Journal for food and beverage manufacturers MAY 2018 Vol. 45 â€˘ No. 5
Beverage Review & Packaging Review
target snacks and confectionery market
gains for chilled food Systems and ingredients
that impact the dairy industry
CONTENTS MAY 2018 | Vol. 45 • No. 5
Behind the scenes at Firmenich
31 Pumps to
increase cheese producers’ productivity 33 Beverage Review BeverageREV IE
Increased demand for macadamia nuts
USDA approves carrageenan use
Microbiological air samplers for safer food
Sandvik now trades as IPCO
Managing risk with ERP
12 SNACKS & CONFECTIONERY How to ensure an accurately seasoned product
Firmenich focuses on integration
Premiumisation for the snacks sector
Extra calcium ensures crispy sensations
Anti-caking solutions in action
Develop a memorable texture
SOUTH AFR ICAN
“All beers are not created equal. Different ingredients, temperatures, fermenting times and steps come together to create an enormous variety of beers” 8 | Volu May 201
Continuous control during freezing
Is nitrogen the perfect gas?
Assa Abloy launches high-speed interior door
Pumps increase output
A car neutral first forbon SA Benefit and dairy altefrom milk rnatives
REVIEW g n i g a k Pac
CAN H AFRI SOUT
20 HEATING & REFRIGERATION
Industrial cheese manufacturing just got easier
May 2018 | Volume
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“X-ray scanners must comply with different specifications, a customer’s requirements and necessary detection rates” May 2018 | Food Review
8 | Number 05
EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 email@example.com
Is food safety dependant on collaboration?
Assistant Editor: Aarifah Nosarka +27 (0)11 877 6209 firstname.lastname@example.org
recently attended a roundtable discussion hosted by Mondelēz South Africa in Johannesburg. A panel of experts discussed ways of restoring consumer confidence in food producers, sellers, processes and government regulation. The biggest take away for me was the need for collaboration between governments, producers and consumers to improve food safety during the handling, preparation and storage of food. South Africa is a signatory to Codex Alimentarius. The body was set up by the Food and Agriculture Organisation and World Health Organisation and sets international standards relating to food production and safety. South Africa also abides by Hazard Analysis and Critical Control Points (HACCP). This is a systematic preventive approach to food safety from biological, chemical and physical hazards. The panel agreed the entire food value chain must adhere to the regulations. This includes producers, processors, distributors, consumers, government and NGOs. Regulators and industry have the responsibility to ensure anything that may have been missed is picked up at some point in the chain. While checks and balances may be in place, there is fragmentation due to the vast number of role players. The South African food control system is burdened by challenges from a complex and fragmented safety and quality system. Food regulation comes under the jurisdiction of several different departments and acts. In some instances, such as the Foodstuffs, Cosmetics and Disinfectants Act of 1972, legislation is outdated. When you look at how fragmented operations are, the question should be: ‘What are we doing to communicate better?’ Mondelēz International is advocating a standard of food safety that can be applied across the world. This is especially important in a global economy, where raw material is sourced from one country; products are processed in another, and sold in a third. It’s vital to encourage developing markets to raise the bar and to think about adopting a global approach that leverages science to set standards – even for smaller suppliers. A single approach to food safety is required, involving cooperation, openness and dialogue between the relevant sectors of government and all industry players. I feel, as I am sure you do too, that efforts from industry are critical in ensuring a food safe environment. I would love to hear your thoughts on this topic. Here is a quick precis on some not to miss articles in this month’s edition. Our focus falls on new ingredients and texture and sensory innovation in the snacks and confectionery sector (page 12). Don’t miss our feature on hygienic equipment and systems impacting the heating and refrigeration market by turning to page 20 now. We also investigate the growing market for beer ingredients and digital systems (page 36) that work towards offering consumers a more transparently produced and healthier brewski.
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Enjoy the read!
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.
Managing director of Symrise South Africa; chairman of SAAFFI.
Head of communications, Tetra Pak Sub-saharan Africa.
Dr Heidi Grimmer Founder, creative director and entrepreneur of Strategic Communications Company (Stratcom).
Gail Angela Macleod
Food Review | May 2018
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Food Review | May 2018
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China’s appetite for macs fuelling SA industry DEMAND FOR MACADAMIA nuts in China is on the rise. The country has increased its nut consumption in recent years and is currently South Africa’s fastest growing importer. Imports top 40 per cent of the total haul, according to data by China’s National Industry Association (CSNC). Valley Macadamias group chairman, Alan Sutton, recently visited China to gain more insights. ‘Demand and consumption of nuts is growing fast and opportunities for the South African macadamia industry is incredible. As the market grows, dynamics change. We feed all relevant information to South African farmers to help them meet global demand.’ In the past when demand outweighed supply, buyers had less choice of style and price. The balance is starting to shift. The Chinese now produce their own nuts (10 000 tonnes in 2017), which is leading to a global increase in supply. ‘The market is now a buyer negotiated space. With greater demand for quality and size, South Africa’s produce ticks all boxes,’ Sutton notes. A long-term challenge facing SA’s trade with China is that Chinese macadamia farmers could pose a threat to export rates. There is still opportunity for growth in specialty nuts and ingredients however. South Africa’s macadamia industry is poised for growth of between eight and 10 per cent this year.
Carrageenan decision applauded DUPONT NUTRITION & Health and a broad coalition of scientists, dietitians, food producers, environmentalists, seaweed farmers and consumers applaud the decision by the United States Department of Agriculture (USDA) to support carrageenan for continued use in US organic food. The agency considered a 2016 recommendation by the National Organic Standards Board (NOSB) to remove carrageenan from the national list of ingredients allowed in organic food, but ultimately decided to renew carrageenan. The USDA considered scientific evidence and stakeholder comments, which ultimately reaffirm carrageenan’s safety and value as a food ingredient. Carrageenan is widely accepted and used as an ingredient in many foods, thanks to its combination of attributes and breadth of functionality. An independent survey of food formulation professionals confirmed carrageenan was the most accepted ingredient for certain food, surpassing all other surveyed ingredients, including those approved for use in organic
products. Carrageenan is the only approved non-synthetic stabiliser currently allowed for use in US liquid organic infant formula. Carrageenan features the following benefits: • The ingredient is sustainably harvested and readily available • Reformulation that eliminates carrageenan may alter colour, odour and taste in some products adding significant costs • Seaweed farming is one of the most environmentally friendly types of aquaculture • Carrageenan farming has helped lift families out of poverty and improved the economic well-being and social fabric of thousands of communities in countries across south east Asia and Africa • There are decades of research affirming carrageenan’s safety as an additive.
New name and brand
KEEPING IT CLEAN THE LISTERIOSIS OUTBREAK has created consumer panic and mistrust in the food and beverage industry. Contamination resulted from inadequate food safety management. Insufficient cleaning and maintenance, led to the proliferation of bacterium resulting in high levels during packaging of processed products. It was indicated that cross contamination from one area to the next could not be prevented due to inadequate separation of these areas in the plant. Food and beverage companies are usually equipped with clean room facilities for key aspects in their process. These facilities are specially designed to have a controlled level of particulates per cubic metre. The classification range is ISO 1 to ISO 9 with ISO 1 described as the cleanest classification i.e. it has the least number of particulates per cubic metre. Microbiological air samplers are specialised monitoring equipment utilised to detect and monitor particulates to ensure maintenance at correct levels. To maintain
relevant sterility levels, the environment should be cleaned in accordance with a defined schedule. Utilising sterilised clean room wipes (specialised swabs/cloths made from a nonwoven cellulose polyester material that affords superior strength and enhanced absorbency) is ideal for this type of environment. It is important to consider the largest contaminant in any environment - people. To maintain sterile levels of a controlled facility, suitable garments must be worn to keep particulate levels at a minimum. The design of a clean room must allow for personnel to gown and de-gown. It should also ensure contaminants are not carried into the clean room. Tacky mats (multi-layered clean-film adhesive layers) effectively capture dirt and dust from foot traffic and wheels before entering a controlled environment. DG Lab Services’ clean room products division is a level 1 B-BBEE manufacturer of clean room garments and supplier of microbiological air samplers, clean room wipes and Tacky mats.
for leading steel belt manufacturer IPCO IS THE new name for one of the world’s leading suppliers of steel belts and associated industrial process systems. Previously operating as Sandvik Process Systems, the company is now an independent company within the Wallenberg group and has 600 employees, more than 35 sales and service offices and annual sales in excess of €200 million. In joining the Wallenberg group, IPCO has gained the stability of being part of a business with approximately 600 000 employees and more than €140 billion in total annual sales. The company’s network of regional offices will enable it to continue to provide local, on-the-ground expertise backed up by a service organisation with the ability to support customers in any location around the world.
May 2018 | Food Review
I N D U S T RY TA L K
success with ERP Working across multiple spreadsheets where each department runs in isolation can mean constantly averting one crisis after another. Integration in a business is critical when trying to work efficiently.
ealing with large batches of sophisticated products can come with a new set of challenges. One tiny mistake such as not ordering enough stock and overpromising can end up costing you time, your reputation and money. Many industries require refrigeration and heating products to keep their business running, so they become an integral part of the business. Every restaurant or kitchen has a different environment with its own set of unique needs. It is the responsibility of the manufacturer to understand these needs and serve bespoke products that will please customers.
FULFIL THE DEMAND TO AVOID THE KNOCK ON EFFECT Components used to produce a processing plant’s fridge or heating system can differ greatly. Ordering stock on a large scale can also affect business. With many projects on the go, visibility across the board is needed so you can understand the probability of success in completing a product. Problems in maintenance, repairing or delivery of this piece of product can have a knock on effect for many other areas of the business. It is important to remove all silos and integrate parts of the business to make everything seamless. An ERP system adds value by giving you an overall view of all that is required
Food Review | May 2018
“Without using an integrated system, that shows you what is happening on the project or procurement side, you risk the chance of overspending” including stock and capacity. It answers questions such as: Do we have enough time, resources and capacity based on the demand to fulfil the orders? What are the production timelines, and are we capable of meeting our deadlines without being sleep deprived? ERP systems also provide insight on the typical lifespan and other behaviours in the different environments where product is placed. This allows the manufacturer to advise its customers on the warranty period, how long it will last and how often servicing should happen.
MANAGING RISK Without using an integrated system, that shows you what is happening on the project or procurement side, you risk the chance of overspending. If the finance team is not kept in the loop on what is happening until it is too late, they will likely have to figure out a way to fit the stock purchases into the cash flow. The finance team will have to keep juggling balls to make sure payments are
satisfied so they don’t receive bad ratings from suppliers. If a stock shortage is not visible, business needs to remedy the situation. Otherwise you will work at a crisis point where you are managing risks and trying to ensure all projects can be delivered on time. You end up sourcing product from anywhere and could possibly get low quality products or risk overspending because you don’t have time to get the right suppliers or negotiate the right price. ERP systems assist in providing visibility across the organisation, allowing for improved planning and collaborations lowering the potential of risky situations. With the growth of AI across different industries, Syspro is developing artificial and IOT capabilities into its ERP system, along with the right tools and methodology. This will go a long way to help customers to optimally use the technology. By leveraging ERP in the refrigeration industry, customers are guided through the process of asking the right question to ensure they fully use all capabilities of their ERP systems. By utilising an ERP system across the organisation, a business can begin to move from crisis management into strategy management. •
Syspro – za.syspro.com
I N D U S T RY TA L K
Behind the scenes at Firmenich Maryke Foulds chatted to Marco Monteiro, general manager and commercial director of
Firmenich South Africa about the Flavourome acquisition and what it means for the company and its clients. HOW DID THE DEAL WITH FLAVOUROME COME ABOUT? Flavourome has been our exclusive distributor in South Africa since 1998. David Wright, founder and CEO, has been an outstanding partner for Firmenich and has developed a high performing team with an intimate knowledge of our offerings. Their track record for providing best-in-class service to local customers will be critical as we work on growing our business in this strategic market.
WHAT WAS THE REASONING BEHIND THE DEAL? This acquisition will allow us to have direct access to attractive, local customers in South Africa and acquire a high-quality manufacturing facility. This will enable us to service local and global customers operating in South Africa from a dedicated plant.
HOW WILL THE TWO COMPANIES BE INTEGRATED? Flavourome will be fully integrated into Firmenich. This puts together two strong sales and technical teams to unlock value with our customers for growth in subSaharan Africa.
WHAT IS THE BIGGEST FOCUS FOR THE COMPANY THIS YEAR? Integrate, focus and apply. We also want to have some fun whilst doing it.
HAVE THERE BEEN ANY STAFF CHANGES? There have been no staff losses, although we have restructured a bit to bring out
‘This has a great nose.’ From left, Marco Monteiro, Imaan Gaffore and Thomas Steynberg
the strengths of the team members. Team is everything at Firmenich. We are a family owned business and our team values echo this.
TELL ME ABOUT YOUR RESEARCH AND DEVELOPMENT This is one of our strongest differentiators. We have four main research and development centres that serve our global business: Geneva, Switzerland; Shanghai, China; New Jersey, US and Gujarat in India. This reflects our position as an industry leader in innovation. Firmenich has more than 2 900 patents worldwide and we reinvest 10 per cent of our annual revenues back into research and development. Our local solutions and flavour development is done locally in our labs with
clients’ and consumers’ taste preferences in mind. The tools and technologies we have at our disposal are backed by this impressive corporate function.
Thomas Steynberg, technical manager
WHAT IS THE BIGGEST GROWTH CATEGORY IN THE F&B INDUSTRY AND WHY? Alcoholic drinks are one of the fastest growing. This category seems to withstand inflationary pressures and is consistently innovating for growth.
