Food Review June 2017

SOUTH AFRICAN

www.foodreview.co.za

Journal for food and beverage manufacturers JUNE 2017 Vol. 44 • No. 6

Automation

IS CHANGING THE

food industry Thermal processing maximises RTE quality The upside of the credit downgrade

NUTRIPHARMASOLUTIONS

I N D U S T RY U P DAT E

CONTENTS JUNE 2017 | Vol. 44 • No. 6

Thermal processing

PAGE

18

opens a world of possibilities

MODERN SOLUTIONS

PAGE

20

for modern demands

08 NEWS

Symrise launches technology centre

Clarity on food production needed

The future of high fibre pasta

F&HA celebrates successful show

10

INDUSTRY TALK

ID Logistics commits to South Africa

Clamping down on honey fraud

25 Beverage Review

SOUTH AFRICAN

BeverageREVIEW June 2016 | Volume 7 | Number

6

www.foodre view.co.za

“Fermentation tannins are commonly used in the winemaking process. These products are typically used for increased colour stability, mouthfeel and structure”

Focus on cellaring and finishing tannins

UAE ups carbonation tax Major acquisi tion for Symrise

PAGE

28

12 ROBOTICS & AUTOMATION

Yaskawa’s new AirGrip technology

AOL simplifies food processing

A case for automation

The impact of ultrasonic cutting machines

Save costs with these robotics

31 Packaging Review SOUTH AFRICAN

w.co.za www.foodrevie

PackagingREVIEW June 2016 6 Volume 42 | Number

18 CONVENIENCE FOOD PROCESSING

Achieve that just grilled look

Carton packs for the modern consumer

Futuristic filling solutions

“Although decomposable packaging is proposed as a solution to litter problems it cannot be regarded as a general solution”

PAGE

33

The power of plastics

22

RISK MANAGEMENT

Survive the credit downgrade

A quick guide to managing risk

Dispelling biodegradability misconceptions

June 2017 | Food Review

3

EDITOR’S COMMENT

EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmediapub.co.za

Make the change

Assistant Editor: Aarifah Nosarka +27 (0)11 877 6209 aarifah.nosarka@newmediapub.co.za

Layout & Design: Kirsty Thomas +27 (0)11 877 6168 kirsty.thomas@newmediapub.co.za Contributors: Jacques-Olivier Pesme and Penny Ntuli ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmediapub.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmediapub.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmediapub.co.za

R

obotics and automation are impacting the way processors and manufacturers respond to changing demands in the industry. Efficiency, reliability, low spoilage, higher overall productivity and uniformity are just some of the real benefits of upgrading.

There is an ongoing debate on how this impacts job security. The implementation of new technology is often blamed for job losses, but the argument remains: In the long run, automation creates safer and better paying jobs.

In this edition of Food Review, we ask Dave Brownhill of Dale Spiral and Tony Rosenberg of Yaskawa to point out some of the significant benefits of automating. We also look at the ergonomic impact of these new technologies (page 14).

Industrial thermal processing often gets a bad rap due to its association with canned food products. On page 18 we investigate three examples of how different types of thermal processing can increase the quality of ready-to-eat food. The retortable carton pack is arguably the biggest innovation for food since the invention of the tin can in 1810. On page 20 we highlight some of the benefits of implementing this technology in the convenience food sector.

Naysayers are full of doom and gloom about the credit rating agencies’ downgrade of SA’s government bonds. Turn to page 22 where Chris Coombes, CEO of Sovereign Food lists some of the positive outcomes that can be expected.

Globally, wine demand has risen to 242mhl – up from 240mhl in 2014. Wine producing countries must seek to maintain and expand their domestic and international market shares. Fermentation tannins are commonly used in the winemaking process. These products increase colour stability, mouthfeel and structure. Don’t miss our Q &A on tannins (page 28) where experts answer pressing questions regarding their use.

Packaging aficionados are in for a treat in this edition of Packaging Review.

Highlights include an in-depth feature on biodegradable packaging and an Interpack round up. Turn to page 32 where packaging editor Aarifah Nosarka brings you the full scoop.

INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmediapub.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmediapub.co.za Production Controller: Rae Morrison Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park 2092 Tel: +27 (0)11 877 6111 Fax: +27 (0)11 713 9024 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published on behalf of Media24 by New Media Publishing (PTY) Ltd. MANAGING DIRECTOR Aileen Lamb

Happy reading!

CHIEF EXECUTIVE OFFICER Bridget McCarney EXECUTIVE DIRECTOR John Psillos NON EXECUTIVE DIRECTOR Irna van Zyl

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.

HEAD OFFICE

Managing director of Symrise South Africa; chairman of SAAFFI.

Rudy McLean

Head of communications, Tetra Pak Sub-saharan Africa.

Penny Ntuli

Dr Heidi Grimmer Founder, creative director and entrepreneur of Strategic Communications Company (Stratcom).

Gail Angela Macleod

Food Review | June 2017

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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.

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

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Food Review | June 2017

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New espresso capsules

launched

Starbucks has announced the launch of a range of Starbucks Espresso Capsules.

Products are compatible with Nespresso machines. The capsules are made from the finest Arabica coffees. The range comprises classic Espresso Roast, Colombia, Kenya, and Guatemala Antigua.

Instant

red cappuccino is here!

red espresso, the innovators behind South Africa’s much-loved rooibos red cappuccino, are set to shake up the premium gourmet beverage market with the launch of instant red cappuccino. Experience the health credentials of naturally caffeine-free and less than a teaspoon of sugar per serving.

Cider with edgy

hops finish Hunter’s has introduced an innovative hybrid category breaker. Its new beverage, Edge, delivers a gulp of cider refreshment that finishes with the full-flavoured taste of hops.

With its rich, golden colour, and distinctively smooth taste, this refreshing cider is a balanced take on a new product.

SHAKE UP your wake up

Fry Family Food Co has launched SA’s first plant-based, gluten-free breakfast cereal. Kasha is a tasty, versatile protein-packed breakfast cereal, instant shake or snacking option.

The product is available in two deliciously healthy flavours: Cacao, and Vanilla with Chia Seed.

Sweet snacking

innovation

Doubled-up dipping delight

NutriSeed has launched its very latest NuSeed Snacking sensation – Vanilla and Cinnamon Roasted Seeds with Chia and Himalayan Salt. A delicious base of roasted sunflower, pumpkin and sesame seeds have first been coated with cinnamon, vanilla, artificial sweetener (Xylitol) and mixed with Himalayan mountain salt. A truly guilt free indulgence, with a mere two grams of carbs per 100g.

Ouma Rusks has introduced two new additions to its product family: Ouma Premium, and Mini Bite Size Rusks. The former includes ingredients such as farm fresh buttermilk and is available in three variants, Buttermilk & Muesli, Buttermilk & Bran and Buttermilk & Aniseed. The mini bite size offers a scrumptious, one-bite, one-dip delight, and is available in Buttermilk and Muesli flavours.

June 2017 | Food Review

7

NEWS

Innovation and technology centre launched SYMRISE HAS UNVEILED its new AsiaPacific Flavor Innovation and Technology Centre. The facility was officially opened

by Dr Heinz-Jürgen Bertram, CEO of Symrise AG. It marks the completion of the company’s €30 million expansion of its regional headquarters in Singapore.

‘Asia is fast becoming one of the main global sources of influence and inspiration for innovative food products,’ Bertram states. ‘Singapore will continue

to be at the heart of our growth story. I believe the new research and innovation facilities will ignite greater collaboration, connectivity and creativity among industry stakeholders.’ The centre houses several facilities. These have been designed in accordance with Symrise’s research and development strategy, which focuses on connecting megatrends, consumer needs, customer requirements and cost efficiency.

Clarity about food production needed CONFLICTING SOURCES OF information about how food is produced are creating difficulties for families wanting to make smart choices about nutrition and health. This is according to a new study from the Enough Movement, carried out in 11 countries globally.

The consumer survey measured understanding and knowledge of popular food and nutrition topics, including product labels, farming methods, nutritional value and environmental impacts.

8

Food Review | June 2017

Although food and nutrition is a frequent topic of discussion for more than 93 per cent of the respondents, there is a lot of uncertainty about what food claims and labels mean. A majority of consumers report choosing foods labelled “all-natural” or “organic” despite not knowing what the labels meant in terms of environmental impact, animal welfare, and other metrics commonly associated with healthy food choices. ‘The farmto-table movement has

revealed that we all want to know what’s in our food and where it comes from,’ says UK based livestock sustainability consultant Dr Jude L. Capper. ‘It’s hard to separate fact from fiction when it comes to food labels, farming practices, and other food production topics. Distinguishing myth from reality can make a big difference in the choices families make about nutrition, household budgets and environmental impacts.’

Syspro launches optimised web version GLOBAL ERP PROVIDER Syspro is unveiling its candidate programme - a web-based version of Syspro 8 in the fourth quarter of this year. This initiative will proactively enhance its manufacturing and distribution solution for business owners. Chief product officer, Paulo de Matos, says companies have a strong desire to secure their future and optimise their businesses by adopting solutions that are cloud capable and accessible from any device.

‘Syspro 8 will be a dual user-interface offering that allows companies to selectively deploy either the Windows client, or the web-based solution at their discretion. The reason for this is that it provides business continuity, and ensures a smooth transition for users.

‘We believe in proactively innovating beyond functional utility and ensuring that we are creating a rewarding total user experience for our users. With the consumerisation of IT, our users now expect the solutions they use for business at work to be as intuitive, attractive and easy to use as their favourite applications at home. Our key driver is to constantly reimagine the link between innovation and ERP,’ De Matos concludes.

NEWS

Pasta goes high fibre REINVENTING PROCESSED CARBOHYDRATES such as pasta as a healthier, higher fibre option is now possible thanks to a new range of scilia fibres. Ulrick & Short’s range of soluble and insoluble fibres is perfectly suited to binding water to different degrees, meeting the requirements for different food processing applications.

As fibres are highly insoluble, the biggest challenge is to effectively incorporate these ingredients into applications.

A small percentage increase in fibre content is sufficient to underpin claims of high-fibre or simply increased fibre content. The company has achieved an impressive level of 4.5 per cent added fibre content in pasta, with no detriment to taste, texture and mouthfeel. This works against a base claim level of three per cent.

The company’s new sugar displacement product, avanté, enables manufacturers to reduce sugar by up to 30 per cent in savoury sauces and ready meals. The range of ingredients enhance flavours and spices rather than masking them. This provides an improved taste experience for the consumer. Coupled with other solutions such as fat replacers, proteins and fibres, food manufacturers have everything they need to provide consumers with healthier alternatives to their favourite foods.

A successful end to F&HA FOOD & HOSPITALITY Africa (F&HA) 2017 drew to a close after three days of hospitality innovation, trends and networking. ‘A resounding success,’ says Nick Sarnadas, the show’s event director at Specialised Exhibitions Montgomery. ‘We could not have anticipated a better turnout. Our visitors, over 6 600 of them, were impressed with the quality of exhibitors; while our exhibitors reported that lead generation was extremely satisfying during their time at the show. They could connect with key decision makers and were delighted by the standard of visitors in attendance. Well done to all who played a part in ensuring the show exceeded all expectations.’

