that the novel Coronavirus could
in a webinar hosted by Nedbank
cause global supply chains have raised
Business Banking. “What the pandemic
questions on whether South Africa
has made very clear is that there are
could experience food shortages in the
two distinct levels of food security – at
near-to-medium-term. From a national
a national level, which is secure, and
perspective, we doubt this would be the
at a household level, which is very
case, at least for most food products.
precarious,” say's Meyer.
South Africa is an agriculturally endowed
Purchase agrees, saying that the
country, generally a net exporter of
situation was fragile even before
agricultural and food products. What’s
COVID-19. “We must acknowledge that
more, there are prospects for an
the Zuma administration was disastrous
abundant harvest of staple grains and
for South Africans: per capita GDP was
fruit this year, which will increase
cut from $8 000 to $5 200, which means
local supplies.
that South Africans are now roughly 25%
Businesses that are exposed to global markets, and are dependent on income from exports, face a real challenge that
poorer in US dollar terms than before the Zuma years.” Then came COVID-19 and the lockdown
demand is severely contracted. This will
which Purchase says ‘cut off the legs’
ultimately affect cashflow, ensuring that
of the informal food supply network.
pressure will originate as a result of a
A number of initiatives are in place
mismatch in meeting forward exchange
to support this sector, particularly
cover. Nedbank Business Banking has
to weather the storm created by the
solutions to alleviate cashflow pressures
pandemic: the Department of Agriculture,
10
Food Review | July 2020
Land Reform and Rural Development has ring-fenced R1.2 billion to support around 15 000 small-scale farmers, and Agbiz is working with the Office of the Gauteng Premier through the Public-Private Growth Initiative to develop food supply chain security in the informal market, the objective is less about food aid, and more about small-business development opportunities. Nedbank is proud to be an integral partner in the food and fibre value chain. As a bank, its subscribes to the SDGs because they represent a universal agreement on the economic, social and environmental priorities to be met by 2030. Nedbank’s purpose, which guides its business strategy, is to use its financial expertise to do good for individuals, families, businesses and society. •
ABOUT THE AUTHOR MALUTA NETSHAULU is senior manager of Agriculture for Nedbank Business Banking.
Nedbank – www.nedbank.co.za
I N D U S T RY TA L K
Study calls for extension of moratorium on transport height restrictions Many South African industries, especially the fruit industry, could suffer major financial losses if they're not allowed to transport their goods in high cube containers.
G
overnment’s seven-year moratorium
containers from complying with the provision
during transit. The height of 4.6m has been
(2011-2018 and extended to 2019) which
of the regulation.”
used for 30 years when transporting high
exempts vehicles that transport such
In addition to talking to various government
cube containers and has not posed any
containers, has expired. The moratorium is
officials and stakeholders in the fruit,
likely to be extended to June 2021, but that is
shipping, road transport and rail transport
still to be confirmed by government.
industries, Adams asked them to complete a
the moratorium by 10 years so that the
survey on their ideas and solutions regarding
Department of Transport can commission a
the regulation of high cube containers.
study on the safety of transporting high cube
“If the extension of the moratorium is allowed to expire on 30 June 2021, the subsequent financial impact could have a
She says most responders preferred a
specific threat or risk to other road users.” She calls for a further extension of
containers, conduct an investigation into the
debilitating effect on our economy.
height between 4.3 and 4.6m, adding
current regulation and performance-based
Many customers, nationally and
that they were concerned about the
standard (PBS) design projects, and define
internationally, would not receive
financial impact on the fruit industry
and implement the PBS policy.
their products if it becomes illegal
and the country’s economy should
to transport goods in high cube
the legislation remain at 4.3m.
containers,” says Tiffany Adams
“The reason is that transporters
who works as a Solutions Analyst
would need to replace their trailers
in Johannesburg. She obtained
to meet the new legislation, with
her Master’s degree in Logistics Management at Stellenbosch
Tiff
s any Adam
University recently. Adams focused specifically on the fruit
“Extending the moratorium would allow time for a gradual phase-in of any new equipment and infrastructure that has to adhere to the PBS standards during this time. “This would also allow industries to
each trailer costing approximately
operate efficiently for the time being
R300 000. If the legislation is kept
and to obtain the necessary new
at 4.3m, many loading and unloading docks
equipment gradually to meet the current
would have to be lowered to 1.40m to access
legislation, should it remain as is after the
industry, saying it exports 90% of fruit
trailers and containers at a cost of R30 000
moratorium expires.”
produced to international markets via
per dock.
refrigerated containers. “According to Fruit
Adams says transporters should be
“The fruit industry would have the burden
allowed to use trailers with a deck height
South Africa, the industry will encounter
of R27 million to lower the container stations
of 1.40m to meet the legislative height of
a price increase in the cost of transport if
to the height of 1.40m. Productivity, efficiency,
4,3 metres. They should also be issued
the legislation is not amended due to the
product flow and profitability within the fruit
with abnormal load permits until they have
severity of seasonal production and export
industry would also decrease significantly.”
adjusted their fleet to adhere to
volume flows.”
Adams says the respondents also stated that there haven’t been any recorded
the regulation. She adds that government needs to
FINANCIAL IMPACT
accidents or incidents while transporting high
consider all inputs from the various
As part of her study, Adams tried to
cube containers.
industries and determine what would
determine what the financial and operational impact on the fruit industry
“Containers have tipped over because they were loaded incorrectly or the load shifted
be the best course of action for the whole economy. •
would be should the moratorium expire and the regulation governing vehicle height restriction not be adjusted to allow the use of high cube containers on normal trailers at a height of 4.6m. She points out that Regulation 224 (b) of the National Road Traffic Act, 1996 (Act 93 of 1996) legislates that the maximum legal height limit for vehicles without a permit for an abnormal load is 4.3m. “The problem is, however, that a 2.9m container on a flat deck trailer standing at a 1.6m deck height results in an overall height of 4.5m, thus exceeding the legal limit of 4.3m. “Because high cube containers transported on normal trailers exceeded the legislated limit, a moratorium was issued in 2011 that exempted motor vehicles transporting such
July 2020 | Food Review
11
C O M PA N Y F O C U S
FAST FACT:
As a global first, Symrise creates sustainable grapefruit flavours as the farms meet the highest SAI FSA requirements.
Symrise engages in the region in many different ways. One such project is to support beekeepers in KwaZulu-Natal since the insects pollinate the flowers and thereby contribute to preserving biodiversity. The company also invests locally in technical equipment at the Nkwaleni Processors factory.
SUSTAINABILITY AT SYMRISE The group uses thousands of raw manufacturing industry, it is used specifically in the global food, beverage and cosmetics industry. Many experts estimate that KwaZuluNatal will become one of the world’s
Delivering high-quality citrus tastes around the world
and young men and women look for work as a basis to secure their future. Symrise supplier Klaus Boecker
most important sourcing and processing
GmbH operates the citrus fruit factory
areas for white grapefruit.
in the form of a 50% joint venture with
“The unique flavour enriches the palate with a sought-after taste,” McLean exclaims. “South Africa is
the farmers and the Zulu community, represented by a tribal chair. The factory can supply 50 000 tonnes
home to great citrus, yet it is not
of processed citrus fruit per year and
internationally acclaimed like Brazil,
specialises in grapefruit. Symrise and
Mexico, Argentina or Spain. It is time for
Boecker work together in two ways: by
this to change. South African grapefruit
buying the factory’s produce and jointly
has become the new golden benchmark
helping communities and farmers.
for the global citrus industry, and the
Training is of critical importance as some
passionate people behind it are those
workers eagerly take the opportunity to
who are driving this overdue recognition
earn a living by growing and producing
with us.”
agricultural produce.
When cultivating grapefruit, there
academy that provides participants with
since South Africa has unpredictable
knowledge about the latest and most
rainfall. Only about one-eighth of its
sustainable cultivation practices in
land is suitable for field cultivation
order to secure a future.
in general and also in the cultivation
SUSTAINABLE PRODUCTION IN SOUTH AFRICA
of the fruit. KwaZulu-Natal is a positive
Symrise places great
exception. With its humid, subtropical
importance on
climate, some farmers used to even
complying with social
manage without additional water supply.
and sustainability
Grapefruit grow on particularly heat-
requirements in South
tolerant evergreen trees.
Africa and the world.
SUPPORTING ZULU COMMUNITIES
ingredient suppliers.
Symrise cooperates with the Nkwaleni
areas, Symrise employees
Processors in KwaZulu-Natal. Nine large-
live as partners and neighbours
scale and many small-scale farmers have
to the farmers and support
joined forces in this cooperative. The
the local communities with
major ethnic group of the region is Zulu
educational measures.
water supply. Additional water supply plays an important role in agriculture
and availability have a strong business impact. “We have set ourselves a goal of sourcing all raw materials in such a way that it minimises the impact on the environment. It has evaluated 90% of all the company’s main suppliers, who represent 80% of the purchasing volume, according to sustainability criteria. Our commitment does not come with a bestbefore date. We are in this for the long run. This is reflected in our programmes like educating upcoming farmers, joining with Nkwaleni Processors and GIZ,” McLean concludes. •
Symrise – www.symrise.com
Partners aim to set up an agricultural
are a number of factors to consider
where precipitation alone ensures
materials globally and price, quality
Symrise prides itself on its sustainability credentials
The same goes for raw In raw ingredient cultivation
July 2020 | Food Review
13
C O L O U R S & FL AVO U R S
Botanicals add healthy value to products One in every two consumers are concerned about their health and look for naturalness in the products they consume. Food Review looks at some of the latest trends predicted by global ingredient supplier Doehler.
T
he global market for botanical extracts is expected to reach $5 833.4m by 2022 and is driven by
strong health and wellness trends. Nutrition that supports wellbeing and immunity is
Healthy and digital lifestyle drives novel and botanical flavours
of particular interest and consumers are actively seeking out products that are organic, sustainably-sourced, produced and processed. Substances obtained from plants offer a significant boost to products. Many superfoods are known as health enhancing. Aloe vera leads the field, followed by extracts such as olive leaf, moringa and baobab. Consumers associate a positive emotional benefit with plant extracts, which is also increased by demand for more plant-based nutrition. Doehler’s range of highquality products include minimally processed fullspectrum powders, which contain the full load of healthiness from the raw material; to high-end standardised
the multi-sensory and healthy properties of the plants in their entirety.
botanical extracts. These products
HEMP MEETING IMPORTANT CONSUMER TRENDS
guarantee amounts of certain naturally
In our fast and digital life, nutrition must
occurring healthy actives, like antioxidants. These valuable botanicals are paving the way for inspirational natural food and beverage applications with a healthy positioning. Alongside plant extracts, infusions, distillates, essences and natural flavours allow consumers to choose an individual flavour.
SUSTAINABLY-SOURCED RAW MATERIALS A BASIS FOR SUCCESS The African Cape region is botanically diverse and renowned for an abundance of plants known to have a positive impact on consumer health and wellbeing. African botanical extracts are very popular. Plant extracts such as baobab for gut health or immunity, or rooibos for stress relief are on-trend and used in various inspirational and innovative concepts. Doehler offers a broad product portfolio of botanical extracts, which they produce at the place of origin by using gentle technologies. The use of hydro-alcoholic extraction, waterbased extraction, batch distillation and spray-drying, to name just a few innovative technologies, enables them to capture
14
Food Review | July 2020
stand out from the mainstream to have a serious impact. Consumers value experiences over possessions and are therefore searching for unusual ingredients.
FAST FACT
Doehler offers technologydriven natural ingredients, ingredient systems and integrated solutions for the F&B industry. The company’s product portfolio ranges from natural colours and flavours, health ingredients, pulses and cereal ingredients to dairy, plant-based, fermented, fruit and vegetable ingredients.
Cannabis experienced a first peak in popularity in 2019 and is still on the rise: It is the ultimate “natural” health and wellness “super-ingredient”. It addresses the requirement for sustainably-sourced products, since it can grow on arid land and uses up to 1/14th less water than cotton. Hemp, a species of cannabis, is also trending. It is grown industrially, and applications range from food oil to bio-composites in car parts. The hemp trend can mainly be observed in beverages: Consumers accept hemp as a functional ingredient, slowly expanding into other product categories. Globally, one in three consumers perceive hemp to have
winning examples of natural and innovative refreshment with functionality and a healthy positioning. Increasingly, spirits, beer mixes and flavoured beers are proving popular. Doehler’s range offers natural hemp, cannabis, hophemp flavours and a hemp leaf infusion. Neither the natural flavours nor the hemp infusion carry any active components nor any functional properties. Instead, the company provides the entire spectrum of natural flavours, from the characteristic herbaceous, resinous and flowery taste profile of hemp to a wide selection of other hemp nuances. Doehler supports their customers worldwide in formulating new recipes based on premium raw material and in bringing their smart and innovative product ideas to life. •
a positive impact on health. In nonalcoholic beverages, hemp-flavoured sparkling and functional water, juices and CSDs are
Doehler – www.doehler.com
C O L O U R S & FL AVO U R S
Plant-based colours give plant-based products the edge Clean-label colours are a key component to differentiate products in a progressively competitive plant-based market. wGNT launched new resources to highlight the importance of colour in vegan-friendly meat, dairy, cheese and fish alternatives.
