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Journal for food and beverage manufacturers SEPTEMBER 2017 Vol. 44 • No. 9


Beverage Review & Packaging Review

Ingredient efficiencies drive dairy food growth Smart approaches in safety and hygiene

A take on vacuum pumps

Your global partner in vacuum applications:

Counting the cost of changing tastes?

Visit us @ B1-4 31 Oct - 2 Nov

Flavour application you can count on Manufacturing since 1952 and snack specialisation since 1970. Leaders in controlled application of liquid and dry ingredients on a wide range of food products. Powdered seasonings, oil and water-based coatings, slurries, chocolate, yoghurt, release agents and many other coatings.

www Email Cape Town

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CONTENTS SEPTEMBER 2017 | Vol. 44 • No. 9



The vision of a new management team at Busch Vacuum Pumps Africa has ushered in a new season of growth



The New Product Competition celebrates product innovation 07 NEWS Albany’s high speed efficiency New life for permeate market

08 NEW PRODUCT COMPETITION What happened at our judging day?

12 DAIRY FOOD Why we eat what we eat

27 Beverage Review “Wastewater recovery is a concept which is becoming increasingly popular.”

33 Packaging Review



Innovations in lactose-free dairy Cocoa’s infinite opportunities FoodTech appointed DuPont distributor

19 BAKERY Quantum launches development bakery Whey leads the way Celebrate the wonderful world of topping and fillings


"Propak Cape is the place to be for your total packaging solutions. We bring you highlights from the event …"

Use and abuse of chemicals Food safety through traceability Dynamic partners move consulting up a notch

September 2017 | Food Review



INNOVATION is the name of the game


his month’s edition of Food Review investigates a broad range of pioneering technology, ingredients and new food and beverage products. The ability to think out of the box is what defines future-oriented companies. Page through and see for yourself just how trend-setting and advanced this industry really is! The Food Review/Symrise New Product Competition judging has been concluded. Taking all entries into consideration, there was a noticeable theme in the direction of products with lower, no added, healthier and free-from. The number of craft products from the beverage industry also points to tremendous strides in this sector. Turn to page 8 now for some feedback on the day. Professor Yanga Zembe is a socioanthropologist and researcher who has published her finding on why South Africans eat what we eat. Her article (page 12) makes for fascinating reading on how food not only meets our nutritional needs, but also plays a role in our emotional and physiological wellbeing. This month we focus on tremendous opportunities available in the dairy food and bakery industry. Local start-up Food Tech Ingredients has landed a major contract as the sole distributor for DuPont in South Africa (page 18). A new development bakery launched by Quantum Applied Food Science will now allow bakeries to replicate craft or industrial bakery applications. More of this on page 19. Although microbial contaminants often take centre-stage in discussions about safety and hygiene, chemical contaminants and residues should not be underestimated. On

page 23, Linda Jackson, director at Food Focus looks at the recent fibronil scandal and how it raised concerns around the use and abuse of chemicals in food handling facilities. Big news in the beverage industry is the buyout of Inhle Beverages by Long4Life. This acquisition presents a strategic opportunity for the company and positions it perfectly in the rapidly growing beverage sector. Read all about the company’s expansion plans on page 28. Vulnerabilities in the beverage sector are laid bare with continuing water scarcity, escalating costs and stringent regulations. We focus on what water processing systems are available to industry and how the stigma surrounding water recovery and reuse is lifting. Turn to page 29 now for the full story. This month’s Packaging Review has its finger on the pulse with comprehensive articles on security features and end-of-line equipment. Don’t miss our sneak peek on what is available at Propak Cape 2017. All this and more on page 33. I hope you enjoy this edition. If you have any news, views or information to share, please don’t hesitate to send it to me at

Editor: Maryke Foulds +27 (0)11 715 8012 Assistant Editor: Aarifah Nosarka +27 (0)11 877 6209

Layout & Design: Kirsty Thomas +27 (0)11 877 6168 Contributor: Carol Zweep, Gail Macleod, Linda Jackson ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 Sales Executive: Carla Melless +27 (0) 83 260 6060 Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 Production Controller: Rae Morrison Art Director: David Kyslinger

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

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

John Psillos NON EXECUTIVE DIRECTOR Managing director of Symrise South Africa; chairman of SAAFFI.

Rudy McLean

Irna van Zyl HEAD OFFICE New Media House, 19 Bree Street, Cape Town 8001 Tel: +27 (0)21 417 1111, Fax: +27 (0)21 417 1112 Email: Postal address PO Box 440, Green Point, Cape Town 8051

Head of communications, Tetra Pak Sub-saharan Africa.