In the spirit of skills development in the industry, the R30 000 Bryan Montgomery Bursary, sponsored by Specialised Exhibitions Montgomery,

was awarded to Latoya Layhove, a 19 year old second year student at Capital Hotel School. The bursary’s founding member, Bryan Montgomery, had a passion for all things culinary and did all he could to assist prospective students who faced budget constraints in terms of furthering their education. Since 2011, F&HA is honoured to have been awarding the fund through the South African Chefs Association.

‘This year, we worked extremely hard to ensure that our range of exhibitors emulated the high quality associated with the Food & Hospitality Africa powered

by Hostex name. Our aim was to create a valuable, relevant and enjoyable experience for visitors and exhibitors. I am confident we did just that,’ enthuses Gary Corin, managing director at Specialised Exhibitions Montgomery.

June 2017 | Food Review

9

I N D U S T RY TA L K

Multi-channels

are developing and growing our services in other vertical markets. What is important is to upsell to our existing client portfolio by offering additional value-added services.’

In line with the group’s commitment, the South African subsidiary is investing in new technologies and innovations with the objective of increasing second largest provider in the r a m Eric Hé productivity. These include route chilled/perishables market, with optimising software, in-truck live a multi-client approach and the navigation and delivery status, confidence of big branded names digitalisation, narrow aisle and in South Africa. Our team has flexi-reach trucks. Enhancing the strengthened its infrastructure, company’s B-BBEE scores to achieve and consolidated and expanded a Level 4 rating in the next few years, its client portfolio and offering.’ pending promulgation of the latest Etienne Juillard, managing Etienne Juillar d legislation scoring system is a priority. director of ID Logistics SA, ‘Through organic growth and enthuses, ‘Our challenge is to acquisitions, ID Logistics achieved continue to build on the perishable platform revenues of more than €1 billion in 2016 and to extend our warehouse facilities. We and has solid growth in store for 2017. must convince clients in other sectors where Investments will drive our growth over centralisation and insourcing is prevalent the next few years to achieve our aim of to outsource services. This will allow them becoming a leading name in contract logistics to enjoy the benefits of faster turnaround in Europe and Africa,’ Hémar concludes. • times, cost savings, global quality

drive growth I

D Logistics has announced its commitment to South Africa.

Eric Hémar, chief executive officer and chairman of ID Logistics comments, ‘We’ve experienced solid growth in 2016 in South Africa. We opened our network in 2014 with only one customer, Danone. We are now the

FAST FACT HIGHLIGHTS OF ID Logistics SA’s financial year include extending the Danone contract until the end of 2022 and landing 11 new clients in the FMCG perishable sector. New companies include Henties, BRM, Sir Fruit, Crisp, Okin Foods, Deneys Swiss Diary and Woody’s. The company also completed 75 cost-saving initiatives to enhance its network.

IDL FR 2017 177x130mm.indd 1

10

Food Review | June 2017

standards and innovation. It also opens new opportunities, such as collaborations between suppliers and other providers. We

ID Logistics – www.id-logistics.com

5/30/17 8:07 PM

I N D U S T RY TA L K

How do you detect honey fraud?

Food scientists and analysists from Stellenbosch University and the University of Rome La Sapienza have developed a quick and user-friendly method for detecting fraudulent honey.

Producers and distributors can use the system to detect whether the products they are selling are, in fact, the real thing.

A

new article in the international journal Food Control, sets out how near-infrared (NIR) spectroscopy can be used under South African conditions.

Portable and mobile, NIR instruments are ideally used to perform tests on site, such as honey farms or distribution plants.

The work was conducted by lead author Dr Anita Guelpa, which formed part of her earlier postdoctoral research work.

Dr Guelpa was assisted in developing and testing the method for South African conditions by study leader, spectroscopy expert Prof Marena Manley of the SU Department of Food Science; SU research analysists Dr Anton du Plessis and Dr Ruhan Slabbert, and Dr Federico Marini of the University of Rome La Sapienza.

Records of the South African beekeeping industry states that 1 500t of honey is produced locally every year. This is not enough to meet consumer demand. Roughly the same volume is imported – at a lower price than locally produced honey.

Honey is a high-value foodstuff and a target for adulteration and food fraud.

Cheap sugar syrups are sometimes added to honey sold locally. In other cases, high quality honey has been found to be diluted with cheaper low quality versions. Another form of misconduct occurs when honey is labelled as being produced locally, but in reality it has been imported or diluted with imported honey.

Not only is the consumer misled, but it means that local producers cannot

As a high value product, honey is often adulterated

“Records of the South African beekeeping industry states that 1 500t of honey is produced locally every year” compete with the low pricing of these adulterated products.

‘There was a need for a fast, nondestructive, easy to use and low cost classification method to detect adulteration in South African honey,’ Guelpa explains.

Current methods to detect adulterated honey, such as the use of stable carbon isotopic ratio mass spectrometry (SCIRA) or thermal analysis, are expensive, timeconsuming and in most cases destroys the sample used.

The research team decided on nearinfrared (NIR) spectroscopy. The technique

has been used in international studies to determine the floral origin of honey, or to authenticate its geographic or botanical origin.

The technique allows for the authentication of more than one honey sample at a time. By looking at specific spectroscopic “fingerprints” or spikes, it is possible to verify the geographic origin of a sample. It can also pick up whether sugars (glucose or fructose) or non-South African honey was added. This is possible even in cases where only a little bit of extra sugar has been added.

‘Authentic South African samples, despite coming from diverse regions and made from pollen from different types of flowers, share specific spectroscopic characteristics. This helps differentiate them from imported and adulterated honeys,’ Prof Manley explains.

She says the technique could potentially be used to distinguish between different types of South African honey, such as blue gum or fynbos.

Other advantages are that NIR measurements can be done quickly.

It is non-invasive and is easy to perform, especially when using a portable instrument. As samples tested are not destroyed in the process, these can be stored as evidence in further investigations. •

June 2017 | Food Review

11

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

RETHINK

food preparation SIMPLE, SAFE AND FLEXIBLE AIRGRIP’S BOTTLE HANDLING tool is designed to meet the requirements of a reliable, flexible and speedy production process. It is easy to use, has a long lifespan and can handle most glass or bottle types.

Feedback from breweries using AirGrip during production is very positive. Bottles are lifted more securely, production line standstills are minimised and air pressure requirements are low.

Gripping cuffs are made in five standard sizes covering most of the current assortment of bottles used during processing. If required, the company can also develop a custommade design. Rubber gripping cuffs can be replaced by hand and does not require any tools. Bottles are locked in place with air pressure in the cuff instead of mechanical means.

This substantially increases the lifespan of the gripping cuff.

Open ended gripping cuffs allow free bottle weights. This assists in reducing the risk of a production halt caused by jammed caps.

Products can be used for loading and unloading, plastic or glass bottles, bottles, trays and crates and bottles in blocks.

AirGrip advantages • B ottle necks held securely at high speed • Stable and robust gripping heads • Minimal maintenance needs • L ong life span with minimum wear and tear • E asy to clean • L ightweight • P revents jammed caps.

Yaskawa – www.yaskawa.za.com

12

Food Review | June 2017

The days of labour intensive industrial food preparation could be numbered with the launch of an Innovate UK project focused on robotics in food manufacturing. OAL and the University of Lincoln have been awarded £448 850 to develop the innovative April robotic material handling systems for food manufacturers.

The April system is particularly suited to products such as soups and sauces

T

he new project aims to enable a stepchange in the adoption of robotics and automation to enhance productivity in the food and beverage industry.

The one year project is supported by a grant from the UK government via Innovate UK and the EPSRC’s Robotics and Autonomous Systems (RAS) research fund. It will focus on automating the processes of handling, weighing and transporting raw ingredients.

It will also make strides in developing key hygiene and food safety features, critical when using robotic production systems within the food manufacturing sector.

Harry Norman, managing director of OAL explains, ‘Food manufacturers are facing rising costs. With little opportunity to increase their prices, they are seeking new and effective ways of improving productivity.

‘Throughout the project, we’ll be taking a step-by-step approach, working our way through common operations found across the food manufacturing sector. This will include weighing, sieving and moving ingredients.

One criticism of automated systems in the past has been their lack of flexibility. We aim to develop flexible April robotic systems that can handle some of these tasks – taking pressure off food manufacturers.’

Researchers will conduct an in-depth study of all processes currently used in the industry. It will then develop new automated raw material handling systems to integrate with OAL’s existing technologies. By automating the handling and movements of raw ingredients, researchers expect to make

major advances in efficiency, quality and quantity of food products such as sauces and soups when compared with traditional processing technologies.

The University of Lincoln is a key research partner of OAL. It is currently involved in supporting two other Innovate UK projects focused on steam infusion high speed cooking and cryogenic cooling of food products.

Stephen White, OAL’s lead automation engineer on the project explains, ‘I’ve been automating food production systems for nearly 30 years, and the time is right for robotics. There have been a couple of false starts, but the industry needs a productivity boost. The technology is now available at the right price point and it’s really exciting.

April is a great example of this in the way it uses robotics to simplify how we cook food.

We’re able to emulate how you would cook at home with small batches with up to half the amount of capital of equipment required in a traditional system.’

This project tackles directly many of the technical and scientific challenges in material handling for robotic automation of food manufacturing processes. In doing so, it will greatly enhance the potential for companies of all sizes to embrace the improvements in productivity, sustainability and quality that these technologies make possible. •

OAL Group - www.oalgroup.com

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

Automate or liquidate

Increased productivity, efficiency and efficacy are cornerstones that ensure sustainability and businesses growth. Automation in South Africa is at a sticky point of its wholescale assimilation. Common perception still holds that jobs will be lost.

D

ave Brownhill, technical sales manager at Dale Spiral Systems, and robotics expert Terry Rosenberg of Yaskawa Motoman, maintain that jobs should not be lost when automating systems in a company.

‘In the bread industry we are on par, if not ahead of the global curve. Many corporates and big businesses try to keep production processes labour intensive to create employment. This enforces the negative perception and sentiment that often surrounds automation initiatives,’ Brownhill notes.

De-lidding robot at an industrial bakery

Reasons to drive automation are very clear. ‘ As our population grows, there is a need to produce more product quicker to meet increasing demand. It follows that plants need to get bigger and throughput must be increased. This will result in competitive pricing,’ Brownhill explains.

‘As plants get bigger, so does equipment.

Traditionally, manual operations in a bread plant would include lifting and stacking bread tins. This was fine when each pan held four loaves and weighed around eight kilograms. Modern bread tins now hold around 12 loaves each and can weigh in excess of 25kg. It is not ergonomic for workers to lift weights continuously on a high-speed production line. These pans are also expensive, if

World leaders in Food Processing Technology Dale Spiral Systems supplies & designs world class Automated Plant Bakery & Spiral freezing systems for the Global Market.

Dale Automation provides state of the art design solutions including fully automated robotic systems for the Food Processing Industry.