IN CLOSING… Firmenich is one of the largest privately owned flavour and fragrance companies in the world. Being a family-owned business is what drives us to make positive contributions to our communities. This has always been a priority of ours and therefore sustainability is core to our strategy. We bring creativity and science together to address global challenges such as nutrition, health, climate change, hygiene and sanitation. •
Firmenich – www.firmenich.com
May 2018 | Food Review
C O M PA N Y F O C U S
one year of integration Frutarom is known for its aggressive acquisition trail. Last year’s buy out of Unique Flavors has been favourably concluded. Managing director Darrell Gray predicts the company will regroup and integrate fully in 2018. It aims to do this by focusing all its efforts on business activities throughout the sub Saharan region. By Maryke Foulds
rutarom’s business model has proven Unique Flavors with the company’s global to be very attractive to customers on product portfolio relevant to the South the African continent. The company African market. is committed to driving this model across a ‘Our sales force has vast experience across broader product offering. ‘While integrations the African continent. In typical Frutarom often don’t meet the desired outcome, style, we will continue to drive our we are happy to report the activities and widely accepted integration with Unique product range, delivering the Flavors was a tremendous correct value equation,’ success,’ Gray enthuses. Gray notes. ‘By the end of 2017 we Frutarom has Frutarom South Africa registered positive implemented is home to a state of the art growth. Our aim this a systematic emulsion production line. A year is to leverage approach towards priority has been set to target the benefits of innovation, based all users of emulsions to integration into the on the principles of leverage advantages in emulsion capability. market place. We expect professional project a very positive response management, rapid from our customers.’ prototyping and joint An inspiring and creative innovation. ‘Our innovation environment results in innovative teams across Europe make thinking, knowledge and knowledge based this philosophy visible and tangible development. This approach underpins the by bringing together resources of knowcore values of Frutarom. Support from the how and inspiration for new product best raw materials, latest technologies and developments, spanning everything from comprehensive know-how is a sure-fire creative brainstorming, designing new recipe for business success. flavours, tailored and customer oriented A key activity for the year is to showcase all-in-one solutions, to concept evaluation the combined portfolios of Frutarom and and communication.’
DID YOU KNOW?
Frutarom currently produces product at two facilities, situated close to each other in Midrand and Centurion, Gauteng
LOOKING AT AFRICA Population growth estimates for sub Saharan Africa present a favourable outlook for food and manufacturing production across the continent. The local appetite for good products in Africa is certainly a milestone shift from the historical trading preferences that dominated business activity for almost a century. The need for companies like Frutarom to align with this trend will serve local companies and people favourably in the future by creating business opportunities and jobs, thereby driving the economy. At the core of a successful enterprise is its staff. ‘Frutarom is rapidly expanding in Africa. Our investment into recruitment and training of staff is high on our agenda to develop our people. Frutarom’s unique style fits well with the typical customer’s habits and needs on the African continent. As we build our business, we remain committed to the local needs of the food and manufacturing industry on the continent. Frutarom respects its competitors and we are continually looking for ways to ensure the value we bring to our customers is at a superior level,’ Gray concludes. •
Frutarom – www.frutarom.com
FACTS & FIGURES
30 000 customers in over
research and development laboratories
67 production sites globally
70 000 products 10
Food Review | May 2018
C O M PA N Y F O C U S
Golf for a
FRUTAROM HOSTED ITS first annual golf day at the Bryanston Country Club in Johannesburg. It was a fantastic event and would not have been possible without the generous sponsorship from suppliers. ‘The event was a huge success,’ enthuses Darrell Gray. ‘Mont Blanc sponsored a brand spanking new BMW as a hole in one prize, but unfortunately nobody won it. The golf day achieved its
aim as an event focused on networking and marketing between our client and supplier base. We also managed to raise R20 000 for our chosen charity Four Paws, which focuses on creating a world where humans treat animals with more humanity, respect, empathy and understanding. A big thank you to all who attended, and to PGA professional Ulrich van den Berg who hosted the day.’ 2
A fantastic networking platform was created by combining clients, suppliers and Frutarom staff as four ball alliances
Frutarom South Africa showcasing innovation, taste and friendly client service
The professionalism lies in the small details - well organised, lined up in a row and even named according to the four ball alliance team names
J anene van Niekerk of Frutarom provides a welcoming smile during registration
I t’s all about the correct stance, follow through and sometimes just a little bit of luck
F our Paws animal charity received R20 000 from Frutarom South Africa
D arrell Gray, Ulrich van den Berg and Kelvin Gray soaking up the sunshine at the first Frutarom Golf Day
May 2018 | Food Review
S N AC K S & C O N FE C T I O N E RY
On-machine seasoning offers bigger scope Tna has unveiled a new version of its flagship on-machine seasoning application system, the tna intelli-flav OMS 5.1. The system is designed to IP65 standards to facilitate maintenance and meet the highest hygiene and sanitation standards.
new range of features is on offer. These include a high-capacity stainless steel drum; heated oil circulation system and integrated bulk powder fill technology. Units can be used to accurately season a wide range of products, from fried, baked and puffed snacks to gummies and confectionery. It can also be used for frozen food applications that require more rigorous sanitation procedures like meat and seafood. This is the only on-machine seasoning system that offers wet and dry seasoning in a single drum and provides food manufacturers with the highest level of flexibility. To prevent dust and water ingress and meet strict IP65 (NEMA 4) protection requirements, tna’s engineering team have
applied bespoke methods to seal edges, limit the use of wires, enclose feeder motors and facilitate drainage of surface water. The new single load cell design of the tna intelliflav OMS 5.1 keeps maintenance requirements to a minimum thanks to fewer moving parts and easy-access construction. Besides the product’s renowned lightweight polymer flavour drum, units can be equipped with a robust stainless steel drum to ensure superior equipment reliability when filled with high temperature product (exceeding 40°C/104°F). The system has also been fitted with a strong, high density drive to allow instant load capacity increase from five to eight kilogrammes or 1600kg/hour. Robust monocoque construction provides extra structural support.
Epsilon Series Introducing the new Yamato Epsilon Multihead Weigher. The Epsilon can handle a wide range of products with speed and high accuracy. Time To Weigh Up The Benefits: • High Speed
• Cost Effective
• Easy Operation & Maintenance
Sales: Craig 076 811 8704 General enquiries: Natasha 064 515 3906 Spares/Service: Andre 071 613 6390 Email: SalesSA@yamatoscale.co.uk www.yamatoscale.co.uk Yamato Scale Dataweigh (UK) Ltd is a limited company registered in England and Wales. Registered number: 2919226. Registered office: Unit 6B, Millennium Way, Leeds LS11 5AL
Food Review | May 2018
The system delivers an accurately seasoned product with minimum waste
A new heated oil circulation system can keep even hard fats, such as palm olein or butter in liquid form as they travel through the machine. For dry seasoning applications, customers have the option to equip units with an integrated, automated bulk powder fill system. Featuring a vacuum conveyor, the new bulk fill continuously monitors seasoning levels and automatically discharges powder into the hopper as it runs out to provide a uniform, quality product. It also reduces the amount of airborne seasoning in the production hall. Tna’s innovative right product right bag technology ensures only the correct seasoning is applied. This provides manufacturers with a fully integrated seasoning solution. •
Tna – www.tnasolutions.com
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S N AC K S & C O N FE C T I O N E RY
drives snacks segment S nacking is central to the strategy of ambitious and creative companies, with explosive growth in the number of new snacks launched between 2010 and 2017. This growth means healthy snacking is now an intensely competitive and crowded space, according to a new report by New Nutrition Business, Strategies in Healthy Snacking. ‘Companies have to work even harder to create a product that brings a real point of difference for the consumer,’ says Julian Mellentin, author of the report. The report outlines 10 strategies for success in healthy snacking, illustrated with 15 case studies of healthy snacking brands in the US and Europe. Creative new product development and innovation are key for success in snacking, says Mellentin. ‘Businesses that are proving successful are the ones that are creating new markets with differentiated snack concepts, often using new ingredients and processes, and selling them under new brands and messages,’ he explains. Today’s consumers are all food explorers, willing to
adopt foods and flavours that would have seemed strange 10 years ago, and willing to pay more for them. Premiumisation: This is the new normal in the healthy snack category. Brands that deliver an innovative snack product, targeted at ever-fragmenting consumer preferences, can command premium prices. The 15 case study brands included in the report, sell at a significant premium of up to 830 per cent compared to mass-market brands. Leveraging technology: New ways of processing natural ingredients and new packaging technologies are behind the success of many new snack concepts. • GLK Foods, America’s largest producer of sauerkraut and pickles sold in jars, tapped into the snackification trend by giving its traditional pickled vegetables a snack-sized format. It reduced the messy brine, put them into resealable packaging with modern, fresh flavours including Hot & Spicy, and launched them under a new brand called Oh Snap!
• Biena’s founder based her roasted chickpea snacks on a traditional Indian idea, but used processing technology to make the texture more acceptable to Americans. ‘Our mission is to create the next great American snack,’ Poorvi Patodia told New Nutrition Business. ‘Chickpeas have been very much on trend. Hummus brands have done a great job of educating American consumers for 10 years, and we have benefited from that foundation. People have never heard of roasted chickpeas and are coming across this type of snack for the first time.’ Consumer ideas about what is healthy are becoming ever more diverse and this creates a wealth of white spaces for new snack products. •
Africa’s premier food & drink tradeshow
Africa’s Big 7 welcomes thousands of f&b professionals from across the continent and with so much content, features, networking and industry insight it is the essential event for the industry. What you can look forward to at the show: 200+ Exhibitors From over 25 countries
The food leaders Forum A 70+ speaker conference
Competitions you won’t want to miss The NEW Inter Hotel Culinary Cup The Global Pizza Challenge
Lots of FREE accredited training Barista and mixology classes Farming skills course Food Hygiene workshop
Register now for free entry www.africabig7.com AFRICA HOSPITALITY WEEK: Powered by:
Food Review | May 2018
S N AC K S & C O N FE C T I O N E RY
Crispy sensations with a
ure enjoyment is no longer the only consumer requirement when it comes to snacking. The role of snack products is expanding and snacks are being served as replacements for complete meals. Simple packaged food solutions that are at the ready and yet offer indulgence are flying off supermarket shelves. The landscape for manufacturers is competitive. To be successful, they must satisfy evolving consumer selection criteria, which includes taste and texture. A perfect fit for these demands is the natural ingredient calcium carbonate. Omya Calcipur is a range of high purity calcium carbonate that can help formulators achieve their goals in multiple ways. Naturally derived and available in a variety of mastered particle sizes, they can be used to improve the nutritional profile and texture of a vast range of sweet and savoury snacks and other extruded products such as breakfast cereals. Calcium carbonate is a natural nucleating agent and an extrusion aid. It facilitates the
Snack with 0.5 per cent Omya Calcipur 110-KP
Snack without extrusion aid
formation and homogenous distribution of fine gas bubbles, advancing expansion and texture. Just 0.5 per cent of the ingredient induces a notable increase in size, resulting in an improved ratio of raw material input to final product output. For an advanced mouthfeel, Calcipur prolongs crispness and enhances the perception of saltiness or sweetness.
Official Distributor for RSA
Omya Calcipur can deliver health benefits, too. Dietary surveys1 undertaken during the past decade among the adult population of South Africa have shown that the mean calcium intake is far below the recommended level. Thanks to its high elemental calcium content of approximately 40 per cent, Omya Calcipur is one of the most concentrated sources of the mineral on the market. This makes it possible to use up to five times less of the ingredient than other available alternatives while achieving the same calcium dose in the finished foodstuff. Swiss company Omya is a global producer of calcium carbonate with more than 130 years of expertise in delivering tailor-made solutions to customers. Ecologically, these natural ingredients convince with their reduced carbon footprint and low generation of waste during production. Omya is represented locally by CJP Chemicals. •
CJP Chemicals – www.cjpchemicals.co.za REFERENCES: 1. Z andile, J., et al. (2015): A Review of Dietary Surveys in the Adult South African Population from 2000 to 2015, Nutrients 2015, 7, 8227-8250; doi:10.3390/nu7095389
Omya Consumer Goods omya.com
For a crispy sensation... add calcium to your formulation! Omya Calcipur ® 110 - KP, at a concentration of 0.5%1.5%, improves expansion index, texture, crispness and bubble distribution of extruded cereals and snacks. This dosage also enables a calcium claim.
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Food Review | May 2018
S N AC K S & C O N FE C T I O N E RY
Fibres that ensure anti-caking Powders and spices can cause some difficulties during storage and handling. CFF GmbH & Co. KG is a producer of natural and functional dietary fibres for the food industry. Its range of products is supplied locally by Savannah Fine Chemicals.
lagship fibre ingredient, Sanacel, is used globally in various applications. There is an enormous and innovative application field for functional dietary fibres in dry powder mixes. These include: •S pices and spice blends •V egetable or fruit powders • Premixes •M ixes for instant products. Besides its use as a nutritional ingredient, Sanacel fibres can be used in powder mixes and spices to improve stability, workability and reduce the stickiness of fruit pieces. Adding Sanacel fibres to a dry powder can affect physical properties, depending on the type of fibre used. With high-water binding capability, Sanacel fibres can be used to improve the stability of powders and powdered mixtures. They can also be used in snacks and confectionery to reduce surface holes on extrudes snacks or as a bulking agent for easy sugar replacement.
Lumping is one reaction indicated by powders and powder mixtures based on suboptimal storage conditions. Intensity and occurrence of lumping is dependent on temperature, moisture and pressure during storage. Other factors that influence the tendency of building lumps are size and distribution of powders and powder mixes. Powders with a unique particle size are not that sensitive in building lumps. Those with a range of coarse and fine particles show a higher tendency for caking. The reason is the points of contact between the particles. Another reason for caking is interaction between particles. Residual moisture or friction can cause lump formation. Besides the physical properties of particles, chemical properties can influence the tendency of developing lumps. A determining factor is the hygroscopicity of a product. High
hygroscopicity means a high affinity to attract water from air. Hygroscopic powders are more susceptible for caking. Sanacel oat 30G can reduce the affinity of caking and building lumps as it affects several particle properties. This reduces the availability of water for powders and powder mixes when added. A significant reduction of caking can be reached with a dosage of 2.5 per cent of Sanacel oat 30G. •
Savannah Fine Chemicals – www.savannah.co.za
2018/05/11 9:54 AM
May 2018 | Food Review
S N AC K S & C O N FE C T I O N E RY
The soft claim with a firm impact Historically, texture has been an overlooked aspect of the consumer’s overall eating and drinking experience. Not anymore. Severine Bensa, senior marketing manager for texture at Ingredion, discusses why the need for manufacturers to develop memorable signature textures is here to stay.
efore a consumer has even opened a yoghurt, a pack of crackers or a drink, they have an expectation of what they are about to experience. Consumers expect indulgent yoghurts to be thick and creamy, crackers to crunch and meat to be succulent. Texture becomes an important channel to offer consumers a sensory and memorable eating experience, whether they’re conscious of this or not. When we eat or drink, we typically notice smell, appearance or taste. The language of texture is often omitted from the story. The more intangible a sense, the harder it is to define. The texture of products we eat and drink is as important as other attributes and if it fails to meet expectations, consumers will notice.