T
he new resources, available on the company’s website is
coupled to an animated video charting the rise of plant-based food and drink. This is also linked to the evolution of colours through recent decades. With many consumers now reducing or eliminating animal products from their diet 1 2 plant-based alternatives are experiencing phenomenal growth in demand. As of last year, global sales of plantbased meat substitutes had grown by an average of 8% annually since 2010. The plant-based beverage market, meanwhile, grew approximately 33% each year between 2014 and 2019. 3 With more options on the shelf, it is vital that plant-based food and drink products deliver a fresh and appealing appearance.
heading toward ‘plant-based 2.0’, with manufacturers reformulating their products to meet modern consumer expectations. As such, using plant-based colours for plantbased products has never been more important. These ingredients offer a future-proof solution, helping to deliver an ideal appearance while maintaining clean and clear labels.” To learn more about the importance of colour in plant-based meat, dairy, cheese and seafood products and watch the animation, visit: https://exberry.com/ plant-based. •
In this health- and ethics-driven category, consumers are motivated to demand cleanlabel, plant-based ingredients.4 Exberry offers a wide and comprehensive range of colours on the market, helping to ensure that plant-based meat, dairy, cheese and seafood alternatives deliver the visual impact desired. All products in the range are made from fruit, vegetables and edible plants without any chemical solvents, ensuring they are 100% vegan-friendly and support clean and clear labelling. Maike Frerichs, who leads GNT’s plant-
YouGov 'Young Americans less likely to be meat-eaters' (January 2020) 2 YouGov 'Is flexitarianism the diet of the future?' (March 2019) 3 National Research Council Canada 'Plantbased protein market: Global and Canadian market analysis' (March 2019) 4 Euromonitor International 'The Unstoppable Rise of Plant-Based Alternatives' (March 2020) 1
Exberrry Colouring Foods – www.exberry.com GNT – www.gnt.com
based category team says, “We are
July 2020 | Food Review
15
C O L O U R S & FL AVO U R S
Elevate your no-alcohol drinks, with premium botanicals Kerry, the Taste & Nutrition company has released its Botanicals Collection Zero. This extensive range of high-quality, authentic botanical extracts contains 0% ethanol and is designed specifically for the low- and no-alcohol beverage markets.
T
he portfolio currently includes 15 standard products and 35 additional products. The range includes amongst
others, juniper, rosebud, elderflower, cocoa, turmeric and cinnamon. Investigations are ongoing to add more exciting tastes producers and consumers will love. With Botanicals Collection Zero, beverage producers can now create sophisticated low-alcohol spirits and no-alcohol options with the taste of gin, rum, cocoa, ginger, while still meeting emerging clean-label and quality requirements. The result is a premium drinking experience for those seeking to moderate their alcohol consumption. The growing global trend to moderate and control alcohol intake looks set to continue
ABOUT KERRY
From its beginnings as an Irish dairy co-operative, Kerry has grown into a large international food industry leader. The company has offices in 32 countries, 151 manufacturing facilities and just over 26 000 employees globally, including over 1 000 food scientists. The group is focused on its strong food heritage, coupled with over 40 years of experience, global insights and market knowledge, culinary and applications expertise, which is coupled to a range of innovative solutions that anticipate and address customers’ needs.
FAST FACT
The Botanicals Collection Zero range of distillate from botanical sources enables the creation of great-tasting low- or no-alcohol beverages to address consumer demands for moderation without compromising on taste.
for the foreseeable future. Consumers are seeking authentictasting drink taste options beyond simply soft drinks. This makes low-alcohol spirits or no-alcohol beverages a growth market, with trade sales in the area expected to record a 41% increase over the period 2015 to 2021. With botanical extracts in alcohol beverages already a $500 million business and growing by 9% per annum, producers that can offer
Juniper berries (left) are just one of a wide range of botanical sources for Kerry flavor extracts to form many different premium low- or no-alcohol drinks
tasty and healthier upscale beverage choices will see a significant and growing market opportunity in the years to come. “Kerry is pleased to make this range of high-quality authentic botanical distillates available to beverage producers interested in producing more refined and bettertasting low- or no-alcohol drinks,” says Michel Aubanel, flavour ingredients global development manager for Kerry. “I believe that consumer expectations are currently not being met by mocktails and other no-alcohol options. This is due to the fact that products often resemble juices rather than alcohol. Consumers want the upscale experience of the glass, ice and taste, but without the alcohol content. This portfolio can deliver a premium drink that tastes great.” The range also offers many advantages: it’s fully traceable, clean-label, Halaal-certified,
16
Food Review | July 2020
Kosher-suitable, ethanol-free and also free of
to suit specific local and regional tastes
any alternative solvent.
and requirements.
The portfolio allows manufacturers to
Collection Zero contains more than 45
maintain a low (or zero) alcohol content
single distillate profiles and five fusions
and permits a “0.0%” claim. In comparison
distillates that can be blended and tailored
to other ethanol-free technologies, the
to suite specific markets and create unique
Collection Zero range is more stable, with
winning tastes. Some of the available
no haze, no sedimentation, and a fresher
botanical taste sources include juniper,
botanical taste and mouthfeel.
ginger, rose bud, chamomile, lemon, mint,
Kerry’s extensive expertise and experience
orange, dandelion, cola nut, rhubarb,
in natural extraction fosters innovative
burdock, elderflower, black tea, cocoa,
“fusion distillates” that are based on a
cumin, fennel, turmeric, and cinnamon,
capability to blend natural botanicals (leaves,
among others. •
flowers, seeds, etc.) and then magnify taste by running a distillate following a period of slow maturation. This allows for tailored extracts or blends that can be made to order
Kerry – www.kerry.com
C O L O U R S & FL AVO U R S
New charter commits to a more sustainable future ADM has joined almost one hundred fragrance and flavour companies in signing an ambitious new Sustainability Charter seeking to improve sustainability across the two industries.
T
he new charter was launched in early July by The International Fragrance Association (IFRA) and the International Organization of the Flavour Industry (IOFI). This is a voluntary framework for
companies in the sector and represents a collective commitment to making a difference to the planet, its people and business. The Charter covers sustainability in every sense, taking a life-cycle approach based on five focus areas – responsible sourcing, reducing
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the environmental footprint, employee wellbeing, product safety, and transparency and partnerships. The IFRA-IOFI Sustainability Charter complements other longstanding sustainable development commitments and initiatives, such as ADM’s recent pledge to reduce greenhouse gas emissions an additional 25% by 2035. It aims to help the sectors as a whole make further advances by sharing best practice, providing tools, and benchmarking progress. “The IFRA-IOFI Sustainability Charter is an important initiative for businesses to collaborate and promote sustainable development across the fragrance and flavour industries and we are delighted to be a part of it,” said Alison Taylor, chief sustainability Officer. “At ADM we believe that it is vitally important to plan for generations to come, and this collective commitment will help ensure our industry is making the right steps forward to a brighter and more sustainable future.” The charter has been in development since 2016, shaped through wide consultation of member companies and external experts, and acknowledging the United Nations Sustainable Development Goals. It has been designed to be aspirational and inclusive, with clear and achievable goals that allow companies of all sizes to contribute to improving the overall sustainability of the fragrance and flavour industries. The document continues to be open to signatories from fragrance and flavour companies around the world. Signatories will provide data on progress against 18 commitments in the five focus areas, feeding into a benchmarking report that will be published early in 2021. • For more information on the Charter, go to ifra-iofi.org.
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Industry initiative promotes sustainable development in the fragrance and flavour industry
www.heatandcontrol.com | info@heatandcontrol.com Cape Town +27 21 948 5934 ADM – www.adm.com
SAFoodReview_July2020_88.5w x 262h_CEIA.indd 1
17
July 2020 | Food26/06/2020 Review 1:10:07 PM
ADVERTORIAL
18
Food Review | July 2020
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
Get a warm feeling with the right cold storage support Regulating and maintaining the right temperature and humidity in a cold storage facility is tricky. Materials handling expert Jungheinrich has introduced its new EKX Cold Store High Rack Stacker, which offers an alternative to traditional stacking units. Maryke Foulds looks at some of its core features.
T
raditional temperature monitoring
• Maximum efficiency - High throughput
systems depend solely on the
with proven lower energy consumption.
experience of the operator, who
This is due to the use of synchronous
must be on-site to adjust and manage the
motors and new and enlarged
whole system.
battery capacities.
Correctly maintaining the temperature
• Extremely flexible - Various features of
of perishable products is necessary to
EKX standard portfolio available– a wide
preserve quality and safety from the point
range of further options to customise to
of manufacture through the supply chain
your operation.
to the consumer. Failing to maintain proper
• Proven technology - Intelligent RFID
shipment leads to textural degradation,
tracking offers all possibilities for
discolouring, bruising and microbial growth
optimal system integration.
of food products. Certain perishable foods, ready-to-eat products, can become unsafe if
AT HOME IN A VARIETY OF WAREHOUSE ENVIRONMENTS:
not kept at the appropriate temperatures.
• Narrow aisle pallet racking - Available in
particularly seafood, pre-cut produce and
a range of designs and configurations,
“The stacker sets new benchmarks for flexibility, ergonomics, and costeffectiveness and ensures maximum throughput performance in most warehouse configurations” The latest generation of EKX stacker can
the very narrow aisles of multi-bay Novel and updated technologies include energy recovery and effective energy management. This enables the operator to use the stacker for two shifts under normal operation without having to change the battery. Once installed with integrated RFID
racking systems allow the EKX Cold Store to stack and retrieve pallets on the firstin-first-out principle. • Under pallet carrier UPC racking - A high degree of space utilisation is of importance for the efficient operation of
transponder technology, the EKX Cold
a cold store. The UPC cold store version
Store informs you that “You have reached
operates in temperatures as low as -28°C
your destination” after every journey. This
in conjunction with the EKX Cold Store.
take your warehousing operation to the next
sophisticated warehouse navigation directs
level. The unit is efficient, powerful and safe
your truck to the pallet locations with
motor technology, aisles are created only
to use, and can be supplied with warehouse
perfect precision.
where access to the particular pallets are
navigation technology as an optional extra.
required, thus making the most out of
it to operate comfortably in various racking
MADE-TO-MEASURE COLD STORE BENEFITS:
scenarios. Units are tailor-made and supplied
• Robust in the cold - The stacker is
The versatility of the new stacker allows
for particular cold store environments. The
manufactured using low-temperature
stacker sets new benchmarks for flexibility,
steel for main components. It makes
ergonomics, and cost-effectiveness and
use of low-viscosity hydraulic oil with
ensures maximum throughput performance in
anti-stick slip additives and a two-fold
most warehouse configurations.
polycarbonate cabin screen window.
20
Food Review | July 2020
• Powered mobile racking - Driven by
available floor space. • Push back racking - This is achieved through trolley cars or inclined rollers to provide high-density storage. •
Jungheinrich – www.jungheinrich.co.za
Lift your productivity to a new level. Taking all the features and benefits of the EKX into cold storage.
If you are looking for a quality alternative in the cold store environment, then look no further than the new Jungheinrich EKX Cold Store Stacker. Benefitting from years of experience at the forefront of VNA expertise, the EKX Cold Store builds on all the features and technology of the award-winning EKX Stacker, creating a serious contender in this demanding environment.
0800 984 001
www.jungheinrich.co.za
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
Improved inventory logistics ID Logistics, a European leader in contract logistics has gone one step further in the digitisation of its warehouses. The company now incorporates Full Pallet Inventory, a technology developed by Zetes.