Tel: +27 (0)11 462 0044 • E mail dale@spiralsystems.co.za • www.dalespiralsystems.com

14

Food Review | June 2017

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

“Once automation becomes the core of a large manufacturing operation, production and sales increase”

dropped and damaged, they will then require replacing.

This is another reason for automating a factory.’

Rosenberg echoes this sentiment. ‘You cannot stick your head in the sand and ignore new technology. In the global market, competing products are made automatically.

Every component is identical.

This is impossible when done by human hands.

‘With robotics, your product is consistently the same quality; production is easier to predict and waste is radically reduced. Most importantly, it doesn’t replace people. Robots are best suited to jobs that are hazardous to humans.

Robotics and automation take over when tasks cannot be carried out by humans. There is no substitute for automation when it comes to handling weight, speed considerations and dealing with high temperatures,’ Rosenberg emphasises.

Once automation becomes the core of a large manufacturing operation, production and sales increase. This in turn creates the

Pan store robot

need for additional support staff. ‘Instead of producing 100 loaves, a company can now produce 1 000. This means their business has increased tenfold.

‘To run smoothly, a company would need additional drivers, administration staff and sales people.

I have yet to see a company that automated have lost people their jobs.

They are redeployed in other sectors of the business. In most cases an increase in living standards is seen,’ Brownhill maintains.

‘There’s little loss of jobs when automation comes into play. Automation allows a bakery to increase volume to satisfy demand. It also means that additional workers will be redeployed in support activities. This is generally for the better. As working conditions improve there are further downstream benefits for everyone,’ Rosenberg concludes. •

Dale Spiral – www.daleautomation.com

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Peter Hogbin T: +27 (0)73 210 3625 Email: peter@bluebelt.co.za Philip Sheldon T: +27 (0)83 444 7828 Email: philip@bluebelt.co.za Office +27 (0)11 462 0044 Cosmo Business Park, 41 Malta Road, Cosmo City 2188

Pozidrive™ belt is fed onto the spiral cage/drum using a unique PATENTED tapered plastic guide way machined with a reducing radius to gently feed the belt onto the cage/drum teeth. Likewise the belt is gently removed from the drum using the same principal.

Because the belt is driven positively by the cage/drum, there is very little belt or product movement so discharge presentation is as uniform as the in feed.

Downtime is greatly reduced because of the positive drive. The presence of oil and grease do not present a problem as they did with the overdrive spiral system. Excess oil and grease relate to excessive slip and Christmas treeing. By eliminating this sanitation problem coupled with the other benefits:YOU MAXIMISE YOUR PROFITS!

June 2017 | Food Review

15

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

At the cutting edge of cake slicing Automation manufacturer Newtech, looked to Mitsubishi Electric for the design of a new ultrasonic cutting machine for the bakery industry. The result is an innovative design that can cut cakes to the highest level of precision. The unit works flexibly on different portion sizes and quantities - eliminating the danger of damaged products.

technologies can result in uneven, messy cuts and unacceptable levels of damaged product.

Newtech set out to overcome these limitations by combining ultrasonic cutting with robotic actuation of the cutting blade. The solution offered

by Mitsubishi Electric was built around an RF13 13kg payload, six axis robot, mounted within a stainless steel cell. One of the fastest robots in its class, the RF13 is highly dextrous, can reach behind itself and is very close to the base. This offers a highly flexible and compact working area.

FLEXIBLE CAKE CUTTING PERFORMANCE Robot integration delivers the ultimate in flexibility for cake portioning within the bakery industry. The in-line format machine provides a compact, multi-product platform. The highspeed ultrasonic blade offers precision, clean cutting as standard - even on the most detailed of cake products.

In operation, a through-conveyor indexes product in and out of the machine, from left to right. Product is fed into the machine in standard size bakery industry aluminium trays.

A series of inductive sensors identify the tray size, ensuring it is in the right position in the machine cell. The tray is fixed and held in a precise position by a series of clamps. Accurate positioning is important as ultrasonic blades must not have any contact with the tray edges.

Once the tray is in position, the robot actuates the ultrasonic blade to portion the product based on the parameters entered on the HMI. During the cutting process another tray can be loaded onto the conveyor. Once the cutting cycle is complete, the next tray is indexed into the cell.

WORKING WITH SMALLER TRAY SIZES

N

ewtech is a specialist supplier of standard machines, which provides today’s food manufacturers with cost-effective, high quality automation systems. The adoption of ultrasonic cutting technology gives the best available cut quality for products, which are difficult to process using conventional methods.

Cakes are difficult to cut reliably: machines tend to be time consuming to set up for different cake sizes, depths and portion numbers. Traditional cutting

16

Food Review | June 2017

Newtech specialises in ultrasonic cutting technology

In addition to standard size bakery trays, the machine can cut products in smaller foil trays.

In this mode, foils are placed in a row of three on a nested product board. The same clamp arrangement is used for accurate positioning.

The robot automatically selects a smaller blade (purposely profiled to fit within the shape of the foil tray) via an automatic head change unit.

An innovative feature of the machine is a cleaning tank to wash the ultrasonic blade. During the cleaning cycle, the robot takes the relevant blade to the cleaning tank, and a series of water jets spray both sides of the blade. The blade is then dried as the robot passes it through an air blast.

‘Robot integration makes the entire process easy,’ comments Newtech managing director Steve Rawlinson. ‘The high capability robot, combined with a full automation product and software package, made it simple to integrate the robot into the machine. This enabled us to take advantage of ultrasonic for precise, neat, damage-free cake cutting.’

Mitsubishi Electric is supplied locally through Adroit Technologies. •

Adroit Technologies – www.adroittech.co.za

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

Save costs with

smart robots Warehouses are turning to industrial mobile robot solutions to improve efficiency and turnaround times. This is to offset remote locations and time-consuming transportation.

O

mron introduced its first industrial mobile robot product line, the LD platform in January 2017. ‘The technology is now available to the broader African market. This bears testament to how highly we regard opportunities to accelerate its uptake of innovation,’ explains Omron field application engineer Evert Janse van Vuuren.

Omron mobile robots provide a new level of efficiency and cost-savings when it comes to moving goods around large facilities. This unique family of mobile robots is developed for rapid and reliable materials transported on a 24/7 basis.

Ideal for conveying goods throughout warehouses, distribution centres and manufacturing facilities, the LD mobile robot platform has a payload capacity of up to 130kg, depending on the model.

Compared to traditional automated guided vehicles (AGVs), Omron mobile robots can self-navigate entirely based on the natural features of the facility.

The LD Cart Transporter

No costly and time-consuming infrastructure modifications are necessary. This means there is no need for floor magnets, tapes or laser beacons typically associated with classic AGV deployment.

‘The simpler the technology is to get up-andrunning, the sooner the end user can start to reap the benefits. This is of particular importance in Africa, where skill levels in terms of automation and robotics are scarce,’ Janse van Vuuren highlights.

Flexible factory layouts are possible - taking space and size constraints in industrial areas into account. This is now possible as delivery points can be modified for the mobile robots. Omron mobile robots complement traditional automation, such as conveyors, and provide traceable movement of goods,’ Janse van Vuuren adds.

The latest Omron technology can integrate seamlessly with older systems prevalent in Africa.

Technological development is currently lagging behind mature markets like Europe and the US by a significant margin.

Equipped with patented Acuity technology, Omron mobile robots have a robust self-navigation system.

On-board intelligence allows them to avoid obstacles and choose the best path to complete a task. This “smart” movement makes them safe to operate alongside people.

A typical fleet can comprise up to 100 vehicles.

These can be managed centrally by fleet-manager software, which interacts with factory or warehouse management software such as manufacturing execution systems (MES) or warehouse management systems (WMS).

The LD Cart Transporter is an additional automated materials-handling solution. It includes an automatic engagement device and can adjust its approach path to engage the cart automatically.

This makes it an ideal solution to provide line-side replenishment for assembly line or for e-commerce order fulfilment in any distribution centre in Africa. •

Omron - www.industrial.omron.co.za

Food & Beverage Manufacturing Advanced Automation Solutions

As a partner in all your automation requirements we offer personal solutions, knowledge and expertise.

• Vision Inspection • Machine Controllers • Database Connectivity • Pick & Place • Temperature Control • Components & measurement sensors

www.industrial.omron.co.za

Omron Electronics ZA 011 579 2600 info.sa@eu.omron.com

June 2017 | Food Review

17

CONVENIENCE FOOD PROCESSING

Thermal processing

opens a world of possibilities Unfortunately, industrial thermal processing often gets a bad rap, mainly because of its association with canned vegetables. We investigate three examples of how different types of thermal processing can greatly increase the quality of ready-to-eat (RTE) food.

THAT JUST GRILLED LOOK Bar marking has been used for many years to make frozen RTE proteins like chicken breasts and hamburger patties look like they just came off the grill. In a traditional bar marking process, the product is fully cooked first, and then put into the bar marker. This means additional cooking time, which could decrease the quality of the final product.

An alternative is to use a real flame grill, which produces the desired bar marking effect. This gives food the authentic taste consumers want.

Flame grilling seals in flavour (like searing meat on a stovetop), before finishing cooking in the oven. When you flame grill before fully cooking the product, you don’t have to add any extra energy.

Less is used, and flame grilling can cut the total cooking time by about 10 per cent.

PORTION CONVENIENCE MEAT FOR READY meals, where the microwave time is indicated, must be within small tolerances of weight variations. Portion cutting is based on scanning technology. A high-speed camera takes 150 images per second of the changing laser line which the software will transform into a 3D object with its volume. With this information, in combination with the density, the machine knows exactly where to cut for the required weight. To portion different kinds of products, there is the possibility to use different knives. For the softer types of meat, thin knives of 1.5mm are used, where two millimetre knives and heavy duty knives are used for harder or thicker products. The increasing number of installed intelligent portioning machines proves the trend to move away from manual portioning to an automated process.

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Food Review | June 2017

The Marelec PORTIO combines state of the art technology for creating a high precision yet economic portion cutting machine

FAST FACT UNITHERM FOOD SYSTEMS is known for its innovative approach to creating thermal food processing equipment. These units can help food manufacturers maximise yields, while enhancing the safety of products and increasing profitability.

HOT-FILL, COOK-SEAL PASTEURISATION FOR READY MEALS RTE products like ready meals are looking and tasting a lot better. This is primarily due to the trend for hot-fill, cook seal pasteurisation.

In a traditional ready meal manufacturing process, food is cooked, then chilled and then assembled into meals.

Pasteurisation is done

Unitherm Flame Grill

CONVENIENCE FOOD PROCESSING

heated only once during production, resulting in a more attractive appearance and a much better taste.

ENSURING ATTRACTIVE NATURAL COLOURS

Unitherm’s grilling and searing processes are designed to produce products that look and taste like they came off a backyard grill

post-packaging, which means the product is heated and chilled a second time. When the consumer gets home, the product is usually heated again before eating.

That’s three stages of thermal processing - two of which are done after the food is already fully cooked. It’s easy to understand why the final product often looks about as appetising as a soggy newspaper and doesn’t taste much better.