TEXTURE AS A TREND At Ingredion, we have predicted that texture will be a key industry trend for several reasons. In a society focused on sharing
everyday experiences, including images and descriptions of food through social media, consumers are more aware of the properties of the food and drink they consume. Manufacturers are responding to the trend, rather than considering it as a short-lived phase. Last year, 20 per cent of food and drink products launched in Europe featured a texture description, representing a rise of 17 per cent compared to 2016. Texture can make or break a product. If an on-pack claim doesn’t align with the eating experience, consumers will not get what they expect, making brand loyalty and repeat purchase unlikely. The challenge for food and drink manufacturers is to develop textures that will create memorable and positive eating experiences for consumers and inspire longterm brand advocacy.
Traditionally, manufacturers are focused on achieving the right flavour for their products, leaving texture as an afterthought. Our recommendation is that texture is built first and flavour optimised afterwards.
• SALES / RENTALS OF A FULL RANGE • RELIABLE, ROBUST & QUALITY DESIGNED PRODUCTS • COMPREHENSIVE AFTER-SALES SERVICE • 24 HOUR PRODUCT & TECHNICAL SUPPORT TEAM
Food Review | May 2018
DEVELOPING A TEXTURE STEPBY- STEP
Defining texture has traditionally proved challenging, due to the complex link that exists between consumer perception and a product’s physical properties. Ingredion approaches texture quantification through a range of methods to ensure all aspects are considered and the final product meets consumer expectations. We consult our in-house sensory experts, as well as a texture lexicon (such as our own Texicon™) to examine Figure 1: Starch acts as a base, bringing viscosity and thickness, before a texture measurement and co-texturiser is used rheology. Into this mix we add
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research, market insights and texture maps to build a bigger picture. Using these tools, we can develop definitions of texture for specific products. To use dairy as an example, key textural attributes include: •S poon indentation - The indentation made by a spoon • Firmness - The force required to compress the product • Evenness of mouthcoating - The extent to which sample evenly spreads over the palate during manipulation • F atty/dairy mouthcoating - The amount of fat perceived in the sample.
S N AC K S & C O N FE C T I O N E RY
The co-texturiser concept Allows you to create dramatic differences in texture and the sensory qualities of your products N-DULGE® C1 co-texturiser Thick, full mouthcoating, slow meltaway. Example products: Caramel sauce.
N-DULGE® C2 co-texturiser Slight mouthcoating, slippery, even meltaway. Example products: Chocolate fondue.
Control Light-bodied, gradual meltaway, like a typical pudding.
N-DULGE® CA1 co-texturiser Creamy, firm, even mouthcoating and meltaway. Example products: Creamy peanut butter.
N-DULGE® SA1 co-texturiser Provides clean spoon-cut and creamy, slightly firm but rapid meltaway. Example products: Custard.
Figure 2: Creating a signature texture by evaluating the functionality of select ingredients against the desired attributes of the end product
BUILDING WITH TEXTURISING AGENTS Texturising agents provide texture to a food or beverage and are a tool kit to design products that satisfy consumer expectations. Either alone or in combination, these agents can create viscosity, gel, mouthfeel, pulpiness or crunch or maintain quality when fat or sugar content is reduced. We approach texture design in two stages. Using the example of starch, an incredibly versatile and cost-effective co-texturiser, we would use a viscosifying starch as a foundation ingredient to bring viscosity and thickness, followed by a co-texturiser to fine-tune and create differentiation.
STEP ONE - Building the foundation Firstly, we would select an appropriate viscosifying starch base, depending upon the following product and process circumstances: • Consider process constraints - Establish heat and shear parameters • Determine application constraints Evaluate freeze/thaw/pH stability
• Evaluate raw material usage - Corn = cost-effective, tapioca = ideal for dairy flavours, etc • Define label requirements - Will the product be subject to any claims, for example, clean label?
STEP TWO - Fine-tuning with a co- texturiser After process evaluation, texture attributes need to be determined using texture maps and product characteristics decided upon. If the product is a snack will it need to be light and crispy or hard and crunchy? Does the consumer expect it to be thin and blistered, or thick and crumbly? This is where the importance of the formulation process can really be appreciated. During manufacturing, texturising agents can be sensitive to a number of environmental conditions, and the influence of other ingredients. Starches are affected by shear, pH, temperature and salt and hydrocolloids are sensitive to salt and pH. It’s vital to understand ingredient features and their performance
during manufacture in order to ensure they are working at their optimum level in the end product.
ADJUSTING TEXTURE IN EXISTING PRODUCTS Texture isn’t always built before product development - it can be adjusted at a later stage to cater to new consumer trends, or to retain sensory qualities when reducing ingredients such as sugar and fat. If a manufacturer replaces traditional ingredients, this will modify a product’s qualities. The aim is retain these as far as possible to ensure seamless consumer appeal. When replacing sugar in a drink, we may recommend our Enliten® stevia sweetener and N-Dulge® C1 co-texturiser to rebuild texture and mouthfeel. When creating lowfat mayonnaise, the texture lost due to fat removal could be rebuilt with Ingredion’s Ultra-Tex® 2131 starch, to compensate for the loss of viscosity, alongside the fat mimetic N-Dulge® CA1 co-texturiser. This combination would ensure the mayonnaise retains viscosity, oiliness and has the glossy appearance consumers want and expect.
THE KEY TO CONSUMER SATISFACTION AND DIFFERENTIATION Although texture is an area of food science that has traditionally been overlooked, this is changing as its potential continues to be realised by the industry. Texture is a powerful tool which holds a lot of potential. It not only enables manufacturers to maintain product appeal and quality while formulating for gluten-free, clean label, nutrition plus, nutrition minus and authenticity, it also offers a way to make their products stand out and compete on differentiation, rather quality or price. For many, this could mean the difference between failure and success in a highly competitive marketplace. •
Ingredion – www.ingredion.co.za
May 2018 | Food Review
H E AT I N G & R E FR I G E R AT I O N
UNIQUE CONTINUOUS CONTROL
for spiral freezers
GEA has launched its S-Tec spiral freezer series for the food industry. Systems feature unique Callifreeze control technology.
he system ensures all products are frozen precisely to user requirements. Callifreeze takes its name from its ability to calibrate the freezer thereby controlling the level of frozenness of products. This reduces power consumption, improves efficiency and assists manufacturers to produce quality frozen food. S-Tec was first introduced to the market in 2015 for poultry, meat, fish, ready meals, bakery and dairy applications that require capacities of up to 6 000kg/hr. The system conforms to CE and PED regulations.
TOTAL FREEZE CONTROL The system is exclusive to GEA spiral freezers. It can calibrate freezer parameters through continuous measurement of the level of frozenness of product at the freezer exit. GEA has enhanced its control system to continuously monitor the level of crystalised water in products. It adjusts retention time, air temperature and fan speed to achieve the precise level of freezing required, with minimum energy consumption. The S-Tec spiral freezer, with Callifreeze, uniquely provides continuous control of the frozenness of food products
Food Review | May 2018
Mathieu Nouhin, GEA’s product manager freezing says there is no point in continuing to cool a product beyond 100 per cent frozen. Until recently there has been no way of checking the level of frozenness of products as a continuous part of the process. ‘GEA’s unique sensing and control technology measures the level of frozenness of every product in the spiral,’ he explains. ‘It then adjusts the machine to achieve perfect freezing in line with customer requirements.’ He notes that for several applications, 80 per cent level of frozenness at freezer discharge is sufficient with the product being finished off in the cold store for energy saving purposes. Results from one plant operating seven GEA freezers has showed a 10 to 15 per cent production capacity increase with a reduction in energy consumption.
HIGHLY EFFICIENT FREEZING Pure horizontal airflow is a unique feature of GEA spiral freezers. This provides
consistent airflow and temperature distribution across all products wherever they are in the spiral. This consistency, throughout the full height of the spiral, ensures there is a very small temperature differential within the machine. This reduces product dehydration and significantly improves yield, keeping power usage to a minimum.
HYGIENIC DESIGN The S-Tec uses a fully welded construction for the whole of the product-contact belt area. This eliminates any dirt traps that would be created by a bolted structure and creates a perfect surface for cleaning. The S-Tec is optionally also available with a fully welded modular floor that does not require floor heating. This removes dirt traps with structure elevated on pins welded to the floor for easy cleaning.
FLEXIBLE CONFIGURATION Units configured to meet each user’s needs with a choice of enclosure and floor types, single- or twin-drum configurations, and a selection of infeed/outfeed options – straight through, 90° turn, 180° turn, 270° turn and top-down or bottom-up operation. There is also a range of cleaning in place (CIP) options including the ultimate 6-Zone Recirculating CIP with full zone coverage and a recirculating system that captures and recycles water and cleaning agents after filtration, heating and new chemical dosing. •
GEA – www.gea.com
H E AT I N G & R E FR I G E R AT I O N
Nitrogen: the ideal clean gas B y volume, dry air contains over 78 per cent nitrogen and nearly 21 per cent oxygen. In any cryogenic air separation unit (ASU), the largest liquefied gas produced is nitrogen. Nitrogen has no taste, colour or odour and it is non-toxic. It is mostly inert, making it ideal for use in excluding moisture and oxygen from the likes of pillow packaging for products such as potato crisps. As a normal constituent of air, nitrogen also has no global warming potential so there are neither pollution nor emission problems associated with venting used nitrogen into the atmosphere. Being non-corrosive also means nitrogen can be used in pressurised systems manufactured from a wide range of costeffective common materials. The only proviso is that the material can withstand process pressures and temperature involved.
FLASH FREEZING Liquid nitrogen exists at a temperature of -196 °C. On contact with a food item, it freezes it very rapidly. Compared to freezing food using mechanical chillers, cryogenic freezing using nitrogen is up to four times faster. This
results in smaller ice crystallisation, as water inside and outside the cells of the food all freeze at the same rapid rate. This keeps cells intact and retains natural freshness, flavour and texture of products. This process is called flash freezing and better preserves nutrients, taste and texture of frozen food. When defrosted for cooking, it is nearly indistinguishable from its fresh equivalent. Technology represents a hi-tech departure from traditional approaches of mechanically freezing food products on a conveyor belt or immersing them directly into a pool of liquid nitrogen. With the flash-freezing process, food on a conveyor is surrounded by a stream of high-velocity, extremely cold nitrogen vapour. Food frozen in this way is called individually quick-frozen (IQF). Through Linde and its state-of-the-art Cryoline® CW multipurpose cryogenic freezing technology, Afrox can offer a variety of IQF poultry, meat and seafood solutions to African markets.
A CLEANER COLD CHAIN
As an alternative to relatively slow mechanical refrigeration, total loss systems using liquid nitrogen are now available. The use of nitrogen avoids having to keep the truck engine running while loading and offloading produce. Instead of diesel exhaust fumes being released into the atmosphere around the area, nitrogen gas is emitted. This is harmless to the environment and to the people loading the vehicle. Linde’s Frostcruise indirect cryogenic refrigeration system is purpose-designed for the food trucking industry. It can overcome the environmental challenges associated with diesel consumption and eliminates potentially harmful refrigerants used in mechanical systems. Using nitrogen-based systems such as Frostcruise for food transportation enables the food industry to better monitor and control chilled and frozen food safety and quality. It raises the creditability of food and supermarket brands, while protecting the environment. •
Cold food transportation is estimated to be responsible for nearly two per cent of total emissions.
Afrox – www.afrox.co.za
Your coolest refrigerant partner Whatever your refrigerant application, wherever you are, Afrox can meet your needs for delivery, handling and management of refrigerant gases, from traditional fluorocarbons to natural refrigerants including R744, R717 and the latest environmentally friendly HFO range of gases.
Our products are vital for the refrigeration industry, whether it be in air-conditioning or for chilling applications; our superior quality affords our customers peace of mind. Afrox believes in a cleaner tomorrow and we are committed to the responsible use of natural resources, the development of clean technologies and the replacement of harmful substances with more eco-friendly alternatives. We have the expertise to help you reclaim and reuse refrigerants wherever possible. Together with our global partners, we continue to identify alternatives to hydrochlorofluorocarbon (HCFC) and hydrofluorocarbons (HFC). Our aim is to provide products that offer satisfactory cooling performance with zero ozone depletion potential and lower global warming potential. Developed by Arkema, Forane® R427A is an ideal retrofit solution
Customer Service Centre: 0860 020202
Refrigerant Advertorial 130x177.indd 1
Shop online: www.afroxshop.co.za
for many existing R22 systems. We are also focusing on the fourth generation fluorine based refrigerants (HFOs) used for the replacement of HFCs that have a high global warming potential (GWP). Afrox prides itself on not only superior quality of refrigerants but also its experience in handling refrigerant gases and we can provide support and guidance to our customers relating to all aspects of these gases. Shop online at www.afroxshop.co.za or visit www.afrox.com for product information and safety recommendations. Alternatively you can call our Customer Service Centre on 0860 020202. It’s all good with quality you can trust.