Penny Ntuli

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

Gail Angela Macleod

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


Food Review | September 2017

Food Review is published by New Media Publishing (Pty) Ltd 11 times a year and circulates to executives in the food and beverage industries. Views expressed in this journal, other than where specifically stated, are not necessarily those of the publisher. The editor welcomes for publishing consideration news items, press releases, articles and photographs relating to developments in the food and beverage industries. No responsibility is accepted should contributions be lost.

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High speed efficiencies reduce carbon footprint

Ribbon cutting ceremony

ALBANY BAKERIES HAS invested R350 million into a new bakery in Bellville, Cape Town. The building occupies 6 884m 2 compared to a previous area of 3 766m 2 . ‘We took the environment into account. We increased emissions efficiency by reducing the factory’s energy consumption, and placed emphasis on improving safety measures,’ managing director Matshela Seshibe says. Two Tweedy mixers add to the output capacity from 6 000 loaves per hour to 12 000lph. This will effectively double output achieved previously.

New bread coolers and ovens are energy efficient and perfect the baking process. Revamped high-tech bagging system is another aspect that adds to the overall efficiency The new plant saves 3964 litres, a total usage of 11 877 litres compared to the 15 841 litres previously consumed. Waste water is recycled and used to wash the trucks. ‘It is our vision to become the best baked goods company in the Western Cape. We have improved our recipe based on recommendations from consumer tests and have enhanced the taste profile of our breads,’ Shesibe concludes. •


Standard sparks permeate market to life THE FINAL APPROVAL of a Codex Alimentarius international standard for dairy permeate powder has been welcomed by the dairy industry. The new science-based standard establishes global criteria for the identity, composition, safety and quality of powdered milk and whey permeates. It is expected to accelerate demand for permeate and generate sales opportunities for this valuable and affordable ingredient. Permeate is still relatively new in the food industry, and is a by-product of whey manufacturing. It is a low-cost, carbohydrate ingredient often used as a bulk sweetener in snacks, chocolate, confectionery, ice cream, desserts, beverages and bakery products. It is highly valued for its ability to replace other, more expensive milk solids in food products without altering the taste or texture. Used as an alternative to whey powder, demineralised whey powder and lactose, whey permeate can optimise product quality in a range of applications. Until recently, there was no Codex agreement for dairy permeate, a factor that deterred many countries from allowing it in food and beverage products. •

September 2017 | Food Review



Who will be the next

NPC winner?

The Food Review/Symrise New Product Competition celebrates product innovation of food and beverages we all desire: tasty, authentic, healthy and responsibly produced. By Maryke Foulds


his year was no exception with pioneering flavours, ingredients concepts, clever packaging and successes in environmental responsibility heading the product line up. The competition is also an excellent gauge to see how industry is adapting to the latest and upcoming developments in the global sphere. Judging took place at the well-appointed and trendy PnP Good Food Studio located in Johannesburg. Now in its 23rd year and with the continued support of sponsor Symrise, a sensational and pioneering mix of 36 products entered. The grand prize is a fully paid trip to SIAL 2018 – the Michael Gristwood, Cynthia Mabela, Janusz definitive show for the retail Luterek, Dr Heidi Grimmer and Clive Glover trade and the food, beverage and catering market. This event will be held in Paris, France from 21 to evident in this category that even though a 25 October 2018. product might have won the sensory vote, it ‘We were faced with a great number of often fell spectacularly short on its labelling entries this year, but the presentation and and packaging. This was true for bigger tasting arrangements were so well prepared brand owners and smaller manufacturers. that the process of judging went As the day progressed off very smoothly. Products it became clear that a entered were of a reasonably number of products were high quality. Taking all entries neither R146 compliant, nor into consideration, there seems complied with regulations to have been a noticeable theme laid down in the Liquor Act. in the general direction of lower, ‘It is good to know the no added, healthier and freeenthusiasm surrounding from,’ says Michael Gristwood new food products is still who looked at product contents such an upbeat feature with fellow judge Heidi Grimmer. of our daily life. There She was particularly impressed was evidence of several with one product, which showed awesome and creative incredible technical dexterity as its sugar ways to present the products under scrutiny. reduced version now eclipses its more From alcoholic beverages to normally traditional counterpart. mundane snacks, the pack designs were Brand owners and manufacturers are eye catching and challenged our taste required by law to comply with food and buds,’ enthuses Clive Glover who judged beverage labelling legislation. It became the packaging category. ‘In the end, there

“We were faced with a great number of entries this year"


Food Review | September 2017

must be a balance between packaging and the product to secure brand loyalty into the future. We must accept the fact that brands clamour for innovative ways to engage with shoppers. Differentiation plays a big part in securing a porthole of opportunity to make the initial purchase.’ Janusz Luterek ensured that all labelling and regulations were adhered to

NEW PRODUCT COMPETITION FAST FACT More than 50 per cent of current revenue comes from products introduced to the market in the last five years. This makes swift and successful innovation even more critical to the long-term strategy and success of food and beverage organisations. synthetic base oil technology.



