OCTOBER 2019 Vol. 46 • No. 10
Journal for food and beverage manufacturers
Create exciting solutions with
unique flavour compositions Meat, fish & poultry Technology and solutions that make the grade
Labelling Make your first and best impression
Meet 2019’s NPC winners!
beverages
dairy farming
dairy processing
utilities
transport
food
core technologies
Milking & Cooling
Seperators
Decanters
Homogenisers
Valves
Spray Drying
Aseptic Filling
Brewery & Dairy
Compressors
Packages & Skids
Ice Machines
Freezers
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CONTENTS
OCTOBER 2019 | Vol. 46 • No. 10
PAGE
10
27 MATERIALS HANDLING & WAREHOUSING
BI secures Masta distributorship
Make the case for drum motors
32 FLAVOURED ALCOHOLIC DRINKS
“Symrise can offer solutions that tailor the taste of plant-based protein to consumer preferences”
07 NEWS
Firmenich acquires a stake in Robertet
Ishida opens office in East Africa
Goscor aims high with ISO certification
Plastic packaging goes full circle
Regenerative beer stabilisation
33 BEVERAGES
Don’t compromise taste when reducing sugar
Sidel installs state-of-the-art bottling line
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09 PRODUCT UPDATE
Fuji introduces new fill, form & seal technology
12 NEW PRODUCT COMPETITION
Celebrate with this year’s NPC winner
14 INGREDIENTS
Its all about being sustainable
Targeted formulations in meatfree alternatives
18 MEAT, FISH & POULTRY
PAGE
42
Label versatility creates success Convey
35 INDUSTRY TALK
Decoding the BRC Global Standard
New guidelines for recyclable plastics
PHT’s seminar a smoking success
37 LABELEXPO EUROPE 2019
Give your burger that juicy edge
Let your label do the talking
HPP is perfect for safe meat processing
Labelling’s biggest show yet!
Fast and efficient weighing technology
40 LABELLING
Packaging solutions for IQF chicken
25 FOOD SAFETY TRAINING
Create a culture of food safety
The lowdown on pesticide analysis
Give your brand a voice
Versatility creates success
Rotolabel pushes sustainability
Digital solutions for the modern printer
October 2019 | Food Review
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EDITOR’S COMMENT
EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmedia.co.za
Rushing headfirst into 2020
T
he last quarter of the year is always incredibly busy for the Food Review team. This is when we hold our New Product Competition judging day and awards ceremony - followed closely by trips abroad to various food, beverage and packaging shows. Anuga, held in Cologne, Germany was an enormous highlight for me this year. The show celebrated its 100th anniversary and even the terrible weather, with wind right off the North Sea, didn't dampen the excitement of the throngs of people attending. I particularly liked the Anuga Trend Zone and was amazed at the sheer number of innovative product launches, which indicates that new product development is showing no signs of slowing down. Watch out for the November edition, where I will bring you a full roundup of the event. Don’t forget to turn to page 14, where we bring you the highlights from our incredible NPC competition awards evening. A representative of Woolworths (2019's NPC competition winner) will be attending SIAL 2020 in Paris with me – another fantastic show! We are already in the planning stages for the 2020 event, so don’t forget to email either myself of Natalie da Silva at natalie.dasilva@newmedia.co.za for more information. In this edition, we look at flavour innovators, Symrise. The article on page 10 offers a fascinating glimpse at how culinary arts make use of scientific findings from polymer research and how the interaction of physics and cuisine can create the foundation for food science. The alternative meat sector has intensified and is currently estimated to be worth 10 per cent of the global meat industry’s market share. We delve into the partnership between
Mane and Deli Spices, and see first-hand how their product portfolio can assist companies to respond to challenges experienced by formulators on the African continent. More on page 16. For meat enthusiasts and processors, industry partners PHT and Schröter had something special up their sleeve. They hosted two masterclass events on the thermal treatment of meat in Johannesburg and Cape Town. Turn to page 18 now to find out about hygiene challenges in food processing and how to create a culture of preparing safe food. This year’s Anuga saw ADM introduce two innovative sugar-reduced products. The company combined components from its sweetener profile to produce flavourful, harmonic and well-rounded results despite the reduced sugar content – perfectly in line with consumer demand for sugar-reduced beverages. We end this edition with a comprehensive labelling feature. Of special interest is the venture between Rotolabel and Avery Dennison. These two companies are partnering for a sensational new initiative to recycle Glassine liner backing, saving tonnes of liners from ending up in landfills. More on page 44. I hope you enjoy the October edition. If you have any comments or suggestions, please mail me at maryke.foulds@newmedia.co.za. Happy reading,
Dr Aubrey Parsons With a PhD in biochemistry, an MBA and a Institute of Brewing and Distilling diploma Heidi also serves on the Innovation Hubs BioPark and UNISA’s Life Science advisory board.
Dr Heidi Grimmer CEO of Stratcom Branding, founding member of the glba (Global Local Branding Alliance)
Gail Angela Macleod
4
Food Review | October 2019
Contributors: Anisha Ramnarayan, Darcy Simonis, Shawn Bezuidenhout ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmedia.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmedia.co.za INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmedia.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmedia.co.za Production Controller: Mandy Ackerman Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park 2092 Tel: +27 (0)11 877 6111 Fax: +27 (0)11 877 6198 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published by New Media, a division of Media24 (Pty) Ltd MANAGEMENT TEAM MANAGING DIRECTOR: Aileen Lamb COMMERCIAL DIRECTOR: Maria Tiganis BRAND STRATEGY DIRECTOR: Andrew Nunneley CHIEF FINANCIAL OFFICER: Venette Malone HEAD OF HR: Camillah West
EDITORIAL ADVISORY BOARD Two doctorates in chemistry; leader in the field of palm oil; SAAFoST president 1993-2001 and honorary life member; past president, Society of Cosmetic Chemists SA.
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CEO: MEDIA24: Ishmet Davidson
Managing director of Symrise South Africa; chairman of SAAFFI.
Rudy McLean She is a qualified food technologist with an honours in Bachelor of Commerce in Business Management and a PMD at the Gordon Institute of Business Science.
Kerusha Pillay
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NEWS
Firmenich acquires a minority stake in flavours firm Robertet
F
irmenich has acquired a 17 per cent minority stake in flavours and fragrance firm Robertet from First Eagle Investment Management, for a price of €683.30 per security. Robertet produces a wide range of flavours for customers in the food industry and operates 15 manufacturing sites around the world. Firmenich said in a statement that it may consider taking a controlling interest in the company ‘should it be invited to do so’, though it also stated that it was willing to be a passive long-term stakeholder in Robertet for the time being. Patrick Firmenich, chairman of the board of Firmenich says, ‘Firmenich has the greatest respect for Robertet, with its family values, long term vision of the industry and leading capabilities in natural ingredients. As a long-term oriented shareholder, this investment reflects Firmenich’s commitment to best support Robertet’s continued growth'. Gilbert Ghostine, CEO, Firmenich adds, ‘With its strong naturals portfolio in perfumery, flavours and ingredients, Robertet is well-positioned to benefit from consumers’ continued demand for authentic natural products. This investment is fully in line with our vision for sustainable and natural solutions.’ •
Ishida strengthens East Africa presence I shida Europe is opening a dedicated office for East Africa to provide localised sales, service and spares support to food processors and packers throughout the region. The new office in Nairobi, led by sales manager David Mulwa and service engineer Daniel Ambuka, will include a fully equipped demonstration area, featuring a selection of Ishida’s latest cost-effective weighing, packing and inspection solutions. The equipment is suitable for use in a wide variety of markets including snacks, fruit and vegetables, nuts and seeds, confectionery, biscuits and bakery. It will enable the company to provide a fast-response service in the supply and support of individual machines and the design and installation of complete packing lines.
The office is also co-located with international food processing equipment specialist Heat & Control. This will allow snacks companies in the region to benefit from the Ishida/Heat & Control alliance for the devising of comprehensive wall-to-wall snacks processing and packing line solutions that deliver maximum throughput and efficiencies. ‘Ishida’s success is based not only on the performance and reliability of our equipment but also on the impeccable standards of service and support that we provide to our customers,’ comments Steve Jones, marketing director, Ishida Europe. ‘Our new office will ensure that companies throughout East Africa can experience the same high levels of commitment and maximise the value of owning an Ishida solution.’ •
The Ishida and Heat and Control teams
LET’S THINK DIFFERENT Together for Business and Environment
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October 2019 | Food Review
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NEWS
Simei expects record numbers
T
he 28th edition of the event has lots of new features in store and will take place from 19 to 22 November at the Fiera Milano Rho in Italy. Simei has established itself as one of the larger networking events in the wine industry, recording significant numbers every year: 30 000 professional operators from all over the world, over 500 high-profile exhibiting companies, and 400 delegates from more than 90 countries. •
GCE attains
ISO 9001:2015 certification
G
oscor Cleaning Equipment has attained the ISO 9001: 2015 certification. Managing director Gregory Venter says the successful certification is a testimony to the company’s focus on high levels of service, efficiency and product quality. Attained in July 2019, the standard ensures that there are processes and policies in place to give customers quality service. ISO 9001: 2015 standard expects organisations to understand their objectives before establishing a Quality Management System. This requires them to take a fresh look at their current quality processes, consider the external and internal
issues that affect quality, and clearly define end goals towards achieving consistent customer satisfaction - central to GCE’s operating philosophy. The ISO 9001:2015 standard is intended to help organisations achieve excellence through a stronger customer focus and improved business performance. The revisions to the standard will enable organisations to enhance their existing quality management programme by defining and documenting processes, training employees, ensuring better supply chain relationship management and adopting a risk-based approach to quality. •
Valio brings recycled plastic to food packaging
V
alio is among the first food companies to use recycled plastic. This development is part of a larger goal: the food company wants to cut milk’s carbon footprint to zero by 2035. Packaging has a vitally important task to prevent the larger environmental hazard of food waste. It’s now possible to use recycled plastic in food packages. Valio’s range of delicacy cheeses’ new packages are now made from at least 90 perper 90 cent cent recycled recycled plastic. plastic. ‘Using recycled plastic reduces the plastic industry’s environmental emissions by 40 to 60 per cent compared to making plastic from fossil oil. Our goal is that in 2020, all Valio sliced cheese packages in
Finland are made from at least 50 per cent recycled plastic. In the future, roughly 10 per cent of all our packaging plastic in Finland will be recycled. That matters a lot when it comes to the environment,’ says Juhana Pilkama,Pilkama, Juhana packagepackage development manager. In 2015, Valio introduced 100 per cent plant-based cartons to Finland’s stores. These cartons are made from wood and the thin protective plastic film from the sugarcane industry’s waste. The caps are also fully plant-based. In 2019, Valio is discontinuing its use of blackdyed plastic in Finland. Current recycling devices cannot identify the black colour, which means black plastic packages don’t get recycled. •
Plastic becomes a problem if it ends up in nature
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13294 - HOSTEX 2020 VIS 65x177 FOOD REVIEW PATHS.indd 1
Food Review | October 2019
2019/10/16 07:59
P R O D U C T U P DAT E
Pioneer of the packaging industry Fuji’s range of form, fill and seal packaging equipment is known for its high speed, reliability and ease of operation. Food Review spoke to Bevan Challenor of supplier Goldpack about the range of equipment on offer and how it can assist the food industry.
H
e says, ‘The equipment initially
In addition to the horizontal pillow
We are delighted to be sole agents
wrapped caramels before we
wrapping machines, Fuji has improved its
for Fuji machinery in South Africa’
applied this technique to chewing
peripheral equipment to fit the needs of
Challoner concludes. •
gum and candy amongst other products.
the times and evolve its product range.
Fuji were among the first in the packaging
‘Tasks that used to be performed by
industry to apply electronic controls and
workers are now fully automated. For
develop packaging robotics. The company
example, film roll exchanges once done
has always made efforts to carve its way
by humans are now performed by two-
by providing quality products.’
armed robots. The company continues to
Of the major product line, horizontal
Goldpack – www.goldpack.co.za
challenge itself to further automate and
pillow wrapping machines have continued
streamline the packaging process.
to evolve since the first models. Adding electronic control has made additional improvements and Fuji continuously challenges itself to increase packaging
Fuji continually challenges itself to reduce the unit’s energy consumption
speed, shorten maintenance time, reduce energy consumption and strengthen usability and sealing.
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October 2019 | Food Review
9
C O M PA N Y F O C U S
Surprising combinations: Have you heard of food pairing? Do you marvel at the menus of hip and experimental restaurants in your neighbourhood, daring to try something different for once?
W
ith surprising and popular scent and taste combinations, unexpected food pairings are a massive gastronomical trend. The approach assumes the more flavour components two products share, the better they taste together i.e. if two ingredients contain one of the same substance, they are compatible. The charm of food pairing lies in ingredients that although completely different and seemingly strange at first, occasionally have complementary molecules. Dark chocolate and chilli is one such example. If these combinations taste especially good, then the chef has matched them successfully. The question to ask then is why do we prefer some tastes over others and exactly what happens when we taste food?
ON THE SCENT OF GOOD TASTE Prof Thomas Vilgis, a project leader at the Max Planck Institute for Polymer Research and professor of theoretical physics at the University of Mainz is working on these questions. He established a working group for soft matter food physics. This studies the physical aspects of food, including ingredients and their preparation. Specifically, he analyses food and how flavours develop. The team is particularly interested in how individual ingredients behave in the mouth as each releases flavour in very different ways. Some substances reach receptors first and are the primary flavour. Others tend to stay in the background. When we eat chocolate, sugar and how we perceive it plays an important role, as does the way cocoa butter melts in the mouth. Certain water-soluble flavour compounds and volatile fragrance compounds pair up. Saliva releases scent-producing molecules and influences how we perceive the chocolate’s texture as it transitions from hard to soft.
10
Food Review | October 2019
Symrise has been researching flavourful food ingredients since 1874
With this research, Prof Vilgis established a scientific foundation for molecular gastronomy. He collected his knowledge in a book titled Aroma - Die Kunst des WĂźrzens (Flavour - The Art of Seasoning) (Vierich/Vilgis). Even at home, food ingredients that seem to be opposites can be combined appetisingly.