2018/04/17 3:21 PM
May 2018 | Food Review
H E AT I N G & R E FR I G E R AT I O N
High-speed door solutions offer food for thought Door and loading dock solutions specialist, Maxiflex has introduced the new Assa Abloy HS9020GHY high-speed interior door. The unit is designed for corrosive and humid environments. It is a perfect fit for the food processing industry with its stringent hygiene demands.
nits feature several unique design features for smooth, seamless and reliable operation and long life-cycle. Industry-leading opening and closing speeds of up to 1.2m/s and 0.5m/s respectively and excellent sealing capabilities help to reduce costs and improve efficiencies. Doors contribute to lower energy consumption through heat loss reduction and constant interior climate control. ‘By effectively keeping out drafts, dust, dirt and humidity, these high-speed doors create the necessary hygienic, comfortable and safe working environment and contribute to improved productivity in the workspace,’ notes Maxiflex managing director Bram Janssen. The motor is driven by a frequency inverter, which ensures a soft start/ stop. This function ensures smooth operation, prolonged motor lifespan and exceptional reliability. Janssen confirms the Assa Abloy HS9020GHY is constructed with stainless steel, unique side column technology and PVC curtain. It seals on all four sides of the door and meets all hygiene
standards for the food and pharmaceutical industries. It is easy to clean and has an impressive lifetime expectation of one million cycles. A new, advanced DCS control system incorporates numerous features to ensure worker safety. The soft bottom edge has no rigid parts and moulds around any obstruction to prevent injury or damage. If an object hits the door, the fabric curtain absorbs the impact and releases itself from its side guides without causing damage or being damaged. The door is equipped with a breakaway and automatic repair system, which ensures the curtain reintroduces itself after a crash. Janssen points out that in addition to safety, this technology also saves time and costs by reducing downtime and maintenance. The control box is easy to operate and programme while the mechanical main switch and emergency stop makes it foolproof. The clear display makes a wide range of important information easily visible. Thanks to their compact dimensions, these medium-sized doors take up very little space and can be easily installed in restricted or confined interior spaces. Manufactured from 2.0mm thick PVC and available in eight standard colours, the door curtain can be equipped with windows or vision panels to increase the admission of daylight and visibility. High-speed doors adhere to all required specifications including wind load resistance Class 1, water penetration Class 2, air permeability Class 1 and thermal transmittance. Doors can maintain optimal functioning in temperatures ranging from five degrees Celcius to +40°C. Other turnkey industrial entrance solutions from Maxiflex include a range of the following: • industrial sectional doors • vertical-lifting fabric doors for large openings and heavy industry environments • loading dock equipment • PVC strip curtains • protection screens and impact doors that meet a massive variety of applications across diverse industries. •
Maxiflex – www.maxiflex.co.za
The Assa Abloy HS9020GHY high-speed interior door
Food Review | May 2018
MAY 2018 THE OFFICIAL NEWSLETTER OF THE SOUTH AFRICAN NATIONAL BOTTLED WATER ASSOCIATION
Make a Clear Choice SAFE DISTRIBUTION PRACTICES
CERTIFIED SAFE AND SUSTAINABLE WATER SOURCE
OESN’T S D T I AY IF AUDITED ENVIRONMENTAL STEWARDSHIP
SEAL OF QUALITY, SAFETY AND AUTHENTICITY
AUDITED SANBWA BOTTLED WATER STANDARD
ADHERENCE TO FOOD LEGISLATION
” ? T O
TESTED FOR PURITY
ADHERENCE TO HYGIENIC FACTORY DESIGN AND OPERATION
P.O. Box 7649, Halfway House, 1685 South Africa | www.sanbwa.org.za | Tel: +27 11 884 5916 | Fax: +27 86 568 4862 | email@example.com
Ripples & Waves
Message from SANBWA’s Chairman
What a hectic whirl the last five months have been for the bottled water business in the Western Cape. Our one-in-a-hundred-year drought has endured for years now, with some very interesting effects on local bottlers.
OR MANY YEARS, I’ve thought the importance of bottled water will only resonate with consumers when water pallets are no longer packed on the shelf, but moved to the shop floor and opened for customers to select. That time has arrived here in Cape Town – so much so that there have almost been fist fights between customers arguing over the last few five litre bottles on the pallet. SANBWA members have been putting on double shifts in an attempt to stay ahead. The holdup has been the supply of five litre bottles, with supply falling short of demand. Interestingly, the same situation holds true for the supply of 5 000ℓ and 10 000ℓ Jo-Jo tanks. A few weeks back, I did some work up in Laingsburg and passed five bakkies with trailers bringing tanks from up north. Another consequence of huge seasonal demand is that unknown labels have proliferated with quite a few newcomers. Folk are imagining this is a big business opportunity. While I hope buying bottled water becomes a habit and creates sustainable demand, I also hope these opportunists realise the huge demand is a specific seasonal spike - unlikely to be maintained in the long run. Activism of Cape citizens with regard to in-house reverse osmosis and ozonation systems is a plus. The realisation has hit home that these systems are selling municipal water, water that citizens are
being urged to save, and these same citizens are super-charged when their 5 000ℓ per month is exceeded. To further raise the levels of ire, citizens now realise that for every litre of water sold, another litre goes down the drain. Quite a few systems have closed. Restaurants selling water from under-the-counter bottling systems do so at big reputational risk. There is nothing activist citizens enjoy more than to name and shame transgressors on talk-radio. A further consequence has been the number of radio and TV talk shows I have appeared on while representing SANBWA. Every time SANBWA issues a media statement, we get a few requests for one of us to appear on their shows. On most of these shows I am asked about quality controls, and can always punt our logo. There’s been a flurry of media reports about micro-plastics detected by researchers in bottled water. This research was conducted on behalf of Orb Media. To quote from their Twitter account, ‘Orb Media is a non-profit fusing #datajournalism and #socialjournalism with on-theground reporting to produce transmedia packages on #global development issues. Washington, DC.’ Orb Media’s position on microplastics seems to be based on the faulty premise that if this substance is found in a bottled water product, it represents a health concern
(see page seven for SANBWA’s full media statement). Neither the WHO nor the US Food & Drug Administration has issued any statement or regulations concerning microplastics in foods and beverages. Microplastics in our environment are ubiquitous. They are found in all the food and drink we consume, and the air we breathe. A major source of microplastics in the environment is tumble driers. Most clothing, sheets and towels have some plastic in them, and when dried they shed. A study in Paris estimates that the ‘rain of microfibers from the air dumps between three and 10 tonnes of fibres on Paris annually.’ This worries me. I fear that this is about to become another of those Internet scare stories that will plague our industry for a long time to come. Herman Bock of Polyoak has written a very good one-pager about microplastics. He opens the article saying it is a storm in a teacup. I hope so. Yours in quality
John Weaver Chairman
Ripples & Waves
facts consumers should know about BOTTLED WATER AND THE DROUGHT
ROUGHTS HAVE A major impact on a nation’s emotional, social, economic and political well being. Consumers should equip themselves with the facts, rather than rely on urban legends or fake news. We asked environmental advisor, speaker and author, Dr Anthony Turton and SANBWA chairman John Weaver, five questions about the bottled water industry and the drought in the Western Cape.
Do you believe the bottled water industry is negatively impacting on water available for reticulation? Dr Turton: No. Literature on water scarcity tells us when problems become acute, the impact is not evenly distributed in society and underlying tensions are amplified or magnified. The drought in the Western Cape is such a case. The public is increasingly alarmed at plastic bottles, so they deflect that anger towards the bottled water industry. Water used for bottling is small compared to total volumes in each system. Given the relatively high value of bottled water, there is an incentive not to waste it.
John Weaver: No, the activities of SANBWA members in the Western Cape – located in Franschhoek, Paarl and Ceres – are not exacerbating the drought in the province. The reasons for this are threefold: • 90 per cent of SANBWA members’ water sources are bottled from underground sources. That is groundwater as opposed to surface water. These sources must be audited to ensure long-term sustainability prior to membership being granted. All SANBWA members in the Western Cape bottle from groundwater sources. • Groundwater is strongly buffered against drought influence. Recharge or aquifer renewal, is replenished at between five to 20 per cent per year depending on the underlying geology and topography. • Water from these groundwater sources would naturally enter the municipal system via rivers and dams. Bottled water originates from sources licenced to private entities by the Department of Water & Sanitation specifically for the use of the water for commercial purposes (bottling water). Volumes extracted are monitored against the licensed limit.
What is the bottled water industry’s role during the drought? Dr Turton: When Day Zero arrives, bottled water will be one of the vital ways of delivering water to distressed individuals.
John Weaver: The bottled water industry exists as a healthy beverage alternative. In addition, the industry is too small to be the long-term solution to drought. Compared to the total beverage market (including alcoholic) it is tiny – just 3.8 per cent in 2016. Its total size nationally, not just in the Western Cape, for 2016 was 502 million litres. This annual figure is less than the 520 million litres daily target consumption for the City of Cape Town. Members have independent plans to donate and provide water at cost when possible. This includes donations to Water Shortage South Africa and Gift of the Givers, SAPS offices, Western Cape Disaster Management and Blood Bank stores, firefighting teams when they are out on call, and vulnerable communities such as the aged and the disabled.
Do you believe bottled water bottlers should be forced, by government, to bottle water for distribution or that government should annex/attach bottled water companies?
Dr Turton: The fundamental driver of the current Cape Town crisis is the perceived inability of government to provide infrastructure needed to get water to individuals and businesses. It’s a blatant failure of the nationalisation of water that occurred under the 1998 National Water Act. In contrast to this, the bottled water industry is in private hands, and it is not in distress. The logic used to conclude that because a nationalised resource is failing, we need to nationalise the remaining portion of that resource that is still functional, is nothing short of collective suicide. John Weaver: No, government should not get heavy-handed with bottled water bottlers. Of concern is the misconception that bottling water is an inexpensive business, and that bottlers should easily be able to slash prices. In addition to the licensing fee, there is the considerable cost of ensuring sustainability of source and bottling, packaging and distribution. This includes the investment in plant and equipment, and compliance with
health and safety regulations, packaging and labelling legislation. Another irrational assumption is that industry can simply increase production to supply a spike in demand. The fact is that bottlers’ licences strictly regulate the volume they may extract for bottling.
What is the biggest behavioural change South Africans should make to their daily lives? Dr Turton: South Africans need to hold elected officials accountable and insist that only technically competent people are placed in charge of water infrastructure management. They need to demand the de-politicisation of water.
John Weaver: I like Dr Turton’s answer but there must also be behavioural changes. When the rains come and our dams are full, we must not go back to our wasteful ways just because there’s an abundance of water. Sustainable water use and PET recycling, just like switching off the light when you leave a room, must become second nature.
What will bottled water’s role be post drought?
Dr Turton: Droughts come and go. The current Cape Town crisis is not about drought. It’s about a failure by the state to adequately provide the bulk infrastructure needed to buffer the economy from the natural variability of our climate regime. Bottled water will play a vital role in the height of the crisis, and will continue to play an important role in post-crisis reconstruction. The challenge for the industry is how to manage the waste arising from discarded bottles. John Weaver: Bottled water is legislated as a food product in South Africa and competes against other packaged beverages found on retailer shelves, not against tap water. It exists to give consumers a choice, and is the healthiest packaged beverage option for societies plagued by diseases such as obesity and diabetes. Bottled water is the best packaged beverage option for Dr Anthony Turton the environment.
Ripples & Waves
aQuellé trucks water to and from KwaZulu-Natal to Cape Town
ANBWA MEMBER AQUELLÉ, was one of several which lent a hand to the drought-stricken Western Cape ahead of Day Zero. Its managing director, Arno Stegen (seen in the photograph handing his completed paperwork to warehouse manager, Gladson Songelwa), joined a convoy of trucks from the company’s KwaZuluNatal headquarters in February to deliver an initial donation of approximately 30 000ℓ of bottled water to the needy in Cape Town. ‘The drought in the Western Cape is of great concern to us,’ says Stegen while en route after leaving the Kranskop plant. ‘As a brand that is committed to being 100 per cent for people, this is a crisis which we could not simply watch unfold from the sidelines.’ The company delivered the donation to NGO, Water Shortage South Africa, which
in turn distributed the water to registered institutions in the Mother City. This was to aid the elderly and those who would not be able to stand in queues for their daily water quota. aQuellé products consist of natural spring water, sourced from renewable groundwater, which is replenished on an ongoing basis. As a member of SANBWA, aQuellé adheres to the stringent environmental and quality measures to ensure sustainability. There are two sources for the water: the main plant situated in Kranskop, KwaZuluNatal and a smaller secondary plant in Franschhoek, which services the Western Cape and was set up to reduce the carbon footprint in transporting the product from the main plant. The sources are monitored on an ongoing basis and together with experts in the hydrogeological field, a sustainable extraction rate is determined.
Delivering much needed help to needy areas
Di Bella Spring Water upgrades bottling facility
i Bella Spring Water has upgraded its water bottling facility in the eastern Free State. The 1 000m2 plant has moved from being a completely manual bottling, blowing and filling operation to a fully automated operation. The plant now fills both PET plastic and glass bottles. According to managing director, Maurizio di Bella, SANBWA’s annual general meeting in October last year in part inspired this upscale in production and efficiency. The concurrent
Propak Cape Expo provided an excellent opportunity for networking, he says. ‘Di Bella placed orders for a variety of production machinery shortly after these two events. The machines subsequently arrived from various points and were quickly commissioned. Production is now in full swing,’ he says. ‘Di Bella now blows and fills more than 2 000 PET bottles an hour for its 500mℓ, 750mℓ, one litre, 1.5ℓ, and five litre sizes. Its
Di Bella has moved from a manual to fully automated sysem
new mono-block machine washes, fills, caps, labels, and wraps bottles, cases, and pallets, and its new glass filling line was expected to come on-stream in early April 2018. ‘With this intensification of productive capacity, Di Bella can meet its growing demand for spring water both still and sparkling within and outside South African borders. Di Bella employs five full-time employees. It is now looking for a full-time experienced technician to support operations.’
Ripples & Waves Increased PET in the Western Cape puts pressure on recycling
HIS EARTH DAY (April 22), Capetonians faced not one, but two, significant challenges – that of running out of water and the potential waste crisis as the city’s landfills rapidly reach maximum capacity. Reports quoted the Western Cape Environmental Affairs Department as saying that some of the province’s landfill sites could reach full capacity in less than a year. Environmental Affairs MEC spokesperson James-Brent Styan says less than half the province’s 164 landfill sites are operational. One of the factors contributing to this situation is the opposition towards new initiatives like regional waste disposal sites and waste-to-energy plants (http://www. infrastructurene.ws/2018/04/11/wastecrisis-looms-in-the-western-cape/). With the increase in consumption of bottled water in Cape Town, the volume of bottles needing recycling is threatening to overwhelm local recycling capacity. It’s a fact South African National Bottled Water Association (SANBWA) members are working to address. According to SANBWA executive director, Charlotte Metcalf, joint efforts driven by PETCO and supported by its members and associate members (including bottled water producers) aim to prevent these additional bottles having to be sent to landfill.