Angel Heart Beverages | Ginifer Gin Range

Angel Heart Beverages | Ginifer Bitters Range Beyers Chocolates | Chocolatier’s Collection Beyers Chocolates | Dream Bears
 Beyers Chocolates | Sweetie Pie Range Cerebos | Artisanal Salt Range
 Dairymaid | Cadbury Crunchie Blast Dairymaid | Oreo Cone

Marketing guru, Cynthia Mabela

Dairymaid | Oreo Ice Cream Sandwich
 Darling Brew | 2017 Range
 Futurelife | Futurelife Smart Fibre 2 in 1
 Garden Morris | Braai & Choc
 Imperial Concepts | Imperial Stevia Range Montagu Foods | Denny Mushroom Burgers NOMU | Instant Cappuccino
 NOMU | Unsweetened Cocoa Drink
 NOMU | Vanilla Essence
 NuSeed | Vanilla & Cinnamon Roasted Seeds
 Old Mason’s | Cocktail Spritzers Range Parmalat | Melrose Melts
 Phat Fox | Dairy Free Ice Cream Range Premier Foods | Blue Ribbon Sandwich Squares Premier Foods | Thrive
 Redespresso | Instant Red Cappuccino
 The Alternative Power | Switch Energy Range

Dr Heidi Grimmer, Michael Gristwood and Clive Glover

The Alternative Power | WOZA Cooldrink Range The Duck Farm | Smoked Duck Breast Fillets

In terms of marketing, Cynthia Mabela was impressed with the quality of most products entered this year. ‘One of the biggest mistakes I picked up is the poor link between the product image and its target market. A brand needs to appeal to its audience. They must find it attractive first before they taste it. The packaging, logo, colours and messaging must all tie up to create an image worth aspiring to. Remember the are many products competing for the same market. Your success comes with the ability to cut through the noise and clutter and stand out. With the increase in social consciousness, brands must position themselves as responsible corporate citizens that understand the socioeconomic dynamics and find alignment with the environment in its markets. We need more socially responsible products to assist with the many ills that consumers are already battling with,’ she explains. The Food Review/Symrise competition’s award ceremony took place on 13 September at The Venue in Sandton, Gauteng. Don’t miss out on the October edition of Food Review where we will pay tribute to the manufacturers and producers who lead the way in fostering innovation in the food and beverage sector. •

"Your success comes with the ability to cut through the noise and clutter and stand out"

The Whey Group | Mi Whey Protein Ice Cream Tiger Brands | Oros Lite Range
 Vital Health Foods | Bars & Bites Range Woolworths | Brewed Iced Tea Range Woolworths | Coconut Water Range Woolworths | Cold pressed fruit and vegetable shots range Woolworths | No sugar Cookies Range Woolworths | No sugar Rusks Range Woolworths | Waffle Rusks

One of the sample tables September 2017 | Food Review



Smart solutions for smart customers

The vision of a new management team at Busch Vacuum Pumps Africa (Busch) has ushered in a new season of growth. With managing director Sean Pieterse in the hot seat, the company continues to build on its reputation as a professional, flexible and solution-based vacuum specialist. By Maryke Foulds


apid sales growth of 30 per cent per annum has resulted in Busch taking the market lead in most sectors where vacuum technology is needed. ‘The main factors for sustained growth is that we have shifted business interests. From previously only selling a limited range of vacuum pumps and doing basic service work, we are now the first line supplier for most sectors, including the food and beverage industry. ‘The drive to market a full and comprehensive range of vacuum pumps

and blowers, and by focusing on systems business has been a catalyst for growth, despite the economy experiencing tough times,’ Pieterse explains. A focus this year is the launch of the R 5 RD 0360 A (R 5) rotary vane vacuum pump at the Propak Cape exhibition, which will be held from 24 to 26 October. This unit requires 20 per cent less motor power than previous models. The new vacuum pump is based on rotary vane technology and is further optimised to make energy savings possible.

REDUCING THERMAL LOAD Vacuum pumps such as the R 5 range generate waste heat that can negatively affect production and processing rooms or air-conditioning systems. The waste heat can be drastically reduced and utilised. An oil/water heat exchanger on an R 5 rotary vane vacuum pump can significantly reduce waste heat and reduce energy costs. The heat exchanger can be used to generate warm water used during operation. R5 rotary vane vacuum pumps can be retrofitted with heat exchangers. If four packaging machines operate in one packaging room and each is fitted with an R 5 rotary vane vacuum pump with 5.5 kW of motor power, the energy required for cooling is approximately 6.0 kW. If the vacuum pumps are operated with a heat exchanger, the energy requirement for cooling is reduced to approximately 1.5kW. During an operating time of 4 500 hours/ year and an assumed electricity price of 0.18 euros/kWh, this results in annual energy cost savings of approximately R85 000.