THE PERFECT FLAVOUR PAIR Since 1874, Symrise AG has been researching flavourful food ingredients. The company and Prof Vilgis are working on a joint project to combine and add to existing expertise. They are studying how the culinary arts can make use of the scientific findings from polymer research. The interaction of physics and cuisine creates the foundation for applied food science and thus product development at Symrise. Food technicians of the global group examine global recipes for harmonies and contrasts that make their natural ingredients taste particularly good. They thoroughly select ingredients,
prepare individual steps for the meals and use the same tools as consumers would in their own kitchens. Prof Vilgis and Dr Gerhard Krammer, head of flavour research and development at Symrise, work hand in hand. Prof Vilgis researches molecular food physics and Dr Krammer applies the findings in food manufacturing. Molecular gastronomy often uses these exact findings. Symrise offers its food and beverage manufacturers and consumers, tasty combinations that these companies then introduce to markets from Asia to South Africa.
THE NEXT CHAPTER The science of good taste can do even more, and it extends beyond research at institutes and universities and its use in the flavour industry. Until recently, the most important question was combinations of ingredients with harmonising flavours. In their joint project, the team are looking at which preparation methods produce the best flavour combinations. They consider how the
C O M PA N Y F O C U S
The science of flavour pairing “Thanks to its comprehensive application expertise, Symrise can offer solutions that tailor the taste of plantbased protein to consumer preferences” physical properties of the ingredients change depending on the preparation method in addition to taste. This could include questions whether fresh, green notes harmonise with fruity, juicy notes and if these ingredients should be roasted, grilled or smoked. It is also important to note taste largely depends on smell, how the scent of a dish is perceived. Good taste is a result of the harmonious combination of aromas. In cooking, you can create a specific taste by deliberately combining aromas - like a perfume. The combination of flavouring substances can have a huge impact on taste.
Based on this information, Symrise works with raw materials that emphasise complementary ingredients well to create a satisfying taste experience. The company also considers how the molecular structure can change the scent and ultimately the taste of food.
A CULINARY DELIGHT The team skillfully infuse scientific findings into flavour combinations so that consumers can best enjoy soups, cold beverages or gums. At Symrise's headquarters, there are facilities for processing flavours that resemble large pressure cookers and produce a similar flavour profile. They can also vary the concentration of the product and positively influence the intensity of the taste.
FOOD PAIRING 2.0 – A SUMMARY
GROUP CHARACTER Prof Vilgis distinguishes between specific flavour groups that have characteristic flavouring substances. Symrise AG uses this knowledge to create the ideal flavour combinations for its products. Symrise application specialists know exactly what flavours appeal to the sense of smell and taste - particularly savoury. They know which taste components are heat-resistant and change when heat is added during the cooking process. For a typical meaty flavour, the Maillard reaction is necessary through pan-frying or heating something in the oven.
protein sources, like soy, pea or oat proteins. These often have an unpleasant aftertaste or an off-putting texture or consistency. The company uses its findings to develop flavours for plant-based protein products. Due to its comprehensive application expertise, Symrise can offer solutions that tailor the taste of plantbased protein to consumer preferences. These include friction in the mouth, fracture properties when chewing and the taste and scent released. Symrise has an eye on these parameters and is working on creating a pleasant mouthfeel and a convincing taste for modern meatless products. Knowledge of the effects of molecular structure on scent and taste is also applied. Symrise is introducing flavour into reduced-salt dishes. ‘Our priority is the overall functionality of the ingredients to produce a flavourful product,’ Dr Krammer explains.
Food pairing is on everyone’s lips
The company uses state-of-the-art measuring techniques to reach a consumer’s preferred taste. The flavour analysis in the lab supplements this with sensory panels. Panellists are specially trained and can detect and describe subtle differences in flavour. Symrise uses the results of the combined analysis to develop flavouring substances. This is especially interesting given the rising demand for alternatives to animal
Through their work, Symrise and Prof Vilgis have enriched classic food pairing with a decisive component. They are looking at the combination of similar food and the general molecular interaction of ingredients and their physical properties. Spice harmonises with sweet, savoury with juicy – roasted, sautéed or even cooled. Just as painters skillfully mix the colours of their paintings and complete the picture with an accent colour at the exact right spot, Symrise creates exciting solutions for the food industry with flavour compositions and the interactions between them enriched with the knowledge of our perception of taste in the mouth. •
Symrise – www.symrise.com
October 2019 | Food Review
11
NEW PRODUCT COMPETITION
A luxurious win for this year’s NPC The Food Review/Symrise New Competition Awards is a highlight on the industry calendar. This year’s event was held at the beautifully appointed, The Venue GreenPark in Sandton - the perfect spot to host a night of luxurious indulgence. By Maryke Foulds
B
espoke cocktails from our famous mixologist team and a gorgeous Jozi sunset, set the scene for a memorable night. A total of 29 products were entered this year. In the brutal world of new product development, staying ahead of the curve is the only way to thrive. Understanding food trends is central to success. It is only through the analysis of emerging eating habits that it is possible to identify the food and beverage trends of tomorrow. Taste is, and always will be, the top criterion by which food is measured. The culinary experience is also about pleasure and a feeling of fulfilment and satisfaction. Coupled with this are several other trends that impacted product development this year. There is no slowing down in product categories featuring plant-based and organic foodstuffs, and consumers continue to look for craft and bespoke products. As an ingredient, added protein continues its upward curve on the menu, while beverages offer enormous scope for a developer with craft beverages, CBD, added protein and sugar-reduced variants hitting the spot. This year also saw a resurgence of nostalgic and luxury dairy items, with convenience an added selling point. The food and beverage market must tap even further into a time-strapped audience who are looking for convenience but don't want to sacrifice their health. The goal is the ability to marry consumer health goals with new ingredients, flavours and formats. A highlight of the evening was a presentation by master storyteller Pierre du Plessis. His habit of
12
Food Review | October 2019
making the familiar strange and turning the world upside down resonated with guests – inspiring the industry to think differently when formulating new products. This year’s overall winner is Woolworths’ Mini Chocolate & Caramel Ice Cream Bars. Judging took place on the following criteria: Sensory and organoleptic, marketing, packaging and compliance. A winning product must conform and exceed all these expectations. The judges felt that Woolworths did an amazing job in marrying taste, format innovation, excellent packaging and delicious taste and sensory appeal. A representative from the company will be flying to SIAL Paris 2020 in Paris, France. The prize includes return airfare, accommodation and entry into the show. As one of the world’s leading trade fairs, showcasing the latest development in processing, raw ingredients, trends and finished products this is truly a trip of a lifetime! While the key to successful innovation is the ability to offer the right product at the right time, it is also about capturing the attention of consumers. When you make a connection it often results in repeat business. The networking possibilities offered by the event is fantastic and it was wonderful to see so many guests sharing information. The Food Review team are passionate about innovation in the food, beverage and packaging industries. It is an exciting time, coupled with many challenges and myriad opportunities. If your brand can decipher truly awesome taste, innovative formulation and incredible packaging we look forward to seeing your product in our judging line-up in 2020! •
AND THE WINNERS ARE: 2019 Range category • Winner – Woolworths Double Cream Strained Yoghurt • Runner up – Pesto Princess 100 per cent PlantBased Fresh Soup Range • Second runner up – Woolworths Tonic Water Range
2019 Individual category • Winner – Woolworths Mini Chocolate & Caramel Ice Cream Bars • Runner up – Pioneer Foods Wellingtons Sweet Jalapeno Sauce • Second runner up – Darling Brew – Pixie Dust
Packaging Award • • •
Winner – Ceres Cider Company – Loxtonia Cider Range Runner up – SAB Brutal Fruit Ruby Apple Spritzer Second runner up – Woolworths Raw Cacoa Treats Range
Editor’s Choice Award • Beyers Chocolates – Beyers Craft Range
2019 New Product Competition winner • Winner – Woolworths Mini Chocolate & Caramel Ice Cream Bars • Runner up – Woolworths Double Cream Strained Yoghurt Range • Second runner up- Pesto Princess 100 per cent Plant Based Soup Range
NEW PRODUCT COMPETITION
ABOUT OUR SPONSOR
Symrise is a global supplier of fragrances, flavourings, cosmetic active ingredients, raw materials and functional ingredients as well as sensorial and nutritional solutions. Its clients include manufacturers of food and beverages, perfumes, cosmetics, the pharmaceutical industry and producers of nutritional supplements as well as pet food and baby food. The company comprises three segments: Flavour, Nutrition and Scent & Care. www.symrise.com
Guest speaker Pierre du Plessis
Natalie da Silva, Mishkah Samie of Woolworths and Maryke Foulds
Having a good time
The winning Woolworths team with Rudi McLean of Symrise and the Food Review ladies
Our awesome cocktail specialists
Rudi McLean of Symrise with Emis Christopolous
PURE INDULGENCE AT YOUR FINGERTIPS
‘It was the first time the Frozen Department at Woolworths entered a new product competition, but it certainly won’t be the last. We value this award tremendously. A key focus for our team is the ability to lock in flavour and freshness. This product speaks volumes about flavour and quality and serves as a stepping stone for what is to come. As a concept, it is a first to market in South Africa. While similar concepts are available abroad, none are available in the same format. Our product allows portion control for indulgent eating – necessary in today’s world. I believe this award has allowed the industry to look at frozen products differently, not just a two-litre tub of ice cream and bag of mixed vegetables, but instead pure indulgence and convenience at your fingertips. New product development is limitless, exciting and challenging!’ Carol Weideman - Woolworths
Enjoying a spectacular sunset with custom cocktails in hand
FAST FACTS
The competition and subsequent exposure in print and online allow local industry to see the latest trends, innovations and developments in today's food and beverages. The 2019 edition saw a resurgence of products that pushed the luxury factor, plantbased innovations, sugar-reduced ingredients, craft beverages, protein and CBD-derived products. A big thank you to our sponsor Symrise who has supported this competition for 25 years!
October 2019 | Food Review
13
INGREDIENTS
Sustainability is the latest food trend Consumers are food smart, evaluate food production methods and are asking questions about transparency and how their food is sourced.
A
wareness continues to grow around
achieving the United Nations Sustainable
lower carbon footprint in production than most
the huge amount of land, food, energy
Development Goals. In 2012, pulses were
animal sources of protein. One kilogramme
and water required to raise animals
recognised by the United Nations for their role
of legume only emits 0.5kg in CO2 equivalent,
for human consumption. An animal-based diet
in improving the environmental sustainability of
whereas one kilogramme of beef produces 9.5kg
is not enough to meet the protein demands
farming practices.
in CO2 equivalent. People see food as being
of a growing world population - leading
AGT Food and Ingredients is a large supplier
intimately connected with wellness and their
many to seek plant-based alternatives. This
of value-added pulses, staple foods and food
trend reflects an increased focus on health,
ingredients. The company produces a full range
While a whole food plant-based diet
wellness, food safety and diet, coupled
of pulses and speciality crops, including lentils,
will always be the best option, plant-based
to concerns about animal welfare and
peas, chickpeas, beans and canary seeds and
processed foodstuffs are appearing on the
environmental sustainability.
ingredients such as pulse flours, proteins,
shelves. A whole food plant-based diet is one
starches and fibres.
that includes whole, unrefined and unprocessed
One of the best plant-based alternatives is pulses. Nutritional and biological attributes
‘To meet consumers’ nutritional needs with
of pulses play a huge role in reducing poverty,
fewer resources, we must use more pulses,’
hunger and improving the sustainability
explains George Tomazos, AGT Foods Retail and
of agro-ecosystems. All this contributes to
Food Ingredients, South Africa. ‘Pulses have a
broader value system.’
food. It is made up of fruits, vegetables, whole grains, beans, legumes, nuts and seeds. Plant-based eating is becoming accessible and convenient. Demand for lentil pasta, chickpea pasta, pea protein smoothies and veggie burgers are on the rise. Even though processed plant-based food is not necessarily healthy like whole-food, consumers are happy there is no animal cruelty and they are helping to decrease their environmental impact. AGT Foods also produces pulse flours and pea protein for inclusion in the manufacture of a variety of food, such as cereals, bread, protein powders and bars. Pea protein is a non-genetically modified (GMO-free) and a hormone-free alternative to soya in the baking and food manufacturing industries. ‘Sustainability is a positive step in improving our planet and world,’ Tomazos concludes. ‘We must continue educating consumers on the benefits of pulses, which play an important role in food security in the developing world and are a cornerstone
Some consumers feel food production should go back to traditional processing technologies
14
Food Review | October 2019
ingredient in humanitarian food aid.’ •
AGT – www.agt.co.za
INGREDIENTS
“The alternative protein sector is witnessing rapid innovations, from diversified raw materials and novel flavour blends to sophisticated biotechnology that allows for creations that closely mimic meat”
Encouraging a taste for alternatives Demand for meat-free substitutes continues to soar globally and the African continent is set to respond to opportunities and challenges ahead. points and finding cost-effective solutions. At
becomes too difficult or too expensive. A
the same time, catering to country-specific food
good example of this is Meattech T72, recently
demands and creating locally relevant flavours
launched as a partial substitute mechanically
are crucial too - while dealing with further
deboned meat (MDM).
challenges connected to supply chain logistics or quality support services. With almost 150 years’ expertise in natural
T
UNDERSTANDING CONSUMER PREFERENCES
flavours and product development, these are
Mane undertakes regular research to gain
issues that fragrance and flavour house Mane is
local insights relevant for food and beverage
he meat-alternative sector has
familiar. The firm has been conducting business
manufacturers in the region. This year alone, it
rapidly intensified in recent years and
on the African continent for more than 70 years
conducted market studies among both lower
is currently estimated to be worth
and understands the needs of consumers in the
and high-income consumers in South Africa to
US$19.5 billion or 10 per cent market share of
region and specific market requirements. To
gain insights into their protein consumption
the global meat industry. In conjunction with
further its local expertise, the company agreed
habits. It discovered that 18 per cent of well-
consumer clamour for ethical, sustainable
on a joint venture partnership with Deli Spices
to-do South Africans consider themselves
and healthy sources of protein, there is a
in 2017. The company is one of the biggest
flexitarian, and 51 per cent expect to eat more
practical reason behind the trend too: By
seasonings and additive blend suppliers to the
plant-based alternatives in the next five years.