T
he system, part of the ZetesMedea
ability to use imaging technology integrated
logistics execution solution, uses vision
with the WMS, a clear boost from ID Logistics
technology to rapidly count palletised
in the logistics automation career. Full Pallet
inventory. A specially designed ImageID mobile
Inventory's implementation has required
reader mounted on a forklift travelling at
close collaboration between ID Logistics'
speeds up to 10 km/h undertakes a full pallet
various departments (IT, operations and re-
inventory. The system continuously adapts to
engineering) and the Zetes team.”
the speed of the forklift itself and enables the
“The key differentiator of Full Pallet
time spent inventory counting in the warehouse
Inventory, in addition to image capture on
to be reduced by 50%.
the move and in real-time, is the ability to
The Full Pallet Inventory operation requires
translate data into the WMS language. This
pre-mapping the rack heights to minimise
process automation reduces the margin of
barcode scanning. The various heights and
error that may occur during data transfer,
pallet locations in warehouse are consolidated
which allows a much more comprehensive and
into grouped locations to simplify counting
rapid analysis. We strongly believe that this
routes. The system reads the data matrix
innovative system will allow retailers to save
code and decodes the pallet and location
significant time in their inventory process
tag, translating it into the language of the
optimisation of time and resources and an
operations and that it will also help gain
warehouse management system (WMS).
improvement in warehouse productivity.
greater visibility,” Simón Ben Hamú, country
Mercedes Espárrago, ID Logistics'
“Using ImageID gives us much higher data
re-engineering project manager points
quality and reliability. Until now, inventory
out. “The ability to carry out inventory
counts were carried out manually with the
counting on the move, minimising scans
help of radio frequency systems or even paper.
per warehouse aisle, translates into an
The system designed by Zetes gives us the
22
Food Review | July 2020
manager of Zetes Spain concludes. •
Zetes – www.zetes.com
M AT E R I A L S H A N D L I N G & C O L D S T O R AG E
COVID-19 ripples into the container industry An estimated 20% of the global population is in some form of lockdown, says Kashief Schroeder, owner and co-founder of CIT Container.
The impact of the pandemic has been felt sharply in the container industry
C
onsidering the coronavirus pandemic, many industries and businesses had to adapt and change to embrace a new normal.
China, the world’s manufacturing powerhouse’s restrictions and lockdowns had a huge impact on the manufacturing of goods and
Decades of science, imagination, and commitment that help bring your best products to market
containers. As production and exports from China were halted, demand for shipping containers were drastically reduced, locally and internationally, as fewer goods are being shipped and fewer containers are being produced.
DECREASED VOLUME Along with the delayed production in China, South Africa started a government-mandated lockdown on 27 March 2020. The lockdown only allowed for essential goods to be imported and exported into and from South African ports. The combination of these events led to a decrease in the volume of containers entering South Africa – with a drastic effect on South African demand for containers.
INTERNATIONAL PRICE HIKES Schroeder foresees an increase in the prices of containers to alleviate lost revenue from ceased
Heat and Control has been on a mission to modernise equipment solutions since our founding in 1950. For 70 years, our passion for advancing the food, pharmaceutical, and other industries has guided our work. From the machinery
we manufacture and the customers we serve, to our process breakthroughs and the partnerships we develop, we have always found new approaches, believed in bold ideas, and put people first. That is the essence of who we are and how we lead.
Kashie f Schroeder
production of containers and exported goods. Fewer containers are being circulated internationally, which will contribute to a rise in prices. “It is important to look ahead and plan a way forward in these uncertain times. Although COVID-19 will have an enormous impact on the global economy, there are also new business opportunities arising that industries can invest in. “South Africa, and the rest of the world, are dependent on Chinese production. This is the time for Africa to become more self-sufficient. The continent has abundant natural resources and vast land with many agriculture and manufacturing opportunities. In the future, we should manufacture our own goods and work towards being exportrather than import-driven,” he concludes. •
info@heatandcontrol.com Learn more > heatandcontrol.com/alwaysinnovating
CIT Containers – www.citcontainers.co.za
SAFoodReview_July2020_88.5w x 262h_H&C.indd 1
26/06/2020 1:26:23 PM
July 2020 | Food Review
23
R O B O T I C S & AU T O M AT I O N
Robotics – the food industry’s renaissance The Cama Group has been producing robotised systems since the end of the 1980s, when its founder, Paolo Bellante, designed and produced the company’s first industrial robots for the bakery sector, which required high production capacities.
I
ts first two-axis robot, the Cama RB 504, was a revelation in the food product packaging sector thanks to its cutting-
edge innovation and it saw wide adoption across the world. This is the view of Annalisa Bellante, joint owner of the Cama Group.
1
2
1: ’90 2 Axis robot 2: 2 Axis Y shape Integrated Robot MN530 3: 2 Axis first robot ’80 Age 4: Cama 12 Triaflex robot in action on a IG top loading machine
Following these early successes, the firm established integrated multi-purpose robots, specifically adapted to the needs and characteristics required by the packaging sector. In-house development means the company delivers robotic control from the machine’s PLC, rather than relying on proprietary black-box controllers running on bespoke, isolated software. The use of robotics also fostered new
“The use of robotics also fostered new approaches in the packaging sector, such as pick-and-place simulation of the work carried out by human operators”
approaches in the packaging sector, such as pick-and-place simulation of the work carried out by human operators. This revolutionised the development of automation processes in large food production companies across the world. With the market's continued and growing requirement for flexible and agile packaging systems, Cama continues to develop new robotised applications. The end of the 1990s saw the first in-house developed advanced four-axis robot models, which could be tightly integrated into packaging systems including the company’s own high-speed continuous motion machines. In the early 2000s, backed by highly successful collaborations with research bodies and universities and significant internal investment, Cama delivered its next major breakthrough to the food sector.
“In 2007, we completed the range with the production of the first four-axis delta robot. Fully and tightly integrated into the company’s machines – in terms of mechanics, electrics and software – the turnkey solutions delivered by this combination of technologies proved immensely popular in the market, thanks to our ability to tailor performance to the precise needs of an
3
application – something our strategy has The company’s 100+ patents, reinforces
always involved," Bellante points out.
its intense and constant activity in research
By 2010, thanks to its strengthened internal Robotic Division, Cama had
and development, with a focus on three
cemented its position as a multinational
types of robotic applications: two-axis
company in the robotic automation sector
robots, with fixed or movable pivot pins;
for the food production industry. This is due
and delta robots, combined with advanced
to its ability to design and produce robots
monitoring systems for packaging products
dedicated to specific applications.
that are loose or those that come in more
4
than one flavour. “Cama has come a long way in the development of robotic applications for the packaging industry… and generally in regards automation for the food & beverage industry. During the current COVID-19 crisis, we must look at the organisation of both companies and their production processes to ensure maximum flexibility and longevity. Over the course of the next few years, the field of automation will undergo significant development and there will be an extensive review of where and how the industry works," Bellante concludes. •
CAMA – www.camagroup.com
24
Food Review | July 2020
MEAT
www.foodreview.co.za
JULY 2020 No. 4
Journal for meat industry professionals
Quality processes and ingredients: an essential part of the meat value chain
Use preservatives to your advantage | The first step in better-textured meat | Is your facility COVID-19-ready?
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
JULY 2020 No. 4
ADVERTISING
Journal for meat professionals
Sales Executive: Anita Raath +27 (0) 82 976 6541
IN THIS EDITION
anita.raath@newmedia.co.za Sales Executive: Carla Melless
Page
6
E D ’ S N OTE
Using COVID-19 to our advantage
Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918
CIRCULATION
T
Happy reading!
carla.melless@newmedia.co.za
càndida.giambò-kruger@newmedia.co.za
he meat industry has been forced to come up with creative solutions to combat the effects of the global pandemic. Cooperation and collaboration are vital to address evolving consumer patterns and tap into markets that can bolster the industry. Cooperation between the commercial feedlot industry and the South African government is vitally important to access new markets. Amid these trials, the industry has learnt that there are still markets willing to work and negotiate with us. South African red meat, in particular, has a good international reputation and is still in demand because of our marketing approach, our biosecurity protocols and how we present our products on the global market. This is the view of Dewald Olivier, CEO of the South African Feedlot Association. The COVID-19 pandemic has negatively impacted the entire agricultural industry. However, these challenges can create new opportunities. The future will see shifts in consumer behaviour, which means we need to change our approach and outlook to anticipate and match these changes. On the plus side, industry players feel that the pandemic will emphasise the need for consumers to buy local so that everyone can contribute to the South African economy. If you have any comments or suggestions, please don’t hesitate to contact me at maryke.foulds@newmediapub.co.za.
+27 (0) 83 260 6060
Circulation Manager: Felicity Garbers felicity.garbers@newmedia.co.za
Quality processes – an essential part of the meat value chain
3 CJP Preserving the bottom line
PUBLISHING TEAM General Manager: Dev Naidoo Production Controller: Mandy Ackerman Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park 2092
4 Maccallum The perfect meat glue for all your requirements 5 Orchem Speciality cultures for meat
Tel: +27 (0)11 877 6111 Fax: +27 (0)11 877 6198 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published by New Media, a division of Media24 (Pty) Ltd MANAGEMENT TEAM MANAGING DIRECTOR: Aileen Lamb COMMERCIAL DIRECTOR: Maria Tiganis
6 Matrix Quality processes – an essential part of the meat value chain
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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
8 LTL Dedicated to the industry for 30 years A D IN D E X Certification Partner Global..7....... www.cpg.global CJP Chemicals............................ 3....... www.provianprotects.com LTL Consultants/MLS Labs..8....... www.ltlconsultants.co.za Maccallum ..................................4....... www.maccallum.co.za Matrix Software........................6....... www.matrixsoftware.co.za Orchem ........................................ 5....... www.orchem.co.za
Meat Review is published by New Media Publishing (Pty) Ltd 11 times a year and circulates to executives in the food and beverage industries. Views expressed in this journal, other than where specifically stated, are not necessarily those of the publisher.
The editor welcomes for publishing consideration news items, press releases, articles and photographs relating to developments in the food and beverage industries. No responsibility is accepted should contributions be lost. Meat Review is printed and bound by Novus Printers - Cape Town
Readers are prohibited from using the contact details displayed in any advertisement or editorial within the pages of this publication to generate and/or distribute unsolicited bulk emails or other forms of mass marketing correspondence.
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Preserving the bottom line Known and trusted across the globe as a proven inhibitor of Listeria monocytogenes, Provian K is associated with many other benefits.
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iacet’s Provian K is a novel, sodiumfree, acetic acid-based powder alternative to conventional liquid preservative systems. Its proven efficacy against L. monocytogenes has resulted in the ingredient being widely adopted around
Niacet & CJP Chemicals Based in the Netherlands, Niacet is a leading producer of dry organic salts, including propionates and acetates as well as their clean-label alternatives based on natural fermented vinegar. CJP Chemicals represents Niacet, and the Provian range, nationally to customers in the meat, catering, ready-to-eat and spice blend industries. The two companies have combined their collective experience and high levels of service to offer expert support and assistance with the correct Provian K dosages. Visit www.provianprotects.com or use the QR code below to find out more.
the globe, but did you know of its many other benefits?
Improved shelf-life This highly effective acetate-based preservative inhibits bacterial growth for extended periods of time, keeping food safer for longer. Provian K prevents the growth of pathogens and lactic acid bacteria. This ensures the safety and shelf life of these food items and leads to a reduction of food waste and returns – a significant cost advantage!
Greater efficiency Like all Provian products, Provian K requires a low dosage owing to its proven high efficacy. The extremely high preservation capacity of acetates means that dosage rates between 0.5 and 0.8% are effective against a range of bacteria. These preservatives are produced as a 100% pure, dry powder, which is far easier to transport and store than a liquid solution.
This reduces both formulation, storage and operational costs, as well as the product’s environmental impact.
Fewer food recalls Food safety recalls hurt the bottom line. Beside the loss of sales, cost implications include crisis communications, impact on the supply chain and management of consumer relationships. Most importantly, there’s the very real threat of irreversible brand damage. Acetate-based preservatives have been shown to be significantly more effective at inhibiting bacterial growth than lactate alternatives, thereby preventing future recalls, with its associated costs, and ultimately, protecting the brands’ reputation. • CJP Chemicals – www.cjpchemicals.co.za Niacet – www.niacet.com
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M ACC ALLU M
The perfect meat glue for all your requirements Transglutaminase preparations have been developed by Ajinomoto for specific applications. Meat expert Dr FD Mellett explains why this product is ideal for use in culinary portion control and improved texture of reduced-size particle-meat products such as salami, minced sausages and viennas.
T
G preparations greatly accelerate and strengthen protein bonds formed in addition to chemical and physical extraction and coagulation of proteins by means of salt and phosphate extraction, tumbling and massaging. This process is normally followed by heat or acid coagulation. Since the expiry of the Ajinomoto patent, copies of the original TG have become available – usually diluted on maltodextrin. “None of the copies are based on the original molecule. To date I have not experienced the same results using any alternatives,” Mellett explains. The meat industry generally makes use of TG-GS for binding of large pieces of meat and TG-S-NF for improved texture on smaller particles. TG facilitates the formation of permanent bonds between adjacent proteins of neighbouring meat pieces or fractions.