DID YOU KNOW? Behind the scenes technical support


Food Review | September 2017

Vacuum packaging in the food industry remains the number one industry for Busch on the African continent.


DON’T BE CAUGHT OUT… BUSCH ONLY USES 100 per cent genuine OEM parts to service and overhaul its equipment. Technicians are trained in Europe to the highest standards of workmanship. In South Africa, there is a disturbing trend in the vacuum market where unqualified service technicians in fly-bynight companies are cutting costs by installing non-genuine knock off parts such as exhaust filters and vanes into high spec vacuum pumps. The result is often catastrophic failures leading to costly production downtimes for the customer. At best, these non-genuine parts result in inefficient vacuum pumps with regular downtime for customers. – Sean Pieterse

The R 5 RD 0360 A, an energy efficient rotary vane pump will be unveiled at Propak Cape in October

CONTROLLING PACKAGING PROCESSES The actual evacuation time in which the vacuum is required only accounts for one third of the cycle time. The rest is taken up by transportation, sealing, ventilation and sometimes treatment with gas. Using intelligent technologies in the vacuum supply chain, i.e. optimised control systems to frequency control offers several options for optimisation. Companies that package foodstuffs on several thermoforming packaging machines, tray sealers or chamber machines should consider using a centralised vacuum supply. Energy cost savings of 50 per cent and more can generally be expected. This is possible as fewer vacuum pumps are required for this than for a decentralised vacuum supply. Performance control can be precisely adjusted to fit the requirements of overall operations. Centralised vacuum systems offer maximum reliability and safety as all systemically relevant components have a redundant design. If a vacuum pump fails or needs maintenance, full vacuum power remains intact. Busch central vacuum systems can be equipped with various vacuum pumps. In addition to oillubricated R5 rotary vane vacuum pumps, dry Mink claw vacuum pumps or Cobra screw vacuum pumps can also be used as components. The investment costs

“Rapid sales growth of 30 per cent per annum has resulted in Busch taking the market lead in most sectors where vacuum technology is needed”

can be reduced during purchasing by including already existing vacuum pumps in the system installation.

WHAT THE FUTURE HOLDS… ‘The Busch South Africa staff compliment has doubled in the past three years and now includes five mechanical and chemical engineers with in-depth vacuum knowledge. We are well resourced for future growth and the only expected staff growth will be in area sales executives in outlying regions of South Africa. The South African economy is in recession. This means less capital expenditure and the need for plant and equipment to last much longer and still be reliable and efficient. ‘It is more important than ever for customers to partner with product and service providers that can add real value to them. Busch has positioned its

Only 100 per cent OEM parts are used during service

products at fair and competitive pricing. We hold extensive stock of pumps and spares in South Africa. A differentiator is that we offer field service as well as service centres in Johannesburg, Cape Town and Durban. An extensive fleet of loan units is also available to our customers when needed. ‘Busch has also shown strong growth outside the borders of South Africa. We’ve established agents in Egypt, Kenya, Tanzania, Uganda, Rwanda, Namibia, Mauritius and Botswana. We are now finalising agency deals with Nigeria, Ghana and Angola. In 2018 we will appoint country managers into east and west Africa,’ Pieterse concludes. •

Busch Vacuum South Africa –

September 2017 | Food Review



Calories are cultural Professor Yanga Zembe is a socio-anthropologist and researcher at the University of the Western Cape. She recently presented her findings as part of an ongoing study on how a strong socio-political context frames the food landscape in South Africa, at the first Yoghurt Summit held in Johannesburg.


outh Africa is a post-apartheid have shaped the richly diverse and current food landscape in particular multi-cultural ways. Pre-1994, South Africans faced country, but diets tell a domestic and global isolation and different story as dietary for each population group in the diversity in South Africa country, this meant limited exposure is in fact quite low. A to a broader food culture. Post 1994, national study on food South Africa opened in political and consumption in children socially dramatic ways; an influx of (NFCS) showed a very global food products, cultures and monotonous type of diet trends, suddenly proliferated what with specific deficiencies had been an otherwise closed food including: energy; iron; environment. This resulted in more Professor Yanga Zembe zinc; calcium; vitamins food choices from convenience A; C; E; B6; B2; niacin and stores. This increased exposure to food, folic acid. This is largely due to much of the complicated people’s food choices a great population consuming large amounts of deal. In this new food space, healthier maize meal, bread and sugar with low intakes foods like maas, bread or pap enjoy limited of animal protein and fruit and vegetables. popularity than in previous times, because It is known that a diverse diet is more likely they are associated with the days that were to contain all the essential nutrients than a linked to hardship or they are considered monotonous one. Maslow’s famous Hierarchy unmodern. On the other hand, unhealthy of Needs places physiological needs, like food options such as take-out meals are food and water, at the forefront of a person’s consumed far more regularly because of needs. Yet results from the 2013 South their association with upward social mobility, African National Health Survey showed wealth and notions of having arrived. that almost three in ten people in South The challenge for health practitioners Africa go hungry daily, while one in four go trying to help people eat healthier is hungry most months of the year. Prof Zembe to acknowledge these tensions and confirmed this contrasts with soaring rates complexities. Prof Zembe urges that of obesity. in this context, we should strive to She added the major political transitions adapt to the eating patterns of South experienced in South Africa during and Africans rather than trying to change them