With the hot-fill, cook seal method, the pasteurisation step isn’t a post-package afterthought, but integrated into the production line. The product is put into the tray fully cooked, sealed and0940_DFS_Food pasteurised. Review That means the product is Advert_R6_CS6 R2.pdf

“With the hotfill, cook seal method, the pasteurisation step isn’t a post-package afterthought, but integrated into the production line” 1

10/03/2017

15:58

As humans, we identify food by how it looks and smells. These senses keep us from eating badtasting and potentially contaminated foodstuffs. It is extremely important that RTE food looks appetising, usually equated with looking natural.

In addition to flame grilling and searing, impinged air and infrared cooking can be used to produce natural colours. Importantly, both processes result in a very high quality product, with very low yield loss.

• Impinged air - This technique involves forcing high velocity air onto a product surface. It is perfect for developing uniform colouring on non-uniform surfaces, like meat, poultry and pizza.

• I nfrared cooking - This practice uses a flat surface burner head. This technique allows processors to develop natural colours with highlights on products like sausage patties.

Unitherm and Marelec are represented by DFS Process Solutions in southern Africa. •

DFS Process Solutions - www.dfs.za.com Unitherm - www.unithermfoodsystems.com Marelec - www.marelec.com

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June 2017 | Food Review

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CONVENIENCE FOOD PROCESSING

MODERN SOLUTIONS for modern demands

The Tetra Recart package, available from Tetra Pak, brings convenience and a fresh natural image to food historically packaged in cans. The pack is lightweight, sturdy, 100 per cent recyclable and FSC-certified. By Penny Ntuli

T

he retortable carton pack is arguably the biggest innovation for food since the invention of the tin can. Its key benefit is that it brings fresh, healthy and wholesome food in a convenient format to consumers. The pack is shelf stable, convenient to use and can protect food for up to two years.

“Tetra Pak’s R2 line can handle up to 6 000 packs per hour, while the Tetra Pak R1 handles volumes up to 24 000 packs per hour” The Recart pack has been around for 15 years, but is far more modern than the canning process, which was invented in 1810.

Initially, food was pushed into jars, corked, sealed with wax and wrapped in canvas before heated to kill any germs that made it into the jar. The advent of the tin can came two years later in 1812, and today’s carton pack is its modern equivalent.

On the production side, the processing line is available in two primary formats. Tetra Pak’s R2 line can handle up to 6 000 packs per hour, while the Tetra Pak R1 handles volumes up to 24 000 packs per hour. To run these lines, only four to five operators are needed.

The pack offers numerous benefits to the supply chain. The equivalent 400g can requires nine times the space to transport prior to filling.

Once filled, the Recart requires 40 per cent less space than the equivalent industry-standard can. This is great for a company’s transportation costs, as lower weights (64 per cent less than the equivalent 400g) results in less fuel use.

Less weight also impacts on overall materials handling and logistics, while on-shelf presence is increased through continuous facing for eyecatching consumer presentation. More products per pallet, faster shelf replenishment, lower waste handling, and efficient use of shelf space results in improved direct product cost for retailers.

More than 80 studies have been conducted that show the carton and the product packed is perceived as fresh. This offers producers the opportunity to expand its product offering in line

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Food Review | June 2017

The Tetra Recart is ideally used for vegetables, tomatoes, baked beans and sauces

FAST FACT CARTON PACKS ARE available in a range of sizes: 200ml, 340ml, 390ml, 440ml and 500ml.

with modern consumer trends. Being retortable means product is heat treatable in cartons, not cans and glass.

It’s very easy to use carton packs since they are easy to open with laser-perforated closures. The product can also be closed for cool storage once opened, featuring no lids or sharp edges. Once the contents are used, it’s easy to send the empty packaging for recycling. It is simply folded flat and transported to recycling centres.

The pack is already used by 150 brands in 50 markets worldwide. It lends itself to products such as vegetables, beans, tomatoes, baked beans, ready meals, soups and sauces. •

PENNY NTULI is communications director of Tetra Pak South Africa.

Tetra Pak – www.tetrapak.co.za

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STEEL BELTS PLUS

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STEEL BELTS & HYGIENIC PROCESS TECHNOLOGIES FOR THE CONFECTIONERY INDUSTRY Sandvik steel belts offer unparalleled versatility. A smooth flat surface with outstanding thermal properties delivers perfectly baked cookies, biscuits, cakes and bread, and that’s why more companies are upgrading to steel belt-based baking. But we offer far more than just belts.

From conveyors and our QuickCleaner process to high performance pastillation and scattering systems, we’re able to offer complete production solutions.

 Solid and perforated steel bake oven belts – service and upgrades  Belt only or complete conveyor systems incl. tracking etc.  QuickCleaner system – fast and easy removal of carbon residues  Rotoform 4G FD pastillation system for chocolate, emulsifiers, fats and more  Rotary screen scattering for decorative patterns on baked goods

WWW.SANDVIK.COM/STEELBELTS Sandvik Process Systems, Sandvik (Pty) Ltd, PO Box 25038, East Rand, 1462, South Africa · T: +27 11 570-9610

R I S K M A N AG E M E N E T

Tips on

surviving the downgrade The international credit rating agencies’ downgrade of South Africa’s government bonds to below investment grade, will not necessarily have a catastrophic effect on the country’s poultry industry. This is according to Chris Coombes, chief executive officer of Sovereign Foods.

T

he situation could potentially open a window of opportunity for new market access and exports. Coupled to developments in the global poultry industry, it could also help to facilitate a short-term clamp on cheap imports. The latter is currently hurting and destabilising the local industry. In relation to existing and future exports to foreign markets and new market

access, Coombes predicts local currency depreciation (predicted to accompany the downgrade) could benefit the industry.

‘A weaker rand opens opportunities to increase market share abroad. South African bone-in whole and value-added chicken exports becomes a more affordable alternative to poultry imports from markets with stronger currencies,’ he explains.

Coombes is optimistic about new market access through bilateral trade agreements.

‘To bring South Africa perfectly in line with global compliance for exports will take at least two years. This is an urgent priority for government to pursue.’

Global developments also offer a breath of relief for the industry. ‘To a certain degree, the downgrade offers some respite

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Food Review | June 2017

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R I S K M A N AG E M E N T

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‘A scenario of increased inflation and tougher economic times because of downgrades will influence the consumer’s food basket. Empirical data shows that South African poultry consumption remained relatively stable and in a much better position in relation to red meat producers during depressed economic times.

“To bring South Africa perfectly in line with global compliance for exports will take at least two years. This is an urgent priority for government to pursue” ‘This is because chicken remains the protein staple in South African households. In less socio-economically privileged households, 20 per cent of the monthly food bill goes to chicken and that figure increases to 27 per cent in middle to higher income groups. A report by the Department of Agricultural, Forestry and Fisheries examined the consumption

GRANULATE

SHRED

patterns of selected agricultural products during the 2008 recession. Consumption of beef declined by 4.9 per cent, mutton fell one per cent and pork increased marginally by 0.3 per cent. Positively, consumption of poultry increased with 1.3 per cent.’

Chicken price increases remained well below the All Food Index during the 2008 recession, and was accessible for poorer households. In the higher segment of the market, ready-to-eat meals and pre-packaged convenience foods have a displacement effect on restaurant dining.

‘For poultry producers with a strong value chain of diversified products serving especially retail, this is a potentially positive development,’ Coombes stresses.

‘A downgrade of this nature is not necessarily the final nail in the coffin of a country’s economy or the local poultry industry. It could inspire sensible and positive policy changes.’ •

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for local producers that compete against imported equivalents and presents an opportunity for import replacement.

‘A scenario of a depreciating currency; the recent outbreak of Avian flu in Europe, and the meat scandal in Brazil, could create increased demand for locally produced chicken. This is in the face of the import pipeline becoming disrupted as demand for EU and Brazilian chicken imports comes under pressure.’

A weaker currency would have the effect of increasing input costs into the poultry supply chain. ‘A weaker rand will increase inputs into the poultry supply chain, such as maize, soya, vaccines and medications, fuel, plastics and capital equipment. These are either priced at import parity or are dependent on raw material, priced globally in US dollar or the Euro,’ he notes.

Coombes stresses the short-term crises in global poultry production territories could open a four- to six-month window period for government and local industry. During this time, swift and decisive measures to stabilise the effect of cheaper imports on the market must be investigated.

Coombes further predicts that local consumer preferences and demand will not be disrupted by the downgrade.

5/06/2017 8:42:55 AM

June 2017 | Food Review

23

R I S K M A N AG E M E N T

Rockwell Automation outlines four key areas for managing industrial risk

Best practice for managing risk Industrial organisations around the world struggle to manage risk. Incidents, such as product recalls, data breaches and worker injuries, have immediate consequences. It can negatively impact customers, employees, intellectual property and revenue.

R

ISK MANAGEMENT SHOULD be focused on where problems originate. In many cases, that is within the automation infrastructure.

Rockwell Automation has outlined four key areas for managing risk at its source.

‘We view enterprise risk management as a continuous cycle of improvement that includes assessments, technology and infrastructure,’ states Scott Lapcewich, vice president and general manager, customer support and maintenance, Rockwell Automation. ‘Our unique blend of expertise in manufacturing

24

Food Review | June 2017

processes, automation, operations, safety and security helps customers mitigate enterprise risk within their plant environments.’

By addressing risk in these key areas, companies can effectively manage brandcritical safety, quality, security and obsolescence challenges at their source.

An e-book outlining the four key areas of risk management is available on the Rockwell Automation website. •

Rockwell Automation – www.rockwellautomation.co.za

FOUR AREAS OF RISK •E QUIPMENT OBSOLESCENCE: Modernising production systems can play a major role in minimising downtime and improving quality, safety and security.

• QUALITY: Harnessing the power of existing operational data can improve quality management and help drive adherence to regulatory requirements.

• SAFETY: Addressing safety in crucial areas of culture, compliance and capital helps reduce the number of safety incidents and improve operational performance.

• SECURITY: Embracing end-toend security across facilities and enterprises helps to protect people, intellectual property and physical assets.

SOUTH AFRICAN

BeverageREVIEW June 2017 | Volume 7 | Number 6

Tannins IN A nutshell

www.foodreview.co.za

UAE taxes carbonated drinks Major acquisition for Symrise

NEWS

Key partnerships

HEAVY TAX for bubbly beverages The United Arab Emirates (UAE) will soon impose a 50 per cent tax on carbonated soft drinks, and a 100 per cent tax on energy drinks. The tax will be applied directly to the retail price of products and will take effect in the fourth quarter of this year. The move is aimed at protecting the Emirates’ economy from changes in the price of crude oil, which has fallen from a high of US$156 a barrel in 2008, to US$51 a barrel in May this year. The UAE’s new tax on certain products, including energy drinks and carbonated soft drinks, is a change of tack for the country. Previously, the UAE avoided taxing the sale of products directly. Unlike sugar legislation, the UAE’s soft drinks tax is not connected to the amount of sugar in the product, but is instead a tax on carbonation. Products like sparkling water and sugar-free versions of popular soft drinks will also be taxed since they are carbonated. According to an industry spokesperson, the impact of the new tax is complicated and vast.