2050, the global food system expects to face
sub-Saharan food industry.
the dietary demands of more than 10 billion
Mane creates targeted formulations using
With over 300 professionals throughout the continent, Mane offers 360-degree support
people and Africa looks set to see the biggest
its expertise in processing different vegetable
including sales and technical assistance.
population growth.
proteins and masking off-notes as a base.
Looking to the future, the company plans to
The alternative protein sector is witnessing
Furthermore, Deli Spices has over 30 years’
open a new research and development centre in
rapid innovations, from diversified raw
experience in meat protein replacement with
Cape Town in March 2020. With 3 500m2 of high-
materials and novel flavour blends to
plant protein, which can be used in either meat
tech labs, pilot plants, a training kitchen and
sophisticated biotechnology that allows
or meat alternative products.
a 40-seater auditorium, the facility will allow
creations to closely mimic meat. Meat
‘Most typical requests from our African
clients to take a product from the idea stage
alternatives have already gone mainstream in
clients relate to support in bringing innovative
to semi-industrial trials, and participate in
many global markets.
new products to market,’ says Robin Haller, CEO
innovation workshops and sensory evaluations.
The African meat alternative sector is on the
of Deli Spices. ‘Local producers are also under
Eric Davodeau, savoury category director at
rise too, as producers throughout the continent
pressure to provide affordable solutions. We
Mane concludes, ‘By combining global expertise
look for plant-based portfolio expansions.
pursue a practical approach by connecting their
and local knowledge, our major aspiration is
There is an interest for new local protein
sales experience with our technological and
to let our African partners benefit from the
sources that are low in cost and environmental
formulation know-how.’
consolidated experience of our food scientists
impact - e.g. sorghum, cowpea or insects. The
The company strives to bring local cuisines
and technologists, as well as our market and
alternative trend has become particularly
and flavour preferences into meat’s new
regulatory experts. Our experts assist the
evident in South Africa, where several
product arena. It has enhanced the recipe
whole product development process to support
mainstream restaurants have introduced
of popular products in the region such as
manufacturers in creating new products and
plant-based menus, and major retailers have
viennas or polony sausages with the flavour
finding the right marketing concepts. We help
launched plant-based ranges.
of Chakalaka, a South African spicy vegetable
our clients get to the forefront of affordable,
relish. Mane also helps clients become
convenience meals.’ •
COST-EFFECTIVE SOLUTIONS
resilient to raw material shortages and price
Local producers are facing several challenges,
fluctuations. The flavour expert develops
most of them relating to meeting low price
replacement ingredients when meat sourcing
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Food Review | October 2019
Mane – www.mane.com
SERVED WITH LOVE VEGETARIAN BOBOTIE
VEGETARIAN/FLEXITARIAN BOBOTIE Yield: ± 2.3 kg (Makes half insert) Vegetarian/Flexitarian Bobotie Mince 200 g (1 packet) Live Well Range™ Curry Base R/P (08229030) 600 mℓ (2½ cups) Water, for soaking 90 mℓ (6 Tbsp) Oil, for frying 500 g (2 large) Onions, chopped 85 g (½ cup) Raisins 125 mℓ (½ cup) Mild Fruit Chutney (07656040) 200 g (2 medium) Carrots, grated 100 g (1 small) Apple, grated Method: 1 In a large bowl soak the Live Well Range™ Curry Base R/P in the allocated water for soaking and set aside. Allow the ready pack to soak for ± 30 minutes. 2 Heat the oil in a large pot and fry the onions until soft and transparent.
3 Add the soaked Live Well Range™ Curry Base R/P and mix in the raisins and Mild Fruit Chutney. 4 Add the grated carrots and apple and stir continuously until the mixture boils. 5 Reduce the heat and simmer for ± 10 - 15 minutes, stirring occasionally, until the sauce has thickened. 6 Spoon into a half insert. 7 Preheat an oven to 180°C. Egg Mixture 300 g (6 large) 375 mℓ (1½ cups)
Eggs Milk
Method: 8 Beat the eggs and milk together and pour over the meat mixture. 9 Bake for ± 10 - 15 minutes or until the egg custard is set before serving.
PEOPLE PASSION INNOVATION
M E AT, FI S H & P O U LT RY
The long relationship between heat and meat Cooking meat over fire was discovered almost one million years ago. Today we are still doing it and refining how we use heat during food preparation. 1
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ndustry partners PHT and Schröter recently hosted two masterclass events on the thermal treatment of
meat in Johannesburg and Cape Town. Thermal treatment means manipulating the temperature of food, either by heating or cooling, and includes processes such as smoking, cooking, roasting, intensive chilling and defrosting.
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“Thermal treatment means manipulating the temperature of food, either by heating or cooling, and includes processes such as smoking, cooking, roasting, intensive chilling and defrosting"
meat-containing products. Knowing how to control heat during these production processes allows tasty, attractive and safe food to be prepared. An industry event like this is a great opportunity for colleagues to learn about new developments and share ideas about working effectively.
HOT AND COLD One of the most popular thermal treatment techniques used in the food processing industry is smoking, specifically for flavouring meat, fish and poultry. Conventional hot smoking involves cooking meat at a low temperature in the presence of smouldering wood chips. This allows the flavour to develop gradually and uniformly. Alternative methods such as cold smoking, steam smoking and liquid smoking are also possible. Each offers a specific taste or processing benefit. Strict safety standards apply when smoking meat. During hot smoking, the air temperature inside the smoker and the internal temperature of the meat must be monitored continually to ensure the food stays out of the so-called danger zone for bacterial growth. After smoking, meat must be cooled and packaged rapidly to keep food out of the danger zone.
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Food Review | October 2019
handle products and have one-on-one interaction with Schröter specialists,’ he notes. ‘Customers can also find out about the latest innovations and trends. It is a great way for them to gain insight
Thermal treatment is especially topical in preparing ready-to-eat meat or
1: Sepp Messmer, founder of PHT; Penny Campbell, director: food control, National Department of Health; Deléne Boshoff, managing director of PHT South Africa. 2: Linda Jackson, director of Food Focus; Willie Lötter, general manager at Eskort 3: Sepp Messmer welcoming delegates at the Gauteng event
MEET THE MASTERS Schröter understands the intricacies of smoking and processing meat. Its business revolves around developing systems that can assist clients to produce quality meat products. In their systems, heat distribution, airflow and climate conditions are controlled precisely. This ensures that products develop optimal flavour and mature uniformly, without compromising final product weight, texture or safety. They also offer intensive chilling and defrosting systems as an addition to their cooking systems. This provides clients with a complete thermal treatment solution. Their approach to thermal treatment systems is based on a solid understanding not only of the physical principles of using heat in food processing, but also of clients’ specific needs. The company can tailor its systems to ensure efficient workflow in whatever configuration is needed. ‘We are committed to quality, performance and innovation,’ says Dietrich Schröter, a fourth-generation executive at the helm of the familyowned company. ‘We strive to offer our clients systems they can rely on. At an event like this masterclass, customers can get to absorb knowledge,
into what the future holds.’
HYGIENE MATTERS Heat can be a help and a hindrance in a food processing system. If not handled correctly, thermal treatment can cause temperature fluctuations that may create conditions that promote bacterial growth. Some harmful microorganisms can also withstand high temperatures. Food processing systems should minimise microbial action at each production step. PHT understands the hygiene challenges in food processing and is passionate about helping its clients install and maintain tailored hygiene systems. ‘Food hygiene is about more than compliance; it’s about creating a culture of preparing safe food,’ says Deléne Boshoff, managing director of PHT South Africa. Co-hosting this masterclass was an opportunity to heighten awareness around safe food processing practices and to share solutions to challenges in the meat processing industry. With their shared commitment to high-quality food processing, it is clear why Schröter and PHT are respected as industry leaders. •
PHT - www.pht.co.za and www.pht.group Schröter – www.schroeter-technologie.de
M E AT, FI S H & P O U LT RY
Give your burger that juicy edge A new fibre blend, launched by CFF GmbH & Co, has been developed for use in meat applications, especially hamburger patties.
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he fibre, Sanacel add 026, has a
structure of the patty and its bite. Soluble
slightly beige colour and offers high
and insoluble fibres have the properties to
water and oil binding capabilities.
physically bind water and oil - resulting in a
The ingredient is economical, nutritional, efficient and features reduced shrinkage and an improved sensory impact. These dietary fibres are clean label, highly
juicy and tasty burger. A target for meat processors is the production of a round-shaped burger patty with a homogenous look. During the frying
raw materials. All products are eco-friendly
functional and offer a good nutritional
process, meat loses moisture and yield.
and supplied locally through Savannah
profile. Apart from the nutritional benefits, it
This results in shrinkage and the patty can
Fine Chemicals. •
also handles easily. Processing the meat-fibre
become dry. By adding Sanacel add 026,
mix is easy: Simply add fibres with additional
the moisture performance is improved
water to the meat and other ingredients. The
and shrinkage reduced. It also adjusts the
handling process is improved as fibres start
juiciness and texture of the meat. Longer
absorbing free water from the meat. This
fibres will support an excellent sensory
results in less stickiness on the metal walls
mouth feeling.
of the forming machines, meat mincers and Pattys.pdf 1 19.09.2019 14:26:09 cutting Burger machines.
For sensory and technological evaluation, the dietary fibre network will support the
ABOUT THE AUTHOR DANIEL WEILE is a product manager food international at CFF GmbH & Co. KG.
The range of functional and nutritional solutions include the following: Topcel, Technocel, Diacel, Sanacel, Sensocel and Qualicel from natural and biodegradable
Savannah Fine Chemicals – www.savannah.co.za
Passionate about fibres
SANACEL® add 026 C
Clean Label
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www.savannah.co.za
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Next-Level burger patties with functional dietary fibres improved moisture performance and shrinkage better bite and burger texture easy handling and processing
CFF GmbH & Co. KG Arnstaedter Str. 2, 98964 Ilmenau
SANACEL.cff.de cff@cff.de
October 2019 | Food Review
19
M E AT, FI S H & P O U LT RY
The perfect strategy for safe meat processing Food safe critical control points can make or break your product. In a process line, these points are found from raw material and ingredient handling to processing and slicing before packaging. HPP is a non-thermal and post-packaging technology that guarantees food safety and avoids any kind of recontamination.
I
mplementing critical control points along the production process is critical to guarantee food safety. The three most important points in any food processing line are: • raw material handling • pathogen inactivation • all stages between inactivation and packaging. Raw materials must be stored in appropriate conditions with regards to temperature, humidity and light control. These must be coupled to the highest level of facility, equipment and food handling hygiene. When all these parameters are aligned, pathogen control is assured - although it is difficult to guarantee 100 per cent efficacy as human and environmental factors cannot be controlled.
20
Food Review | October 2019
BMG-LMH30092019 - Food Review Monday, 30 September 2019 3:22:23 PM
Thermal processing can minimise and even eliminate microorganisms and pathogens. Despite the benefits of pathogens inactivation, it is often not applied as colour, flavour and texture changes can occur during processing. It is not always effective and it cannot be applied when processing raw products. To avoid recontamination in the prepackaging stage, hygienic measures and microbial load control processes (active packaging, refrigeration, etc.) must be applied. If hygienic measures fail, microbial controls are usually not efficient for products with a long shelf life. High-pressure processing (HPP) is a nonthermal technology, gaining popularity as an alternative to these measures and disadvantages. The technology can be
During HPP processing packaged food is subject to pressure of between 400 and 600MPa
M E AT, FI S H & P O U LT RY
applied in a wide variety of food products including beverages, meat, baby food, pet food, seafood and dairy. Its application guarantees safe and natural products with a long shelf life.
isostatic process: Pressure
DID YOU KNOW?
is transmitted uniformly
Although HPP modifies the colour and texture of raw meat product as indicated in the report HPP: Putting a New Squeeze on Meat, its use in fresh meats is ideal for minced products when commercialised in the Horeca channel’
HOW IT WORKS During the conventional HPP process, packaged food is subjected to pressures between 400 and 600MPa. This incapacitates pathogens and food altering microorganisms, while preserving the quality and organoleptic properties of the fresh product. It is an
along the whole product, regardless of its shape or size. It has been widely demonstrated
the shelf life of food during refrigeration storage (Bajovic et al., 2012). The possibility of processing products that cannot be subjected to thermal treatments such as fresh or cured meats, makes HPP the best solution to guarantee food safety and to extend shelf life. It is very effective when
that high pressure,
used for products such as hams, mortadella,
without any heat
bacon, salami, sausages or ready-to-eat
application, is effective to inactivate the most important microorganisms responsible for foodborne illnesses (Simonin et al.,
meals. In 2002 Hugs et al. demonstrated the shelf life of cooked ham, cured ham and marinated meat processed by high pressures could increase by up to 120 days. •
2012). The process is also known as cold pasteurisation. As it is a post-packaging technology and avoids any possible recontamination. This contributes to prolonging
Hiperbaric – http://blog.hiperbaric.com/en/hpp-putting-anew-squeeze-on-meat
HPP mitigates pathogen growth
October 2019 | Food Review
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M E AT, FI S H & P O U LT RY
Consistency is critical for efficiency A large 14-head multihead weigher with seven litre hoppers from Ishida’s advanced RV series is providing high levels of speed, accuracy and reliability. The equipment forms part of a major investment at one of the Netherlands’ top fish processors.