They are achieving this by transporting baled bottles to a recycling facility with excess capacity in Gauteng for processing. Consumers can also play their part. ‘Working together with PETCO, SANBWA has sponsored another truckload and so too has Woolworths, which saw bottled water sales soar during February and March this year,’ she says. ‘I spend a considerable part of my day seeking additional sponsors so we can relieve the pressure on recycling facilities in the Western Cape. Consumers can help by following a few simple guidelines laid out by PETCO.
‘SANBWA urges Capetonians to look at both their water usage and their waste processing in a new light, and to make the change that a sustainable future in this beautiful part of the world requires. ‘It also challenges bottled water bottlers and retailers to follow Woolworths’ example to sponsor transport of baled bottles to recycling facilities in other parts of the country.’ Chandru Wadhwani, joint managing director of Extrupet and PETCO board member explains: ‘For me the pressing driver is to ensure the extra volume of PET bottles that has found its way to the Western Cape on the back of the water crisis finds a home in recycled products. ‘Just by way of scale, each of the 15MT loads sponsored by SANBWA and Woolworths represents half a million bottles recycled; half a million bottles that otherwise would not have been. This is the ultimate value of this initiative and companies like Woolworths, and bodies like SANBWA, need to be commended for setting the perfect example of what extended producer responsibility entails.’ South Africa currently recycles more than 55 per cent of its PET, one of the highest rates worldwide. Extrupet has a fibre producing plant in Milnerton in Cape Town and a Bottle2-Bottle plant in Wadeville, Johannesburg. Here recycled PET plastic bottles are used to manufacture new bottles for many food-grade applications or recycled into a myriad of new and useful products such as polyester fibre for duvets and pillows, jeans and t-shirts, and reusable shopping bags. This process has made South Africa a self-sufficient manufacturer of polyester fibre, no longer reliant on imports.
SANBWA welcomes new associate member Fontana Manufacturers
ANBWA welcomes new associate member Fontana Manufacturers into its fold. This manufacturing company specialises in plastic packaging for the beverage industry. Fontana provides an extensive range of carbonated and noncarbonated beverage closures, preforms and blown bottles. All manufacturing is done in KwaZuluNatal, while depots in Cape Town, Johannesburg and Port Elizabeth allow it to
service customers throughout the country. Fontana has been accredited with an AA pass by the BRC packaging materials standard for the past four years. It is proud to have been acknowledged as the first in this line of business in South Africa and Africa to achieve this prestigious accreditation. BRC Packaging Materials Standard is recognised globally and is the first standard in the world to be recognised by the Global Food Safety Initiative (GSFI).
Ripples & Waves
Plastic, plastic everywhere
ate in March, the media gave considerable coverage to a story claiming that leading brands of bottled water are contaminated with tiny plastic particles that are likely seeping in during the packaging process. ‘Widespread contamination’ with plastic was found in the study, led by microplastic researcher Sherri Mason of the State University of New York at Fredonia, according to a summary released by Orb Media, a US-based non-profit media collective. Researchers tested 250 bottles of water in Brazil, China, India, Indonesia, Kenya, Lebanon, Mexico, Thailand, and the US. Plastic was identified in 93 per cent of the samples, which included major name brands. Plastic debris included polypropylene, nylon, and polyethylene terephthalate (PET), which is used to make bottle caps. Particle concentration ranged from ‘zero to more 1 2018/05/10 than 10 0001.pdf likely plastic particles in a16:49 single bottle.’ On average, plastic particles in the
100 micron (0.10 millimetre) size range, considered ‘micro plastics’, were found at an average rate of 10.4 plastic particles per litre. ‘In this study, 65 per cent of the particles we found were actually fragments and not fibres,’ Mason says. ‘I think it is coming through the process of bottling the water. I think most of the plastic we are seeing is coming from the bottle itself, it is coming from the cap, it is coming from the industrial process of bottling the water.’ SANBWA’s affiliate agency in the US, International Bottled Water Association, issued a formal statement: The non-peer reviewed study released by Orb Media is not based on sound science. There is no scientific consensus on testing methodology or the potential health impacts of microplastic particles. Therefore, this study’s findings do nothing more than unnecessarily scare consumers.
Scientific experts in the field told the BBC News, ‘The particles below 100 microns had not been identified as plastic’ and that ‘since the alternatives would not be expected in bottled water, they could be described as probably plastic’. Those notidentified substances made up the vast majority of particles counted. The study even acknowledged that the make-up of those particles was not confirmed but could ‘rationally expected to be plastic.’ The study’s ‘probably plastic’ findings are weak at best and reporting it as news is alarmist and not responsible journalism. Microplastic particles are found everywhere – soil, air, and water. As the report states, currently there is no evidence that microplastics can cause harm to consumers.
Ripples & Waves Orb Media is not an objective news outlet. In the past, Orb Media has shown itself to be an organisation that has preconceived positions on issues and produces studies that support its point of view. Consumers can remain confident that bottled water products, like all food and beverages, are strictly regulated by the US Food and Drug Administration (FDA) and are safe for consumption. The bottled water industry is committed to providing consumers with the safest and highest quality products. Provided below are additional points, in more detail on this study: • The Orb Media-sponsored research focuses solely on bottled water products. However, it is important to note that thousands of other food and beverage products also use plastic containers and, perhaps even more important, that microplastic particles are found in all aspects of our environment – soil, air and water. • To date, there is no applicable regulatory framework or scientific consensus with respect to the adequate testing methodology or potential impacts of microplastic particles, which could be found in any bottling environment. • There is no scientific consensus on the potential health impacts of microplastic particles. The data on the topic is limited and conclusions differ dramatically from one study to another. • A recent scientific study published in the peer-reviewed journal Water Research in February 2018 concluded that no statistically relevant amount of microplastic can be found in water in single-use plastic bottles. (Analysis of microplastics in water by micro-Raman spectroscopy: Release of plastic particles from different packaging into mineral water by Schymanski et al.) • Orb Media’s position on microplastics seems to be based on the faulty premise that if this substance is found in a bottled water product that it presents a health concern, even if no regulatory standard has been established. Because there is no scientific consensus about the potential health impacts of microplastic particles, the US Food and Drug Administration (FDA) has not issued any regulations concerning these substances in foods
and beverages. Any regulatory action concerning microplastic particles would need to be based on sound science, including demonstrating a correlation between the levels of this substance found in food and beverages and any potential adverse health effects. • Despite the claims about microplastics by Orb Media, consumers can remain confident in the safety and quality of their bottled water products. Bottled water, as a packaged food product, is strictly and comprehensively regulated by the FDA. All bottled water products are produced utilising a multibarrier approach. From source to finished product, a multi-barrier approach helps prevent possible harmful contamination to the finished product as well as storage, production and transportation equipment. Many of the steps in a multi-barrier system is effective in safeguarding bottled water from microbiological and other contamination. Measures in a multibarrier approach may include one or more of the following: source protection, source monitoring, reverse osmosis, distillation, micro-filtration, carbon filtration, ozonation, and ultraviolet (UV) light. • As always, the bottled water industry is committed to providing consumers with the safest and highest quality products and we are following any scientific developments on this subject closely. SANBWA believes it is limited in its ability to provide an informed response to what appears to be an unsubstantiated and non-peer reviewed research project because it has not seen the research. It does believe, when considering the report’s findings, journalists and consumers should be mindful of the fact that thousands of other food and beverage products also use plastic containers; therefore, it cannot be assumed that these findings would be limited to bottled water.
Two worthy causes to look out for
ycleforWater, a team that travels on bamboo bikes across a different continent each session to try to raise awareness of access to drinkable water, begins this year’s cycle across Africa in South Africa. Keen to get involved? Visit www. cycleforwater. org for more information and to sign up. Another worthy cause is The Joinery at www. thejoinery. co.za. It is a sustainable lifestyle brand priding itself on designing and producing bespoke sustainable products and ethical fashion and accessories, all the while striving for a high-end design aesthetic with an African conscience. Co-founder, Kim Ellis, explains, ‘We see ourselves as pioneers in the sustainable product and fashion design arena and are winners of the 2017 PETCO awards for ‘Best Product using recycled PET’ as well as recent winners of the Eco Logic Awards for ‘Eco Innovation. ‘Our bespoke products and fashion collections are produced by sewing cooperatives and artisans based in and around the townships of Cape Town. We use eco fabrics such as tencel, linen, rayon and hemp where we can, and fibres that are grown without the use of toxic pesticides and synthetic fertilisers. ‘We are proudly conceptualising bespoke responsible fabrics made form 100 per cent recycled plastic bottles. Saving plastic from landfills allows us to create beautiful, upcycled products and apparel. We work with suppliers that share our commitment to the environment by supporting practices that reduce their carbon footprint, opting for carbon-neutral or carbon-negative materials wherever possible. ‘Work, dress and live sustainably. Our manifesto is do something, anything…,’ she concludes.
Ethical and bespoke fashion accessories
Ripples & Waves
SANBWA Member Update
Name • Address • Telephone • Facsimile • Contact Person Members
aQuellé Private Bag 260, Kranskop, 3268 • 032 481 5005 • 032 481 5006 • Ruth Combrink
Boxmore Plastics International PO Box 772, Harrismith, 9880 • 058 624 2200 • 058 635 1300 • Leonard Engelbrecht – Chief Executive Officer
Bené PO Box 1098, Walkerville, 1876 • 082 881 9860 • 078 644 7780 • Wendy Anderson
Caltech Agencies PO Box 32414, Camps Bay, 8040 • 011 791 6510 • Bheki Tsabedze – Sales Manager
Bonaqua – Coca-Cola South Africa 116 Cnr Oxford & Glenhove Roads, Melrose Estate, 2196 • 011 644 0666 • Rufaro Jere
End In Mind Consultative Solutions Africa (Pty) Ltd Postnet Suite 1, Private Bag X75, Bryanston, 2021 • 011 513 3415 • Shawn Henning – Director
Ceres Spring Water division of Ceres Fruit Juices PO Box 177, Ceres, 6835 • 023 313 3701 • 023 313 3410 • Paul Collingridge
Extrupet (Pty) Ltd PO Box 14112, Wadeville, 1422 • 011 865 8380 • Fax 011 865 4254 • Harry Havenga – National Sales & Marketing Manager
Clover Waters: Nestlé Pure Life PO Box 6161, Weltevreden Park, 1715 • 011 471 1400 • Sally Witherden
Fontana Manufacturing (Pty) Ltd 150 Maclean Street, Umkomaas, 4170 • 039 973 2690 • Cameron Buys – Sales Manager
Di Bella Spring Water PO Box 1516, Ladybrand, 9745 • 082 862 0752 • Maurizio Di Bella
Krones Southern Africa (Pty) Ltd Private Bag X 42, Bryanston, 2021 • 011 796 5230 • 086 522 6176 • Des Haddon – Sales & Marketing Manager
Durr Bottling: Aquabella, Fontein PO Box 502, S-Paarl, 7624 • 021 863 3485 • 021 863 0590 • Leslee Durr
MPACT P O Box 14093, Wadeville, 1422 • 011 418 6058 • 086 574 6481 • Johnny Magalo – Sales Manager
La Vie De Luc PO Box 15, Franschhoek, 7690 • 021 876 2559 • 021 876 2652 • Christian Von Palace
Nampak Closures PO Box 6993, Bryanston, 2021 • 011 719 6300 • Clinton Farndell – Divisional Director
MultiSource Beverages P.O. Box 234, Somerset Mall, 7137 • 021 854 6477 • Richard Whitehead
NSF-CMi Africa PO Box 12900, Die Boord, 7613 • 021 880 2024 • 021 880 2840 • Wouter Conradie – General Manager
Oryx Aqua PO Box 474, Naboomspruit, 0560 • 014 743 2421 • Berend van den Berg Swig Postnet Suite No 13, Private Bag X12, Greenside, 2034 • 074 191 4976 • Nigel Price • firstname.lastname@example.org
PET Recycling Company NPC t/a PETCO P.O. Box 680, Constantia, 7848 • 021 794 6300 (Cpt) • 011 615 8875 (Jhb) • Cheri Scholtz – Chief Executive Officer
Thirsti Water P.O. Box 13559, Cascades, 3202 • 034 314 9801 • Rob Hoatson
Polypet (Division of Polyoak Packaging) PO Box 125, Plumstead, 7801 • 021 710 9200 • 021 712 1342 • Wessel Oelofse – National Executive: Polypet
Valpré – Coca-Cola South Africa 116 Cnr Oxford & Glenhove Roads, Melrose Estate, 2196 • 011 644 0666 • Rufaro Jere
All correspondence and enquiries should be addressed to Charlotte Metcalf at: SANBWA, PO Box 7649, Halfway House, 1685 Telephone: (011) 884 5916
Facsimile: 086 568 4862
Visit us on our website: www.sanbwa.org.za
DA I RY F O O D
Pumps to increase cheese
producers’ productivity Watson-Marlow Fluid Technology Group has produced a white paper. It explains how MasoSine Certa pumps, using Sine technology, offers significant benefits compared with rotary positive displacement types such as lobe pumps.
dvantages include gentle product handling, improved yield and easier cleaning. This makes Sine pumps ideal for cheese manufacturing. Independent testimony and a relevant case study are evidenced throughout the white paper.
PRODUCT INTEGRITY To remain competitive, producers in the cost sensitive dairy sector are being driven by the need to increase output. In cheese manufacturing, for example, it is essential to maintain high product integrity and avoid waste. Careful handling of curds and whey is one method that allows both quality and profitability to remain high. The white paper sets out in detail how low
“To remain competitive, producers in the cost sensitive dairy sector are being driven by the need to increase output”
FAST FACT • Sine pumps maintain product integrity and improve yield in cheese manufacturing. • ROI achievable in just six months.
shear sine pump technology helps to reduce the number of fins and retain fat within the cheese curds - a vital aspect of ensuring product integrity. This capability results in improved yield due to an increased amount of cheese manufactured from the same quantity of milk. Product quality increases due to the pumps’ gentle handling, helping cheese producers command an increased price for a higher quality product. The white paper also explains the concept and design of sine pumps, and how they compare to competing types. A further area of focus is hygiene and the benefits this brings to those in the cheese manufacturing sector.