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Beverage Review | June 2017

Imperial has won the national contract for Diageo South Africa’s 3PL logistics services. Continuous improvement initiatives have been implemented, and are currently being rolled out by Imperial, including retail centralisation for Diageo.

This entails consolidating stores to their distribution centre for replenishment needs. A minimum order value initiative has been put in place, and is delivering the benefit of a reduction in the number of drops, which translates into cost and time savings.

A pilot project is underway, in which Imperial is delivering directly to home depots, thereby bypassing the Elandsfontein warehouse. By replenishing stockholding home depots directly from the factory, Imperial is reducing storage, transport, handling and security costs for Diageo. ‘Imperial has proved that it has the ability, flexibility, scale and reach to successfully manage Diageo’s peak trading periods (and volumes), which are notoriously testing in the alcoholic beverages sector,’ Rossouw notes. ‘The peak periods of October, November and December account for approximately 38 per cent of Diageo’s annual volumes. Imperial supports direct deliveries for larger volume orders to Diageo’s customers, which frees up resources across the supply chain. This ensures that despite heightened activity, we still delivered against demand.’

Symrise acquires Cobell THIS ACQUISITION WILL strengthen the company’s position in the UK beverage market. Cobell, established in 1999, is one of the largest suppliers of processed fruit and vegetable juices in the country, and a leading supplier across Europe. ‘”Know-how that meets innovation”’ is the guiding principle of our acquisition of Cobell. The group is firmly anchored in the UK market, and represents an ideal match for Symrise. In recent years, we have seen increased demand for innovative beverage solutions.

By combining Cobell’s impressive application and manufacturing capacities with our strong portfolio of natural flavours, we will become a driving force. We will significantly enhance our customer proximity acting as single source for beverage ingredients and formulations in the UK,’ enthuses Dirk Bennwitz, president of Symrise’s flavour segment.

Symrise has been active in the country for more than five decades and is a highly valued supplier to the food and beverage industry.

WINE

A perfect

Connecting Global Competence

ALL-ROUNDER The GEA Wine Decanter skid covers a spectrum of five applications in the process stage of juicing, clarification and lees processing during the wine making process. Utilising the equipment can result in significant time and quality gains. It also results in substantial cost-savings.

The new GEA skidder offers tangible benefits to the wine industry

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T

he major strength of the new wine decanter is its unparalleled grape juicing quality. The deterioration in quality, which occurs in conventional processes after around 50 per cent of the grapes are processed, is now a thing of the past. Processing time with the skid in continuous operating mode is under 90 seconds instead of the usual one to three hours. The added value for the winegrower is that payback time is typically just 1.5 years.

Due to its innovative design, the skid is multifunctional and can be used for juicing, must clarification and treatment of flotation sediment, must and wine lees. ‘This makes the skid a perfect allrounder in wine production. It is ideally suited for round-the-clock application and the economical processing of small batches,’ Frank Schauz product manager sales at GEA explains.

The wine decanter can be deployed in all areas of red and white wine production, including thermovinification, thermoflash process and mash fermentation. As a pre-mounted skid with a wide selection of machine sizes, it offers customised solutions for most wineries. The complete skid requires just one machine operator for on-going operation, supports CIP processes and is simple to operate and maintain. ‘Those are optimal pre-conditions for wineries of all sizes to produce red and white wines in consistently high premium quality, with optimised productivity, yield and profit,’ Schauz concludes. •

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June 2017 | Beverage Review

27

WINE

Targeted tannins create quality wine

Fermentation tannins are commonly used in the winemaking process. These products are typically used for increased colour stability, mouthfeel and structure. Other uses include anti-oxidative action, inhibition of certain enzymes due to rot (laccase) and the reduction of bitterness. Cellaring and finishing tannins are increasingly used by new world winemakers to give their wine that final stamp of quality.

T

annins improve mid-palate and/or ageing potential. It also increases the perception of certain wood components (American or French Oak), and is successful in suppressing green and other unwanted aromas.

Two new tannins, Scott’tan FT Blanc Citrus and Scott’tan FT Rouge Berry, have been added to the Anchor Wine Ingredient’s tannin range. The versatility of these new products allows them to be used as fermentation and finishing/cellaring tannins.

When used during fermentation, they impart upfront citrus (white wines) and berry (red wine) character to the wine. Other benefits can be very useful for winemakers who want to produce early-to-market white and red wine.

As finishing/cellaring tannins, Scott’Tan FT Blanc Citrus and Scott’Tan FT Rouge Berry also have appeal. The former can be used on Chardonnay or Pinot Gris, seeing that the citrus character enhances wine aroma, and adds sweetness to the pallet. The latter can complement varietal aromas in red wine, by adding nuances of strawberry, blueberry and cherry.

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Beverage Review | June 2017

Q&A TANNIN ROUND-UP

WHEN AND HOW SHOULD I USE TANNINS? The earlier the better. For red grapes, addition at crushing or at first pump over will depend on the sanitary state of the grapes. For a red fermentation, addition during fermentation allows better integration of the tannin in the wine - providing better colour stability and improved mid-palate.

Additional tannins can be added during the subsequent pump over. For white grapes, addition at the crusher or during mixing in a tank is advisable.

CAN TANNINS BE ADDED TO WHITE WINE AND JUICE? Addition can remove off-odours, facilitate clarification and inhibit the laccase enzyme. The latter originates from a Botrytis infection.

SHOULD TANNINS BE USED FOR PREMIUM RED GRAPES? Fermentation tannins can be added at the crushing stage for colour protection and phenolic structure. Adding certain tannins during extended barrel maturation can limit oxidation associated with a

White and Rosé

WINE

Fruit, Cider and Mead Promotion of colour, body and fruit Protection from oxidisation for white wine Mouthfeel enhancement for the white wine

desired outcome and the tannin product used, Enhances structure addition might take place before barrel ageing (cellaring tannins), or Enhances mid-palate volume before bottling (finishing tannins).

Stabilises colour

fruit CAN TANNINS HAVE A NEGATIVE IMPACT decrease inEnhances ON BARREL AGEING? structure and French oak character No. Tannins play an important anti-oxidative freshness. Cellaring American oak character role during barrel ageing. This is why there tannins can also be added during racking Vanilin is oak character such a difference between wine aged and tank movements to facilitate better in an a new barrel. The latter SO 2 management.

Protects grapeold, fromversus rot offers more protection against oxidation, Enhances ageing potential as more tannins are available in the older ARE OAK CHIPS A CHEAPER SOURCE Perception sweetness one.ofAdding tannins during barrel ageing not OF TANNINS? only offers an anti-oxidative effect, but also Tannins in oak chips might contribute Lowers perception of alcohol

slows down wine ageing. It plays a definite supporting role during barrel ageing.

WILL TREATMENT WITH TANNINS INFLUENCE ASTRINGENCY OR BITTERNESS? Yes. Bitterness in wine is caused by tannin imbalances or tannin complexes that are not sufficiently bound. Bitterness and imbalances can be corrected by adding a highly polymerised tannin. The perception of fruit might also be improved after such a tannin treatment. •

Anchor Wine Ingredients – www.anchor.co.za Scott Laboratories – www.scottlab.com

towards oxidative protection and provide oak aromas, but it will not improve mid-palate. A tannin product that contains wood and proanthocyanidic tannnins will improve colour stability and structure.

CAN THE ADDITION OF SUPPLEMENTARY TANNINS AFTER ALCOHOLIC FERMENTATION BE BENEFICIAL? This will have a positive impact on structure and flavour. Depending on Table and image above courtesy of Scott Laboratories, Inc.

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Tel: +27 11 708 0408 Fax: +27 11 708 0415 kerri@brewtech.co.za henry@brewtech.co.za

P.O. Box 6928 Weltevreden Park 1715 South Africa

We are excited to announce…

We now do Change Parts ● ● ● ●

Star Wheels Ploughs Scrolls Bottle and Can Inverters

Call us now to set up an appointment

June 2017 | Beverage Review

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WINE

China leads the

new wine order Figures in the annual report of the International Organisation of Wine and Vine (OIV) confirms the world’s wine industry is undergoing considerable change. Dominant European nations are finding their positions challenged by the emergence of countries such as China, both as producers and consumers. By Jacques-Olivier Pesme

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lobally, demand has risen slightly to 242 million hectolitres (mhl), down from its peak of 250mhl in 2008, but up from the low of 240mhl in 2014. Signs are positive for long-term growth. Per-capita consumption is stable, falling slightly among the French, Spanish and Portuguese.

An encouraging sign for the industry is that new customers are starting to drink wine in countries with large populations.

In the early 1990s the US market was ranked sixth in the world, but by 2016 it had climbed to the number one spot, at 31.8mhl, followed by France (27mhl), Italy (22.5mhl) and Germany (20.2mhl).

A substantial market has already been established in Brazil, despite the negative economic trends in 2017, and there are great expectations for India.

Consumption in Canada has been rising steadily for some years. The government is making efforts to stimulate national production. Local production is even emerging in Ethiopia, where the highlands are well suited to grape cultivation. There is also a substantial non-Muslim population (approximately 66 per cent out of a total of 100 million).

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Beverage Review | June 2017

AN INDUSTRY LEADER IN WINE Wine enjoys great symbolic value, linked to the fact it’s a product of the land and has strong historical ties. It also functions as a “high class” social marker. China is now the sixth leading consumer of wine in the world.

“ Local production is even emerging in Ethiopia, where the highlands are well suited to grape cultivation” As consumers become familiar with wine, they begin to try more from other countries. This represents an important growth lever for international trade. 40 per cent of the wines produced globally are currently exported, compared to just 20 per cent in the early 1990s.

FRANCE CONTINUES TO LEAD

BY VALUE For the French wine industry, the landscape might have shifted, but the foundations remain solid. France continues to challenge

Spain and Italy for the title of the world’s number one producer by volume, and continues to lead the world in terms of value. France produced 43.5mhl of wine in 2016 compared to 50.9mhl for Italy (15 per cent less), yet the value of France’s exports was 8.2 billion Euros compared to 2.6 billion for Italy. This is three times more and represents 28.5 per cent of the total value of the global wine market.

These figures confirm that French wines are perceived and purchased as high added-value products. While Spain is the leading exporter by volume, the price of Spanish wine per unit remains low on the international markets, with a total value of just 2.6 billion Euros.

THINKING STRATEGICALLY In the coming years, as wine-producing countries continue to seek to maintain and expand their domestic and international market shares, they’ll also need to adapt to ongoing climate change. For example, Brazilian production dropped 55 per cent between 2015 and 2016 because of a strong El Niño, while production fell in droughtstricken South Africa. An increasingly strategic approach is being developed, including specialised research schools. At all levels around the world, stakeholders are engaging with governments and decision makers to increase the industry’s competitiveness and how to better tackle new international challenges. •

JACQUES-OLIVIER PESME is the director of the

Wine & Spirits Academy at Kedge Business School.