In the binding process, fat particle encapsulation is enhanced, resulting in a firmer product with less cooking or drying loss and an excellent mouthfeel. It has been argued that these preparations are only suitable for top-of-the-range meat products. Yield improvements provide evidence that these preparations also have cost benefits in MDM/soya preparations such as emulsified and cooked products. Unevenly shaped meat cuts suitable for grilling or roasting can be permanently fused in a regular shape, such as beef, pork and ostrich fillets that taper sharply. When two fillets are treated with TG-GS and placed in opposite directions, they can be fused into one piece of meat with the same thickness over the entire length. Once cooked, carving results in even mass and shape of the medallions with no evidence of fusion.
Improvements to boerewors, meat patties, burgers and salami-type products are achieved by utilising TG-S-NF in combination with bovine collagen. Texture and yield is improved with a much juicier product. Since collagen is prepared from meat it is meat by classification; this makes it possible to include collagen into meat products that do not require long periods of cooking to soften the collagen, such as oxtail and cured pork hocks and knuckles. Salamis can be produced with shorter curing and ripening times with improvements on sliceability and yield. A further advantage is that sliced and vacuum-packed slices separate easier after opening the pack and do not stick together. •
Maccallum – www.maccallum.co.za
Proud supplier of quality ingredients into the South African processed meat industry. Supplying proteins, starches, gums, dextrose and other ingredients including Ajinomoto transglutaminase, ACTIVA®.
www.maccallum.co.za www.ajinomoto.com www.transglutaminase.com/index.php/home
4 M EAT REVIEW
· ISSUE 4 2020
ORCHEM
Speciality cultures for meat Fermentation, curing and drying are natural ways to process meat products to preserve and develop their organoleptic features.
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ost of these processes use selected starter cultures as a proficient resource for texture, colour, taste, protection and flavour development and to maintain microbiological quality of meat products. DuPont’s range of Texel meat cultures and Holdbac protective cultures are perfectly adapted to a wide selection of dried and semidried fermented sausages, but also to other types of processed meats, such as dry cured meat, fresh ground and cooked meat products. The starter cultures provide five important functionalities: • pH reduction - The acidifying bacteria metabolise the added sugar into lactic acid thereby enabling the pH drop essential for protein coagulation, texture development and homogeneous drying. • Nitrate reductase activity - Nitrate is converted to nitrite, providing the substrate for subsequent chemical reaction with meat protein, thus colour development and
stability. Where nitrite salt is used, some nitrate is generated during this reaction. This is reconverted into nitrite by the culture, optimising colour development. • Protease and lipase activities - Proteolytic and lipolytic enzymatic activities of the cultures actively contribute to the development of distinctive flavours. • Catalase activity - Catalase and pseudocatalase activities of culture bacteria degrade the oxidizing peroxide produced by intrinsic spoilage flora, thus preventing off-flavour, greening and rancidity. • Inhibiting properties - Acidification and specific inhibitory systems, such as metabolites and competitive exclusion, control the growth of undesirable microorganisms, including spoilage and pathogenic flora. Texel maturation cultures delivers a full spectrum of functionalities, suitable for developing texture, colour and flavour intensities. Maturation starters can also be
used in the development of new meat products. Texel range of surface cultures consist of single strains or blends of mould (Penicillium sp.) and yeast (Debaryomyces sp.) strains and are traditionally applied in the manufacture of products to secure an optimum product appearance, authenticity and consumer appeal. •
About Orchem The Orchem’s Food Ingredients Division’s goal is to partner with customers to help their businesses grow, by supplying world class ingredients, high service levels and advanced food science technology. Its food technology services include new product development, recipe optimisation and troubleshooting. Orchem is the official distributor of the DuPont Danisco range of functional ingredients.
Orchem – www.orchem.co.za
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MEAT REVIE W 5
M AT R I X S O F T WA RE
Quality processes – an essential part of the meat value chain During the meat supply and processing sequence, all processes must be accurately documented - from the farm to the final packed product. As processes and product lines continue to evolve, it is important for quality control to evolve too.
“Matrix Software has developed a customisable, integrated quality control module that allows for the elimination of paperwork” as well as update relevant data within the process for Matrix Software. These allow for improvements to quality control to be pro-actively managed resulting in quality products for the customer. The platform is aimed at being easy to use, customisable, and able to fit into and evolve your quality control system. This is done through the creation of your
On premise ERP factory floor solution Time driven stock control Multiple warehouses Industry specialists Unique serial numbers Accurate stock ageing
own document templates which is used to capture your data instantly. The easy to use platform gives quality controllers the chance to manage the process on the move and as part of the production process, with visibility of product flows at all times. • Matrix – www.matrixsoftware.co.za
Hardware integration (Scales, Printers, Probes etc) Forward and backwards traceability Manufacturing yield management Various technologies used (mobile solutions included)
SOFTWARE SOLUTION FOR THE MEAT, FOOD AND BEVERAGE INDUSTRY
6 MEAT REVIEW
· ISSUE 4 2020
www.matrixsoftware.co.za
Q
uality control can be time consuming and tedious, often leading to reactive corrections after results are collected. These challenges have resulted in the need for instant, bespoke solutions that fit each level of the production line. With instant data collection, data analysis can be done faster and pro-active solutions can be implemented. Matrix Software has developed a customisable, integrated quality control module that allows for the elimination of paperwork by allowing users to electronically capture predefined customised templates. These documents are web-based giving support to use with tablets and mobiles. These templates can be populated with information from processes automatically,
CPG
Take care of all your certification needs Certification Partner Global is a full scope JAZ-ANZ and SANAS accredited (SANS 10330) certification body.
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he company strives for excellence in certification without being pedantic and breaking the sprit of our clients. “We want them proud and excited about certification and the audits,” Elsie Stricker, certification manager enthuses. Although an international certification body, the agency for Africa is run from South Africa. This allows CPG to charge local rates with local auditors that understand the country’s unique set of challenges. Audits conducted include the following: HACCP SANS 10330, HACCP Codex Alimentarius, FSSC 22000, GFSI Basic, GFSI Intermediate, ISO 22000, ISO 9001, ISO 14001, ISO 45001, ISO 22301, ISO 27001, ISO 20000, ISO 50001, upgrade audits and upgrade training. “We also offer integrated audits. New ISOs allow us to do integrated audits - one audit a year for all facilities’ ISO standards. it is also accredited to conduct HACCP (SANS 10330) audits to assist our clients in the
3 Year Audit Cycle Stage 1
Stage 2
Surveilance 1
meat industry to comply to the regulations. Having a Certified Food Safety System not assists in ensuring safe products, and aids in traceability, import and export, sales to major retailers, compliance to legal requirement and peace of mind,” Stricker explains. The certification process is a relatively easy. A client can request certification or move from one certification body to another in any stage of the audit cycle regardless of the contract signed. If scheduled for a surveillance 2 before the switch, the new body will conduct a surveillance 2 in the scheduled month so the cycle will not be disrupted in anyway. The process is as follows. • Request certification/take- over • Form sent for information
Surveilance 2
Trienial/Recert
about organisation • Complete the form and send it back • Quote • On acceptance a date is scheduled • Audit will be done • Report will be sent • If audit was satisfactory, a certificate is issued. •
There is a discounted rate for all members of SAMPA, RMAA, SAFA and butcheries. It is also open to readers of Food Review and Meat Review. Use the code MR072020 when you request your quote to qualify.
Certification Partner Global – www.cpg.global
CPG is a fully JAS-ANZ accredited Certification Body and is SANAS Accredited for SANS 10330
Certification/Audits On: HACCP SANS 10330 HACCP Codex Alimentarius FSSC 22000 ISO 22000 GFSI Basic GFSI Intermediate
076 443 0235
Elsie.stricker@cpg.global
ISO 9001 ISO 14001 ISO 45001 ISO 22301 ISO 27001 ISO 20000 ISO 50001
Foot Print in South Africa and Africa
CPG
cpg_certification
CPG SA
ISSUE 4 2020
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MEAT REVIE W 7
LT L
Leaders in the food industry for the last 30 years LTL Group is made up of two independently run companies - MLS National Laboratory Services and Supplies and LTL Auditing and Inspections services.
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oth aim to work with clients to ensure the safe production of food and beverage items and are committed to competitive pricing so that everyone, regardless of the size of the enterprise, can have access to audits, inspections, and laboratory services. Facilities are open 24 hours, every day of the year. “No matter the day, time, or location we can always assist,” enthuses Joubert De Roubaix – technical manager for LTL Group. MLS National Laboratory Services and Supplies is a fully SANAS Accredited Laboratory. The company is based in Midrand
and Cape Town with a large footprint throughout the whole of South Africa. “Our Methods enable us for certain tests to provide a prelim report within 48 hours and a final report within five days,” laboratory manager Daisy Khumalo points out. “Our latest addition is the rapid detection of the SARS-COV-2 (Coronavirus) Virus on environmental swabs. “ Services include microbiological, chemical, organoleptic, nutritional, aflatoxins, allergens, DNA, effluent water, pesticides, residues, shelf-life, sample packs, sample collections, trend analysis and more. An electronic Lims System allows clients to access all their results and trend analysis, graphs and monthly or quarterly or annual reports within a dashboard personalised to them.” LTL Auditing and Inspections Services have been conducting food safety, hygiene, health and safety, COVID-19, pre-and post-cleaning audits and inspections, technical assistance, regulatory assistance, complaint investigations amongst
Fast fact:
MLS and LTL have a discounted rate for both audits and laboratory analysis for the meat Industry. Members of SAMPA, RMAA, SAFA and butcheries already qualify for this rate however we are opening it up to all readers of the Food Review and Meat Review until the end of the year. Use the code MR2020 when requesting your quote.
others. The industries we are currently working with includes farms, feedlots, pack houses, abattoirs, food and beverage, processing plants and packaging, amongst other sectors. “We have qualified, knowledgeable auditors in all provinces of South Africa and well as some African Countries that enable us to assist anyone anywhere at a moments notice,” De Roubaix concludes. •
LTL Group – www.ltlgroup.global
Industries Services
Food and Beverage Farms/Feedlots Packhouses Manufacturing (All Industries) Abattoirs (All) Processing Plants (All) Retail Catering Restaurants QSR - Quick Service Restaurants Petorleum Pet Food Packaging
Food Safety Audits Hygiene Audits Health and Safety Audits Inspection Services COVID-19 Inspections Technical Assistance Regulatory Assistance Complaint Investigations Mystery Shopper
Connect with us 010 010 0685
Task@ltlgroup.global
082 853 2247
LTL Group SA
8 MEAT REVIEW
LTL Group
· ISSUE 4 2020
Our Methods enable us for certain test to submit prelim results within 48hours and final reports within 5 days
Services
Effluent Water Pesticides Residues Shelf-Life Sample Packs Sample Collections Trend Analysis
Microbiological Chemical Organoleptic Nutritional Aflatoxins Allergens DNA
Connect with us
Footprint in South Africa and Africa
ltl_group
082 853 2247
MLS National Labs
Info@mlslabs.co.za
LTL Group
Labs in Midrand and Cape Town
mls_labs_
From one
brave team to another‌
Thank Thankyoyou u to toeveryone everyone in manufacturing and an essential d essential services serv ices for keeping for keepithe machines ng t he machines running run and heves shelves sto stocked, cked, durin duringthe the COVID-19 V I shutdown. th e
You are the unsung heroes!
Our #PurplePeople salute you!
New Media, a division of Media24 (PTY) Ltd.
M E TA L D E T E C T I O N & I N S P E C T I O N
Ensure quality and food safety with product inspection technology Microsep offers a comprehensive range of product inspection equipment solutions for all packaging and processing aspects of the F&B industry. Peter Anderson takes us through some of the applications for the weighing and inspection of wet, dry, fresh and frozen food.
T
he product range includes dynamic
dairy and bakery products, slurries, semi-
METAL DETECTION SOLUTIONS
checkweighers, sophisticated metal
solids and fluids. The technology ensures
contaminant detectors and innovative
complete product safety and integrity,
The versatile range of Safeline Metal Detectors
X-ray-based inspection technology systems.
thereby protecting consumers and helping
These units can be integrated into production
manufacturers avoid product recalls.
lines using state-of-the art software to
It utilises innovative technologies designed
facilitate greater control and traceability in
to provide complete inspection coverage. Units
all processes.
are capable of simultaneously performing various inspection and in-line product
X-RAY-BASED INSPECTION SYSTEMS
quality control and integrity checks at high
Mettler Toledo Safeline X-ray systems offer
production-line speeds, without damaging
safety and quality assurance throughout the
products. Product quality checks include
production process for raw, bulk-flow (loose),
the automatic detection and rejection of
pumped and packaged products. Neither
contaminated, missing, trapped or damaged
foil nor metallised film packaging affect the
products in packaged and unpackaged
sensitivity of contaminant detection by using
items, monitoring of fill levels, cap and
X-ray technology. F&B manufacturers rely on
container inspection in glass and canned
Safeline X-ray systems to protect the welfare
food applications. X-ray systems can be easily
of consumers, safeguard brand reputations,
integrated with existing production conveyors
minimise the risk of expensive product recalls
and take up minimum line space, providing
and assist with regulatory compliance.
quick, easy and cost-effective inspection.