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stablished for over 30 years,
continuously to ensure high-quality
process is fed back down the line. This
NorthSeafood is a leading supplier
products are preserved throughout.
enables the speed and temperature of
As part of this, the reliability and
the freezing process to be adjusted to
of deep-frozen fish to the retail
and foodservice sectors. The company
consistency of Ishida weighers are
ensure a smooth flow of product, with no
installed a second packing line at its
essential. The weighers are handling
unwanted build-up.
factory in Urk and upgraded the existing
breaded fish products packed into
line for the fast and efficient handling
cartons at target weights between 160g
installed incorporates a unique newly-
of breaded fish products. Both lines
and 300g. After weighing, each portion of
developed software feature. This system
feature Ishida weighers as part of the new
fish is discharged into a holding hopper
helps to deliver even greater weighing
investment. The supplier project managed
and then placed directly into the tray.
efficiency. For most multihead weighers,
The latest Ishida weigher to be
if a single weigh head contains too much
the installation of the RV weigher in conjunction with the gantry, feed and filling systems. These were supplied by its partner MACS Machinebouw. The availability of the second line has given NorthSeafood additional flexibility. It enables the company to react quickly to new customer requirements and
product, it must be rejected. By rejecting
“Typical speed for a 300g carton is 40 packs per minute, enabling the weigher to handle around 720kg of product each hour”
the overweight product, the weigher cannot deliver a good weight during the rejection stage. Ishida’s new No-Miss-Cycle software means a successful weight combination can be achieved on the seven heads on the different side of the weigher from the
the development and introduction of
overweight head. The successful weight
new products or pack formats while maintaining throughput of existing products. Both lines must operate
can be discharged while simultaneously
A typical speed for a 300g carton is 40 packs per minute, enabling the
emptying the overweight head through
weigher to handle around 720kg of
a separate discharge chute and outlet.
product each hour.
This clever system prevents the weigher
Weighing accuracy
from losing a cycle and enables maximum
for this challenging
speed and throughput to be maintained. A further software benefit is the ability
product is within two to
to monitor the time the product has
three per cent and
stayed in a hopper and reject it after
information on
a specified period if it has not been
the overall speed
selected. This avoids the potential
of the packing
for a frozen product to thaw while in the weigher. To maintain a consistent temperature
1: 14 head multihead weigher with sevenlitre hoppers 2: Typical speed for a 300g carton is 40 packs per minute
1
during the weighing process, both weighers are fully enclosed. Their robust waterproof construction also delivers maximum hygiene and ease of cleaning. NorthSeafood is a long-established customer of Ishida Europe with its first multihead weigher, supplied in 2004 still in operation. ‘Our Ishida weighers deliver consistently excellent performance,’
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confirms Juriaan Romkes, the company’s technical service engineer. ‘They are fast and accurate and easy to set up and operate. NorthSeafood prides itself on the quality of all its products and ensures a fast and efficient packing operation is a vital part of this.’ •
Ishida – www.ishida.com
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Food Review | October 2019
Retail ready. Smarter, faster, together.
Every business has challenges; ours is to help you overcome yours. Whether you need a single machine or a complete production line, we can provide you with a solution tailored to meet your exact needs. Our industry-leading technology can support meat, poultry, fish and seafood applications, including fresh, sticky, coated and marinated products. Our expert know-how covers every stage of the production process, from weighing, grading and tray sealing to x-ray inspection and packing automation.
Smarter Faster Together
To set the wheels in motion visit ishidaeurope.com
M E AT, FI S H & P O U LT RY
Keeping it fresh, sealed and in the bag A large portion of Buckle Packaging’s business lies within the meat, poultry and fish sector. The team was approached by Theron’s Meat Products and Eagle Valley Poultry to find a solution to seal a range of meat products and individually quick frozen chicken pieces.
P
hilip Smit, operations manager
Theron’s decision to go with this unit, part
operation from parent breeders to supply
at Theron’s Meat Products says
of the Fischbein range of equipment, was due
fresh and frozen poultry to the retail,
the company prides itself on its
to several reasons. The machine features a
wholesale and foodservice markets.
commitment to good food and hygienic
durable, hygienic, stainless steel housing -
manufacturing practices. ‘We are known for our
ideal for use in the food industry. The sealer
double shift and supply 70 per cent of total
wide variety of sausages. We were challenged
produces neat, attractive bag closures, which
production to major retailers. The company
to bag our sausages into plastic bags, securely,
are strong enough to resist breakage or
wants to increase its penetration into the
quickly and hygienically,’ he explains.
spillage during handling and transport. With
fresh retail market segment.
They produce 60 000 birds per day on a
Earlier this year, Theron’s Meat Products
increased efficiency, the SH1000 guarantees
The new generation heat sealer has
purchased a Saxon SH1000 hot air bag sealer
improved productivity. Maintenance is also
been designed with proportional integral
from Buckle Packaging. The team delivered
greatly simplified.
derivative (PID) temperature control
and commissioned the machine three days
Poultry processing abattoir, Eagles Valley
technology. This makes it a highly accurate
after the order was placed and were on site to
Poultry situated in Hartebeespoort has a
sealer with an efficient heat transfer system.
give professional training to the operators and
total of four Saxon hot air SH1000 sealers on
Other innovations include a direct-drive
maintenance personnel. With the purchase
its IQF line.
system and improved airflow design. The
of this Saxon hot air SH1000 bag sealer, the
Daniel Voges, maintenance manager at
supplier offers post-purchase servicing of the
Eagles Valley Poultry explains the company
machines and all the necessary consumables.
offers a comprehensive ‘farm to fork’
result is a sealer that is faster and can accommodate thicker bags. ‘Should your product come in different bags sizes, a format change is easily managed through the machine’s user-friendly controls. These include a variable speed direct drive system. Pedestal height is easily adjusted to accommodate different sealing heights of various bag sizes,’ Voges points out. The latest model SH1000 sealer sports a new touch button control display making it user-friendly and hygienic. Buckle Packaging’s Saxon hot air SH1000 sealer is an ideal solution for closing IQF bags and meat products. •
The Saxon SH1000 heat sealer at Theron's Meat Products, left and Eagles Valley Poultry, right
BUCKLE PACKAGING (PTY) LTD Bag Closing Technology
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Food Review | October 2019
Buckle Packaging – www.bucklepackaging.co.za
F O O D S A FE T Y T R A I N I N G
Create a culture of food safety When we conduct training, are we actually training employees and equipping them with the tools to carry out their jobs in relation to food safety? Or are we merely conducting training for compliance with standard requirements, asks Anisha Ramnarayan.
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raining programmes should be
resources to maintain compliance with a
designed to change behaviours
food safety management system.
- food safety can be improved
that employees will comply with rules.
TIPS FOR DESIGNING TRAINING MATERIAL
You must determine what the employee
• Keep it simple and user-friendly
understands and what confidence they
• Make it short and to the point
have in the training they receive.
• Emphasise topics and behaviours that
through regular training. It is not a given
Employees are more likely to implement safe food behaviour and in the process influence others when they understand and have confidence in training provided. It should not, as so often happens, only
are of greater risk or more frequently associated with foodborne disease • Use pictures, icons, drawings – visualisation accelerates learning and facilitates the communication process • Use mistakes as teachable moments
focus on the negative, but also on the
• Pay attention to the causes of mistakes
importance of the training itself and the
• Do not ignore or hide mistakes, but
danger of non-compliance.
learn from them.
Training must be done at all levels of an organisation. Senior management must not be excluded. If senior
Adequately trained food handlers can
management is excluded, this tier will
improve food safety and reduce risks and
lack the fundamental understanding
behaviours commonly associated with
of food safety risks and the Testing need -for foodborne illness and outbreaks. • SA Food Review - NOSA 7 October.pdf 1 2019/08/22 13:50:57
ABOUT THE AUTHOR ANISHA RAMNARAYAN is a food safety & quality consultant and FSQ Excellence.
FSQ Excellence www.fsqexcellence.com
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NOSA Tes�ng for CO2 analysis and tes�ng now accredited When it comes to beverages, carbon dioxide (CO2) provides effervescence, a level of acidity and some protec�on against microbiological growth without the beverage looking, smelling or tas�ng strange, and without any undesirable levels of trace impuri�es. The food industry also employs carbon dioxide for food processing applica�ons, such as chilling and freezing, modified atmosphere packaging and temperature control for products being stored and transported. Did you know? NOSA Tes�ng’s methodologies and facili�es for CO2 tes�ng are now accredited by SANAS, under ISO 17025, and are equipped to provide chemical tes�ng for all CO2 methods. This means that gas suppliers (and similarly, carbon dioxide users), who must iden�fy, measure and control the levels of trace impuri�es in purified CO2 can take the appropriate steps needed to ensure they con�nue to match both industry and legal standards with NOSA Tes�ng’s full scope of services. NOSA Tes�ng is equipped to provide chemical tes�ng for all CO2 methods. Should you require any addi�onal informa�on on our capabili�es rela�ng to comprehensive CO2 analysis, please feel free to contact Keshav Beachen (NOSA Tes�ng Na�onal Sales Manager): keshav.beachen@nosa.co.za or +27 (0)76 114 9420 NOSA Tes�ng is a Level 2 BEE contributor
October 2019 | Food Review
25
F O O D S A FE T Y T R A I N I N G
Neglect pesticide analysis at your peril
Pesticide testing with tomatoes
The chemical diversity of pesticides used within agriculture presents a considerable challenge to food safety. Chemists employ a wide range of analytical techniques to extract pesticides from food samples. These samples must accurately and efficiently determine the identity and concentration at the trace level.
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odern agriculture uses over 1 000
The chemical may degrade because of the
SRMs are used for the quantitative
pesticides in various combinations
molecular make-up of the insecticide and
determination of a single pesticide. It also
and at different stages of
because of factors such as sunlight, moisture
looks at the toxicologically conversion
cultivation. They are also used during post-
and temperature. It could also dissipate by
of products, e.g. through metabolism or
harvest storage to protect crops against a
growth dilution (e.g. as the fruit becomes
degradation in foodstuffs where tolerance
range of pests, fungi and to provide quality
larger, the residue concentration will decrease
levels have been established.
preservation. Pesticide residue often finds its
even without physical or chemical dissipation).
way to cereal samples, posing a serious risk to
In farm animals and some plants, metabolism
quantifying more than one pesticide in more
human health.
and excretion are the primary mechanisms.
than one food. These methods are commonly
These residues originate when a crop or
The degradation products make up most
MRMs are capable of detecting and
used for surveillance and monitoring, to
animal bred for food purposes is treated with
of the remaining residue. In a few cases,
determine which pesticides (and how much
a chemical, is unintentionally exposed by
chemical residue concentrations may actually
of these) are present in a given food sample.
drift, in irrigation water, feed or through other
increase over time, after exposure has
Some MRMs are rapid while others are more
routes. The size of the residue depends on:
stopped. This could result from weight loss
comprehensive and therefore more time-
• exposure level (i.e. the treatment rate)
by the commodity, e.g. loss resulting from the
consuming. In general, MRMs may be used for
• dissipation rate
conversion of grapes to raisins after treatment
screening and quantitation.
• environmental factors
with a relatively stable, non-volatile chemical.
• physical and chemical properties. Insecticide sprayed on apples will ‘volatilise’
Determining these pesticide residues is
The wide use of pesticides to maximise agricultural yield should not blind us to
tricky. The size of the object is small and
their full effects on human health and
into the atmosphere. This is influenced by the
extraneous substances extracted along with
the environment. As consumers become
insecticide's volatility or vapour pressure and
the pesticide residues can interfere with the
progressively aware of what is in their food,
temperature wind movement in the orchard
results of the analysis.
the importance of pesticide analysis is only
where spraying is taking place. Removal by
There are two general types of analytical
rainfall or overhead irrigation will depend
methods for determining residues in foods:
on the insecticide's water solubility and the
single residue methods (SRMs) and multi-
amount of rain or irrigation water.
residue methods (MRMs).
further amplified. •
NOSA – www.nosa.co.za
SPECIALIZING IN THE TRAINING, FACILITATION AND ASSESSMENT OF FOOD SAFETY MANAGEMENT SYSTEMS With more than 15 years of hands-on experience, I focus on providing know-how and detailed understanding of the food safety aspects of your business.
Committed to you
My training programmes are detailed and will give you comprehensive exposure to the concepts of food safety to equip you to implement the required standards and methodologies needed to ensure safe food handling or production. The food safety management systems I develop are practical and easy to follow but detailed enough to ensure your food safety risks are identified and controlled. My assessments are risk-based because, for me, assessment of your business risk is much more than providing you with a checklist. Food safety management is a complex concept, but my practical interventions surely lighten the burden when needed most.
www.haccpforfoodsafety.co.za
26
Food Review | October 2019
Committed to the consumer +27 (0)83 415 0758
HACCP@POLKA.CO.ZA
M AT E R I A L S H A N D L I N G & WA R E H O U S I N G
A complete product cycle for bearings Bearings International (BI) continues to secure distributorships with international brands to boost its product portfolio. The latest brand to be added is the Masta Group of India.
B
ased in Gujarat, the company boasts
First to be introduced will be the standard
Masta bearing housings offer exceptional quality at a highly competitive price
extensive BI branch network. It will be
in-house production facilities,
SN-type housings with standard felt strip
backed-up fully by the BI team, with the
complete with its own foundry and
seal. ‘We will stock the SNL and SNH range,
added support of a dedicated product
and the SD range of housings. These are
manager to assist clients in product
very common in the local market,’ Trevelyan
selection and correct use. A design and
backed by highly trained and experienced
explains. Industries and applications range
drawing service will also be offered, as well
personnel. Products are manufactured using
from materials handling to mining, steel,
as product training.
advanced materials testing and inspection
power generation, industrial fans, cement,
techniques. Customer-specific designs can
pulp and paper, sugar and others.
machine shop. Masta Group offers robust quality,
be accommodated, thereby offering a full inhouse bearing housing service.
Looking at future opportunities for the brand locally, Trevelyan reveals that other
‘We concluded the latest distributorship
new products will be added at a later stage.
to offer our customers an alternative choice
‘For now, we will focus on the bearing housing
BI business unit head Ross Trevelyan
of bearing housing of exceptional quality at a
offering, and grow this in response to
reveals that BI plans to bring the full range
highly competitive price,’ Trevelyan highlights.
market demand.’ Customers will be advised
of bearing housings to the South African
A major feature of these bearing housings is
as soon as initial stocks arrive, in conjunction
market. ‘We signed the distribution deal
that they are dimensionally interchangeable
with a concerted marketing and social
with Masta in July. We anticipate our first
with other well-known brands.
media campaign. •
stock to arrive in the latter part of 2019, and into 2020.’