SOUTH AFRICAN

www.foodreview.co.za

PackagingREVIEW June 2017 Volume 43 | Number 6

Futuristic filling solutions

The power of plastics Dispelling biodegradability misconceptions

NEWS

A wealth of information

Local producer lauded for its ethics

T’S A RELIEF to see the plastics industry has been paying attention to the hype surrounding biodegradable, or completely compostable packaging. On page 33, Plastics|SA and SAPRO come together to dismiss misconceptions surrounding biodegradables.

One thing to keep in mind is, although words like ‘biodegradable’ and ‘green’ have a sustainable connotation, there is no guarantee it is in fact planet-friendly. Therefore, it’s crucial environmental claims are backed by sound science and standards. Plastics accounts for one third of the packaging industry as well as, one third of this edition of PACKAGING REVIEW. Don’t miss out on the plastic packaging materials article on page 37, and other insightful information like the Interpack show review on page 38.

ADDIS, LOCAL HOUSEHOLD brand producer, has been awarded international accreditation for ethical business practices and labour relations.

This makes the company the first South African-owned manufacturer to fully comply with the international requirements of the Supplier Ethical Data Exchange (Sedex) Global Conformance Program.

Sedex is a non-profit organisation dedicated to driving improvements in responsible and ethical business practices in global supply chains. The Sedex audit is a popular, progressive and credible audit format. It encompasses all aspects of responsible business practice, including labour standards, health and safety, the environment and business ethics.

‘We are incredibly proud of this achievement because it reinforces that Addis is a world-class manufacturer on par with top international producers when it comes to implementing

I

Enjoy the read.

Assistant Editor Aarifah.Nosarka@newmediapub.co.za

responsible business practice,’ says Errol Stern, CEO at Addis.

The family run business has been dedicated to progress throughout its history as a South African manufacturer, which dates back to 1914. It has a total of 700 employees.

The most recent audit was conducted in accordance with Sedex Members Ethical Trade Audit 5.0 protocol. This is the most comprehensive review of the audit format to date.

Addis’ COO, Clive Grey with Errol Stern, Francois Labuschagne, a consultant at DQS and Suja-Ud-Din Tolker, Addis’ director of manufacturing

Tel: +27 11 708 0408 Fax: +27 11 708 0415 P.O. Box 6928 Weltevreden Park 1715 South Africa

kerri@brewtech.co.za henry@brewtech.co.za

We are excited to announce…

We now do Conveyors ● Turnkey Solutions ● Installations ● Modifications

Call us now to set up an appointment 32

Packaging Review | June 2017

I N D U S T RY TA L K

Know your plastics Plastics|SA and the South African Plastics Recycling Organisation (SAPRO) share concerns about the misconceptions surrounding biodegradable packaging.

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he general perception is that degradable plastics will dissolve and disappear over time, compared to conventional plastics, which will be around forever. However, the organisations say this is not the case.

Biodegradability does not imply there is no harm to the environment, as this type of material does not readily decompose in a landfill. These plastics decompose under the combined influence of abiotic factors like UV light, water, heat and biotic living organisms such as bacteria, fungus, and algae.

There are two stages. The first is where materials lose cohesion and disintegrate into fragments. Secondly, organisms metabolise fragments.

Materials that are not certified as biodegradable are not metabolised by organisms. These may pollute the environment for longer periods.

Biodegradable plastics are not visibly different from ordinary non-biodegradable plastics. To differentiate one from the other, there should be clear markings denoting whether a material or product is biodegradable or designed for composting.

These types of plastics can be manufactured from fossil (non-renewable) resources as well as from biomass (renewable resources).

It is however, not the case with biodegradable additives that are added to traditional plastics, e.g. oxobiodegradable materials. In this case the material is still marked as a PE-LD and contains a biodegradable additive. This will contaminate the recycling stream, and may lead to a failure of products as degradation occurs. It will hinder market acceptance, further leading to reduced value of recycled material in South Africa.

Although decomposable packaging is proposed as a solution to litter problems, from a technical and behavioural standpoint, it cannot be regarded a general solution.

The biological degradation without the required conditions such as microorganisms,

DID YOU KNOW? Biodegradability is not determined by raw materials but by the nature of the material.

temperature, and humidity can take up to several years.

It may add to the litter problem in the country in spite of consumers’ belief that biodegradable plastics disappear quickly in the environment.

Bio-degradable plastics often leave a larger carbon footprint. The cost of these packaging materials are often much higher than that of traditional plastics.

BEHAVIOURAL AND INDUSTRY CONCERNS Preventing litter requires a combination of awareness. More money and resources should be spent on educating the public about recycling and establishing proper recycling infrastructure.

Plastic recycling is an integral part of South Africa’s economy. Last year 264 758t of plastic was collected and recycled – this is the equivalent to 200 milk bottles per person.

Recycled plastic waste is used to make new long-term plastic products.

The plastics industry remains concerned about the impact of degradable additives, once plastics are recycled and used in second and successive applications.

Another concern is that this type of packaging is composed of nonrenewable fossil fuel-based inputs.

There is little difference in energy and resource usage when compared to conventional disposable packaging. If it is meant to break down in a landfill environment, products will not be recovered through waste management and recycling initiatives. This will result in a loss of resources, which is the calorific value of plastics.

There are products that are not recycled where compostable and biodegradable materials have a role. Examples include refuse bags for pet waste, nappies, cigarette butts and even sweet wrappers.

PROLONGED RECYCLING

CRUCIAL FACTORS

Can biodegradable materials be included with other plastics for recycling? Yes, as long as these are clearly marked. Plastics recyclers have sorting mechanisms in place to sort different plastics prior to recycling as different materials cannot be recycled together. The biodegradable material will be selected for a different recycling stream or composting.

It is crucial that environmental claims are backed by sound science and standards.

All environmental claims such as biodegradability, compostability or bio-based content are in compliance with appropriate standards such as ISO 14021.

Plastics|SA and SAPRO emphasise that market requirements remain a determining factor in choosing the plastic grade with the desired property profile. •

Plastics|SA – www.plasticsinfo.co.za South African Plastics Recycling Organisation – www.plasticrecyclingsa.co.za

June 2017 | Packaging Review

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C O M PA N Y F O C U S

A world-class accolade Earlier this year, Extrupet received renewed accreditation for its Wadeville facility, which is home to its B2B Starlinger and Vacurema processes.

It has been British Retail Consortium–IOP grade AA certified.

T

he grading was revealed after an audit be viewed as a benchmark for other recycled conducted by the BRC in February. polymers and packaging mediums aspiring Chandru Wadhwani, joint managing to attain a cradle-to-cradle solution for director at Extrupet says the sustainable packaging. company maintains its position ‘The AA rating adds to the as the only PET plastic credibility of this resin, recycler in the world which should see certified by the BRC. even more interest ‘This is an going forward.’

BRC certified AA status means the company’s extraordinary With increased PhoenixPET may be used in achievement for the attention from all punnets and drinking company and its recycling government and the bottles by Britain’s operation. It has more possible introduction of top retailers than one time, previously new legislation targeting achieved an A status. The AA packaging, brand owners rating is the highest achievable and convertors can strengthen certification for announced audits. It their corporate image with a is rarely achieved by companies worldwide,’ sustainable message. ‘By using PhoenixPET, he explains. the demand for virgin material decreases, The certification means that postless energy is used and a huge reduction consumer recycled plastic from its modern in net carbon emissions is achieved. The bottle-to-bottle recycling plants meet the integrity of the product would not change UK’s stringent food safety standards. since the facility can achieve the same intrinsic viscosity as virgin polymer, which THE JOURNEY makes PhoenixPET a valuable new resource,’ Extrupet’s major transition began by Wadhwani comments. installing new state-of-the-art Bottle-2Bottle recycling equipment at its PhoenixPET plant in 2014.

The technology, supplied by Starlinger recycling, was engineered to fulfil a number of expectations. These include standards required for bottles for carbonated soft drinks, bottled water and other forms of polyethylene terephthalate (PET) packaging.

The facility, which provides PET resins to the packaging industry, will supply an additional 14 000t per annum. This project is earmarked to eventually divert from landfill an additional 22 000mt of post-consumer PET bottles per annum.

It is also expected to create jobs and save landfill space, in line with the Waste Amendment Act’s drive to achieve zero waste to landfill.

DID YOU KNOW?

SUSTAINABLE SOLUTIONS Extrupet has been at the forefront of plastic packaging recycling for more than 15 years.

Wadhwani says the PhoenixPET facility is to

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Packaging Review | June 2017

ABOUT THE COMPANY EXTRUPET IS AN advanced recycler of PET bottle materials. The company specialises in reclaiming and converting waste PET bottles into various grades of PET chips and flakes. These are then converted into fibre, thermoforming, food-grade and strapping grade material to produce high quality and reliable end-products for use in packaging and other applications. Extrupet’s manufacturing plant is audited and accredited in accordance with the ISO 9001:2008 evaluation and BRC standards.

PhoenixPET has surpassed international standards in a drive to deliver extraordinary quality required by customers. ‘The attainment of the BRC–IOP certified grade AA demonstrates Extrupet’s continuous drive to exceed its customers and the country’s requirements in bottle-to-bottle recycling. In addition to being the only European approved food grade rPET in South Africa, it assures all users in the value chain the highest food saftey and hygiene standards have been met and maintained,’ he concludes.

Extrupet has also announced the recent appointment of Harry Havenga as the company’s new national sales manager.

ESTABLISHING THE PROGRAMME The BRC together with the Institute of Packaging created the BRC/IoP Global Standard for Packaging and Packaging Materials. They established internationally recognised packaging standards.

Gaining BRC/IoP certification gives a brand an internationally recognised mark of quality, safety and responsibility. The programme was designed to be efficient, reduce the need for multiple audits and help companies improve processes.

Among the benefits, is the acquisition of increased consumer confidence as well as opening the business to new opportunities.

The BRC standard demands high levels of compliance. The certification programme is wide ranging. It includes gaining management commitment, hazard and risk management, and product and process control. •

Extrupet – www.extrupet.com

The grade AA certificate

A Working to the A highest standard Because Food Safety and Hygiene matters to everyone.

Extrupet has reached a new milestone by achieving an AA audit grade for BRC Global Standards for Packaging and Packaging Materials, the highest grade possible for announced audits.

The BRC Global Standard for Food Safety is a framework to manage product safety, integrity, legality and quality, and the operational controls for these criteria, in the food and food ingredient manufacturing, processing and packing industry.

First published in 1998, and now in its 7th issue, BRC certification is the recognised global standard for Food Safety. Extrupet has moved from a grade A in 2016 to a grade AA in 2017, a great achievement.

The BRC Global Standard focuses on: • • • • • • • • •

The importance of management commitment HACCP (Hazard Analysis and Critical Control Point) based food safety programmes Quality management systems Auditing good manufacturing processes – not just a paperwork audit Auditing areas which often have the highest rate of product recalls and withdrawals, such as labeling and packing Developing systems to reduce exposure to food fraud Ensuring consistency of the audit process Providing a BRC Global Standard that is portable enough to allow Additional Modules to be added to reduce audit burden Promoting greater resilience, transparency and traceability in the supply chain

To our customers and stakeholders, we extend our sincerest thanks for their ongoing support. Extrupet is proud to share this achievement with them all.