These systems offer versatility across many
X-ray systems placed early in the production
offer maximum detection sensitivity to detect smaller metal contaminants when inspecting products that are wet, hot, chilled, cooling or packed in metallised film in food and beverage product applications. Detection of all metal types including ferrous, non-ferrous and even difficult to detect non-magnetic stainless steel is possible. Various models and options are available to inspect bulk, free-falling fine powdered and granular products, as well as pumped liquids, pastes, slurries, high-viscosity fluids and vacuum-packed products. Metal detectors can be integrated with conveyors, other equipment and into production processes to reliably detect a contaminated product and reject it from the process flow, providing fullyautomated in-line inspection. The equipment assists with compliance to national and international food safety standards and with
applications and are designed to effectively
line ensure contaminants can be removed
detect and reject dense contaminants
at the source before further value is added,
within products, irrespective of shape, size
reducing food waste, saving costs, ensuring a
or location. X-ray systems deliver superior
future-proof investment and thus reducing the
HIGH-PERFORMANCE CHECKWEIGHERS
detection of contaminants such as calcified
total cost of ownership (TCO).
Garvens’ range of high-performance
bone, stone, glass, glass-in-glass and high-
checkweighers combine reliable weighing
density metal, plastics or rubber within a wide
accuracy with rugged machine design.
range of retail packaging, glass containers, canned foods, unpackaged food products (includes frozen-formed products), bulk-flow food products prior to packaging, pumped products (typically poultry and meat),
retailers’ own codes of practice.
Systems are available with IP69-rating, Safeline X34 x-ray system's automated product set-up and intelligent software improves production uptime, reduces manufacturing costs and enhances detection sensitivity.
are fully waterproof, proven resistant to most caustic detergents and highpressure cleaning and ideal for use in harsh production environments. Checkweighers verify the weight of a product on the
The Safeline X3725 X-ray system simultaneously inspects products for contamination and performs product integrity checks to ensure brand protection
production line, with the capability to detect and remove any underfilled or overfilled packages from reaching consumers. Load cells that power the checkweighers are able to filter out environmental noise that could influence the weighing result, meaning a reduction in false rejects. This ensures manufacturers comply with the local weights and measures regulations and industry standards. More importantly, it helps to lower production costs by reducing wasted product through the use of realtime feedback and automatic adjustment to filling equipment. •
Microsep – www.microsep.co.za
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Food Review | July 2020
Looking for the Perfect Solution for Your Food Safety Inspection Needs?
We understand that you need total confidence in your product inspection systems to maintain product quality and meet international food safety standards and local retailer codes of practice.
METTLER TOLEDO product inspection solutions can help you achieve: • Brand protection • Cost reduction • Compliance • Increased productivity
Checkweighing Solutions
Metal Detection Solutions
www.mt.com/productinspection
X-ray Inspection Solutions
Johannesburg: Tel: (011) 553-2300 • Cape Town: Tel: (021) 914-0393 Durban: Tel: (031) 701-4705/6 • Port Elizabeth: Tel: (041) 365-5168 e-mail: info@microsep.co.za www.microsep.co.za
M E TA L D E T E C T I O N & I N S P E C T I O N
Foreign material detection that beats the myth The use of X-ray technology during food inspection is growing in popularity. These machines can locate metal particles, glass, ceramics and even dense plastic. contaminants float in the water, it is not necessary to perform further testing. Under usual circumstances, a single energy X-ray system will not be able to find it. If it does not float, it is worth to discuss with X-ray experts, who might have local test facilities for further investigation.
MYTH 2: X-RAY INSPECTION NEEDS SPACE In the food industry, space is always an issue, especially for the integration of new equipment into existing production lines. One approach is to fully integrate a X-ray unit into a thermoforming and filling machine (FFS), e.g. for yoghurt cups. Another approach is combined units: There are always specified space requirements for radiation protection, so this space can be used to fulfil other inspection tasks. The
Easy product setup on the SC-2000 Mini
Wipotec-OCS SC-W is an example of a fully integrated solution of check weighing and
B
X-ray with low space consumption, with esides looking for foreign bodies,
Soda-lime glass consists of silicon
additional vision inspection. If these systems
there are more checks available with
dioxide – but there is a variation
are integrated, there are additional benefits:
an X-Ray unit. It facilitates quality-
concerning the percentage. Packers of
The product changeover is much faster; it
and filling checks on bottles and cups,
glass products use mostly recycled glass,
works on one common statistic and less
ideally used with products such as yoghurt
which could lead to differences as a myriad
training is needed.
or tomato sauce. In other food segments,
of ingredients, additives and contaminants
pizzas are checked if they are perfectly
are used - increasing the absorption of
developed the SC-2000 Mini X-ray scanner.
round, pralines counted in the tray and
glass dramatically. Silicon alone has an
It is designed for small products, like soup
cheese classified according to ripeness.
atomic number of 14, similar to Aluminium
pouches, cereal bars, chocolate or small
(13), which leads to similar absorption. If
trays. Depending on the application, it only
MYTH 1: HIGHER DENSITY LEADS TO HIGHER DETECTABILITY
the glass is contaminated with a little bit
requires 500mm of line space. If a reject
lead (atomic number 82) it will have a much
is required, machines with 700mm line
A common belief is that X-Ray systems
higher absorption rate – even if the density
space are possible. The width of the unit
rely on the density of a foreign body for
might be similar.
is also small. The modular design enables
the system to detect a contaminant. This
This effect becomes more important
For small products, Wipotec-OCS
individual solutions for each application.
knowledge is not wrong, but not correct
when it comes to comparison tests
Nevertheless, the SC-2000 can work with
either. The reality is that the material
between different X-ray systems. When
an inspection speed of 90m/min, high
characteristic that describes the absorption
different test spheres are used, it is not a
X-ray power (and therefore detection) and
of radiation (and therefore the detectability)
machine comparison, but a comparison of
the same powerful software as all the big
depends on its atomic number.
the absorption of the test spheres.
Wipotec-OCS machines. Wipotec is supplied
For the detection of glass, this
Speaking about density for day-to-day
information is crucial. Glass is not a strictly
applications is not wrong: If a foreign
defined material composition like Stainless
object occurs in the factory, quality
Steel 316.
assurance can perform quick tests. If
36
Food Review | July 2020
locally through USS Pactech. •
USS Pactech – www.usspactech.co.za
HYBRID DRINKS
Heavy beverage loads just got lighter A large South African beverage producer found that its forklift side-shift pads could not cope with typical two-tonne beverage loads - carried by a single double-pallet-handler forklift. The company turned Vesconite Bearings for a solution.
S
ide-shift pads are located between the forklift attachment and the carriage of the forklift. It allows the user to shift a
load for quick and accurate placement by a stationary forklift onto a goods truck. In this case, the originally-installed pads were quickly bitten into by the forklift attachment when moving the heavy beverage-containing pallets. “The original nylon pads lasted about two weeks until they started being bitten into. We then had to use silicon spray,” explains the company’s forklift technician.
“…company supplied a modified pad design with smooth dirttrapping grooves on the loadbearing side, which would allow a smooth side-shift motion on a self-lubricated surface while trapping environmental dirt and debris”
The side-shift pads, have shown almost no wear in five months
other South African distribution-hub forklifts.
that extends the forks to create a double-
Forklifts operate at 80% weight capacity since
pallet handler.
its forklifts can handle three-tonne loads. Since forklifts are an integral part of the company’s business, which relies on efficient materials handling and logistics to supply large volumes of beverages, an intervention was needed.
Since the Vesconite Hilube side-shift pads
The polymer will eliminate the use of grease on the forklifts, which will be desirable in a
are working so well, the manufacturer is also
food-contact environment and ensure clean,
investigating other parts of the attachment
grease-free packaging. •
in which grease-free Vesconite Hilube can be used. This includes plain bearings on the shaft
Vesconite – www.vesconite.co.za
Vesconite Bearings answered this requirement by supplying load pads in Vesconite Hilube, its proprietary engineered, self-lubricating, wear-resistant polymer. The bearing and wear material company supplied a modified pad design with smooth dirt-trapping grooves on the load-bearing side, which would allow a smooth side-shift motion on a self-lubricated surface while trapping environmental dirt and debris. The design was further modified to have two larger fillets on the reverse side where the locating pins protrude from the pad to combat the stress concentration caused by the side-shift movement. The side-shift pads showed almost no wear between September 2019 and February 2020 - a more than 1 000% improvement on durability experienced in the past. The beverage company has installed Vesconite Hilube side-shift pads on one operating unit’s factory forklifts and one of its other unit's forklifts, in South Africa and will roll out the polymer pads on its
New canning lines moves with the times Twizza has commissioned a new production canning line at its factory in KwaZulu-Natal for its popular Clark & Sons mixer range.
A
s a small start-up, the new plant
as well as all can sizes. The plant is
marks a significant milestone and
positioned as a modern production line
is an indicator of its growing
producing the highest quality beverages. •
presence in the carbonated soft drink sector. The line can run 3 600 cans per hour and the cannery will also offer contract packing as and when it has spare capacity. A fasthigh spec line has been installed, which is automated – from depalletiser to palletiser and through to the finished product. The plant, which runs preprinted cans, has been designed to be flexible and accommodate any configuration on packaging
July 2020 | Food Review
37
HYBRID DRINKS
Combidome carton bottle makes a splash SIG Combibloc Obeikan and the Zaki Group have launched a first in UHT liquid dairy – the one-litre combidome carton pack – in the Middle East and Africa. Food Review looks at this innovative technology and how it can impact the local market.
T
he new premium family-size pack
witnessed an increase in demand for
under the Qirat Iraq brand will
family-size shelf-stable milk since the
cater for three product categories:
COVID-19 pandemic started together with
full fat, low fat and fat free white
an increased global demand1. As families
milk. This announcement represents a
are staying safe at home, purchases
continuation of the group’s strategy after
have been focused on shelve-stocking of
the recent launch of its first single-serve
milk products.”
dairy product in the region. Bahaa Zeidan, general manager of the
He adds, “We firmly believe combidome is an excellent fit for the company’s ideas.
Zaki Group, says, “With our new packs,
For the UHT filling of products, the packs
we are presenting UHT milk products that
must meet the highest requirements for
are unique and premium – shifting our
sterile use. Germs can reproduce much
strategy to cater to growing demand in
more readily in a low-acid environment
family-sized products.”
such as milk than they can in a product like
Combidome is an innovative pack
juice. The filling machines for combidome
that looks and handles like a bottle
and the corresponding carton packs take
while offering the benefits of a carton
this into account, so manufacturers can
pack with regards to environmental
flexibly fill all kinds of beverages.”
and logistical advantages. The aseptic process ensures that consumers can rely on high-quality, tasty beverages with natural nutrients, vitamins, flavours and colours. The carton structure blocks light and air. This ensures that products can be stored for a long time without refrigeration or preservatives.
COMBINED EXPERTISE MOVES FUTURE PACKAGING Established in 2001, the joint venture is a result of the shared vision of SIG Combibloc (Switzerland) and the Obeikan Investment Group (Saudi Arabia) to offer total aseptic packaging system solutions and tailored customer support to the food and beverage industry across the Middle East and Africa. The combined expertise of the two companies has enabled SIG Combibloc Obeikan to offer the very best in technology to the region and further strengthened its position as a total aseptic packaging solutions provider. With nine offices located strategically across MEA and a state-of-the-art production facility in Riyadh, the companies retain its fundamental purpose: to offer worldclass products and services while understanding first-hand the local needs and requirements of customers and the market they operate in. SIG Combibloc Obeikan’s portfolio of clients contains some of the biggest brands within the long life milk and juice market segments.
“The market launch of milk beverages in combidome marks a milestone in this
Combidome, the carton bottle from
market with locally produced products.