The Masta product range will be made
Bearings International – www.bearings.co.za
available countrywide throughout the
Maintaining freshness with MAPAX® and FoodFresh™ The way foodstuff is packaged is critical when it comes to prolonging shelflife and food safety for consumers. To prevent loss of natural freshness and quality of packaged products, Modified Atmosphere Packaging (MAP) was developed by employing the properties of specific gases or gas mixtures to slow down those decay mechanisms that have the dominant effect on packaged food products. MAP offers food manufacturers a way to extend shelf-life without altering the physical or chemical properties of foodstuffs or adding any unusual ingredients. Developed by Linde Gas and available from Afrox, MAPAX® solutions are application-specific packaging solutions to extend shelf-life, the natural way. MAPAX® solutions are customised for the following industries: dairy; dry foods and bakery; fish and seafood; fruit and vegetables; meat; and prepare and catered foods. Customer Service Centre: 0860 020202
Afrox MAP Advertorial 177x130.indd 1
Shop online: www.afroxshop.co.za
Afrox has also created a MAP gas range called FoodFresh™ to meet the special quality requirements of the food industry, and to assist customers in complying with strict food standards legislation in packaging, storage and distribution. The FoodFresh™ range of gases and gas mixtures cover all current MAP processes. With over 80 outlets across the country and a comprehensive nationwide delivery service, Afrox has the supply option to best suit your needs. For more information about MAPAX® solutions and the FoodFresh™ range of gases and gas mixtures, contact the Afrox Customer Service Centre on 0860 020202 or visit www.afrox.com. Africa’s leading gases and welding solutions partner
www.afrox.co.za
2019/05/09 12:04
October 2019 | Food Review
27
M AT E R I A L S H A N D L I N G & WA R E H O U S I N G
An illustration of a conveyor belt with drum motor
A drum roll for drum motors Belt conveyors are traditionally driven by gear motors, including those used in the food industry. Motor rollers, also referred to as drum motors, are growing in popularity as a modern alternative.
I
n this article, a research team at the
“Drum motors scored better than gear motors in all three application scenarios. This is due to its encapsulation, which does not provide microbes with a surface they can attack”
department of food and drugs at the
two technologies during meat production.
requirements, demonstrated by a series of
The research was supported by Interroll.
binding standards and regulations. Heat generated by these systems was
during food processing. Conveyor belts
also measured and must be considered
powered by electric motors are normally
when assessing the suitability of a system
used. These are usually attached beside or
that encounters perishable foodstuffs,
underneath a conveyor line and connected
such as meat. These products cannot be
to one or more belt conveyor rollers via a
processed or stored at high temperatures.
power transmission system (belt or chain).
Energy consumption is closely related to
When compact drum motors are used, redundant. A compact electric motor is
these factors and is a key contributing factor to operating costs. The study also examined installation,
integrated into the rollers, which produces
cleaning and maintenance work. Depending
the necessary torque. These systems offer
on the application, space and noise
certain advantages when installed. Motors
emissions were examined. Considering
driving the belt conveyors do not need to
occupational safety provisions and the
be attached externally, but are directly
productivity of employees, noise emissions
integrated into the conveyor framework.
must not exceed certain levels.
COMPLIANCE WITH HYGIENE REQUIREMENTS
HYGIENIC CLEANING OF THE CONVEYOR SYSTEM
In the run-up investigation, scientists
The study identified three possible cases
analysed the types of applications conveyor
within food industry applications where
technology used. A specific feature of
drive solution concepts are used.
food processing is stringent hygiene
• Conveyor lines located in the non-food
28
Food Review | October 2019
found in areas where packaged goods are transported. • The second application is the food area and describes a situation where around them. Here the conveyor
the advantages and disadvantages of the
this complex transfer mechanism becomes
hygiene. These processing zones can be
foodstuffs encounter the environment
University of Parma in Italy, compared
Hygiene requirements play a critical role
area are largely non-critical in terms of
system must be cleaned manually and without water. • The third scenario encompasses washdown areas where perishable foodstuffs meet the environment around them. This makes it necessary to clean the conveyor system frequently with water and cleaning agents e.g. high pressure, foam or gel.
COMPARING MOTOR AND MANUFACTURING TYPES Gear motors and drum motors from different manufacturers were used during the study. A motor type can influence the result of the comparative study in an application. Wherever possible, the writers tried to work out whether certain differences can be traced back to the specific design of the selected component or fundamental design features. They point out that equipment, which is old or unsuitable, is often used in practical applications. The advantages of converting to a different system may be
Smart, economical, flexible The Interroll Modular Conveyor Platform The new conveyor modules from Interroll transport and sort at the highest flexibility and efficiency. They offer maximum availability and adapt extremely quickly to new demands • Flexible configuration
• Easy maintenance from the top
• High throughput
• Fast delivery for Standard Modules as well as local planning support by experienced application engineers
• Quick and simple installation • Extremely quiet operation • Energy-efficient drive solutions
Interroll S.A. (Pty) Ltd 37 Director Road · Spartan EXT 2 · Aeroport · South Africa Phone: +27 11 281 99 00 · E-Mail: za.sales@interroll.com interroll.co.za
M AT E R I A L S H A N D L I N G & WA R E H O U S I N G
Maintenance of a frozen conveyor system during the washdown phase
greater than the differences ascertained
Delicate salmon slices during conveying
For these two assessments, gear motors
by this study.
and drum motors are more or less equal in
DRUM MOTORS IN HYGIENICALLY SENSITIVE AREAS
comes to complying with hygiene requirements.
washdown zones. The results of the study are clear when it
These differences, as concluded by the
Drum motors scored better than gear
study, clearly support the use of drum
motors in all three application scenarios.
motors in most cases. These units
This is due to their encapsulation, which
scored highly in the comparative criteria
does not provide microbes with a surface
for space requirements, installation
they can attack.
and maintenance. In terms of noise emissions, advantages
Units are easy to clean with highpressure jets. In sub-criteria, including
are found in favour of gear motors in the
the danger of contamination, cleaning
food and washdown areas. In the food
options and accessibility of microbe
area, they performed better in terms of
contamination, drum motors present the
heat generation and energy consumption.
clearest advantages. •
Air compressors that are TÜV-certified as "oil-free" (ISO 8573-7 CLASS 0)
30
Food Review | October 2019
A CONVINCING CASE FOR DRUM MOTORS
The study indicates there are good reasons why drum motors are becoming popular in the food industry. Benefits include the following: • Compact design and inexpensive operating costs • Reduced cleaning effort required • Hygienic in food processing and wash down areas.
Interroll – www.interroll.co.za
DISCOVER THE WORLD
OF NATURAL COLORS with plant based coloring solutions
Sensient Technologies South Africa Ltd. Email: sfc-zaf@sensient.com Tel: +27 11 053 5200 Discover colorful insights at www.sensientfoodcolors.com
FL AVO U R E D A L C O H O L I C D R I N K S
Regenerative beer stabilisation for smaller breweries
With its movable base, the Innopro Ecostab S can be flexibly integrated into the production process. The stabilising system is characterised by low media consumption and cost of investment.
E
ven if the best before date on beer
They can harm buying behaviour.
bottles suggests otherwise, beer does
For this reason, a beer that has been
not spoil. ‘It simply changes,’ says Gerold
transported a long distance or stored for
Tandler, head of product management process technology at KHS. ‘After a while, haze substances and small lumps form, which are often thought to be yeast. These are in fact compounds of protein and polyphenols. They form large agglomerates that precipitate in the bottle and then become visible.’
a long period must be stabilised.
LOW MEDIA CONSUMPTION AND RELIABLE PRODUCTION
the suitable solution for companies
KHS' Innopro Ecostab product line
with yearly outputs of more than
offers regenerative stabilisation using polyvinylpolypyrrolidone (PVPP) for this purpose. This process removes some of the haze-forming polyphenols from the beer.
50 000 hectolitres.
EASY TO USE, LESS EXPENSIVE TO BUY KHS technology is highly relevant even for many smaller brewers with yearly
“...beer that has been transported a long distance or stored for a long period must be stabilised”
outputs from 10 000 to 70 000 hectolitres or breweries that only want to stabilise a small part of their production. With the Innopro Ecostab S, KHS offers its customers its tried-and-tested solution in a smaller size that is easy to use and carries a small price tag. Thanks
First, a frequency-controlled pump doses PVPP into the product line. Beer is then stabilised in a small module where the PVPP is retained by bound tannin molecules. ‘Since the PVPP doesn't remain in the beer, the result is low mixing phases, low media consumption and reliable production,’ Tandler explains. The PVPP in the modules is then regenerated and returned to the dosage tank where it is ready for the next stabilisation cycle. Regeneration improves the use of raw materials significantly. The technology was intended for large and medium-sized breweries. Developed for continuous stabilisation, the Innopro Ecostab C with an output of 150 to 600 hectolitres per hour is ideal for companies with an output of more than Regenerative beer stabilisation is possible for smaller breweries with yearly outputs of up to 70 000 hectolitres
32
Food Review | October 2019
400 000 hectolitres per year. The Innopro Ecostab B stabilises between 50 and 240 hectolitres per hour in batches and is
to its compact design and its movable base, the Innopro Ecostab S is mobile and can be flexibly integrated as required into the production process. Brewers can decide which share of their beer to stabilise - and which not to stabilise. Milk pipe fittings are used to connect the machine. ‘Everything required for stabilisation under constant conditions is in the system itself,’ emphasises Tandler. No additional equipment is required and the simple and fully manual operation eliminates the need for any integrated software. The Innopro Ecostab S additionally features low media consumption and low cost of investment, which usually means a return on investment in less than two years. •
KHS - www.khs.com
B E V E R AG E S
ADM hits all the right trends Demand for products containing little or no added sugar continues to grow. At the Anuga trade fair in Cologne held in October, visitors could get acquainted with the latest market-ready product concepts from Archer Daniels Midland Company.
F
or many consumers, the relatively
fruit juice with no added sugar
for all beverage concepts whose calorie
high natural sugar content in juices
or sweeteners.
content is reduced by up to 30 per cent.
contradicts a health-conscious
Fruit content and the associated
Reducing sugar content even further
diet. ADM’s experts have created new
calorie amount can be adjusted according
used to lead to a less pronounced taste
blends containing juices with fewer
to the desired positioning and market
profile and meant that sweetness was
carbohydrates, such as coconut water.
requirements. This allows a limitless
only briefly noticeable. Another problem,
array of flavour variations. “Just 19” is a
especially with low-calorie variants,
sugar, tastes lighter and less sweet overall
new range created by ADM that carries
was the off-taste frequently associated
- while still being full-bodied and fruity.
the low-calorie content in its name.
with high-intensity sweeteners. With
The resulting product contains less
This meets the wishes of many consumers,
the SweetUp 4D System, ADM product
SUGAR REDUCTION IN 4D: INDULGENCE WITHOUT THE COMPROMISE
developers have balanced out the change
groups that have gotten accustomed to
In the past, removing a certain amount
of sweeteners, potentially with sugar,
less-sweet products and people who tend
of sugar from a beverage recipe led
provides the desired sweetness.
to prefer less-sweet products. Beverage
to a compromise on mouthfeel and
manufacturers can expand their juice
taste profile.
who enjoy the benefits of juice, but would like to consume less sugar. Included in this demographic are target
portfolio with an interesting, modern
This is no longer a given. ADM experts
in mouthfeel with Fibersol, a maltodextrin. An application-specific combination
Finally, ADM’s flavour expertise ensures a harmonious overall concept with an improved taste for beverages
product range while simultaneously
have combined components from the
whose sugar content is reduced by 50 per
offering customers new flavour variations.
ADM sweetener portfolio to produce a
cent or more. •
Current consumer habits of conscious
flavourful, harmonic and well- rounded
nutrition also present an opportunity for
result despite the reduced sugar content.
products consisting of only water and
The ADM Body-Add-Back System is suitable
ADM – www.adm.com
Tel 011 608 4944 Fax 011 608 4948 Email sales@sensetek.biz
FLAVOUR DIRECTLY FROM THE SOURCE Sensetek.indd 1
2017/02/14 12:01 PM
October 2019 | Food Review
33
B E V E R AG E S
Secure line performance and label quality Levissima had to address the growing demand for bottled water in Italy with a new complete line, producing its redesigned 1.5l bottle.
S
idel assisted the company to improve
With the patented vertical melter and
energy savings. The latter is achieved by
the quality of its label application
the laser engraved glue roller, glue is
the individual cap-elevating system that
while increasing output capacity. This
melted on demand and circulated at a
eliminates the need for compressed air during
is an achievement that took advantage of the
precise temperature. This reduces glue
cap extraction for better quality caps and
new EvoDeco Roll-Fed, the latest addition to
consumption for better overall quality and
reduced environmental footprint. OptiFeed
Sidel’s labelling portfolio.
improved sustainability.
also features an integrated inspection
Levissima’s redesigned 1.5 l bottle features
system, ensuring 100 per cent caps quality.
square shape. Output now exceeds 46 000
COMBINING FOOD SAFETY WITH HIGH PERFORMANCE
Tool (EIT) is a part of the solutions supplied
bottles per hour (bph). ‘We were familiar with
Levissima wanted to significantly increase
by Sidel. Automatically recording 24/7 raw
the equipment’s high quality and hygienic
performance and production capacity, with
production data, EIT calculates a wide array
standards,’ explains Franco Simoncini, plant
no compromises on food safety. Integrating
of KPIs to help measure performance, analyse
manager at Levissima.
blow moulding, filling and capping processes
production issues, detect efficiency loss
into a single system, the Sidel Matrix Combi
sources and perform root cause analyses. It
connected to the new bottle and label,
reduces operating costs and uses up to
is designed to ultimately decrease unplanned
Sidel installed a labeller with two stations,
30 per cent less floor space compared with
downtime, reduce waste and costs and
running on every other bottle, handling
traditional standalone equipment. Using
increase output. By giving employees at all
lightweight containers and ultra-thin labels.
fewer component machines, the solution
levels of the organisation real-time access
The ergonomics of the entire solution
offers up to four per cent higher efficiency
to relevant and actionable information on
have been optimised for performance and
levels than standalone machines, on top of
production-related issues, it makes sure that
efficiency, with all main components fully
lower energy consumption and faster format
the quality of the water, as well as the line
visible and accessible during production.
changeovers. This results in a reduction of
capacity, stays at the desired level. •
With no need to disengage the station, this
operating costs by up to 12 per cent, saving
open design is particularly beneficial during
labour, raw materials and spare parts.
a shorter neck but is still in the brand's iconic
To tackle Levissima’s specific challenges
changeover and maintenance. The label
with a Sidel SF100 no contact filler,
ensures a very stable and accurate process
ensuring optimum uptime and the highest
at high speeds. This addresses the two most
productivity. The reduced filler enclosure
important points for the water producer:
allows for utmost hygiene while minimising
excellent quality and high reliability.
the use of water and chemicals during the
performed automatically during production
Sidel – www.sidel.com
The Combi at the site is equipped
application on the new squared bottles
The cleaning of the EvoDeco Roll-Fed is
The highly flexible Efficiency Improvement
2
external cleaning process. This is how the solution achieves full food safety.
by a system installed on the vacuum drum, changeover and maintenance operations.