AFRISTAR AWA R D S

2016

GOLD MEDAL

Product of

Proudly associated with SAN BWA

SOUTH AFRICAN NATIONAL BOTTLED WATER ASSOCIATION

Food Grade Plant

Contact: 011 865 8360 | Email: info@phoenixpet.co.za | Website: www.phoenixpet.co.za

D RY G O O D S , FI L L I N G & B AG S

Sophisticated

Flexicon’s bulk filler

FOOD PACKAGING Food manufacturers face the difficult task of controlling dust when filling different sizes of dry goods into bags. Aarifah Nosarka looks at economical solutions such as pneumatic and impeller filling systems, dust-tight valve bags that are leak-free and automated systems that eliminate aeration.

T

he engineering industry faces a special task of developing the right solution to suit modern market requirements as well as specific customer requests.

Existing for more than 80 years, Germanbased company Behn + Bates develops filling machines for free-flowing bulk food products.

These products are filled into valve and openmouth bags with weights of 1.5 to 50kg, and big bags of up to 1 800kg.

Filling dusty products in a large variety of grain sizes can be challenging for the food industry. The company therefore relies on pneumatic and impeller filling systems to optimally fill all fine and coarse grain sizes.

The pneumatic packer operates according to an air filling principle, while the impeller packer fills the product via a productspecific impeller wheel. These packers can be operated manually, semi-automatically or fully -automatically. This is done in combination with a frontline automatic valve bag applicator.

A common request is dust-tight valve bags that do not leak after being filled. For the hermetical valve closure, the company uses its proven ultrasound sealing technology, which is a standard. It is an integral part of modern packaging lines in the worldwide food industry. The sealing station is

integrated into the filling machine frame.

The filled bag is sealed directly at the filling spout. The bag’s air tight sealing fulfils customer requirements for clean, dust-free packing areas.

There is a further allowance of high packaging outputs and sealing rates of up to 99.5 per cent. Plant components, such as conveyor belts and palletisers, are not contaminated by product deposit residue.

Wear and tear, as well as time and costintensive maintenance work at all plant components are reduced to a minimum.

Behn + Bates manufactured a packaging system, the Intergra, which best suits the highest requirements of quality and hygienic standards. It unifies the filling applicator, valve bag sealing technology, the control system, operator unit and discharge belt conveyor in one compact cabinet. Dust and noise emissions are considerably reduced.

Product dust pollution is minimised, adding to the overall safety of the environment and well being of operation personnel.

AUTOMATION IMPROVES SANITATION Anchor Products installed a Flexicon automated packing line for filling bulk bags of sodium caseinate. The line eliminates

Behn + Bates valve filling machines

aeration experienced with rotary sack fillers. It cuts dust and packaging waste by 90 per cent, while achieving a bag weight accuracy of one per cent.

The powder is automatically transferred and filled by a system comprising two flexible screw conveyors, a 1500ℓ capacity surge hopper and a bulk bag filler.

The bags are automatically conveyed from the filler to a heat sealer. It is thereafter conveyed to bulk storage. The PLC-controlled system ties to the plant PLC. Sodium caseinate is used to manufacture coffee creamer.

The company selected the flexible screw conveyors as the most effective method to move this difficult-to-convey powder into a restricted space.

Flexicon’s bulk bag fillers range from basic stand-alone units to sophisticated systems. The company can match the budget and capacity requirements of each customer’s application.

Its Swing-Down filler has been designed for medium to high capacity applications.

Described as a revolutionary design, the technology brings the filling head to the operator at floor level for faster, safer and easier bag connections. Flexicon also offers rear-post fillers, with filling head height adjustment, intended for medium to high capacity applications. • Machines filling sugar into bags

Behn + Bates – www.behnbates.com Flexicon – www.flexicon.com

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Packaging Review | June 2017

P L A S T I C PAC K AG I N G M AT E R I A L S PP plastic preforms

P The plastics portal Plastic, whether rigid or flexible, is considered one of the most economical forms of packaging. It is believed to provide more protection than paper bags or corrugated boxes. PACKAGING REVIEW focuses on factors boosting the consumption of plastic, different plastic resins and suitable applications for this packaging medium.

By Aarifah Nosarka PET bottles

WHAT’S DRIVING PLASTIC PACKAGING’S GROWTH? USUALLY, DOMINANT PACKAGING format use is attributed to the growth of food and beverage consumption.

The growth rate varies in different countries. Consumption is however proportional to general economic growth, more particularly, the growth of the middle class.

Plastic packaging is still gaining share from other packaging formats, specifically glass. Glass has strongholds in perfume and spirits, while plastic and PET are increasingly gaining share in beverages, pharmaceuticals and food.

lastics are a dominant packaging material relied on for use in just about every industry. Enabling much of the convenience associated with modern living, this type of packaging is not only light, flexible and robust, but preserves and protects the product it houses.

David Drew, chief In most countries, commercial officer at beverage bottles Boxmore Packaging and closures are the (Boxmore) says together applications where plastic packaging is with refrigeration, food and used the most. beverage plastic packaging is one of the most world-changing inventions. ‘Had it not been for this type of packaging, creating products for distribution would either be impossible or limited to the privileged few.’

Although each country has different tendencies, the trend is generally similar – plastic packaging is growing. ‘The level of local manufacturing is a major influencer,’ Drew explains. ‘A large quantity of packaging on the African continent is imported’.

DID YOU KNOW?

“PET’s glass-like clarity shows consumers the characteristics of the product it holds” This means in categories like home and personal care, trends are largely global. Food is more often locally produced and beverages, almost always locally produced. Where product is made locally, the availability of plastic packaging can become a limitation as it would for glass, for instance. As such, there is growth in plastic packaging production in Africa in key markets. The availability of local or regional production can also boost consumption and conversion from one packaging format to another. Drew says a country’s population and wealth are determining factors for plastic packaging consumption. A country with more people and a higher GDP are good indicators of the total consumption in a specific region.

PLASTIC RESINS AND SUITABLE APPLICATIONS The main plastic resins are low-density polyethylene (LDPE), PET, polyvinyl chloride (PVC) and high-density polyethylene (HDPE). Drew says HDPE, which is relatively soft material, is ideal for extrusion blow moulding or injection/compression moulding for closures. It is generally used in colour applications because this type of resin is opaque. It is also the most widely used type of plastic. HDPE can handle high temperatures, which makes it useful for

Cling film is commonly made using PVC

producing retorted products. HDPE does not possess good tensile strength and according to Drew, cannot be used to produce pressurised products.

PET is a naturally flexible transparent polymer with good tensile strength. It is ideal for stretch blow moulding and the production of food and beverage bottles.

There is no need to use additives with PE which may contaminate the product itself.

‘PET’s glass-like clarity shows consumers the characteristics of the product it holds,’ says Drew. Although PVC is clear in its purest form, it is not as clear as PET. It was widely used in the past, yet concerns around the recyclability of PVC and health safety during production are the reasons this resin has become less popular.

LET’S TALK RECYCLABILITY Most polymers can be recycled. The question is whether they are in fact recycled? There are industry led initiatives in South Africa that have contributed to the growth in recycling materials like PET, HDPE, LDPE, polypropylene, polyolefin, glass, aluminium and paper. Products made from unusual or mixed materials are not as widely recycled as more common materials. •

Boxmore Packaging – www.boxmore.co.za

June 2017 | Packaging Review

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2 017

Spotlight on Interpack 2017 From 4 to 10 May, Interpack 2017 saw a record number of 2 865 exhibitors travel to Düsseldorf, Germany to take part in the trade fair. PACKAGING REVIEW highlights some of the exhibitors’ successes and demonstrations at the show.

A

bout 74 per cent of the 170 500 visitors (pre-audit) to the show had travelled from outside Germany. Three quarters of these representing companies were decision makers. There was a high percentage of German and international experts from about 168 countries among the exhibitors.

Friedbert Klefenz, president of Interpack 2017 says the event provides unique momentum for the industry.

‘It is not only a one-of-a-kind performance showcase, but also the place where suppliers

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Packaging Review | June 2017

and customers get together to network and do business.’

loading and closing of cartons from corrugated or paperboard materials, won the Rockwell Automation Best Future Machine Award 2017.

The awards were created to recognise high levels of innovation in the packaging industry. They were split into five categories: modular machines; smart machines; ease of use; sustainability and traceability as well as product safety. A prestigious judging panel chose the finalists.

Cama was nominated in each classification, winning the Ease of Use category. The company rated highly in the other categories too.

Cama will demonstrate a BreakThrough Generation machine at Propak Cape in October. This will be at Cama’s local agent, USS Pactech’s stand in Hall 1.

BEST FUTURE MACHINE AWARD 2017

MULTIPURPOSE ECODESIGN PACKAGING

The Cama Group’s (Cama) innovative IF318 machine showcased its development of Industry 4.0. It drew a record breaking attendance at the stand and gained several awards.

The new ‘pitch-less’ monoblock platform for the robotic forming,

Serac and Coveris received the ecodesign award from PackTheFuture for Optys, a 100 per cent decorated bottle thermoformed from a pre-printed plastic sheet.

The awards ceremony took place at the event.

The Optys bottle

2 017 Annalisa Bellante and Daniele Bellante, CEOs of Cama Group

Launched last year by Turkey-based dairy products manufacturer, EKER, the bottle was designed with the environment in mind. It provides outstanding product presentation with lower manufacturing costs.

As one of the PackTheFuture winners, both companies will be added to the candidate list for the World Packaging Organisation’s 2018 Worldstar Awards.

The Optys bottle is produced in a single stage by vertical thermoforming of an extruded PP sheet on Serac’s machine. This is done at a medium output up to 10 000 bottles per hour. There is no further operation required for the bottle’s decoration as the PP sheet is pre-printed by Coveris.

This simple, cost-efficient single step process allows a saving on supply and manufacturing costs. It also reduces the footprint of the packaging line by removing the labelling machine or sleeve applicator.

The artwork, which covers the bottle from the neck’s bottom to top, is printed using rotogravure technology.

This anticipates distortions occurring during thermoforming. The bottle can be used for dairy products, sauces, juices and non-food products in the home care and personal care markets.

Optys offers a wide variety of possibilities in shapes, colours, two-colour bottles, one for the outside and one for the inside, and light and oxygen barrier protection properties.

The Optys concept allows for a reduction of the global carbon footprint of the bottle at every stage of its lifecycle.

An additional benefit for the environment is the good level of hygiene and bottle’s closed neck, which eliminates water usage and chemical products for decontamination.

The bottle’s cleanliness can also have an impact on shelf life.

ADVANCED COMPRESSION TECHNOLOGY Sacmi’s 200m2 stand showcased technology available to the industry. This ranged from modular labellers to new Sacmi packaging robots. The stand was shared with long-standing Sacmi brand, C&M Holding – producer and marketer of confectionery packaging solutions. The company also displayed new compression technology applications for coffee pods. One of the applications exhibited was a 32-cavity CCM press. This offers short cycle times and comprises injection technology. The technology’s special plastic extrusion process, which with compression, occurs at lower temperatures and provides energy savings of more than 30 per cent. There is a complete guarantee of process repeatability as it is possible to manage each cavity independently and incorporate the advanced vision systems produced by the Group’s Automation & Service division. Applicable to both “proprietary” systems and the manufacture of compatible pods, the system ensures the lowest running costs on the market. There have also been additional innovative applications recently developed for the production of ecocompatible and self-seal pods.