Sine pumps are perfect for use in the dairy industry
To illustrate what can be achieved using sine pump technology, an interesting and relevant case study is presented focussing on a dairy producer in Scandinavia that produces 70 000 tonnes of cheese a year. Savings are set out in terms of increased cheese yield and increased productivity, detailing how investment in the latest sine pump technology can lead to payback in just six months. For more information on this white paper visit the website listed below. •
Watson Marlow – www.wmftg.com
䴀愀渀甀昀愀挀琀甀爀攀爀 漀昀 挀愀欀攀 瀀椀攀 昀椀氀氀椀渀最猀Ⰰ 琀漀瀀瀀椀渀最猀Ⰰ 礀漀最栀甀爀琀 昀爀甀椀琀 瀀甀氀瀀猀Ⰰ 挀愀爀愀洀攀氀 琀爀攀愀琀Ⰰ 洀椀氀欀猀栀愀欀攀 猀礀爀甀瀀猀Ⰰ 猀愀氀愀搀 搀爀攀猀猀椀渀最猀Ⰰ 洀愀礀漀渀渀愀椀猀攀 愀渀搀 猀愀甀挀攀猀⸀ 䤀渀渀漀瘀愀琀椀瘀攀Ⰰ 挀爀攀愀琀椀瘀攀 ☀ 瘀愀氀甀攀ⴀ愀搀搀攀搀 猀甀瀀瀀氀椀攀爀⸀ 䌀甀猀琀漀洀椀稀攀搀 瀀爀漀搀甀挀琀猀 愀渀搀 瀀愀挀欀愀最椀渀最⸀
䘀匀匀䌀 ㈀㈀ 䌀攀爀琀椀昀椀攀搀
䠀愀氀愀愀氀 愀渀搀 䬀漀猀栀攀爀 愀瀀瀀爀漀瘀攀搀
伀甀爀 倀爀漀洀椀猀攀 椀猀 椀渀猀椀搀攀 倀栀漀渀攀 ⴀ ⬀㈀㜀 ⠀ ⤀ 㐀㔀㈀㘀㜀㌀ 䔀洀愀椀氀 ⴀ 椀渀昀漀䀀瘀椀瘀椀琀⸀挀漀⸀稀愀 圀攀戀 ⴀ 眀眀眀⸀瘀椀瘀椀琀⸀挀漀⸀稀愀
May 2018 | Food Review
DA I RY F O O D
PERFECT CULTURES for industrial cheese
DuPont Nutrition & Health has launched the latest innovations from the DuPont Danisco range of ingredients: Choozit Swift 600 and Choozit Ameri-Flex. Products were developed to address productivity and cheese quality needs for industrial-sized cheese makers.
lants are under intense pressure to operate efficiently and are sometimes forced to adjust process times due to starter cultures that don’t perform consistently. Choozit Swift 600 is the newest offering in the product line. This range of starter cultures provides a solution for high-volume industrial pizza cheese and pasta filata makers looking to increase productivity, without compromising quality. Product is mostly resistant to bacteriophage and rarely impacted by changes in milk or plant environment. In comparison with other cheese cultures on the market, cultures are formulated for fast and consistent acidification time and produce more consistent texture. ‘Our competitors may offer one to two consistently high-performing starter cultures, but ours allow customers to utilise six rotations,’ explains cheese senior application specialist Brian Bartholomew, DuPont Nutrition & Health. ‘This brings about such consistency that pizza cheese and pasta filata makers can set the cultures and then move on without worry to other steps in the
Food Review | May 2018
production process. Robust culture rotation eliminates production delays often seen in daily cheese making. This allows plants to work at greater speeds without jeopardising texture or overall quality.’ Cheese manufacturers frequently adjust processing times and conditions to obtain desired performance from culture programmes offered by competitors. These adjustments impact the consistency of DID cheese yield in terms of YOU KNOW? attaining moisture and dry Innova Market Insights solid targets to produce cheese includes cheddar, states that from 2012 to cheeses that meet their 2017, new cheese product Colby and Jack. This development increased at customers’ specifications. is a one-bag direct to 15.5 per cent compound Choozit Swift 600 vat culture system. A annual growth rate. cultures are designed convenient single pouch to ensure iso-functional blend of fast acidifying performance and consistent mesophilic and thermophilic and secure acidification. This helps strains is formulated for reliability, food manufacturers improve shelf life and dependability and phage robustness. Two functionality of products while reducing the robust formulations in this range provide potential for downgrades. These are the last flexibility in multiple processing conditions. • generation within the broad portfolio of the Choozit Fit and Swift Cultures range. Danisco – www.danisco.com Choozit Ameri-Flex for American style
BeverageREVIEW SOUTH AFRICAN
May 2018 | Volume 8 | Number 05
A carbon neutral first for SA
Benefit from milk and dairy alternatives
How to add value to dairy drinks and fermented milk
Greener beer bubbles AB INBEV IS rolling out a greener way to put bubbles in beer and reduce its CO2 emissions by five per cent. The beverage giant has developed a technique to generate gas bubbles needed for malting grain before fermentation without the need to boil the water and hops. The company conducted four years of tests at an experimental brewery in Brussels, and at a large scale plant in the UK. The method does not detract from the taste of the finished drink, but uses less water and heat. Traditionally, gas bubbles in the early stages of brewing are generated via steam through the natural cooking process. This requires a lot of water and heat. The new method involves heating the brew to below boiling point and then blowing nitrogen or CO2 into the tank to create bubbles without changing the taste. As beer is brewed at a lower temperature in the early phase, it stays fresh for longer. Bubbles found in the finished product are still produced in the normal way, typically by the yeast’s digestion of sugars or by pressurisation in the kegging process. The innovation is to heat everything up to just below boiling point. This provides 80 per cent energy savings at this point. Less steam is released, which translates to less spend on water – in some cases evaporated water went from five per cent to less than one per cent. AB InBev claims that when it adopts the technique in all its breweries around the world it will reduce its global CO2 emissions by five per cent a year. This is equivalent to the energy consumption of 120 000 families.
ALTERNATIVES TO TRADITIONAL milk are on the rise and include products such as organic, goat, high-in-nutrients and flavoured milks. The addition of flavours can often generate added value for dairy products, particularly when natural flavours or extracts are used. This follows consumer engagement and sensitivity to flavour variations. French brand Michel et Augustin for instance has launched three yoghurt drinks with vanillas from three different origins: Madagascar, Tahiti and Comoros. These products play on the origins of their ingredients, which is the best way to make more traceable and authentic products. Fermented milks form part of the rising popularity of these products due to their probiotic value. That leads to the fast expansion of the ethnic fermented milks segment. Following this trend, Danone has launched Les Danone du monde (The Danone of the world). This range of yoghurts offers products from various cultures: lassi from India, ayran from Turkey, laban from Lebanon, skyr from Iceland and straggisto from Greece. One of the advantages of these products is that they pair very well with exotic flavourings such as coconut, matcha and chai. Flavourings are indispensable during processing for high-in-protein milk drinks. These beverages often have unpleasant off notes that flavours can mask efficiently. Flavourings concepts for protein milkshakes are becoming more innovative, from salted caramel to cookies and cream.
Brewtech Engineering are pleased to advise their new relationship with Dipran, for finest quality Italian manufactured bottle filling and capping machines.
Please contact us for any of your bottle rinsing, filling and capping requirements.
Beverage Review | May 2018
Tel: +27 11 708 0408/9 email@example.com
HEINEKEN INVESTS in Mozambique THE BREWERY IN Mozambique incorporates the latest technologies and represents a US$100 million investment. Located in Maputo, it has a production capacity of 0.8 million hectoliters and will brew high quality beers for the domestic market. The first bottle of beer is expected to come off the production line in the first half of 2019. Heineken Mozambique started its activities in 2016 through a sales and marketing office, importing international beers including Heineken, Amstel, Amstel Lite and Sagres into the country to offer more choice to consumers. The construction of the brewery, a first for Heineken, is a major step forward in solidifying the company’s presence in the country. The initiative is expected to create 200 direct jobs and will support additional indirect jobs through its entire value chain. This is aligned with Heinken’s ambition of sourcing 60 per cent of its agricultural raw materials in Africa by 2020. One of the objectives of this project will be to improve crop yields as well as the capabilities
The new greenfields Heineken brewery in Mozambique
and living standards of Mozambican farmers, contributing to the economic development of the country. Boudewijn Haarsma, Heineken International’s managing director East & West Africa states, ‘We are delighted to enter Mozambique, where we see promising longterm economic perspectives. The project is progressing well thanks to the support of the Mozambican government and its commitment to
bringing investment into the country. Investing in a new market like Mozambique supports our ambition to expand our footprint and be the number one or a strong number two in all markets in which we operate. We aim to be a partner for growth today in Mozambique, as we already are throughout the continent. I am convinced our presence will contribute to the country’s economic and social development.’
Air Products South Africa (Pty) Limited manufactures, supplies and distributes a diverse portfolio of atmospheric gases, specialty gases, performance materials, equipment and services to the Southern African region. Air Products touches the lives of consumers in positive ways every day, and serves customers across a wide range of industries from food and beverage, mining and petrochemicals, primary metal and steel manufacturers, chemical applications, welding and cutting applications to laboratory applications. Founded in 1969, Air Products South Africa has built a reputation for its innovative culture, operational excellence and commitment to safety, quality and the environment. In addition the company aims to continue its growth and market leadership position in the Southern African region.
Service that delivers the
www.airproducts.co.za May 2018 | Beverage Review
I N D U S T RY TA L K
SA’s first carbon neutral brewery T
he brewery is expected to offset a total of 68 796 tonnes of CO over the next Darling Brew, a craft brewery year. This is equivalent to eliminating the same amount of carbon from the based in the Western Cape has environment as 17 829 tree seedlings, grown for 10 years. To become Africa’s first carbon neutral brewery, the brewery calculated its carbon been officially declared Africa’s footprint by means of a greenhouse gas audit. This carbon footprint is then offset South African Food Review, 132 x 200 mm, Hydronomic, CC-en34-AZ190 04/17 first carbon neutral brewery. through impactChoice, a provider of end-to-end environmental sustainability 2
solutions. This ensures emissions are offset via responsible carbon capturing and reduction projects. Darling Brew has teamed up with sustainability consultants Ecolution Consulting who, in addition to guiding the brewery through the carbon offsetting process, are working with Darling Brew to reduce the water and energy consumption, as well as the brewery’s waste to landfill percentage. ‘We are identifying short- and long-term strategies to ensure Darling Brew continues to travel further along its sustainability journey,’ says André Harms, sustainability engineer and founder of Ecolution Consulting. ‘This started with the procedure of tracking and recording consumption and waste data to ensure real progress is being made.’ The brewery has taken to openly and prominently displaying the month-tomonth statistics on its water, waste, energy and carbon use in the hopes of including Darling Brew’s patrons in the journey and spreading awareness. In addition to the carbon offsetting and consumption tracking, Darling Brew has implemented a series of green initiatives in the brewery. These include water efficient fittings, waterless urinals, ongoing recycling and food waste management and the use of upcycled furniture and recycled wood in the brewery and tasteroom area. ‘We are excited to progress on this journey,’ says Kevin Wood, owner and founder of Darling Brew. ‘Going carbon neutral is a massive step for us, but certainly not the last.’ •
Hydronomic #GermanBlingBling #Hydronomic
We do more.
Beverage Review | May 2018
BEERS & CIDERS
for heat resistant bottle moulding
issei ASB is a leading manufacturer of injection stretch moulding machines for PET and other plastics. HSB-6N technology is ideal for the manufacture of products used in the brewing industry. The machine can perform double-blow reheat stretch blow moulding in a compact solution for heat resistant PET bottles with a neck diameter of up to 38mm. Preforms with either amorphous or crystallised neck are moulded with ease. The choice of neck type depends on factors such as neck and cap design, container filling, pasteurisation and cooling specifications. To optimise process efficiency, moulding can be adjusted to apply almost any degree of heat resistance to a PET container as required by the filled product. As the two step, double-blow heat set process of the HSB-6N can achieve heat resistance up to the practical maximum of PET (95°C with a suitable container design), it is extremely effective for projects that exceed the capability of other heat-setting processes.
With fully electric mould clamping, the machine is smooth, quiet and energy efficient. Added flexibility is assured: with a simple change of blow mould and a suitable preform it is equally capable of moulding standard (non-heat resistant) PET containers. At the recent NPE event held in May in Orlando, US the machine demonstrated moulding a heat resistant PET beer bottle that meets standard industry requirements.
This must ensure that a 65°C contents temperature be maintained for 15 minutes to fully kill off any remaining yeast, providing long stable shelf life with no apparent flavour change. Despite this relatively low temperature of pasteurisation; combination of long processing time and carbonation pressure creates additional forces on the container that can only be adequately handled by the double-blow heat-setting process in combination with the 46.5g weight. It can be moulded in standard PET, or where required, oxygen scavenging or carbon dioxide retention additives can be included to further enhance shelf life. The 650ml bottle was moulded at a cycle of 4.5 seconds producing 4 800bph, and the featured container used an industry standard neck suitable for crown caps. This can however be moulded to any required standard. •
Nissei ASB – www.nisseiasb.co.jp
May 2018 | Beverage Review
BEERS & CIDERS
When digital twins brew beer All beers are not created equal. Different ingredients, temperatures, fermenting times and steps come together to create an enormous variety of beers.
his is as true for multinational corporations with many brands as it is for small craft breweries with many recipes. They all share one thing in common: They must always deliver top quality to satisfy their customers – no matter how complex the brewing process may be. Rising cost pressures and seasonal fluctuations in demand present additional challenges. Using digital twins, workflows can be realistically simulated down to the last detail – from the recipe to bottling – in a fully digital environment. This means breweries of any size can test and optimise processes without risk, until they can produce the actual beverage efficiently, flexibly and to the highest standard of quality. Siemens’ brewery solutions demonstrate how the entire food and beverage industry
benefits from digitalisation. The product and solutions portfolio are adapted to meet the needs of the brewery industry has proven highly successful across many different companies in practical application. Of interest to Siemens this year is how companies across the industry are securing decisive competitive benefits using solutions from the Digital Enterprise portfolio. At a recent show, Siemens featured a graphic and easily understandable demonstration of ways in which both the US American bottling company Constellation Brands International (owners of Mexican brand Corona) and craft beer specialist DME Brewing Solutions use Siemens digital technologies and automation solutions. Regardless of the quantity produced, achieving optimum beverage quality is
“Using digital twins, workflows can be realistically simulated down to the last detail – from the recipe to bottling – in a fully digital environment”
top priority. Success is all about the data. Starting with the recipe used through the entire brewing process to bottling, end-toend digitalisation creates a perfect virtual map of each process step. Using the Simatic IT R&D Suite from Siemens, breweries can generate a digital twin of their envisaged product as early as the research and development stage. The twin contains all the relevant data, and permits the downstream processes to be simulated under realistic conditions. This enables workflows to be tested and quality standards to be reliably met and is made possible using Plant Simulation PLM Software from Siemens. Software allows production equipment to be exhaustively tested without disrupting actual production. The result: optimised processes that ensure greater flexibility and a sharper competitive edge.