CONTRIBUTING TO ENERGY SAVINGS AND OPTIMISED UPTIME
This system removes any glue residual for
The Sidel Matrix Combi at also features
overall higher performance. The labeller also
OptiFeed - a cap feeder that is based on a
comes with an automatic label extraction
patented waterfall technology, combining
with built-in light-weight sectors for easy
system. This is protected by a Sidel patent, ensuring that no downtime occurs due to a missing bottle or labels not being properly applied on the bottles.
elevation, orientation and high-speed feeding with
3
1
1, 2 and 3 The EvoDeco Roll-Fed unit at Levissima in Italy
34
Food Review | October 2019
I N D U S T RY TA L K
Decoding the BRC Global Standard As food manufacturers come under pressure to do their bit for the environment, food safety should not be sacrificed. Darcy Simonis talks us through the forthcoming changes to the British Retail Consortium's (BRC) Global Standard for Packaging and Packaging materials and what it means for manufacturers. emphasis on these aspects. To improve relevant control measures, the hazard and risk analysis (HARA) separates hazards into product safety and quality defects (2.2.6) to prevent, eliminate or reduce each product quality hazard to acceptable levels.
AUDIT PROCESS Issue 5 of the global standard offered three audit options for the industry; full announced audit, full unannounced audit and split unannounced audit. The working group involved in the revision of the standard identified that the full unannounced audit option instils ‘extra confidence to specifiers’. The split unannounced audit option will be removed in Issue 6. safety and quality management, site standards, products and process control and personnel. Novel packaging, but is it safe?
A
In August 2019, the latest version of the standard was published, following the revision of a draft version released
growing throwaway culture,
in 2018. Developed in collaboration with
mostly made up of single-use
packaging professionals, the scope of the
food wrapping has created a
revision includes packaging manufacture
ENVIRONMENTAL CONTROL Raw material management is vital in the packaging industry, particularly in areas where there is a high risk of contamination. Section 8 of the BRC standard will see the implementation of new environmental control, involving a risk assessment of loss damage and spillage of materials.
global waste problem. While consumers
and the printing and production of raw
are doing their bit, manufacturers must
materials for the packaging industry. It
take responsibility and look at new ways to
focuses on product safety, with a large
tackle this growing epidemic.
emphasis on functionality and quality.
use, it should not change the packaging
packaging is primarily designed to stop
FOOD SAFETY CULTURE
material that will change. Swapping plastic
contamination and protect the quality of a
All areas of the business should
packaging for a biopolymer alternative
product. Manufacturers must be aware of the
continuously look for ways of improving
rules and regulations that exist surrounding
safety throughout a plant. Issue 6 will
the production and use of packaging.
introduce a new clause (1.1.2) that requires
Despite new solutions being sought,
sites to set up, execute and review an
While food manufacturers will need to rethink the packaging materials they process too significantly as it is only the
won’t change the overall palletising process, meaning minimal disruption to the overall manufacturing process. Issue 6 of the BRC Global Standard for Packaging was released in August
STANDARDS IN ACTION
action plan to improve its product safety
Introduced in 1998, the BRC Global
and quality culture.
2019, and the first audits are set to take
Materials assists those working with
HYGIENE CATEGORIES
participating in the standard should
packaging to deliver products that
The previous revision of the standards
prepare their business to ensure produce
support the transport of safe and hygienic
saw a two-tier approach to hygiene - basic
food. Recognised by the Global Food
and high. In Issue 6, these tiers will be
Safety Initiative (GSFI) as the first global
consolidated as a way of simplifying the
packaging standard, 3 500 suppliers in
standard. The two-category system will
80 countries are certified in the scheme
be replaced with a risk-based approach
to ensure product safety and quality
based on a single set of requirements.
Standard for Packaging and Packaging
management of the food and beverage supply chain. The standard consists of six sections;
MORE THAN PRODUCT HYGIENE
place in February 2020. Manufacturers
remains of the highest standard. •
ABOUT THE AUTHOR DARCY SIMONIS is the industry network leader for ABB’s food and beverage segment.
The BRC Global Standard is not just about
senior management commitment, hazard
hygiene; it also looks at product safety
and risk management system, product
and quality. Issue 6 will place a greater
ABB – www.abb.com
October 2019 | Food Review
35
I N D U S T RY TA L K
New industry guidelines for recyclable plastics The growing impact of the green economy on company profits is forcing brands to radically transform their environmental strategies. This includes how products are designed, made and packaged for customers.
T
o facilitate efforts by companies
The three key phases of a circular value
to think about product packaging
chain include using more materials from
with reuse and recycling in mind,
sustainable sources; a smarter design that
the PET Plastic Recycling Company (PETCO)
eliminates problematic or unnecessary
has released a definitive guide, created
packaging and closing the loop to ensure
specifically for the PET (polyethylene
that packaging can be recycled once the
terephthalate) manufacturing sector.
product has been consumed.
PETCO chief executive officer Cheri Scholtz, says it is essential retailers,
EMBEDDING RECYCLABILITY
brand owners, packaging manufacturers
Packaging design should be compatible
and designers embed recyclability
with recycling technology, collection and
responsibilities into the design process.
recycling infrastructure. PET is 100 per cent
‘Companies failing to address consumer
recyclable if certain basic design principles
demand for environmental performance
are followed.
in product design and development will
‘We asked plastic packaging companies,
find it difficult to compete in the local and
manufacturers of packaging and brand
global market,’ she notes. The Waste Act
owners to review their current portfolio
makes extended producer responsibility a
of PET packaging against PETCO's design
legal requirement.
guidelines. They highlighted aspects where design could be improved and will implement
DESIGN FOR THE ENVIRONMENT
these changes as soon as the opportunity
Minimising plastic waste will occur when
presents itself,’ Scholtz says.
the industry designs for recycling - either
The guiding principle for any PET packaging
through using more recycled content
design should be ‘fit for purpose'. The goal of
(rPET) or improving the recyclability of
improving the recyclability of PET packaging
PET plastic bottles. The latter makes up
cannot compromise product safety or
70 per cent of the current PET market. At
interfere with product functionality. Packs
the moment, all plastic trays, tubs and
must be strong enough to adequately protect
punnets, regardless of plastic make-up,
contents throughout the supply chain.
are not collected for recycling.
“The goal of improving the recyclability of PET packaging cannot compromise product safety or interfere with product functionality” ‘PET plastic remains a lightweight, cost-effective, fit-for-purpose material. Understanding and utilising its postconsumer value and seeing it as an economic resource will assist in establishing a sustainable circular economy. ‘It’s about approaching sustainability, not as an add-on or something to retrofit, but as a service integral to your product,’ Scholtz emphasises.
36
Food Review | October 2019
Key guidelines: • Design PET containers with the available recycling infrastructure in South Africa in mind • Avoid the use of materials and/or components that are known to impede the PET recycling process or reduce the quality of the recycled PET (rPET) • Minimise the number of different plastics used and specify plastics that can be recycled together or easily separated in the recycling process • Design components, such as closures and labels, to be easily, safely, costeffectively and rapidly separated, and then eliminated from the rPET • Include rPET packaging in strategic planning • Be transparent about the recyclability of packaging and usage of rPET content.
FAST FACT:
Designing for ecosystems and keeping plastic out of the environment is at the heart of how organisations approach the circular economy and supply chain.
‘When designing a product, you must consider what happens after its demise. This will soon be as important as its performance,’ Scholtz says. ‘Good environmental practice requires us to use the least material to do the job required, then to reuse or recycle by recovering material or energy from products at the end of their life.’
VALUE OF RECYCLED PET Scholtz says businesses must recognise the recyclability of PET as a business opportunity and sustainable asset as opposed to an onerous environmental obligation. PET bottles, in particular, are made from one of the few polymers that can be repeatedly recycled into the same form. rPET could be used to make new products such as the polyester staple fibre used for clothing, home textiles i.e. pillows and carpeting, automotive boot linings and seat covers, industrial roof insulation and strapping materials. Last year alone, R1.2 billion was injected into South Africa’s downstream economy from the designing, manufacturing and distribution of products made from rPET. ‘From PETCO's perspective, the production and use of both food-grade and non-food-grade rPET resin remain the major growth opportunity for PET recycling in South Africa,' Scholtz concludes. • Email info@petco.co.za for a copy of Designing for the Environment.
PETCO – www.petco.co.za
L ABELEXPO
Labelling is your best spokesperson The appearance of your product is important. If you want to draw consumers closer, you must make them feel special and important. A proven way to do this is to offer personalised information - a variety of choices on their terms, writes Shawn Bezuidenhout.
H
ow effectively can you do this when
noting is represented and exhibits their
packaging suppliers only want to
latest technology and equipment. This
consider minimum order quantities
year was even more special as the fair
(MOQ)? A rule of thumb is that when
celebrated its 40 th anniversary. Just over 600
your business is big enough to conform
exhibitors showcased goods, spread over
to packaging suppliers’ minimum order
approximately 38 000m2 of exhibition space.
requirements it’s fairly simple. Most smaller
This ensured the visit of a lifetime and was
producers rely on a basket of consumer
far different from the first time I attended
offerings to generate business.
the event back in 2006.
As I found myself en route to Labelexpo
While highly regarded suppliers like
Europe 2019, I wondered what latest
Bobst, Mark Andy, Domino, Xeikon, HP
developments I would see in the
Indigo, Lombardi, Omet and Nilpeter were
international market. The traditional print
out in force, what I really wanted to see was
market is under tremendous pressure
the digital pavilion. This sector of the show
globally and locally: Margins are tight and
has grown by 30 per cent from previous
business is competitive.
editions, indicating that international
Labelexpo is arguably the biggest
acceptance of digital packaging’s benefits
event of its kind serving the international
is well in line with industry forecasts and
packaging market. Everybody worth
market projections. All things considered,
“The traditional print market is under tremendous pressure globally and locally: Margins are tight and business is competitive”
with a 350 time faster turnaround time for manufacturers to go to market, who can blame manufacturers moving their packaging in-house? We have already seen traditional manufacturers of labels and packaging investing in high-end digital offerings. Typically, this class of equipment starts from €250 000 or in South African terms, roughly R4 million. How will smaller and boutique type manufacturers compete with that? Perhaps at this time, you could not possibly produce enough to justify such an investment? The answer is simple. Explore smaller solutions specifically designed for your product and market and listen to an experienced supplier in the digital field. Investigate your choices and consider the costs of your investment. Smaller digital label and packaging offerings could start from as little as R35 000, but in some cases exceed R3 million. You need to make sure that what you are investing matches your brand, product and industry requirements. Make sure the investment versus the production price makes you comfortable. Consider the costs in your business such as MOQ, packaging stock, packaging wastage, number of variants and the growing need for customisation. Your current supply cost is not the only cost to consider. •
ABOUT THE AUTHOR Shawn Bezuidenhout is a writer at large and business development director of Nashekele Specialist Imports. Nashekele - www.nsi4africa.com Stands during Labelexpo Europe 2019 October 2019 | Food Review
37
L ABELEXPO
Largest and most international for Labelexpo 2019 The landmark 40th-anniversary edition of Labelexpo Europe 2019 has closed on a high note. A total of 693 exhibitors took part in the event, which ran from 24 to 27 September at Brussels Expo in Belgium.
T
he show was spread over nine halls,
The Gallus stand at Labelexpo
covering almost 40 000m2 of floor space. This is up from 37 600m2 in
2017. The event showcased a comprehensive offering of label and package printing technologies and live demonstrations including the fast-growing areas of hybrid printing, flexible packaging and automation. Poor weather didn’t deter 37 903 visitors from 140 countries flocking to the four-day show - a substantial increase on 2017 figures. Indian machine manufacturers did particularly well, with UV Graphic Technologies selling seven Ultraflex UFO presses. Multitec sold its full servo S1 press to a Russian converter and Monotech Systems, three Colornovo presses. Chinese manufacturers also fared well, with sales highlights including label press manufacturer Wanjie’s sale of a printer to a converter in Spain. Rhyguan sold three finishing systems on Day One - one to an
“The event is moving towards a show that encompasses not just labels, but also package printing”
Italian converter and two to companies in Germany. Demonstrating that the show has evolved from a label show into a wider package
press featuring cold foil, lamination and its new high-speed semi-rotary die-cutting unit. Hybrid machinery was another key trend.
printing show, flexible packaging innovations
Launches included Bobst, who unveiled its new
were highly showcased. Press launches
Master DM5 hybrid label press and MPS, who
included Omet’s new X7 flexo printing machine
launched a new 430mm edition of the hybrid EF
for labels and flexible packaging with 670mm
Symjet press. Mark Andy unveiled a new entry-
web width. Lombardi unveiled its Invicta i2
to mid-level digital hybrid press, which was
line, designed for flexible packaging in the mid
demonstrated live at the show with advanced
web sector, while Nilpeter launched its FA-Line
inline converting.