PROTECTING UV-SENSITIVE CONTENTS

The NX UltraClear PP NXTM 8000 sets a new clarity standard for PP

Milliken Chemical demonstrated how its ClearShield Colorless UV Absorbers bring real value to PET packaging by effectively protecting UV-sensitive contents from degradation while maintaining the material’s clarity and transparency.

Brand owners have been responding to consumer demands by replacing artificial colourants and preservatives with more natural ingredients. This creates a new challenge since exposure to UV light can degrade ingredients in food, beverages and more. This negatively impacts the appearance, fragrance, colour, flavour or nutrient value of the contents.

To ensure product consistency and brand integrity, the contents of PET packaged goods must be protected from exposure both to sunlight and indoor lighting during storage, distribution, retail display and post-purchase storage.

Milliken used real-life examples and case studies to highlight how these additives create a new UV protection performance standard for PET bottles and containers. ClearShield offers an alternative, simpler way to protect against UV exposure. By incorporating the UV absorbers into the PET pack, this technology allows brand owners to remove the often-high loadings of UV additives previously included in formulations of packaged contents.

ClearShield absorbers filter 95 per cent of UV light at up to 390 nanometers. They are effective at very low loadings. They also enable

PRIMARY PACKAGING SOLUTIONS For your dairy product innovation

Discover us at www.dairy-packaging-machines.com www.serac-group.com

June 2017 | Packaging Review

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the use of more highly UV-sensitive natural essences, fragrances and colourants in packaged products. In many cases, by reducing the stabilisers and preservatives needed as a result, it is possible to also reduce formulation complexity, which can reduce cost.

DEMONSTRATING ENGINEERING EXCELLENCE GEA exhibited beyond the food package industry and displayed process equipment, solutions and services for the bakery, Erik Blom, MD of Meyn with Hans-Joachim Boekstegers, MD and Group CEO at Multivac, and Michael Falck Schmidt, senior vice president CCO EMEA at Cabinplant

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Packaging Review | June 2017

confectionery, dairy, beverage and previously available on the other sectors. market. Meyn provides It showcased its complete solutions for ‘revolutionary’, non-invasive, poultry processing. in-line quality control system Cabinplant offers Every three years at for modified atmosphere comprehensive Interpack, more than 2 000 exhibitors from across packaging. The GEA solutions in the food the globe present the OxyCheck holds substantial processing sector latest in packaging market potential. and specialises in the systems.

GEA has designed processing weighing, portioning solutions to match the trends of and precise filling of the times – for a highly regulated products that are difficult to industrial sector, highly sensitive package handle. MULTIVAC’s solutions extend contents and highly critical consumers. to labelling and inspecting finished and The company’s new developments on show secondary packaging. included an entry-level thermoformer The cooperation comprises two model, ultra-hygienic vertical bagger system agreements. These are cooperation between and a coating and wrapping line designed to the three with a focus on poultry processing revive the lollipop market. and collaboration between Cabinplant and MULTIVAC regarding projects and lines for SIGNIFICANT SYNERGIES ready meals, fish and meat. The alliance During the event, representatives from Meyn extends to all markets worldwide. • Food Processing Technology, Cabinplant and MULTIVAC Sepp Haggenmüller signed Cama Group – www.camagroup.com a memorandum of understanding in GEA – www.gea.com Düsseldorf. The three companies agreed the Milliken Chemical – objective was to offer food producers joint www.millikenchemical.com MULTIVAC – www.multivac.com solutions. These range from processing, Sacmi – www.sacmi.com filling and weighing of products through to Serac – www.serac-group.com packaging, at a level of combined quality not

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Candida Giambo-Kruger

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Sales executive +27 (0)83 260 6060

6

Carla Melless

3

Sales executive +27 (0)82 976 6541

8

Anita Raath

The solution 7

To advertise in

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ADVERTISERS’ INDEX JUNE 2017 Afrocet Montgomery......................5.............www.propakwestafrica.com Blue Belt..........................................15.............www.bluebelt.co.za Brewtech Engineering.......... 29, 32.............www.brewtech.co.za Cama Group.................................. 38.............www.camagroup.com Chempure...................................... 28.............www.chempure.co.za CJP Chemicals............................. 26.............www.cjpchemicals.co.za Dale Spiral Systems......................14.............www.dalespiralsystems.com DFS Process Solutions..................19.............www.dfs.za.com Eptech............................................ 42.............www.eptech.co.za Extrupet......................................... 35.............www.phoenixpet.co.za Hahn & Hahn............................ OBC.............www.sapat.co.za Heat and Control.................... 22, 23.............www.heatandcontrol.com

ID Logistics....................................10.............www.id-logistics.com/za Kenrich / Plasieve.........................11.............www.plasieve.co.za Koelnmesse......................................9.............www.anuga.com Messe München........................... 27.............www.drinktec.com Nutri Pharma Solutions............. IFC.............www.nutripharmasolutions.com Omron.............................................17.............www.industrial.omron.co.za Polyoak Packaging....................... 40.............www.polypet.co.za Sandvik...........................................21.............www.sandvik.com/steelbelts Serac............................................... 39.............www.serac-group.com Sirius Engineering....................... 24.............www.siriuseng.co.za Yaskawa..........................................13.............www.yaskawa.za.com

June 2017 | Food Review

41

TRAINING | JOB VACANCY | LABORATORY SERVICES | CONSULTING SERVICES | TO LET | MACHINE FOR SALE | RECRUITMENT | TEMPORARY EMPLOYMENT SERVICES | COURSES

CLASSIFIEDS JOB VACANCY KHS Manufacturing SA, part of the top 100 innovative companies in the beverage industry, is seeking young and motivated individuals with a good understanding in Beverage Machines for the following vacancies: • Sales Manager • Project/Sales Manager • Mechatronic Technician with programming skills Interested and suitable candidates to forward their CV’s to: za.careers@khs.com

NSF CERTIFICATION GLOBAL RECOGNITION WITH LOCAL EXPERTISE

ALE S R

FO

VIDEOJET® 1200 CONTINUOUS INK JET PRINTER

Tel: +27 21 880 2024 Email: foodafrica@nsf.org Web: www.nsf.org Accredited Certification against GFSI and other food standards.

• FSSC, BRC Food, BRC Packaging, IFS, GLOBALG.A.P. • HACCP (SANS 10330), ISO 22000, GMP, GDP, GPP, OHS • GFSI Global Markets Program (Basic & Intermediate)

Designed for printing 6-8 hours per day, 5 days a week, the Videojet 1220 Continuous Ink Jet Printer provides up to 9000 hours of production before required preventative maintenance. It is ideal for single to multiple shift applications, operating at moderate line speeds.

Equipment hardly used. Price available on request.

Conveyor system can be purchased separately.

Contact: Jo-Mari Vermeulen | Email: jo-mari@dddfarms.net

NEW & USED FOOD MACHINERY – IN STOCK

• Chisholm Bean Top & Tailers • FMC 3AR Corn Cutters, rebuilt • Eptech Trim Table for GS10 • Key 4” Hydro Food Pumps x 2 • Eillert Vegetable Washer 2stage • Key Iso-Flo® Dewatering Shakers • FAM Dice, Slice & Strip Cutters • Key Various Vibratory Shakers • FAM TS-1D Transverse Slicer • Kronen Model GS10 Belt Slicer • FAM LVD-2D Leaf Veg Dicer • Kronen Model KUJ Dicer • FAM 7944 French Fry Cutter • Vanmark Potato/Carrot Peelers • FAM MC3D Dicer / Slicer • Urschel 30 Bean Cross Cutters • Feuma Apple Peeler • 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

WEB REVIEW HOME

NEWS

ABOUT

C O N TA C T

AFRI-BLEND Your number 1 choice in food blending. · Raw food blending · Food Manufacturing · Food Packaging · H ACCP accredited · Halaal certified Tel: +27 (0) 12 803 0159 email: francois@afri-blend.co.za admin@afri-blend.co.za www.afri-blend.co.za

Offering the following across all regions in SA: • Food Safety Implementation (BRC, FSSC 22000, GFSI, GLOBALG.A.P.) • Customised food safety training • Pre-certification audits • Coaching and mentoring of Food Safety Manager • Food Safety Systems Maintenance & Support • Tempo paperless FSMS software solutions info@entecom.co.za www.entecom.co.za

DINNERMATES

FLAVOUROME

• Supplier to the hospitality trade and food factories • Service excellence, • Q uality, portion controlled products (chilled/frozen /dried) • Innovation & Flexibility • Meat & chicken products tailored for special applications in the food industry.

• Dried meat products – real meat real flavour!

Flavourome provides our clients

Tel: +27 (0)11 032 8600 email: sales@dinnermates.co.ca Tel: +27 (0)15 516 1515/4 email: factory@dinnermates.co.za www.dinnermates.co.za

formulating services in our fully equipped labs, as well as blending

FORMPAK

KHS

For over 40 years Formpak has supplied specialised processing, packaging and printing machinery to the pharmaceutical, cosmetic, plastic, glass, chemical, food and dairy industries.

The KHS Group is one of the leading manufacturers of innovative filling and packaging systems for the beverage, food and non-food industries. The group has an international production and service network.

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

We are the leading provider of hygiene, food safety and PARTNER für HYGIENE und TECHNOLOGIE PARTNER for HYGIENE and TECHNOLOGY technology solutions for food and beverage companies of any size.

We will help you with design of your food processing plant to comply with hygiene and technology equipment you need for your food processing plant.

We will supply you with the knowledge, service and expertise you need.

Tel: +27 (0)86 1777 993 Email: info@pht.co.za www.pht.co.za

within the food, beverage and health industries with innovative products, solutions and ideas. We are partnered with Firmenich and thus supply the world’s best flavours.

Our state of the art facilities allow us to manufacture, blend and supply various, food colours, sweetener blends, juice compounds, cloudifiers, emulsions, health ingredients and Tea extracts. We also provide services in our powder and liquid facilities, offering our clients a unique and competitive edge.

www.flavourome.co.za

www.khs.com

QUANTUM COLOURS SA Your No. 1 industry leader for the most comprehensive ranges of both synthetic and natural colours – used in food, pharmaceutical, cosmetic and industrial applications.

Our technical team is available to shade and colour match to specific requirements and / or Pantone references and to give legislative support on colours. www.quantumcolours.co.za

When you need a lawyer who understands engineering and food science,

CALL HAHN!

HH

hahnhahn •

intellectual property practitioners

Physical Address Hahn Forum, 222 Richard Street, Hatfield, Pretoria, 0083 Postal Address PO Box 13575, Hatfield, 0028, RSA Docex 219, Pretoria Tel (27) (12) 342 1774 • Fax (27) (12) 342 3027 • 430 7637 Email hahn@hahn.co.za • Web www.sapat.co.za