Use calcium to bake

completely. The adage of going back to one’s roots and culture is relevant. This said; there are ways that one can create a hybrid of culture and modernity. For example: although maas is no longer being consumed, yoghurt is a new modern fermented product that still upholds the virtues of being made from milk and live culture. It also has added nutrients to address nutrient deficiencies.

WHY WE EAT WHAT WE EAT From the emerging findings of the study there is a strong indication that, contrary to Maslow’s Hierarchy of Needs, food is not just about sustenance but a way of meeting both emotional and physiological needs. Food and eating practices are dynamic and influenced by a variety of factors such as fulfilling hunger, helping with expressions and feelings of love, belonging, contentment, self-esteem and social inclusion. Her preliminary findings suggest eating is a complex and tensioned area, not as simple as once believed, and this may be overlooked when healthcare professionals advise their patients on healthy eating. Social media, in particular Facebook, is also a hugely influential space. She appeals to health professionals to penetrate this platform as an avenue to disseminate accurate information on good food choices and nutrition. •

Omya Consumer Goods

Omya high-purity Natural Calcium Carbonate is a well-established source to fortify baked goods


Food Review | September 2017



Unlock lactose-free dairy

More than 70 per cent of the world’s population is currently affected by lactose intolerance. Lactose-free dairy products are becoming increasingly prominent worldwide.


n South Africa, a growing number of consumers are seeking free-from foods, including lactose-free dairy products. Free-from dairy in the region grew by 21 per cent in value sales in 2016, the same year the first lactose-free milk launches of note took place. Lactose-free dairy holds a 23 per cent value share of the free-from category in the region, with sales largely driven by lactosefree infant milk formula.

RESPONDING TO CONSUMER DEMAND Global demand for lactose-free dairy is on the rise, primarily because of its perception as a healthy food product. Consumers are more health conscious and, as a result, are increasingly aware of food allergies and intolerances. For those who suffer from lactose-intolerance, but want to enjoy milk, cheese, and yoghurt without negative side effects, lactose-free dairy products can

provide a welcome solution. It is important to note that lactose-free dairy is no longer reserved only for those unable to digest dairy products. Many of today’s health conscious shoppers opt for lactose-free dairy products as a lifestyle choice, believing these to be healthier than regular dairy. South African dairy producers wanting to keep pace with changing consumer demands can develop lactose-free alternatives of popular food and beverages such as milk, yoghurt, and ice cream, as well as pizza, pasta, cakes and pastries. Moreover, they may wish to serve their customers products that have added health benefits, for example, reduced sugar content or added protein, vitamins or fibre. The availability of lactose-free products in grocery stores, but also restaurants and cafés, makes life simpler for consumers with concerns about digestive health. This could present an opportunity for South African dairy producers.

PARTNERING WITH A DAIRY EXPERT The future for lactose-free dairy in South Africa is promising. Understanding consumers’ preferences and the innovation drivers remains key to successful product development. DSM has helped dairy producers tackle lactose intolerance for over 50 years - enabling healthier options for lactose-free consumers. DSM’s neutral lactase enzyme, Maxilact ® , splits lactose into glucose and galactose, which completely eliminates the discomfort caused by consuming dairy. Maxilact ® also allows dairy producers to achieve sugar reduction by up to 20 per cent. This claim assists lactose-free dairy product appeal even further. • DSM -

Inspection control equals security Improve inspection results with the world’s only multi-spectrum metal detector CEIA’s unique THS/MS21 metal detector achieves the highest sensitivity to smaller metal particles by applying a broad spectrum of frequencies simultaneously and continuously. CEIA’s continuous inspection process simply and accurately distinguishes between metal contaminants and product effects with no reduction in metal detection sensitivity. For fresh, frozen, hot, cold, wet or dry food products.