SIG, combines the best features of a
We are confident that by choosing
carton pack with the best features
combidome, we are setting ourselves
of a bottle, making it different from
up for clear differentiation in the dairy
anything seen before in food packaging.
segment with high-quality products
In 2014, the exceptional design of
specially localised for our customers,”
combidome was recognised with one
Zeidan points out.
of the world’s most important design
Zaki Group’s partnership with SIG
accolades: the iF Design Award. The
Combibloc Obeikan is growing steadily.
carton pack’s remarkable design also
The group benefits from the full flexibility
creates numerous logistical advantages
of existing lines with a vast and varied
with which substantial savings can be
portfolio that includes 13 single-serve sizes
achieved in total system costs. •
(from 80ml to 350ml), and three family-size packs (500ml, 750ml and 1000ml). Abdelghany Eladib, chief operating
Sources: 1. COVID-19 Effect on Packaged Food Study – from Euromonitor International, April 2020.
officer, SIG Combibloc Obeikan, explains, “Zaki Group is a partner that continues to grow and expand while launching new products that should be accompanied by the best innovative solutions. We have
38
Food Review | July 2020
There has been a marked increase in shelf-stable milk demand since the COVID-19 outbreak
SIG Combibloc Obeikan – www.sig.com
E N D - O F - L I N E PAC K AG I N G
Tips for correctly handling vacuum pumps Vacuuming fresh food using chamber machines is a daily activity in the food industry. This article explains the physical operations performed during the packaging process and some practical advice to ensure trouble-free operation and a long service life for the vacuum pump.
F
resh food contains unbound
Figure 1
water, which partially evaporates during vacuum packaging. This
can have an influence on the quality of the product. If the packaging machine is not permanently in operation, the packaging result may deteriorate, or the packaging process may take too long. If this happens, the food to be packaged will lose weight. R5 oil-lubricated rotary vane vacuum pumps from Busch Vacuum Solutions are standard (Fig. 1) in chamber machines and are used by all renowned manufacturers. They have been specially developed for packaging food and have a proven track record. Through continuous advancement, these pumps have achieved the highest possible quality standard (Fig. 2).
Figure 2
“The quality of the oil in vacuum pumps and the correct quantity play an important role in the packaging process and in protecting the pump” Fresh food such as meat, sausages, fish, and cheese are usually vacuum-packed at a pressure of around five millibar. At this pressure, oxygen content in the remaining residual air is so minimal that the activity of various micro-organisms is prevented. This significantly increases the shelf life of the packaged product. These low pressures can also cause water to start evaporating at low temperatures. While water at normal atmospheric pressure only evaporates or begins to boil at a temperature above 100 degrees Celsius, at a pressure of 30 millibar it starts to evaporate at room temperature. At a pressure of 8 millibar, water evaporates already at a temperature of 4 degrees Celsius – even in cooled rooms (Fig. 3). For this reason, fresh food always
Figure 3
BUSCH VACUUM SOLUTIONS' AFRICA OFFERING:
The group is present in 42 countries with 60 subsidiaries and an extensive portfolio of vacuum pumps, blowers, compressors and complete systems. HQ in Africa is located in Johannesburg, with branches in Cape Town, Durban and Accra in Ghana. All offices have workshop service and repair facilities and carry stock of vacuum and overpressure pumps to support industry. Busch South Africa employs engineers and technicians to support its highquality vacuum technologies and provides expert advice to customers seeking solutions for a vast range of manufacturing applications. Food packaging and processing is the most important market for Busch globally and 95% of vacuum pumps sold into the food packaging and processing industry worldwide are rotary vane vacuum pumps. There are currently just over 2.5m Busch R5 vacuum pumps operating worldwide.
generates water vapour during the
July 2020 | Food Review
39
E N D - O F - L I N E PAC K AG I N G
Meet demand for mono material lidding film Fexible packaging and lidding films supplier KM Packaging is meeting the demand for mono-material food packaging with mono polymer structure lidding films.
T
packaging process, and this water needs
inside the pump. This leads to an
to be extracted by the vacuum pump
accumulation of water in the interior and
together with the air from the packaging
in the oil of the vacuum pump.
chamber. If the vacuum pump rarely or
This causes the oil to lose its
never reaches the operating temperature
lubricating and sealing function, which
due to very short run times, the water
can have a negative effect on its
vapour condenses almost completely
performance and service life.
RECOMMENDATION FOR OPERATION
pump and the packaging machine
To ensure the reliable and trouble-
Solutions has developed special
free operation of chamber machines,
oils for vacuum pumps in packaging
the following should be observed:
machines. It is suitable for packaging
1. Let the vacuum pump warm up
very moist products, since it has
before packaging
been designed for the extraction of
he company offers mono polymer
To do this, simply run the packaging
air with a high water vapour level.
lidding films for all food tray types
machine five to ten times without
For less moist food, the VSL vacuum
including PP, Alufoil, CPET and APET. This
any product and packaging bag.
pump oil can also be used. Both oils
Make sure the chamber is dry.
are food-grade synthetic oils with H1
is particularly relevant to the meat, poultry,
functions properly. Busch Vacuum
fish and seafood markets and weld seal mono-
2. Use the service programme regularly
approval. They have a service life of
material lidding films is available within the K
Most chamber machines have
up to four times longer than mineral
service programmes, which ensures
oils. Busch also offers suitable
The packaging features an all-polyester
that condensed water vapour that
oils for packaging with oxygen as a
structure and is available with a high-oxygen
has mixed with the oil is removed
barrier. it offers exceptional transparency, with
from the vacuum pump. This
5. Service your vacuum pump regularly
excellent anti-fogging properties, and weld
should be done at least once a
The vacuum pump in a chamber
seals to rPET or APET trays.
week. Depending on the packaging
machine should be serviced
machine, it takes between 10 and
regularly. The service intervals
manufacturers thanks to the entire single
20 minutes. The vacuum pump is
depend on the operating
polymer pack being designed for recycling in
brought to operating temperature so
conditions, the number of
the PET recycling stream.
that the water in the vacuum pump
packaging cycles, and the type of
evaporates again and is discharged.
goods to be packaged. A reliable
SEAL range.
It is a sustainable material choice for food
modified atmosphere.
KEY FEATURES INCLUDE:
3. Check oil level and oil quality weekly
indicator of when an oil change
• Mono structure made of one material type.
A visual inspection should be carried
needs to be performed is the visual
• Designed for recyclability.
out once a week to check that the
• High oxygen barrier available.
oil quantity and quality are correct.
• Exceptional transparency.
This can be done quickly and easily
• Excellent anti-fogging.
through the oil sight glass. The
filter in the oil separator should
• Ideal for protecting meat, poultry, and fish
oil in the vacuum pump should be
always be replaced as well. For
MD Charles Smithson says, "Manufacturers
colourless or yellowish and clear. If
vacuum pumps with a pumping
within the meat and fish industry face the
the level falls below the MIN mark on
speed of 25m3 per hour or more,
problem of how to move to more mono-material
the oil sight glass, oil must be topped
the oil filter needs to be changed.
solutions to avoid putting multi-layer trays
up. If the oil is milky and cloudy, this
The sealing rings on the service
and films with different plastics combined
is a sign that water has mixed with
openings should also be replaced
into the market? Our product enables them to
the oil and formed an emulsion.
in order to prevent leaks. Busch
switch from hard-to-recycle mixed polymer
The service programme then needs
offers service kits for all R5 vacuum
plastics, for example a PET/PE food tray, to a
to be run. If this has no effect on
pumps, which contain all the
mono-polymer food tray with the same mono-
the visual condition of the oil, an
necessary parts. The company also
polymer top film to seal to it. Offering excellent
oil change needs to be performed.
offers a global maintenance service
weld seals to PET trays, K SEAL has exceptional
Darkening of the oil is a sign that
so that this work can also be
clarity, anti-mist, and an effective barrier,
some substances, for example spices,
carried out by a service technician
performing in the same way as existing films
have been deposited in the oil or that
directly at the customer’s
used by meat and fish packers, while providing
it has aged too much. An oil change
premises. Different types of service
a packaging solution that is 100% designed for
also needs to be performed if this is
recycling in the number 1 PET recycling stream.”
the case.
condition of the oil, as described under point 3. When changing oil, the exhaust
contracts are available. Observing these instructions will
4. Use suitable vacuum pump oils
help to ensure trouble-free operation and
The quality of the oil in vacuum
a long service life for the vacuum pump,
multi-layer and laminated materials for food
pumps and the correct quantity
as well as optimum packaging results. •
packaging due to the difficulties of separating
play an important role in the
them for recycling. •
packaging process and in protecting
Many tray manufacturers are also responding to the demand to move away from
the pump. It is essential to choose
www.kmpackaging.com
40
Food Review | July 2020
the correct oil to ensure the vacuum
Busch - www.busch.co.za
Worldwide No. 1 in Vacuum Packaging Discover the wide range of options for using vacuum in food packaging production and processes. We offer dry-running and oil lubricated vacuum pumps, liquid ring vacuum pumps, blowers, full service and repairs.
Ask for vacuum technology by Busch!
Busch Vacuum South Africa (Pty.) Ltd. 87 Mimetes Road | Denver, Johannesburg Phone: +27 11 856 0650 | info@busch.co.za l www.busch.co.za
E N D - O F - L I N E PAC K AG I N G
Your go-to partner for food processing and packaging tech In January 2020, Bosch Packaging officially stepped out of the Bosch brand and into its own identity – Syntegon Technology. Food Review looks at how 150 years’ experience in future-orientation and a premium technology portfolio has resulted in a reliable and flexible company.
W
ith over 2 000 patented inventions,
and maintenance. Format changes are tool-
of shelf-ready packaging and want the machine
6 100 employees and over 64 000
less, easily repeatable, and can be completed
to pack a wide range of pack styles. Customer
installed machines, Syntegon
by just one operator in ten to 12 minutes. With
requirements for unique packaging designs and
sets standards for others to follow when it
its open-channel stainless steel frame and
format sizes are always individual. Syntegon
comes to developing innovative packaging
angled surfaces, the machine complies with
works closely with its customers to develop
solutions. The company is focused on delivering
stringent sanitary standards. The unit is IP65
suitable solutions. The primary target is to
tailored manufacturing processes designed to
washdown-rated, which makes it easy to clean.
create an attractive and transport-safe case
make high-quality products with the utmost
An additional feature is the optional open
design as well as the possibility to place it on
reliability. Everything is available from a single
flap detection to prevent opened or partially
the shelf in a time-saving and resource-saving
source: from the 150m production line to the
opened cartons from exiting the machine, which
manner,” she elaborates.
0.5mm spare part.
ensures high product quality.
packaging machines. The technology includes
a lot of flexibility in packaging comes true
KEEP UP WITH RISING PRODUCTION DEMANDS
the Kliklok Cascade Loading system with
with the new Elematic 2001 case packer. The
The Sigpack TTM was a new solution for one
direct-drop product timing and loading; the
new machine offers a reduced footprint and
of the biggest key players in Latin America.
Kliklok new BEC entry-level endload cartoning
maximum flexibility in terms of pack styles.
Among their most popular product ranges
machine and mid-range MEC endload cartoner.
Whether you require a full wrap-around, a tray
are their chocolate and cereal bar brands.
For case packing the following units round off
with hood, tray without hood or ledge tray –
To keep up with rising production demands,
the portfolio: Elematic 1001 (RSC), Elematic
everything can be packed on just one machine.
the manufacturer was looking for a way of
2001 for the wrap-around case and high-speed
The system offers high performance, a small
upgrading the previously manual secondary
toploader Sigpack TTM.
footprint and quick changeover times.
packaging process to a faster, automated and
A strong focus for Syntegon is its end-of-line
The dream of having an easy workday and
The Kliklok Cascade Loading system uses a rotor vane system to drop products on the product infeed conveyor flights of endload cartoners, such as the Kliklok MEC. It typically handles 113g or heavier bags of food and stands out for its hygienic stainless steel design, which is IP65-rated. The independent design and computer
more reliable solution.
“… technology includes the Kliklok Cascade Loading system with direct-drop product timing and loading, the Kliklok new BEC entry-level endload cartoning machine and mid-range MEC endload cartoner”
logic of the Cascade Loading system support
into cartons in packs of 6, 12 and 24 − without causing lengthy downtimes. Besides this, a high output would need to be realised within the compact layout of the existing production facilities. During their search for suitable technology,
electronic indexing, to fill each flight of the cartoner’s infeed conveyor. With the cartoner
The cartoner had to be flexible enough to package bars of different shapes and sizes
the company was drawn to the Sigpack TTM The Elematic 2001 case packer impresses
toploading equipment from Syntegon. The
operating at matching speeds and higher
with its flexibility. The flexibility of this case
TTM’s operator-friendly design with fail-proof,
efficiencies, manufacturers will have less wear
packer means that all wrap-around pack styles,
fast and fully-reproducible changeovers, as well
and tear due to “overrunning”. If one bagmaker
such as full wrap-around and trays with and
as its flexible infeed possibilities, won over the
is temporarily removed from operation due to
without hood, can be packed on one machine.