38
Food Review | October 2019
Other machinery launches included Gallus’ Digital Printbar digital embellishing unit designed specifically for opaque white and using inkjet-based digital print technology. Konica Minolta premiered its recently launched AccurioLabel 230, a new version of its digital toner press, while Grafotronic showcased seven new models out of a total 11 machines presented at the show. Lisa Milburn, managing director of Labelexpo Global Series says, ‘We are delighted that our 40th-anniversary edition of Labelexpo Europe has been our largest, most international to date. The event is moving towards a show that encompasses not just labels, but also package printing. This was clear from the incredible
L ABELEXPO
Nilpeter celebrates 100 years of innovation
Indigo 8000 Digital Press, which ran in line with the ABG Fast Track die, and the best-selling HP Indigo 6900 Digital Press, which visitors
Europe 2021. This demonstrates
could see in action with an integrated Kurz DM-
the global label and package
Jetliner finishing module.
printing industry remains as
At the neighbouring Sustainability Insight
vibrant as ever and that this
Café, sponsored by Avery Dennison, Xeikon,
show, 40 years on, is still a vital
Ravenwood Packaging and Sihl ARTYSIO
platform at the forefront of
Packaging, visitors could see how they might
the entire supply chain,’
boost their green credentials with a gallery of
she enthuses.
the latest sustainable innovations.
The show’s hugely popular
The popular educational programme drew
main feature, the Flexible
attendees eager to boost their industry
Packaging Arena, drew large
knowledge. Three expert-led Label Academy
crowds at every one of its 11
hosted master classes covered the hot topics
array of flexible packaging innovations and
live demonstrations. Visitors witnessed a
of inks, coatings and varnishes; digital label
hybrid machinery on the show floor, giving
Xeikon CX500 (digital) and a Bobst M6 (UV
and package printing and flexible packaging.
label converters ever more options to diversify
Flexo) producing indirect food contact flexible
A separate workshop covered self-adhesive
their businesses.
packaging to the latest GMP standards. In
label materials.
‘Feedback received from visitors and
addition, HP Indigo offered live demonstrations
The Label Industry Global Awards 2019
exhibitors has consistently highlighted the
of digital pouch making showcasing the
took place on the evening of day one, with
superior quality of the leads, enquiries and
HP Indigo 20000 digital press, Pack Ready
winners from Avery Dennison, Esko, GMG
contacts. An incredible number of deals were
Lamination and the Karlville pouch-making
and GEW honoured at the 1980s-themed
sealed on the exhibition floor and 83 per cent of
machine making its show debut on their stand.
celebration. The event also celebrated
space is already booked onsite for Labelexpo
Other HP innovations at the show included HP
Labelexpo’s 40th anniversary. •
L ABELLING
Labels that set your brand apart from the rest This is an essential part of your packaging. Labels differentiate products from competitors on the shelf and provide customers with information to motivate purchasing decisions. FAST FACT:
Lebone Paarl Labels is a sharp and nimble operation with optimal empowerment ratings
T
To maximise customer interactivity, Lebone Paarl Label’s SmartStream Mosaic Software can automatically generate hundreds, thousands and even millions of designs from a limited number of base designs, creating a point of differentiation. This allows for the creation of individually unique labels, each with their own combination of images, text and designs.
o optimise a label’s impact, printing
the boundaries of technology to exceed
to precise quality standards. Their world-class
must do justice to the design. It’s
clients’ expectations in terms of on-time
production facility is ISO 9001:2015, FSSC 22000
often the innovative application of
delivery, quality and finish of a product.
and Mellow Colour accredited.
PROFESSIONAL PRODUCTION
quality labels. A designated Colour Champion
modern printing and finishing techniques that drives the design of the most effective labels.
Perfect colour is not negotiable for high-
Novus Holdings set up Paarl Labels
The labelling process is a highly technical
focuses on continuous improvement through
as a separate entity in 2006 to provide a
space with many aspects to consider. Each
the measurement and analysis of colour
specialised label printing service to its
market and product has its own unique set
to ensure consistent, accurate colour
clients. Substantial investment in cutting-
of requirements in terms of performance
appearance. It also conforms to international
edge technology and staff development saw
and compliance. The company is committed
ISO 12647 quality standards.
the business established as a forerunner in
to ongoing investment in the latest label
South Africa in the delivery of high quality,
printing technology and people skills. It also
EMPOWERED DELIVERY
innovative UV flexo self-adhesive and digital
strives to be innovative, which positions
Lebone Paarl Labels' black women-owned
label solutions.
them as a label supplier that can deliver to
B-BBEE Level 1 contributor status further
each client’s unique requirements.
sharpens its competitive edge in the
Building from this sound foundation of production and staff expertise, the
The facility features state-of-the-art
marketplace. It adds significant benefit to its
company recently saw a shift in ownership.
digital and UV flexographic capabilities with
customers in terms of increasing their own
This is reflected in the new name Lebone
inline finishing techniques such as cold/hot
B-BBEE procurement scores.
Paarl Labels, which allows for a sharply
foiling, laminating, screening, UV varnishing,
focused, nimble operation with optimal
variable date and images, die-cutting
empowerment ratings.
and embossing. This ensures your self-
The existing team and operational
adhesive and unsupported labels packaging
CLIENT-FOCUSED SERVICE The company’s philosophy is focused on building strong partnerships with clients and suppliers through providing
infrastructure remain in place to ensure
requirements are met and helps set your
uncompromised service continuity. Lebone
products apart.
a service that’s flexible, responsive and
a truly personal service built around each
UNQUESTIONABLE QUALITY
perfectly presented.
client’s requirements.
Embracing the rapid advancements in
Paarl Labels now has the flexibility to deliver
innovative to ensure every label is always The team is highly skilled and
software and equipment ensures Lebone
experienced, working closely with clients
the delivery of exceptional pressure
Paarl Labels can reliably deliver UV flexo
through each stage of the sales and
sensitive labels through UV flexo and
self-adhesive and digital labels faster and
production process. It provides specialist
digital self-adhesive printing and finishing
efficiently. Systems are fully automated
advice on the best possible substrate,
technologies is at the core of the company’s
and streamlined from start to finish of
adhesive, ink and print process combination
offering. The portfolio includes cost-
the production process, and stringent
that will ensure the label performs
effective solutions for high volume/low
quality processes have been established at
exceptionally through the labelling,
price producers to technologically advanced
each step. Clients can be confident every
distribution and retail of products. •
innovations to enhance products in premium
label on the production run is inspected
price ranges. The company’s approach is to
independently for perfect continuity, full
give every job personal attention and push
brand integrity, functionality and is produced
Spotlighting their clients’ brands through
40
Food Review | October 2019
Lebone Paarl Labels - info@lpaarllabels.co.za
It’s all in the label Your brand is valuable, that’s why no matter the shape or size of your product, we take the time to craft labels that do your brand justice. After all, it’s about the name on the label, and a quality brand deserve a quality label.
Spotlight your brand
+27 21 877 6200 info@lpaarllabels.co.za BLACK WOMEN OWNED B-BBEE LEVEL 1
L ABELLING
Label versatility creates success Sacmi continues to invest in product and process innovation. Its portfolio has grown from the tried and tested Flexi Opera and Kube labellers, to the new Sacmi ERF and advanced computer vision systems that perform real-time output quality control.
W
Flexi Opera - Sacmi hugh speed modular labeller
ith its Opera and Kube range, Sacmi is one of the leaders in high and medium speed
labelling solutions. Featuring modular configuration, these labellers are designed to maximise performance and handle different technologies/formats/ labelling systems in one machine. Labels are a vital product and brand communication tool in the food and beverage industry. Sacmi invests heavily in maximising this potential by developing technologies capable of efficiently handling ever-smaller lots, frequent size changeovers, personalisation requirements, product tutelage and traceability. The company’s latest Flexi Opera version offers
The system can combine various application types (adhesive, cold-glue, hot-melt, roll-fed) and handle different materials (glass, plastic, metal and HDPE for containers, paper or plastic for labels). Customers can enact real-time responses to market
DID YOU KNOW? The company has 2 000 installed systems globally.
terrific configuration flexibility and provides a near-perfect response to every possible packaging need. The modular version ensures high performance, while simultaneously meeting the need for frequent label and/ or size changeovers. This offers matchless versatility and usability.
demand and enjoy ultrahigh-output rates of up to 72 000cph. Samci’s most recent offering is Kube. This medium-speed labeller was developed five years ago with the express aim of maximising flexibility in a
dynamic and fast-evolving market. The system is widely used within the wine industry. As a modular labeller range, units are characterised by a hardwearing, compact structure. Labelling units are connected outside the turret. This offers users the opportunity to
FAST FACT:
In conjunction with consolidated technology, Sacmi invests heavily in process innovation by developing new generation labellers. These offer fresh opportunities in plant flow engineering to improve overall management of a bottling line.
handle, in parallel, different label application technologies including selfadhesive, hot and cold glue with just one passage through the machine. Another solution is the Sacmi ERF. This next-generation labeller innovates the
Food Review | October 2019
All solutions can be paired with Sacmi’s Computer Vision system. This control system is designed to ensure total quality control of the label. Checks extend well beyond proper label application. In part to its Labelling Vision System and the ability to interface individual machines with the Sacmi H.E.R.E. plant supervisor, the company is developing a true production ecosystem. The system will ensure the efficient management of individual lots, real-time process performance monitoring, feedbackgenerated plant correction and direct interfacing with the customer's ERP. •
traditional roll-fed labelling process by applying the label on a filled, capped bottle to ensure maximum adherence.
42
“Sacmi's most recent offering is Kube. This medium-speed labeller was developed five years ago with the express aim of maximising flexibility in a dynamic and fastevolving market”
Sacmi – www.sacmi.com
L ABELLING
Pushing boundaries in self-adhesive labels Rotolabel, in conjunction with Avery Dennison is one of the first companies in South Africa’s labelling industry to become FSC compliant. As part of value-added services in the Avery Dennison Sustainability Portfolio, the Liner Recycling Programme is available for PET and Glassine liners and is currently active in many countries worldwide. Rotolabel is a major supplier to the FMCG food, wine and personal care market. Sustainability is a major talking point with several challenges facing the packaging industry, brand owners and major retailers. ‘The sustainability topic is an extremely complex one. If not understood 100 per cent, the incorrect decision could be made even though a company’s intentions might be honourable,’ Watson says. One of the first steps Rotolabel took was to become FSC compliant. This was driven in partnership with Avery Dennison, which can ensure that all paper material used is sourced from sustainable forests. This certification
A FSC certified forest
T
may seem like a small insignificant step, but is vital in the conservation of global forest
hese two companies have now partnered with an exciting new initiative. They are the first to recycle
Glassine liner backing. This is a revolutionary initiative in the label industry in South Africa that can save tonnes of liners from ending up in landfills. ‘Consumers are becoming very aware of the impact of waste going to landfill. As these facilities get full and run out of space, disposal costs will increase substantially. Most pressure-sensitive labels are produced with a glassine liner. The recycling program helps repurpose that liner waste so that it does not contribute to landfill disposal.
resources. Forests are being destroyed globally
FAST FACT:
often without any control or regulation. It is
The Forest Stewardship Council (FSC) is an international non-profit, multi-stakeholder organisation. The group was established in 1993 to promote responsible management of the world's forests. The FSC does this by setting standards on forest products, along with certifying and labelling them as eco-friendly. By choosing products with FSC labels, you are helping to take care of the world’s forests.
Rotolabel, in conjunction with Avery
join the Liner Recycling Programme for Glassine liners. It is an extension to their existing partnership that enabled Rotolabel to be the first in becoming FSC compliant in the industry in South Africa.
industry to follow suit for the benefit of a more sustainable future. ‘We are busy engaging with raw material suppliers on down gauging materials.This could have a significant impact on the environment while still maintaining the shelf appeal of a product. Along with the down gauging, we have recycled material and material that is 100 per cent recyclable during PET recycling,’ Watson points out. ‘At Rotolabel we have the knowledge to understand what materials are best suited for various packaging formats. Not selecting the
Dennison are driving their sustainability efforts by becoming the first in the label industry to
the company’s aim for the rest of the label
site. Avery Dennison then collects the compacted liner during its delivery process,
right material can result in the main packaging material not being recycled,’ he concludes. •
compiles them into a container to be shipped to India. There they are re-manufactured into products like tissue paper.
Rotolabel – www.rotolabel.co.za
As a part of addressing the growing concerns. of conscious consumers, the Liner Recycling Programme has now expanded its footprint into South Africa. After proof of concept and trial runs following its introduction in Cape Town,
Based on 100 000 m² Normal VS Lite Substrate PP Cavitated PP Cavitated Lite
the programme will be rolled out nationally,’ Watson notes. The Liner Recycling Programme is easy to implement. Liner waste is collected from customers to be compacted at the Rotolabel
44
Food Review | October 2019
PP Clear
PP Clear Lite
Semigloss
Semigloss Fit
Tonnage
Water(L)
10.3 9.3 130,674 110,585 10% Saving 15% Saving 10.7 10.1 155,000 140,200 6% Saving 10% Saving 13.7 12.7 136,080 128,000 7% Saving 6% Saving
Co₂e (kg) 30,381 24,682 19% Saving 36,600 32,400 12% Saving 16,730 15,850 5% Saving
Energy (MJ) 908,284 769,078 15% Saving 921,600 829,100 10% Saving 990,030 925,450 7% Saving
The JASA Sleever
PERSONALISES AND SLEEVES APPLES USING CARDBOARD TRAYS
• Process up to 50 trays per minute with a single belt model or 100 trays per minute with a two belt model • 100% Suitable for recycling
Brand Fresh Produce USING A CALIBRATED TIE, A KWIK LOK, AND A BRANDED LABEL
• Quik Link Binding Machine Integrated with Kwik Lok Labeller • Simple one-pass action • Binds any diameter without damage to the produce • Print the date, lot, bar code or traceability information
CAPE TOWN Tel: 021-534 0215 DURBAN Tel: 031-569 4199 JOHANNESBURG Tel: 011-312 4976 sales@goldpack.co.za www.goldpack.co.za TAS3461
L ABELLING
Digital solutions
for the modern label printer The advent of digital printing resulted in shorter print runs in most sectors of the printing industry and an irreversible change in many areas of the business. Label printing was not one of them: Economies of scale kept longer runs to keep unit costs to a minimum in this sector.