Feb 17_FoodReview_177x130_FoodRev_H&C_Ceia.indd 1


Food Review | September 2017

Distributor in Africa Cape Town +27 21 948 5934 1/02/2017 11:04:06 AM


An enhanced chocolate experience It was not until the beginning of the 16th century that chocolate was introduced to the royal courts of Europe. Prova’s cocoa is imported from West Africa, mainly the Ivory Coast and Ghana. It is processed into a powerful and highly aromatic extract.


he company’s PROCAO Cocoa extracts expensive and scarce raw material, which is and flavours, in liquid and powder prompting the industry to find alternatives. form, deliver an enhanced chocolate Prova’s product guarantees a genuine experience for all dairy products. These chocolate taste with high impact, an are eight to 10 times stronger than cocoa improved consistency, a fresher product powder and suited to both fat and nonthrough lower water activity, a reduced dry fat applications. These extracts are the matter and viscosity. This efficient range is foundation of the company’s heat stable and has a longer shelf life outstanding chocolate flavours. of up to two years. The company’s The use of cocoa powder flavourings solutions provide DID often creates technical a less powdery mouthfeel, an YOU KNOW? difficulties. Existing easier extrusion and whipping. Chocolate is cocoa extracts are very Whether natural or currently one of few, too expensive artificial, all the extracts the top three most and not well adapted. and flavourings produced by popular flavours Additionally, the existing Prova recreates the taste of all worldwide. artificial chocolate flavours chocolates such as pure cocoa, are not well balanced and dark and semi dark chocolate, milk often reflected because of their chocolate, white chocolate chocolatepoor performances. Chocolate, the toffee and chocolate nuts among others. second major taste in the sweet food industry The company states that its cocoa powder is a growing trend. Cocoa is becoming an extenders provide cost-in-use benefits.

As forerunners in cocoa extraction, it is no surprise that Prova processes 2 000 tonnes of cocoa from its vertically integrated production site. It has doubled its previous plant capacity for steady supplies and its applications experts are able to provide sideby-side product development support. •

Prova –

Represented by K-Chem, Contacts Phomolo Moeketsi, Kobus Oberholster, Tel: 012 653 5441

September 2017 | Food Review



The beauty of

cocoa The ingredient is primarily used to add flavour and colour to end products. In dairy applications, pure chocolate or cocoa powder can be used to serve a definitive purpose during formulation.


or cocoa, powdered dairy applications are the most challenging and sensitive. The milk matrix reveals the subtlest variations in the taste of a cocoa powder, including those aspects considered undesirable, could have an impact. Using specific origin products like those sourced in Peru, Tanzania or Ghana will reveal hidden

depths of flavour. These include hints of dried fruits and toffee flavours, fruity and hazelnut notes or caramel with a taste of roasted cereals. Cocoa powder can have an impact on dairy based products. To develop the full flavour and colour of cocoa, processors use a step called alkalisation. Invented by a Mr Van Houten in the 19th century, alkalisation was used to improve dispersion of cocoa powder in milk or water. The process has since evolved with two main goals: •  To develop a wide range of colour, from light brown to black, with dark reddish tones and medium brown colours

Quicker, better and more efficient – if those are your objectives, then you’re in good company with Bizerba. Because we pool all of our extensive experience to develop unique system solutions so that you can achieve your aims.

•  Building on cocoa’s indulgent taste, by increasing the cocoa flavour and reducing astringency and bitterness. Formulators must consider how the pH and alkalinity levels of the powder will affect end results. The pH of cocoa powder will determine how it will interact with other ingredients in the recipe and ultimately impact a product’s final texture. Cocoa in a dairy based product has a complex relationship. Research and development specialists consider how cocoa particles interact with milk proteins; when they stick on the surface of fat globules or air bubbles and how

Label Printers Bizerba GLP label printers can be used for product labeling with shipping and warehouse labels in the food processing industry, in the manufacturing industry and in logistics. In combination with the Bizerba weighing technology it is the perfect entry in manual price labeling.

Weigh price labeling system GLM-Ievo Setting new standards with the GLM-Ievo series. Thanks to the high performance and modular design there are no limits for today’s and future requirements in the industrial food area. These fully automatic weigh price labelers are impressive in terms of flexibility and robustness and the variety of available functions.

Weighing terminals iS The intelligence of Bizerba terminals always matches exactly individual requirements. From solutions for basic weighing and control functions to universal industrial weighing terminals for efficient recording of operating data.

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Food Review | September 2017

Visit us at Propak Cape Stand B68




Dried fruits|nuts


Blond/caramel tofee


Ghana Milk Chocolate

Milk chocolate

the powder’s alkalinity can impact product stability. An important cocoa characteristic is the microbiology of a cocoa powder. Dairy products can be spoiled easily due to certain micro-organisms surviving heat treatment resulting in spores. For this reason, some cocoa powders guarantee a low spore count.