DATA IN ACTUAL PRODUCTION
Workflows are realistically simulated using digital twins
Beverage Review | May 2018
Braumat’s process control system is designed specifically to address the needs of the brewing process over the entire life cycle. Working in conjunction with the Simatic S71500 Advanced Controller, Braumat lightens the work load and ensures a consistent standard of beer quality. The system provides everything, from an intuitive recipe system to an efficient process overview, tank management and customised reporting. Simatic PLC and Simatic’s visualisation system, WinCC ensures transparency in the bottling process and efficient control of production. What is created is a digital twin of both process and product performance which enables on-going optimisation – right back to the research and development stage. Performance data is used as the basis for the improvement of recipes. Data required is captured and analysed using a cloud-based open IoT operating system. MindSphere and a special MindApp are designed to intuitively analyse all relevant parameters. •
Siemens – www.siemens.co.za
Greater flexibility on the path to more individual products Digitalized solutions for the brewery industry siemens.co.za
BEERS & CIDERS
All natural, all malt solutions Chemelco South Africa recently partnered up with Scottish based company PureMalt, which offers a diverse range of traditionally brewed malt concentrates to the brewing industry.
ith access to the finest barley crops grown in the central regions of Scotland and northern England, only the highest quality raw materials are used to produce these malt extracts. To the brewer, these products can provide a cost-effective solution for colour adjustments to brews and allow the brewer to create constant and reproduceable brews every time. Most of the products have a sensory profile, derived from the speciality malt used to produce them. The distinct colour hues and flavour profiles allow the discerning brewer to create a unique brand or enhance existing brands through late addition to beer. The range of malt concentrates is inclusive of pale malt, caramalt, crystal malt and roast malt beer concentrates. •P ale malt concentrates such as ZAB65 showcases a sweet, clean malt flavour with a pale golden colour. It can be used to form
Beverage Review | May 2018
the base for a zero per cent alcohol beer or dilute the alcohol content of a premium beer without compromising body, mouthfeel or the fullness of the final product. •P ureMalt’s Caramalt concentrate CB30/65 is characterised by a sweet malty, toffee flavour and amber colour. It provides body, colour, sweetness and flavour to premium lagers, summer beers, golden ales and nonalcoholic beers. •C rystal malt concentrates offer the perfect blend of colour and flavour balance. The brewer can boldly transform a lager style beer into an array of truly convincing amber and bock style beers. With the simplicity of downstream addition, high quality red lagers and ales are also on the cards with CB400/65. With five different roast malt extracts to choose from, brewers are offered the opportunity to add innovation, complexity, character, colour and flavour to a variety
Liquid malt extract
of lagers, ales, stouts, porters and swartch beer styles. With low addition rates, the body and mouthfeel in LAB/NAB applications can be improved, the impact on foam is positive, flavours are isolated, and colours are easily adjusted. With no additives, it delivers a clean taste and a clean label. The range of PureMalt concentrates will soon be available in South Africa in five kilogramme packaging, ideal for the craft brewer producing smaller volumes. •
Chemelco – www.chemelco.com www.puremalt.com
PackagingREVIEW SOUTH AFRICAN
May 2018 | Volume 43 | Number 5
Integrated Robotics Solutions for flexible, fast and reliable packaging
Sealing technology boosts brands
Extended functionality for
Barrierpackâ€™s gas barrier
The future of inspection systems
XTENSIVE DETECTION CAPABILITIES help food manufacturers provide high-quality products with a longer shelf life. One of the key considerations of X-ray machines is speed. Having a line slowed down is simply not affordable in this competitive food production market. This is why advanced systems have been designed to meet today’s manufacturers’ high throughput targets. Commonly used to monitor product quality, these systems can also measure product mass or density and indicate whether packs are slack filled or overfilled. Innovative packaging designs comprise their own challenges. Machines previously calibrated to scan standard types of packaging have to adapt to accurately analyse new
packaging shapes, sizes and materials. It is therefore imperative certain considerations be taken into account before purchasing the most suitable system. Choose a model based on the shape, size and weight of products it will inspect. Consider the homogeneity, thickness and density of products. Note that the system must meet strict regulatory standards for operator safety and don’t forget line speed is pertinent during the selection process. Read all about the latest additions in inspection and detection technology from page 46.
Ste fan ng Fagerä
Packaging Review | May 2018
Uwe Obermann, director of R&D and innovation at Mondi Consumer Goods Packaging and Carl Stonley celebrate the Plastics Recycling Europe Show award
Until next month
Assistant Editor Aarifah.Nosarka@newmediapub.co.za
At the helm to lead Tetra Pak STEFAN FAGERÄNG WAS recently appointed MD of the multinational food processing and packaging company to replace former MD, John Strömblad. He is an industry veteran who rose through the company’s ranks from management trainee in Sweden to senior management. ‘It gives us great pleasure to welcome Fageräng to lead Tetra Pak Southern Africa as we celebrate its 60 year anniversary in South Africa,’ says Penny Ntuli, Tetra Pak’s communications director SA. Fageräng was MD of North West Europe at Tetra Pak. This was after he worked as MD of the Benelux region stationed in The Netherlands. He served as the VP of marketing and market management for nearly three years in Sweden. His tenure at
BarrierPack Recyclable honoured for innovation
the company spans 27 years in 12 different countries serving in nearly every department within Tetra Pak’s global portfolio. Fageräng has fostered collaboration among government, industry and healthcare experts in Britain to curb poor health and obesity issues. He encouraged measures to develop healthier packaging in sustainable packaging. ‘We have to support people in our communities and our business, markets and the supply chain by doing more with less and driving environmental innovation across the lifecycle of our products and in our own operations. ‘We recognise the need to create cohesion among the various elements of the food chain that go beyond our business and customers into the entire value chain,’ he explains.
THE RECENT ADDITION of an extra layer to Mondi’s award-winning BarrierPack Recyclable laminate’s construction now allows it to be used on more applications. It is a highly sustainable material with performance properties equivalent to conventional alternatives. It is fully compatible with existing industrial recycling streams. Since the product made its debut it has captured judges’ attention at the 2018 Plastics Recycling Europe Awards held on 25 April in Amsterdam. It was named the Best Technology Innovation in Plastics Recycling. This award recognises companies that have developed or applied innovative technologies and provide quantifiable benefits in areas such as production efficiency, quality standards, product performance or profitability. ‘We believe BarrierPack Recyclable is a major breakthrough for flexible packaging. It complements the sustainability benefits already offered by flexibles, such as the reduction of food waste, CO2 emissions and energy use by adding recyclability. This is something laminates made of different materials cannot offer,’ says Carl Stonley, technical account manager at Mondi Consumer Goods Packaging. The material offers exceptional mechanical properties. It is suitable for a range of packaging formats. It is highly functional and flexible packaging material that’s easy to open and reclose for consumer convenience. BarrierPack Recyclable is stiffer, stronger and lighter than a conventional PET/PE laminate of the same thickness. It can be formed directly on form, fill and seal machines and used for premade packaging.
FL E X I B L E PAC K AG I N G
ISW’s new beginning
Printer and converter of shrink sleeves and flexible packaging, Innovation Shrink and Wrap (ISW) can now provide clients with the latest and more efficient services as well as cost-effective offerings. PACKAGING REVIEW looks at how this has been made possible.
he company’s upgraded equipment and efficiencies allow it to service many clients. While being geared for longer print orders it can also offer shorter runs. ‘The fact that we service smaller minimum order quantities and provide excellent decorative finishes shows we are pushing boundaries and striving to supply innovative products. We live up to our name. While we offer highly decorative finishes, we don’t restrict our customers to ordering large volumes,’ says Daniel Hanson co-owner of ISW, situated in Edendale, Johannesburg. This allows its clients to launch new products to test the marketplace before committing to full production runs. ‘It also enables businesses to start up with lower volumes while putting their products in the marketplace with the same high quality and decorative finishes as those of brand owners with greater budgets,’ adds Gareth Ketley, co-owner of ISW.
UNEXPECTED IMPROVEMENTS The company had its equipment upgraded after a flood destroyed practically everything at its former manufacturing facility. This unfortunate turn of events came with a twist because the company soon flourished as a pioneering short run printer for the FMCG sector. ISW also services
Flow wrap and the form, fill and seal offering
selected specialised industries with shrink sleeve, wrap around label, flow wrap and form, fill and seal offerings. ‘Last year was a testing but triumphant time for us. Our team came together like never before, many cancelling family holidays so they could be at work when the new press was commissioned. They continued going above and beyond throughout the year, making it a truly inspiring effort from all staff. We are blessed and proud to have been able to rebuild the business with this exceptional group of people. We extend a special thanks to all our loyal customers, suppliers and partners in the printing industry that came to our aid during this time and still around today,’ Hanson adds.
UPGRADES TRANSLATE INTO SAVINGS ISW’s new premises and warehouse now sports two MPS EPW560 machines, one an eight colour and the other, a 10 colour UV flexo press. It also comprises a full complement of finishing equipment for the conversion and inspection of shrink sleeves, multi-layer sachets and wraparound labels. ‘We are one of only a handful of narrow web printers capable of producing wide lay flat shrink sleeves, achieving a L/F of 276mm from a printed web width of 575mm,’ Hanson explains. The eight colour MPS press has undergone a UV curing system upgrade. The system’s ratings translate into a 40 per cent power saving and increases efficiencies through improved curing. The press has also recently been fitted with an upgraded state of the art inspection system to improve efficiencies by enhanced quality monitoring at higher speeds while reducing spoils and material waste ratios. The primary objectives of ISW are to reduce the operations carbon footprint, improve quality monitoring and management systems. It is dedicating more time to R&D to bring more innovative offerings to its customers coupled with implementing additional relevant certification systems. •
Innovation Shrink and Wrap – www.iswshrink.co.za
May 2018 | Packaging Review
FL E X I B L E PAC K AG I N G
Discover the benefits of sealing technology South African consumer preferences have changed. There is a trend toward stand up pouches. Look no further than Bosch’s flexible packaging technology which is able to produce a variety of bag styles.
Depending on the product and its environment, net weighing systems provide the most accurate means of measuring products for packaging.
Krug says Bosch has the most interesting business model on the market right now owing to its rental concept – Rent a Bosch without Capex. ‘As a manufacturer, you will be able to pay for the Bosch machine on a monthly basis until you either feel the need to return the machine or end the rental contract by buying the machine at any time with incredible discounts.’ •
osch Packaging prides market. VFFS machines provide itself on flexibility, precise control of almost all offering different film types, dust extraction packaging styles, sizes and remote live data DID and options with one analysis. This is YOU KNOW? machine. The four coupled with instant For pouch lengths of 250mm, most popular bags local technical the latest German Bosch baggers save up to 6 250mm² of film. With a are stand-up, four support and spares,’ minimum speed of 40bpm, there is corner seal or says Mathias a 250 000mm² of film saved each gusset, doy and Krug, business minute. This amounts to an hourly resealable bags. responsible director of saving of 15 million mm² of film, which is a saving of over 120m² Block bottom sub-Saharan Africa. of film over an eight bags, which are also These machines hour period. referred to as stand have 12 inch up pouches, are able to touchscreens, balance and stand straight which ensure up when filled with product straightforward setup and can now also be resealed. Not only and diagnostic processes, and are these bags more presentable, they 650mm film reel holders with are completely user friendly. Consumers the capacity of adding hours of can now open and close bags at their runtime. This leads to extensive own leisure. This ensures neatness and cost savings. freshness of produce. Bosch Packaging recently introduced THE LATEST IN VFFS the vertical form filling and seal (VFFS) TECHNOLOGY machines with stand-up technology and Bosch’s SVB Series couples reseal functionality to the African market. recloseable bags with a net While these machines might cost more weighing system, the Bosch Belt than locally produced solutions, they Weigher. This drastically reduces offer easy operation and low maintenance product waste and increases features such as vacuum belt tracking. This filling precision to less than is one of the reasons Bosch thrives in the one per cent variance.
UNIQUE BUSINESS CONCEPT
Bosch Packaging – www.boschpackaging.com
The SVI 2600
Bosch Packaging Discover the Benefit of Bosch Vertical Packaging Solutions with Block Bottom Bags, Doy Zip Bags & Resealable Bags ...Available in our showroom in Johannesburg! Robert Bosch Packaging Technology 96, 15th Road, Randjespark, Midrand | Tel 011 651 9600 Email Aubrey.firstname.lastname@example.org | www.bosch.com
Packaging Review | May 2018
Rent a Bosch – Without Capex
2018/05/11 8:35 AM
A serious problem facing food and beverage manufacturers
Manufacturers cannot afford to compromise on food safety standards. An integral part of this system is not only maintaining ISO certifications, but also preserving reputation and brand integrity.
HIS IS A critical factor in meeting the demanding requirements of major supermarket chains and auditors, locally and abroad.
These factors are easily compromised through mistakes, often made while trying to maintain the fast-paced nature of 24/7 production and the need to satisfy maintenance problems without proper
or could result in a consumer requiring hospitalisation. Secondly, brand and reputational damage is almost guaranteed. The financial implications of such a problem are serious: an entire batch of product can be recalled from the shelf. National supermarket chains, independents and entire bulk raw material stores are often required to discard at a huge cost.
consultation or due diligence. “One of the most overlooked problems facing food and beverage manufacturers in the 21st century is crosscontamination... but can it be solved?” – Matthew
HOW DOES CROSSCONTAMINATION OCCUR? Cross-contamination in the food and beverage industry typically occurs when an artisan or operator mistakenly selects a toxic MRO product to be used in an area where a food safe product is required.