Latin American team.
reduced product availability or maintenance
The unit can also handle different format sizes
needs, the remaining units can be electronically
and packaging designs. “Up to 100 designs and
bespoke interface between the TTM and other
reassigned to maintain full efficiency in filling
more are possible. We understand the market
upstream packaging equipment was developed.
In close collaboration with Syntegon, a
every flight of the cartoner. Simple operation controls enable pocket rededication without disturbing the system’s ongoing performance. The Kliklok MEC is designed to handle a wide range of carton sizes and packs up to 170 cartons per minute. “We’ve designed the unit to meet our customers’ needs for future-proof sanitary construction, ease of use and maintenance. It also stands out for its fast format changes and good access,” says Janet Darnley, product manager at Syntegon Technology. The endload cartoner has full-length doors that allow walk-in access for easy changeovers
42
Food Review | July 2020
The Kliklok MEC is designed to handle a wide range of carton sizes
E N D - O F - L I N E PAC K AG I N G
A feeding wheel copes with the high speeds that
Carton erection can be an Achilles heel in
connect both elements of the line to ensure
automated packaging solutions as it has the
a smooth and harmonious production flow.
potential to slow down productivity. Difficult
The Sigpack TTM’s streamlined design meant
to handle carton materials and formats
installation and start-up was swift. With the
can decrease production output, result in
launch of the new line, the changeover times
faulty boxes and jam the production line.
for cereal bar production was reduced from one
The Sigpack TTM is designed to eliminate
hour to just ten minutes.
these issues and achieve a reliable output
At the factory, the new customised interface
with its quick-change format parts and fully-
ensures that flow-wrapped cereal bars are
reproducible format settings and precise
delivered continuously and at even distances
carton handling.
to the discharging conveyor of the toploader.
With its capacity to package bars of various
Arriving lengthways, the flow-wrapped bars are
sizes in four carton sizes using seven different
then gently picked up by an FWV feeding wheel,
configurations, the Sigpack TTM has been a
which turns the products 90 degrees before
resounding success.
placing them sideways into a PGR grouping unit, ready for cartoning.
The new topload cartoner has allowed the company to reach a level of flexibility The endload cartoner has full-length doors that allow walkin access for easy changeovers and maintenance
Quote:
The Kliklok MEC is designed to handle a wide range of carton sizes and packs up to 170 cartons per minute. “We’ve designed the Kliklok MEC to meet our customers’ requirements for future-proof sanitary construction, ease of use and maintenance. It also stands out for its fast format changes and good access” - Janet Darnley is the product manager at Syntegon Technology.
and production output that they were not previously able to achieve with former manual efforts. The automated process, lightweight format parts and tool-free changeover mean that they have been able to speed up changes between products from 60 minutes down to just ten minutes. A single operator can now run, facilitate the changeover and clean the machine. •
Syntegon – www.syntegon.com
Syntegon is a leading provider of processing and packaging technology. As a highly trusted partner in the food and pharmaceutical industries, we supply customers with intelligent and sustainable solutions worldwide.
Syntegon Technology South Africa (Pty) Ltd. | Postnet Suite 17, Private Bag x40 | Midrand, 1685 | SOUTH AFRICA | www.syntegon.com | Aubrey.Pharatlhatlhe@syntegon.com
July 2020 | Food Review
43
E N D - O F - L I N E PAC K AG I N G
Materials handling is being irrevocably changed The palletising and depalletising market is being shaped by the growth of microbreweries and emergence of new categories, as well as the adoption of automation in manufacturing. We spoke to Reinhard Watermeyer, commercial director of HG Molenaar, about how COVID-19 has changed the manufacturing and packaging landscape.
P
eople shop differently now. Media reports quoting a Nielsen syndicated study in April 2020
indicate that 37% of South Africans are shopping more frequently online due to lockdown and the coronavirus pandemic.
“Shorter runs now last a year or two, which means that packages and products are updated more frequently to meet evolving consumer demands”
Top of their list are packaged and fresh foodstuffs, rather than fashion, travel, and entertainment.
bars, pubs, taverns and shebeens are closed, these establishments must find
IMPACTS ARE PULSING THROUGH THE SUPPLY CHAIN Schools, restaurants, canteens and similar typically order catering-size packs, but due to lockdown, consumers have become accustomed to eating at home and don’t typically buy large, catering-size packs. The upshot is that while retailers may be selling a similar volume of foodstuffs as before lockdown began, they are selling these items in smaller packs. This has increased demand for smaller pack sizes that require bigger production volumes. Similarly, most craft brewers used to sell beer in kegs. Since
alternative packaging such as cans to shift their volumes to consumers. That creates pull for more compact, smallerscale depalletisers.
The supplier can meet the turnkey and standalone packaging requirements for large, medium, and niche operations. It appoints best-of-breed can, glass, PET, and HDPE solutions from the international arena, and innovates and manufactures sensibly engineered, bespoke solutions in its Paarl-based engineering and manufacturing facility.
In the midst of all this upheaval is the consumer – with fickle and constantly changing product requirements. This creates additional pull for frequent changes in the manufacturing process. Shorter runs now last a year or two. This means that packages and products are updated frequently to meet evolving consumer demands, fuelling a drive towards flexible palletisers. Manufacturers need palletisers and depalletisers that can be easily reconfigured for different load patterns. Robotic systems are inherently flexible and that is just one of the reasons for their rising popularity. They are better equipped to be reconfigured
Reinhard Watermeyer
Packaging equipment by HG Molenaar
to handle different package types and can be configured to support two lines, dependent on line speeds.
Robotic palletising was traditionally centralised in larger single cells but that is now also transforming so that we’re seeing more decentralised designs at the end of lines. It supports the need for a wider range of flexibility in how manufacturing systems are designed, and it also reduces conveyor costs and maintenance overheads. Adding a layer to the subtle complexity of this market, manufacturers value the total lifecycle cost of the equipment they use on their lines. One of the ways they exhibit this is by wanting additional serviceable features. Many companies have experienced the challenge of using lower quality and less capable machines and the result is that they are less than confident in automation. Another result of poor quality and less capable machines is that companies do not get the returns they expect. The overall effect of these trends is to shape a palletising and depalletising market leaning toward flexible, easily configurable, highquality and serviceable machines that can economically produce volumes of smaller packs. •
Eight HG Molenaar Agile Prime palletisers installed at a California client
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Food Review | July 2020
HG Molenaar http://hgmolenaar-packaging.com
E N D - O F - L I N E PAC K AG I N G
A new wave in potato packing products Like most bulk, dry agricultural items, potatoes can be bagged several times during its journey from farm to consumer. Buckle Packaging understands the importance of bag closing technology to assist in preserving the safe transport and sales of potatoes.
A
ccording to MD, Anthony Mason there are key performances required for the closing of open-mouth bags. “We
are sensitive to keep costs low,” he notes. “We can supply automatic bagging processes that require very light maintenance for operators, with packing lines running continuously to supply high volume output. With the reliability of operation comes less downtime." Mason continues, “Our range of bag stitching machines offer flexibility to accommodate different bag sizes, bag quantities and bag materials. The secure, stitched closures replace the old method of wire ties which were easy to open and remove potatoes.”
Fischbein automatic bag stitcher with foot control
The company offers bagging solutions
both hands free to handle the bag while
carousel stitching units can fit new and existing
directly to the farmer or packer and works
activating the sewing process by a foot
carousel units.
with all major potato handling and equipment
control switch.
supply companies. Many of these OEM’s insist
With these performance options in place, potatoes will be packed securely and
on the Fischbein 100 'sealed in oil' stitching
AUTOMATIC SEWING LINES
efficiently into the chosen type of bag. Using
head as it has proven to be a reliable, durable
For automatic sewing lines, an important
Buckle Packaging's Fischbein equipment, the
and robust machine.
element of the bag closing line is the Fischbein
potato producer is assured of consistently
sewing head. All major internal parts of the
reliable closures that protect their valued
flexible option for bagging potatoes, as
Fischbein 100 sewing head are sealed in oil to
product from the farm to the market and
the spout of the packaging line will accept
avoid dust and dirt and allow for continuous
eventually to the consumer.
various sizes of bags of different materials
operation with minimal wear and tear. The
(paper, polyethylene, woven polypropylene,
Fischbein 100 comes standard with an oil filter
supplying quality stitching machinery, as well
netting etc).
The open-mouth bag is by far the most
Buckle Packaging remains committed to
and internal oil pump, allowing the machine to
as premium quality threads and spare parts.
The body of the Fischbein'F' portable can
work under pressure. The design of the sewing
Performance and innovation have made the
also be installed onto an adjustable pedestal
head is compact, featuring a durable body with
company the leader in bag closing technology. •
to design a complete range of mini-systems for
variable stitch length, variable speed adjustable
manual or semi-automatic operations. Bagging
pulley, easy adjustments of thread tension and
speeds are increased and the operator has
a high-performance knife mechanism. Fischbein
Buckle Packaging - www.bucklepack.co.za
BUCKLE PACKAGING (PTY) LTD Bag Closing Technology
July 2020 | Food Review
45
E N D - O F - L I N E PAC K AG I N G
Quality and innovation you can see Anchortape’s success stems from the group’s ability to provide personalised solutions to the various industry segments. It prides itself on being a prominent player in the production of customised adhesive tapes for several industries – including the food and pharmaceutical manufacturing and distribution sectors.
W
ith a highly-qualified graphics
• Adhesive tape compact 810H
department and the use of the
Compact 810H packaging tape is
latest production technology
in flexographic printing technique, it stands ahead of its competitors due to its precision photographic print quality and total flexibility and personalised service.
designed for manual or automatic
DID YOU KNOW?
Anchortape is a level 1 Broad-Based BEE contributor.
taping machinery applications. The special compound of the glue allows for a strong tack and holding power. The glue is substantially more aggressive in adhering to the substrate or carton than
Branded packaging tapes not only enhances a
Fast fact:
Anchor Technical Tape is a highlyregarded importer, converter and manufacturer of pressuresensitive self-adhesive tapes in South Africa. The company offers a quality-oriented approach to carton sealing tapes and carton sealing machinery and focused quality control results in a unique, highshear line of tapes.
brand’s image, but also offers security to
adhesion properties and easy unwind
packaged products.
ensure a consistent and reliable
“Our flexographic printing can be
seal to a variety of corrugated and
printed with up to eight colours using
linerboard boxes, keeping boxes
the Secure Print or Sandwich Print
securely sealed from the production
technique. Printing is protected
line to the final destination.
between two layers, namely the film and the adhesive.
• Solvent natural rubber 814
“This allows the printing medium
Natural rubber adhesive penetrates
to maintain its brightness and is also
deeper into the fibres, assuring a
very protective against tampering,
superior holding force (high tack)
scratches or damage. With a barrage of
whether manually or automatically
counterfeit goods flooding the market at
applied. Natural rubber adhesives
the moment, this aspect is particularly important,” explains Françoise Palmer, national sales director.
“The quality control department thoroughly checks and inspects all materials before issue to the production line”
The company’s range of technical products offer a scratch-free and tamper-evident finish
any other generic acrylic adhesive tape. The performance is as good as solvent adhesive tapes. • Adhesive tape with hot melt glue 813 The tape is coated with hot melt glue
“Our priority is to always have
and manufactured with adhesive raw
our customers’ needs and quality in
materials from rubber and synthetic
mind. The quality control department
resins. The product works well on
thoroughly checks and inspects all
challenging carton surfaces, and
materials before issue to the production
offers a good affinity to highly-
line. The finished products are again
recycled cartons with its perfect
inspected to ensure our customers are
initial tack.
supplied with a quality product.” Anchortape offers the latest
The tape offers an easy unwind, making it ideal and suitable for all
adhesive technologies through its range
applications. Hot melt carton sealing
of water-based acrylic, hot melt and
tape offers excellent processing
solvent rubber – the latter is ideal for
performance whether manually or
critical applications.
automatically applied. The aggressive
46
Food Review | July 2020
show outstanding cohesion performances that drive to superior resistance in high and low temperature applications where performance is mandatory. Also ideally suited for highly-recycled corrugated cartons. • Anchor automation The company’s packaging portfolio includes end-of-line carton erecting and sealing, and pallet stretch wrapping equipment. A highly-trained sales team and technical department work with clients to identify the perfect end-of-line solution to suit and satisfy each client’s expectations and requirements. This is backed up with excellent after-sale service assistance and support. •
Anchortape – www.anchortape.co.za
THE TOTAL TAPE SEALING SOLUTION
• Entry Level Automation Solutions to Fully Automatic Carton Sealing Solutions • Operator Fed Units to Operator Free Units
ROUTINECLEANING CLEANINGOPTIONS OPTIONS ROUTINE
As the agent for BestPack, Anchor Technical Tape presents the Stainless Steel Range of Carton Sealing Machinery. The Machines are available in various versions from:
• Sealing for Uniform or Random sized cartons • Side or Quad driven options • All Machinery is supplied with Interlock Safety Gates • Inlet and Outlet Conveyors are available as an optional extra
Stainless steel machinery is available in Grade 316 and is a complete water wash down unit. Our Automation Division coupled with our Packaging Tape Division offers the Perfect End of line Solution personalised to suit your needs and requirements. Anchor Technical Tape: 23 Production Road Amalgam (011)837-0940 info@anchortape.co.za www.anchortape.co.za
QUALITY • • INNOVATION INNOVATION • • CUSTOMIZATION CUSTOMIZATION QUALITY
E N D - O F - L I N E PAC K AG I N G
Packaging technology boosts throughput, quality and consistency To conquer new markets or grow market share you need new and interesting products. It was this need that prompted a South African confectionary company to invest in new secondary packaging technology that would allow it to increase total production output based on the new cereal bar line it had created.