COCOA AND ICE CREAM Cocoa powder with a fat content of 20 to 22 per cent or 22 to 24 per cent is often used in ice cream for a smooth chocolate flavour. Even in an extremely cold environment, the intensity of flavour from high fat powders still stand out. The higher fat


Cereals (puffed rice)

Intense cocoa

Fruity (red fruits)


Roasted cereals

Fruity (fruit liqueur)

content produces a creamier and more wellrounded impression in the mouth.

COCOA AND DESSERTS When changing a dessert from a smooth, chocolatey profile to a dessert with strong cocoa notes, doing more than just exchanging the powder is necessary. Depending on the stabilising system, it may be necessary to adjust stabilisers and thickeners. Flan provides a good example. When using a single recipe for flan and changing the cocoa powder from a neutral pH to alkalised, a strong texture is created. If changed from a higher pH to more acidic, the texture becomes soft and weaker.

Dark chocolate


To create an intense chocolate flavour, it is possible to combine real chocolate with cocoa powder. This combination opens a plethora of creative sensory options. High alkalised cocoa powder will intensify the colour and give a nice cocoa twist to the flavour profile of a product that already contains chocolate. By understanding the complexity of cocoa for dairy products, it is possible to develop recipes that accentuate the flavour and colour of the product, while respecting the texture and structure. •

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A new era of opportunity At the tail end of 2016, DuPont Nutrition & Health were looking for a distributor to service its small and medium customers in South Africa. Two women, with a strong footprint in the food and beverage industry, stepped up to the challenge. The result is a new tour de force in the ingredients landscape. Food Review spoke to Charlé Warnecke and Lezel de Vos to see what makes FoodTech Ingredients tick.


How did the new company come about?

Charlé worked for DuPont for ten years and saw an opportunity to start a business servicing these customers. Knowing the food industry requires a great deal of technical knowledge, she decided to partner with Lezel de Vos, who has a BSc Honours in Food Science from the University of Pretoria.


What is the company’s current focus?

FoodTech Ingredients’ primary focus is the supply of all the functional food ingredients produced under the DuPont Danisco brand to a wide range of food industry producers. Products include, but are not limited to: dairy cultures; yoghurt, ice cream and beverage stabilisers; natural antimicrobials, emulsifiers; soy protein solutions; hydrocolloids; polydextrose and xylitol. The company supports industries in the dairy, ice cream, confectionery, beverage, margarine, bakery, peanut butter, sauces, dressings and mayonnaise sector.


Food Review | September 2017


What can FoodTech Ingredients offer clients?

D edicated customer service; quick turnaround time; value-added service of technical troubleshooting, formulation development and assistance. Access to DuPont’s worldwide network of innovative product development centres is another plus.


Current and future dairy food trends?

The snacking and convenience trend increases the value of cheese retailing smaller volumes in snackable formats. There is a move towards repositioning and reinventing cheese. After 40 years of being demonised for its fat and salt content, cheese stands at the threshold of a turnaround that could see it re-established as a natural and healthy wholefood. Cheese is not harmful – neither for its saturated fat nor sodium content. Cheese could in fact be beneficial to health thanks to its high protein and calcium content. Another trend are combinations which can increase the value of dairy products. Savoury

Lezel de Vos and Charlé Warnecke

yoghurts are getting some additional attention, and the search for products that are authentic, traditional and of local origin is on. There is a definite rise in artisanal and small dairies that produce unique and tradionally less processed products. What product are you excited about?


Choozit RA iD is specifically developed to offer a more authentic Cheddar profile with enhanced mesophile composition for cheese manufacturers. The culture range is a blend of selected Lactococcus lactis ssp. lactis and cremoris with Streptococcus thermophilus. Tests have shown that in using lyophilised cultures with rotation protocols in place improves the consistency of acidification profiles and imparts less temperature sensitivity thanks to the strict and carefully controlled balance between thermophilic and mesophilic strains. This leads to better control of factors such as coagulation and curd composition. •

FoodTech Ingredients -


Food science for baked goods Quantum Applied Food Science (Quantum) is poised to offer an integrated solution approach to a wide range of clients in the food and beverage industry.