Daley, general manager of Rocol Lubricants
We typically see this in above-the-food-
line applications. This is where an edible product or packaging passes underneath toxic chemicals that could potentially
THE CONSEQUENCES ARE SERIOUS Using a toxic product in an area where a food safe product is required is serious. Firstly, consider the sensitivity of some consumers’ health or dietary needs. A contaminated food Rocolmay - Food Review or drink source be fatal to aPRESS.pdf consumer
South Africa is increasing its reach to global food and beverage manufacturers. This situation brings with it stringent controls for end-to-end food safety standards by leading food safety entities such as NSF, BRS and EFSIS. We are seeing a significant increase in the amount of South African manufacturers 2018/04/30 09:00 meeting international food concerned about
safety standards for just these reasons. The most convincing reason to address this problem is the least understood. The risk of not acting is the most serious, as crosscontamination is far more commonplace than manufacturers believe or are even aware of.
CHALLENGES FOR SA Socio economic challenges further exaggerate the problem. A lack of education and corruption are some examples which result in ‘the wrong product for the wrong application’. This also contributes to suboptimal manufacturing and production output as well as premature asset life.
IS THERE A SOLUTION? Few companies have both the product range and expertise to satisfy the diverse manufacturing requirements and complex conditions needed to eliminate the possibility of cross- contamination. Expertise is the most important factor in addressing this problem. Complex manufacturing plants require a thorough analysis and assessment to ensure management systems, risk reduction, rationalisation and compliance, to name a few, are implemented correctly and fit into the plant’s standard operating procedures and ethos in general. • Rocol – www.rocol.co.za
May 2018 | Packaging Review
INSPECTION & DETECTION
Compliant detection technology
X-ray scanners must comply with different specifications, a customer’s requirements and the necessary detection rates. At Danrice, an X-ray scanner’s workload is enormous.
they come from,’ says Kim Kirkeby, CEO of Danrice.
IT BEGINS WITH TESTS
Requirements of X-ray machines are met with test specimens – in this case stainless steel balls and glass beads with diameters of 1.0 and 2.5mm respectively. The sensitivity of the WIPOTEC’s X-ray scanner is so high it can detect even the smallest foreign bodies in a product. The systems are trained to detect stone, glass, plastic or metal particles, which can By Aarifah Nosarka pass through mechanical and other precleaning processes. anrice is an international supplier Owing to the various planes within the of pre-cooked IQF rice, grains and X-ray scanner, radiation cannot escape via pasta for the food industry. It has the transport openings and the unit is safe a particular focus on ready-meals. At its during operation. facility, up to three tonnes of The differences in density of raw goods, which is more the foreign bodies show up than 4.5m 3 of product, pass on the X-ray as different through scanners on a grey scale values. High motorised conveyor performance image belt each hour. processing software To work effectively, the The company uses scans the X-ray WIPOTEC X-ray system X-ray scanners from images to reliably divides the product flow on a conveyor belt into several WIPOTEC-OCS and detect impurities virtual, parallel paths metal detectors as whilst keeping the that are examined required by industry scanning speed high. simultaneously for regulations. ‘We buy our If a foreign body is foreign bodies. products from all over detected, the product the world, to a large extent flow is interrupted only from Asia. It’s not possible to briefly on the appropriate path rule out impurities and the same applies by the opening of a flap. The foreign to rice from Europe. Therefore we have body together with its surrounding product to monitor all products and check them is diverted downwards. The design saves for foreign bodies irrespective of where over 80 per cent of the good product, which
would otherwise be separated out with the foreign bodies. USS Pactech is the South African agent for WIPOTEC-OCS. •
WIPOTEC-OCS – www.wipotec-ocs.com
DID YOU KNOW?
MAXIMUM SAFETY HIGH PRECISION PRODUCT INSPECTION ■ ■ ■
Premium German engineering Broad and modular portfolio Excellent local service
Packaging Review | May 2018
X-ray scanner SC-E
Find the smallest objects before they cause the biggest problems Our quality control systems leave no stone unturned. Or shard of plastic or glass. Or piece of rubber or bone. If thereâ€™s a foreign body in your product, our machines will find it. Reducing product recalls and protecting your brand. Work in harmony with Ishida.
INSPECTION & DETECTION
Advances in metal detection machines
ob Ries, lead product manager, metal detection and X-ray inspection at Thermo Fisher Scientific explores the latest technological breakthroughs in contaminant detection and how it enables processors to improve food safety programmes. He discusses the company’s Sentinel Multiscan metal detector, which eliminates the need for manufacturers to compromise and reduce the risk of costly recalls. The system is capable of scanning up to five user adjustable frequencies at once. This is the equivalent of running five metal detectors back-to-back. The subsequent heightened sensitivity decreases the probability of an escape when compared with single or dual frequency metal detectors. A comparison test was done between a single frequency metal detector and a Multiscan detector. The test included a wide range of products such as iron fortified cereal, shingled sliced cheese and wet spinach. The Multiscan detector typically picked up foreign metal objects that were 50 per cent smaller in volume. In the most extreme cases, it detected metal up to 70 per cent smaller in volume.
Food is about to get safer than ever
One of the most important factors of the improvements is overcoming product phasing. The phase angle of a product is the ratio of its magnetic signal and conductive signal. Various metals have different amounts of each signal. A foreign metal object can go undetected if its phase angle exactly matches the product phase angle. By slightly adjusting the frequency the problem may be solved, but it could result in a different type and size metal object being overlooked. In other words, the problem merely shifts. When scanning five frequencies at once, if a foreign metal object is phased out at one frequency, another frequency detects it. Multiscan metal detectors are designed for flexibility, allowing manufacturers to adjust or disable frequencies to optimise performance too.
Introducing the Thermo Scientific™ Sentinel™ Multiscan Metal Detector Discover the difference of Multiscan.
Find out more at thermofisher.com/Sentinel5000-SA
© 2018 Thermo Fisher Scientific Inc. All rights reserved. All trademarks are the property of Thermo Fisher Scientific and its subsidiaries unless otherwise specified.
Threats to consumer safety exist at every step in the food chain. For manufacturers, failure to keep their The Thermo Scientific products safe and contaminant free can Sentinel Multiscan impact consumer health and safety metal detector while causing damage to a brand or company’s reputation. Multiscan technology virtually ensures no foreign metal objects escape a facility. As food manufacturers strive to meet retailer demands, consumer expectations and industry codes of practice, they can now embrace this advanced technology. •
Thermo Fisher Scientific – www.thermofisher.com
Packaging Review | May 2018
INSPECTION & DETECTION
RAPID RETURNS on your investment in X-ray technology
Ishida Europe has launched a new range of X-ray inspection systems. PACKAGING REVIEW looks at how these technologies help companies comply with global safety standards and meet demands of quality and safety conscious retailers.
•T he IX-G2 series can provide the highest level of quality assurance to processors and manufacturers of complex products. Its dual energy sensor detects what other inspection systems miss. It provides highly effective X-ray detection of low density objects, even in varying thickness or overlapping products. All IX systems have touch screen interfaces with user intuitive software. Everything within the new range has been designed to offer the maximum performance with the minimum cost in personnel training. This is to ensure producers can rapidly gain the benefits of their investment. •
he company’s X-ray (IX) series raises existing business and gaining new contracts the bar in performance and usability. through a competitive advantage. This global range meets all local territory standards and offers customers easy ADVANCED X-RAY SYSTEMS maintenance and stress free operations. The The new range consists of three machines. machines include a robust fail safe system •T he IX-EN series is ideal for manufacturers that prevents contaminated requiring an affordable but highly products reaching consumers in accurate entry level inspection the event of a power outage solution. It is a reliable or breakdown. This helps machine that balances minimise the potential for impressive sensitivity with The IX series offers costly recalls. minimal operating costs to products specifically ‘We have harnessed the deliver a ROI. designed to cater for The IX range latest advances in imaging • The IX-GN series is large packs or bottle technology with the IX range perfect for manufacturers applications. to create industry leading in search of the highest Ishida – www.ishidaeurope.com inspection systems offering level of unrivalled detection of foreign certainty body contaminants,’ says Ciaran and the best NEW & USED FOOD MACHINERY – IN STOCK Murphy, quality control business manager at possible performance for • A&K Corn Cutters & Huskers • Eillert 2-stage vegetable washers • FAM Dice, Slice & Strip Cutters • Key 4” Hydro Food Pumps Ishida Europe. a range of products. It is • FAM TS-1D Transverse Slicers • Key Vibratory Shakers The IX range delivers the level of certainty able to detect pieces of • FAM PMD Poultry & Meat Dicers • Kronen GS10 Slicers businesses need to meet the demands of stainless steel as small • FAM 7944 French Fry Cutters • Kronen KUJ Dicers • FAM 7407 Bean Cross Cutters • Kronen Gewa 3800 Washers their suppliers. All models offer exceptionally as 0.3mm in diameter and • Feuma Apple Peelers • Mado Meat Mincers sensitive foreign body contaminant aluminium, glass, stones, • Femia Bean Snippers • Ramon Bowl Cutters • Herbort Bean Top & Tailers • Many Other Machines Available detection. An additional benefit is the ability rubber, dense plastic and to identify damaged and missing products or shells at high speeds. It is CALL US NOW FOR A QUOTATION components. This helps customers achieve a also suitable for a variety rapid return on investment. Quick commercial of packed and unpacked Food Processing Systems & Technology, Paarl returns are also achieved by ensuring high products and includes Tel: 021 - 868 -1594 | Fax: 021 - 868 - 1599 quality product leaves the factory gate. a compact, built-in air Visit us on http://www.eptech.co.za or mailto:email@example.com This safeguards reputations while securing conditioning unit.
DID YOU KNOW?
ADVERTISERS’ INDEX MAY 2018 Afrox 21 www.afrox.com Air Products 35 www.airproducts.co.za Bosch Packaging 44 www.bosch.com Brenntag 20 www.brenntag.com/south-africa Brewtech Engineering 34 www.brewtech.co.za Chemelco International 40 www.chemelco.com Chempure 19 www.chempure.co.za CJP Chemicals 16 www.cjpchemicals.co.za DMG EMS 14 www.africabig7.com Eptech 49 www.eptech.co.za Eurolift 18 www.eurolift.co.za Foodtech Ingredients 32 www.foodteching.co.za French Trade Commission 13 www.sialparis.com Frutarom OFC www.frutarom.com GEA Southern & Eastern Africa 5 www.gea.com Ishida 47 www.ishidaeurope.com ISW Shrink 43 www.iswshrink.co.za
Krones 36 www.krones.com Maxiflex Door Systems 22 www.maxiflex.co.za Nissei ASB 37 www.nisseiasb.co.jp Omron 41 www.industrial.omron.co.za Rocol Lubricants 45 www.rocol.co.za Roha 15 www.roha.com Savannah Fine Chemicals 17 www.savannah.co.za Siemens 39 www.siemens.co.za SRF Felxibles OBC www.srf.com Symrise IFC www.symrise.com Thermo Fisher Sientific 48 www.thermofisher.com Vivit Foods 31 www.vivit.co.za Wipotec GmbH 46 www.wipotec-ocs.com Yamato Scale Dataweigh 12 www.yamatoscale.co.uk SANBWA Polyoak Packaging
www.polyoakpackaging.co.za May 2018 | Packaging Review
TRAINING | JOB VACANCY | LABORATORY SERVICES | CONSULTING SERVICES | TO LET | MACHINE FOR SALE | RECRUITMENT | TEMPORARY EMPLOYMENT SERVICES | COURSES
BILTONG SLICER ............................................................................. R4 265.00 DOUBLE LEVEL CONVEYOR ........................................................... R22 000.00 PHANTOM METAL DETECTOR ........................................................ R50 000.00 BILTONG ROOM .............................................................................. R445 502.00 BILTONG DRYERS QTY 2 (EACH) .................................................... R20 000.00 FOMACO INJECTOR ........................................................................ R250 000.00 CASING SPOOLER .......................................................................... R15 000.00 HANDTMAN PATTY FORMER .......................................................... R285 000.00 HANDTMAN VF612 .......................................................................... R500 000.00 HANDTMAN FILLER & GRINDER VF616 ........................................... R850 000.00 GROUND MEAT PROCESSOR ........................................................ R285 000.00 TFS-200 ........................................................................................... R1 025 000.00 VACUUM TUMBLER ......................................................................... R15 000.00 TRP- BLENDER ................................................................................ R10 500.00 52 MINCER ...................................................................................... R24 500.00 52 MINCER OKTO............................................................................ R30 000.00 SLICER............................................................................................. R35 000.00 TENDERIZER .................................................................................... R8 500.00 HENCOVAC VACUUM ...................................................................... R32 000.00 ASHIDA OVER WRAPPER ................................................................ R250 000.00 ULMA TAURUS ................................................................................ R700 000.00 ULMA TAURUS ................................................................................ R700 000.00 All prices exclude Vat
Ferdi Lemmer Tel: 033-569 0660 Email: firstname.lastname@example.org For More Machinery Equipment on Sale Visit: www.triple-a-beef.co.za
Triple A Beef.indd 1
2018/05/11 9:11 AM
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C O N TA C T
METROHM SOUTH AFRICA Metrohm SA is a subsidiary of Metrohm AG, a leading Swiss company. We are a regional support centre for all sub-Saharan countries, including Mauritius and Madagascar. We are proud suppliers of Swiss-made analytical solutions that greatly enhance the output, efficiency and reliability of your labs and processes. Our products are widely used in the environmental, pharmaceutical, food, mining, electroplating, petrochemical and water treatment industries as well as tertiary institutions for teaching and research.
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
Tel: +27 (0)11 656 1918/ +27 (0)21 852 0213/ +27 (0)31 265 0067 www.metrohm.co.za
• 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: email@example.com Tel: +27 (0)15 516 1515/4 email: firstname.lastname@example.org www.dinnermates.co.za
formulating services in our fully equipped labs, as well as blending
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: email@example.com or firstname.lastname@example.org 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: email@example.com 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.
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