T
his has now changed. Screen
Screen has designed the Truepress
Graphic Solutions (Screen) and local
Jet L350UV Series specifically for the
distributor Rotocon have introduced
label printing market. It is available in a
the Screen Truepress Jet L350UV+ series of
range of configurations offering standard
printers to the local market. ‘The positive
colour and extended colour gamut in the
response from label printers has been
+ model. It also offers a low migration
astounding,’ enthuses Michael Aegenvoort,
version for food-safe printing with or
managing director of Rotocon. ‘Eight of
without extended colour gamut. As
these presses are currently installed at
consumer tastes continue to diversify,
label printers around the country. What
the label printing industry’s demand
makes this amazing is that four of these
for improved multi-format, short-run
presses were sold at the Propak Africa
capabilities is growing. There is also a
show, held in Johannesburg in March
trend towards using a wider variety of
this year.’
materials in label designs. The Truepress
While digital printing provided an opportunity to handle very short print runs, it presented a challenge in terms
Jet L350UV+ series has been developed to meet these specific needs. Labels for food packaging must
of finishing. Postpress solutions for all
satisfy strict external safety standards.
print types were designed to handle
The Truepress Jet L350UV+LM features
large quantities at very high speeds. On
newly developed low migration (LM)
the finishing side, the arrival of digital
inks and a nitrogen purge mechanism,
printing created a significant problem.
which dramatically reduces extractable
Manufacturers of finishing systems
ink components after printing. Coupled
responded quickly and adapted systems
with decreasing migration risks, these
to work with digital printing presses to
innovations significantly lower typical UV
create comprehensive solutions. Given
ink odours. Together they help to extend
the response from the market, it is little
the considerable merits offered by digital
wonder that all eight of the machines
technologies for variable and short-run
supplied by Rotocon feature the Ecoline RSI
printing to food packaging applications.
330/430 slitting, inspection and rewinder system for finishing of printed labels. Aegenvoort comments, ‘Digital printing
The Low Migration Truepress Jet cannot be substituted with conventional inks due to the inclusion of the nitrogen
is now a mainstream production method
purge system, which aids in reducing
in the label and packaging industry. It
the presence of potentially harmful
offers the benefits of short runs with
odours and improves ink set. The low
high variability. This allows wholesalers
migration inks used in the Truepress Jet
and retailers the opportunity to reduce
L350UV+ are compliant with the EuPIA
The Ecoline RDF 340
FAST FACT: The Truepress Jet L350UV+LM features the newly-developed nitrogen purge mechanism. UV ink curing can be inhibited by the presence of oxygen. This innovative technology reduces its density to an absolute minimum to accelerate curing. A separate nitrogen generator is required when using this system.
Exclusion Policy for Printing Inks & Related Products and the internationallyrecognised Swiss Ordinance and Nestle Guidance systems. ‘Low migration inks are important in the local market as more retailers adopt international standards and regulations governing food safety. Many of the larger The Complete hybrid system
their stock holdings of labels and packaging materials while addressing growing demand for regular packaging design changes.’
October 2019 | Food Review
47
L ABELLING
workflow system. Equios draws on Screen’s
retail groups are demanding that print service providers adhere to these regulations and standards. This is going to put pressure on print service providers to meet these regulations,’ Aegenvoort points out. The extended colour gamut capability of the Truepress Jet L350UV+ includes the recently-launched blue ink and orange ink and allows the ability to achieve accurate corporate colour matching. Additional colours were selected specifically because of their high degree of use in cosmetics, pharmaceutical and the food-packaging sector, which makes extensive use of labels. The L350UV has been designed to meet the specific requirements of the packaging market and includes many of the features accepted as standard in conventional printing prepress systems. Truepress Jet L350UV+ models feature proprietary Screen printheads with four-step droplet technology. The systems’ high-resolution screening, coupled with the wider colour range of the proprietary UV inks, create an impressive depth of natural colour. The Truepress Jet L350UV+ series can print the finest detail, capturing the highest definition and the smallest text point size. The choke function prevents thickening of outline text, providing excellent legibility even for the large amounts of information usually found on pharmaceutical and supplement labels. These features enable one-pass processing of individual lot numbers and other variable printing jobs. A stable transport mechanism controls paper feed to prevent meandering and maintains optimal transfer conditions. In combination with the Truepress Jet L350UV+ series’ efficient printheads and proprietary inks, this ensures consistently high registration accuracy and small droplet size. This precision is essential for the output of detailed dot codes such as QR and barcodes, and other security printing requiring a high level of accuracy. The Screen Truepress Jet L350UV+ is controlled by the Screen Equios printing
48
Food Review | October 2019
CUSTOMERS COME FIRST Established in 2008, Rotocon is a family-owned business led by Michael Aengenvoort and sons, Pascal and Patrick, who all completed their engineering studies in Europe and cut their teeth in the labelling and narrow web industry. Collectively, the trio has 65 years' hands-on experience and intimate knowledge of label printing and finishing machines, accessories and consumables. This allows them to offer consumers a customised full-service packaging anchored in exceptional consultation and aftersales support. Clients who partner with Rotocon receive unrivalled consultation and after-sales support, tailored to their specific printing/converting environment, including: • Trustworthy capital investment advice • Responsiveness and on-site service by seven, fully trained and highly knowledgeable technicians based in Johannesburg, Durban and Cape Town • Comprehensive stock holding of spare parts and consumables • A fleet of branded vans delivering consumables, cutting tools and spare parts wherever needed • Customs, pre-clearance, pick-up and prompt delivery of precisionengineered flexible dies • Local manufacturing of highprecision solid rotary dies, magnetic print cylinders and accessories, including a universal roll-lifter (up to 80kg) • Turnkey project service for preowned printing equipment and spare parts • Technical assistance with older generation machine upgrades of spare parts.
extensive prepress and printing knowledge to maximise the performance of its inkjet technology. Equios offers high-speed processing using Adobe’s PDF Print Engine 4, a colour management system that links to paper information and user-friendly imposition functions that integrate Screen’s full prepress know-how. It incorporates functions such as: • Text choke • Colour matching with existing samples • Spot colour adjustment tool and optional full-colour variable data processing. These functions assist in ensuring print quality remains at the highest standard from one run to the next. ‘State-of-the-art screen printing technology combined with the Rotocon finishing systems and the expertise of our factory-trained engineers means that local customers are assured of the highest levels of productivity and label quality. All local installations have been handled by our in-house technicians. This includes the training of customers’ print operators. We go the extra mile to ensure that customers are fully proficient in all aspects of the systems we supply. This reduces downtime and enhances their confidence in the solutions they’ve installed,’ Aegenvoort concludes. Through the development of high-end digital printing solutions such as the Screen Truepress Jet L350UV press, label production is now firmly entrenched in the just-in-time market. Customers can order lower volumes. This saves time and money and offers them the ability to react quickly with product launches and branding changes. The Screen Truepress Jet L350UV+ is a highly productive press for the modern label printer. •
Rotocon – www.rotocon.co.za
Low migration inks improve safety for food package labels. Labels for food packaging must satisfy outside strict safety standards. The Truepress Jet L350UV+LM features newly developed low migration (LM) inks and a nitrogen purge mechanism that dramatically reduces extractable ink components after printing. As well as decreasing migration risks, these innovations significantly lower typical UV ink odors. Together they help to extend the considerable merits offered by digital technologies for variable and short-run printing to food packaging applications.
Cape Town T +27 021 975 6763 E pascal@rotocon.co.za
Johannesburg T +27 011 397 2172 E patrick@rotocon.co.za
www.rotocon.co.za
Durban T +27 031 701 0383 E akhmuth@rotocon.co.za
To advertise in
Anita Raath
Sales executive +27 (0)82 976 6541
Coffee time Carla Melless
Sales executive +27 (0)83 260 6060
Càndida GiambÒ-Kruger Sales executive +27 (0)71 438 1918
ADVERTISERS’ INDEX OCTOBER 2019 Afrox......................................................27......www.afrox.co.za AGT Foods Africa...............................15......www.agtfoods.co.za Anya Knoetze ......................................26......www.haccpforfoodsafety.co.za Aspirata.................................................25......www.nosa.co.za Atlas Copco..........................................30......www.atlascopco.com/en-za BMG.......................................................20......www.bmgworld.net Brenn-O-Kem.........................................7......www.brenn-o-kem.co.za Buckle Packaging................................24......www.bucklepack.co.za Deli Spices............................................17......www.delispices.co.za DSM Nutritional Products SA ..... OBC......www.nutritionimprovement.com Emirates SkyCargo...............................5......www.skycargo.com/emiratesfresh Eptech Products .................................50......www.eptech.co.za GEA Africa........................................ IFC......www.gea.com Goldpack ..............................................46......www.goldpack.co.za Hiperbaric.............................................21......www.hiperbaric.com
Interroll SA .......................................3, 29......www.interroll.co.za Ishida.....................................................23......www.ishidaeurope.com Lebone Paarl Labels............................41......www.lpaarllabels.co.za Polyoak Packaging..............................39......www.polyoakpackaging.co.za Roha SA.................................................14......www.roha.com Rotocon.................................................49......www.rotocon.co.za Rotolabel ..............................................45......www.rotolabel.co.za Sacmi Beverage S.p.A........................43......www.sacmi.com/beverage Savannah Fine Chemicals.................19......www.savannah.co.za Sensetek ...............................................33......www.sensetek.co.za Sensient Technologies.......................31......www.sensient.com Siyakha Imperial Printing Co............38......www.labelprint.co.za South African Trade Promotions........9......John.t@satp.co.za Specialised Exhibitions ......................8......www.hostex.co.za Symrise SA ......................................OFC......www.symrise.com
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BUTCHER MEAT PROCESSING EQUIPMENT
MATRIX SOFTWARE
BMPE is the leading supplier of superior quality New and Refurbished Food Processing equipment. Providing professional Service, equipment & spares. BMPE has extensive knowledge of current machines, technologies and consumables and provide a modern Service & Maintenance Department to support our customers throughout their process. Servicing a diverse range of customers, from large & small Butcheries, Abattoirs, Supermarket Groups and Franchise Outlets in the Food, Pet Food and other Manufacturing Industries. BUTCHER MEAT
Matrix Software, specialist leading ERP software providers for the Meat and Food industry, offers various solutions to assist the factory floor function in production plants.
PROCESSING EQUIPMENT Tel: +27 11 664 8212
Tel: +27 11 664 8212info@bmpe.co.za info@bmpe.co.za www.bmpe.co.za www.bmpe.co.za
BMPE is the leading supplier of superior quality New and Refurbished food processing equipment to the African market. Our primary focus is to provide a professional service to the food industry with regards to Equipment, Spares and the latest Technological innovation. With more than 30 years hands-on experience, we provide our customers with an excellent service in all areas of the food processing industry and have over the years achieved a good For over 40 years Formpak reputation for being efficient, cost-effective and professional. We import machines for our local clients across the whole of has supplied specialised Africa, ensuring that they benefit from machines of the highest qualityand at an excellent price. processing, packaging Our staff have extensive knowledge of current Machines, printing machinery to the and Consumables and we also provide a modern Technologies Service and Maintenance Department to support our customers pharmaceutical, cosmetic, throughout the process. plastic, glass, chemical, We service a diverse range of customers, from Large & Small Butcheries to Abattoirs, Supermarket Groups, Franchise Outlets food and dairy industries. and Corporates.
FORMPAK
Our diverse range of software offerings features a unique module listing of more than 700 modules (program nodes). Our software solutions are tailored for the Feedlot/Abattoir/ Debone / Production Retail industries. Matrix Software is deployed in 8 countries throughout Africa, Australia, New Zealand and Seychelles. www.matrixsoftware.co.za
PARTNER FOR HYGIENE AND TECHNOLOGY
Tel: +27 (0) 11 828 8870/1/2 Fax: +27 (0) 11 828 8880 email: haase@formpak.com or service@formpak.com www.formpak.com
Leading through Innovation PHT is the leading provider of state-of-the-art technology for hygiene and food safety. Our unique systems offer efficient, effective and sustainable solutions for your hygienic challenges. We develop both individual and integrated hygiene solutions for your company. We are always there for you and we support you through our actions, professionally and reliably. Hygiene and food safety is our passion. We care about our customers, our suppliers and our people – we measure our success by the way we touch their lives. Because we care, we design innovative and holistic solutions. Tel: +27 861 777 993 | info.za@pht.group | www.pht.group
DINNERMATES
QUANTUM COLOURS SA
• Supplier to the hospitality trade and food factories Your No. 1 industry leader for the • Service excellence, most comprehensive ranges of both • Quality, portion controlled products synthetic and natural colours – used (chilled/frozen /dried) in food, pharmaceutical, cosmetic and • Innovation & Flexibility industrial applications. Full demonstration of exclusive machines will be strategically positioned on the stands and this will • Meat & chicken products tailored for receive a great deal of attention which Our technical team is available to shade special applications in the food industry will be of great interest to you our customer. We look forward seeing you attothe show. requirements andto colour match specific • Dried meat products – real meat THE BMPE TEAM and / or Pantone references and real flavour! to give legislative support on colours. Tel: +27 (0)11 032 8600 email: sales@dinnermates.co.ca Tel: +27 (0)15 516 1515/4 email: factory@dinnermates.co.za/www.dinnermates.co.za
www.quantumcolours.com
Improving nutrition with rice fortification
Rice is at the heart of the diet for over half of the world’s population. Fortifying rice post-harvesting with essential vitamins and minerals is an effective solution to provide people with the nutrients they need to lead an active and healthy life, boosting both this generation and the next.
For DSM, quality is a way of life. This is the core of Quality for Life™
DSM has co-developed a robust, trusted and cost-efficient technology to fortify rice without changing its appearance, taste and cooking. We support our customers and partners to improve the nutritional value of rice and help to make a positive contribution to public health.
Contact us: nutrition.improvement@dsm.com www.nutritionimprovement.com