T
he company had a number of options,
of Cama’s new Breakthrough Generation
but eventually opted for an IF 316 from
(BTG), which is setting the global standard
leading global secondary packaging
in secondary packaging. The BTG machines
machine builder Cama Group.
comprise modular, scalable frameworks
According to Lars Fröhlich, managing
that offer easy entry and access, coupled
director of USS Pactech, Cama’s agent who
to a hygienic machine design. Within this
covers South Africa and sub-Saharan Africa,
framework, contemporary automation
“The customer chose the IF 316 for a number
solutions, including advanced rotary and
of reasons in addition to its impressive
linear servo technology, are tightly coupled
operational capabilities. As well as having
to in-house-developed robotics, to deliver
a reduced footprint, which is essential in
giving them high accessibility and simple operation. The decision to opt for Cama was also reinforced by our ability to deliver comprehensive local assistance with our highly trained engineers.” The IF 316 – specifically a monoblock loading unit with integral RB 590 robot, forming and box closing machine is part
the all-important flexibility and adaptability required by modern packaging operations. This machine is designed and built by
areas where factory real estate is restricted, the machine also helps the operators by
Robots were developed in-house
“… the IF 316 also delivers reduced changeover times for both the former and the robots, where the motion parameters can be reset in just a few minutes”
Cama in accordance with its cabinet-free designing concept. As a result, the IF316 integrates the electrical and pneumatic components control cabinets into the machine corner pedestals, which helps to minimise cabling and allows the placement of the motion controls close to the moving parts, providing further benefits in terms of accessibility for maintenance tasks.
Do more with less. . .
Higher output capacity with less personnel, as well as improvements in resource and cost efficiency are just some of the factors that make an investment in automatic packaging solutions economically sensible.
F
rom the processing of your product
and requirements - especially during this
to the finished pallet, Multivac can
pandemic, means we can offer a wide range
assist with designing a purpose-fit
of reliable solutions.
solution that will limit the manual handling of your product. The equipment supplier is an experienced
The company develops and produces solutions for product handling to increase efficiency and ensure optimum product flow.
manufacturer of automated solutions and its
They can be used for product infeed and
complete understanding of clients’ products
discharge, as well as end-of-line applications.
Fast fact:
Multivac Automation will enable you to utilise skilled employees in other areas of your facility, increase efficiency, improve uptime and future-proof to grow with your business.
“Our portfolio extends from simple transport Designed with a purpose in mind
conveyors to handling modules, palletising systems and automatic lines,” explains MD Alex Ferguson. Handling modules can automate a wide variety of tasks, quickly and accurately: loading of products, channelling of packs, rejection of defective packs and box loading of packs. Multivac Belt Systems automate the transport, converging and ejection of packs efficiently and hygienically. “Our MCF or the Multivac Centrifuge Feeder is a hygienic solution for gently and
48
Food Review | July 2020
efficiently separating and automatically loading sausages. It provides improved hygiene due to less human contact and cost-saving up to 60% when compared with manual loading. All components are designed in the in-house hygienic design team,” he concludes. •
Multivac – www.multivac.co.za
E N D - O F - L I N E PAC K AG I N G
Each pocket is moved intermittently based
to the next station, where an integrated
packaging of flow-packed snacks bars, but
“The machine is set up for the secondary
on the loading pitch until a pre-set ‘train’ of
electronic closing machine folds and glues
it can be adapted to pack other kinds of
products is obtained ready for transfer to
the lid. The loaded and closed boxes are then
products and can be easily integrated in a
the loading station. Continuous operation
transferred to the loading unit outfeed.
packaging line just before the palletising
achieved by deploying two trains of pockets
station,” Fröhlich explains. “The IF 318
– each fixed to its relevant independent
dimensions, the IF 316 also delivers reduced
also features a so-called ‘no hollow-body’
toothed belt – and alternating the product
changeover times for both the former and the
structure, which means that there are no
introduction into pockets and their transfer
robots, where the motion parameters can be
closed off or hard-to-reach cavities, as their
to the loading station.
reset in just a few minutes,” Fröhlich adds.
frames have open or opening parts.”
The collated products are then picked up
In operation, products arrive in single
“In addition to its high uptime and compact
“This level of flexibility is essential. Agility
by a two-axis robot with a specialised gripper
coupled to maximum efficiency are especially
lane and are spaced by special accelerating
and are loaded into the boxes (which have
important in the packaging phase, where
conveyors before being positioned
been previously formed by an integrated
as well as product variations, packaging
individually into fixed pockets on a double-
electronic erector) and phased to the loading
can also change seasonally or in line with
belt conveyor driven by brushless motors.
area. After loading, the boxes are transferred
promotional activities. Packaging technology
The IF 316 system
has to adapt to what the market needs, and very quickly. Companies simply cannot afford to reinvest in new technology every time there is a market swing, hence the need for highly flexible, multi-capability packaging solutions.” •
USS Pactech – www.usspactech.co.za Cama – www.camagroup.com
July 2020 | Food Review
49
To advertise in WWW.FOODREVIEW.CO.ZA
Coffee time
Anita Raath
Sales executive +27 (0)82 976 6541
Carla Melless
Sales executive +27 (0)83 260 6060
Càndida GiambÒ-Kruger Sales executive +27 (0)71 438 1918
Just for laughs A teacher asked her students to use the word "beans" in a sentence. "My father grows beans," said one girl. "My mother cooks beans," said a boy. A third student spoke up, "We are all human beans." Source: www.laughfactory.com
ADVERTISERS’ INDEX JULY 2020 AMF Bakery Systems.................... OBC......www.amfbakery.com Anchortape...........................................47......www.anchortape.co.za Buckle Packaging................................45......www.bucklepack.co.za Busch Vacuum SA .............................41......www.busch.co.za Cama Group.........................................49......www.camagroup.com GNT Group ..........................................15......www.exberry.com Heat & Control SA ........................17, 23......www.heatandcontrol.com Ice Cold Bodies....................................19......www.icecoldbodies.co.za
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VACANCY: FOOD TECHNOLOGIST ONDERBERG VERWERKINGSKOÖPERASIE, a progressive multi-million rand manufacturing and international marketing concern, situated on the border of the Kruger National Park, is seeking a competent Food Technologist in Malalane, reporting to the Quality Manager.
NEW & USED FOOD MACHINERY – IN STOCK • A&K Corn Cutters & Huskers • FAM Dice, Slice & Strip Cutters • FAM TS-1D Transverse Slicers • FAM PMD Poultry & Meat Dicers • FAM 7944 French Fry Cutters • FAM 7407 Bean Cross Cutters • Feuma Apple Peelers • Femia Bean Snippers • Herbort Bean Top & Tailers
• Eillert 2-stage vegetable washers • Key 4” Hydro Food Pumps • Key Vibratory Shakers • Kronen GS10 Slicers • Kronen KUJ Dicers • Kronen Gewa 3800 Washers • Mado Meat Mincers • Ramon Bowl Cutters • Many Other Machines Available
CALL US NOW FOR A QUOTATION
Food Processing Systems & Technology, Paarl Tel: 021 - 868 -1594 | Fax: 021 - 868 - 1599 Visit us on http://www.eptech.co.za or mailto:info@eptech.co.za
50
Food Review | July 2020
The purpose of this role is to manage all resources in the laboratory including the responsibility of equipment, employees and product analysis and to ensure a strict adherence to food quality and safety standards and hygiene. Minimum requirements: • • •
A valid Diploma in Food Technology or Degree in Food Science or equivalent; Relevant practical experience of at least 3-5 years in a food processing plant in a Supervisory position; and Experience in food safety and food hygiene.
Should you feel you meet the above requirements, kindly forward your CV to: The Human Resources Manager By e-mail: advertmba@mweb.co.za Fax: 086 684 3861 Please quote the following reference number: OVK-LAB/FT. Your application will not be considered for this position if the reference number is not clearly displayed on your CV. If you are not invited for an interview before 10 August 2020, consider your application unsuccessful.
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BUTCHER MEAT PROCESSING EQUIPMENT
MATRIX SOFTWARE
BMPE is the leading supplier of superior quality New and Refurbished Food Processing equipment. Providing professional Service, equipment & spares. BMPE has extensive knowledge of current machines, technologies and consumables and provide a modern Service & Maintenance Department to support our customers throughout their process. Servicing a diverse range of customers, from large & small Butcheries, Abattoirs, Supermarket Groups and Franchise Outlets in the Food, Pet Food and other Manufacturing Industries. BUTCHER MEAT
Matrix Software, specialist leading ERP software providers for the Meat and Food industry, offers various solutions to assist the factory floor function in production plants.
PROCESSING EQUIPMENT Tel: +27 11 664 8212
Tel: +27 11 664 8212info@bmpe.co.za info@bmpe.co.za www.bmpe.co.za www.bmpe.co.za
BMPE is the leading supplier of superior quality New and Refurbished food processing equipment to the African market. Our primary focus is to provide a professional service to the food industry with regards to Equipment, Spares and the latest Technological innovation. With more than 30 years hands-on experience, we provide our customers with an excellent service in all areas of the food processing industry and have over the years achieved a good For over 40 years Formpak reputation for being efficient, cost-effective and professional. We import machines for our local clients across the whole of has supplied specialised Africa, ensuring that they benefit from machines of the highest qualityand at an excellent price. processing, packaging Our staff have extensive knowledge of current Machines, printing machinery to the and Consumables and we also provide a modern Technologies Service and Maintenance Department to support our customers pharmaceutical, cosmetic, throughout the process. plastic, glass, chemical, We service a diverse range of customers, from Large & Small Butcheries to Abattoirs, Supermarket Groups, Franchise Outlets food and dairy industries. and Corporates.
FORMPAK
Tel: +27 (0) 11 828 8870/1/2 Fax: +27 (0) 11 828 8880 email: haase@formpak.com or service@formpak.com www.formpak.com
DINNERMATES
Our diverse range of software offerings features a unique module listing of more than 700 modules (program nodes). Our software solutions are tailored for the Feedlot/Abattoir/ Debone / Production Retail industries. Matrix Software is deployed in 8 countries throughout Africa, Australia, New Zealand and Seychelles. www.matrixsoftware.co.za
PARTNER FOR HYGIENE AND TECHNOLOGY Leading through Innovation PHT is the leading provider of state-of-the-art technology for hygiene and food safety. Our unique systems offer efficient, effective and sustainable solutions for your hygienic challenges. We develop both individual and integrated hygiene solutions for your company. We are always there for you and we support you through our actions, professionally and reliably. Hygiene and food safety is our passion. We care about our customers, our suppliers and our people – we measure our success by the way we touch their lives. Because we care, we design innovative and holistic solutions. Tel: +27 861 777 993 | info.za@pht.group | www.pht.group
QUANTUM COLOURS SA
• Supplier to the hospitality trade and food factories • Service excellence, Your No. 1 industry leader for the most comprehensive • Quality, portion controlled products ranges of both synthetic and natural colours – used in food, (chilled/frozen /dried) pharmaceutical, cosmetic and industrial applications. • Innovation & Flexibility Our technical team is available to shade and Full demonstration positioned on the andrequirements this will match tostands specific and / or • Meat & chicken products tailored forof exclusive machines will be strategically colour receive a great deal of attentionPantone which references and to give legislative support special applications in the food industry will be of great interest to you our customer. We look forward to seeing you at the show. • Dried meat products – real meat THE BMPE TEAM on colours. real flavour! www.quantumcolours.com Tel: +27 (0)11 032 8600 Manufactured, marketed and distributed under email: sales@dinnermates.co.ca licence of SPECTRATEC INC. CANADA Tel: +27 (0)15 516 1515/4 email: factory@dinnermates.co.za/www.dinnermates.co.za Canada . South Africa . Ireland . Germany . Australia . UK