he company’s highly experienced team is fluent in the latest technological innovations. It can develop, manufacture, source and supply the most cost-effective and appropriate technologies for your company’s needs. Whether this means partnering with clients from concept and formulation through to implementation and production or using a new/existing recipe. The company is all about personalised solutions for clients. Quantum has strong and long standing relationships with a number of leading international companies in the food ingredient and flavour sectors. ‘This enables us to offer the broadest range of technology-based ingredients to bring a competitive edge to the client with a best fit solution both from a functional as well as cost competitive perspective. Quantum offers a broad product range spanning items such as bread and roll premixes through to sponge cakes, fillings and

toppings to decorations and packaging materials,’ enthuses technical manager Trudy Mills. The company recently established a new development bakery in Boksburg on the East Rand. This state of the art facility is fully equipped to replicate craft or industrial bakery Tests are carried out confirming consistency and quality applications, enabling customers to get hands on and participate in the development few years will see Quantum consolidate of their own products. Not only will this its position as a leading improver and facility enable speed to market, it will premix manufacturer in the marketplace. also spawn dynamic innovative ideas. It will offer companies customised The bakery also serves as the site where blending solutions to expand their own tests are carried out daily by Quantum’s product basket. • bakery technicians in order to confirm the Quantum Applied Food Science consistency and quality of the finished - products produced in its factory. The next

September 2017 | Food Review



Rise to

baking challenges Looking for opportunities to give your bakery products extra appeal and better quality during shelf life? Nutrilac wheybased ingredients from Arla Foods Ingredients could hold the answer. The range adds texture, taste and structure and can enrich nutritional profiles with protein and calcium.


t’s quite an art to produce high quality bakery products consistently all year round. Seasonality can influence the quality of the basic ingredients in bakery recipes. It can take some time to make the necessary adjustments and keep the quality of bakery products on track. Unlike flour, eggs and sugar, Nutrilac's solutions perform consistently all year round and from season to season. They offer an important buffer when ensuring the stability of bakery production. They also cut production waste. Cakes and muffins are more robust and less likely to break when taken out of the baking tin, meeting overall quality expectations. That’s good news for processing efficiency.

popular. Yet if they have a high protein content it can prevent consumers from eating more than necessary. Nutrilac’s protein enriched cookie concept is a great example. Using the ingredient produces a crunchy and delicious cookie with up to 19 per cent protein content. It provides excellent strength to both dough and final product, which makes the dough easy to handle and avoids final products cracking. An easy solution to implement in all current production setups. Arla Foods Ingredients is supplied locally through Chempure. •

EGG REPLACEMENT Many customers want to reduce or entirely replace eggs in recipes. Nutrilac offers a welldocumented solution. You can replace up to 50 per cent of egg white and whole eggs without altering cake texture or stability. The range of whey-based egg replacers are easy to use, with no pre-blending or cooling required. It also has a longer microbiological shelf life than eggs – up to 18 months stored at room temperature.

PROTEIN ENRICHMENT Consumers are increasingly looking to incorporate snacking alternatives with a high protein content to help them stay full for longer. Indulgent snacks and in-between meals are also

Chempure –

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Umami Flavor building blocks can be used to:

• Improves the yield in convenience minced products and whole muscle meat

• Boost Flavors

• Improves the firmness and reduces ripening

• Increase taste sensation of other flavors

time in fermented sausages

• Can assist in the reduction of sodium

• Can replace fat, act as an emulsifier and Kokumi Flavor building blocks can be used to:

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smoked sausages

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• Lends an overall balance and richness to food • Heightens the richness and sensation of other flavors • Without sacrificing the taste, Kokumi can reduce sodium, sugar, oil, fat and MSG

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Food Review | September 2017

ONLY A STEEL BELT GIVES YOU THIS MUCH VERSATILITY The unparalleled flexibility of a Sandvik bake oven belt is just one of its many benefits. Hard-wearing and stable, a Sandvik steel belt delivers outstanding product quality with a crisp, consistent bake, and a long working life for excellent ROI. Talk to us and find out what a Sandvik steel belt could do for you.

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The wonderful world of

toppings and fillings These products are the most colourful and delicious way to add interest, flavour and mouthfeel to baked goods - enhancing value to potential customers. Vivit Foods supplies quality fruit preparations, syrups, sauces, jams and confectionery products to the food and beverage, bakery and dairy industries.


he company prides itself on the manufacture of customised products that offer clients value-added solutions and reliable ontime deliveries. All products are available to the South African market and for export into the continent. In 2004, Thinus Grobbelaar acquired the business and changed its strategic focus to the manufacture of high quality products for use in the food and beverage industry. The company’s focus shifted to the development of customer focused solutions. These processes are


Products with natural flavours and colours with no added preservatives are also available. Vivit Foods offers various packing sized to meet the customer’s needs. Products are packed aseptically into bags and then into buckets and/or boxes.

complemented by purchasing superior quality fruit, flavours and other ingredients. ‘We want to understand our customers’ needs. With our experience in fruit preparations we help to create innovative solutions for them. Our clients benefit from more than 30 years’ experience within the food and beverage, bakery and dairy industries,’ Grobbelaar explains. The range of fruit pie-filling and toppings are bake- and freeze-thaw stable on request and can be used for cheesecakes, cupcakes, cakes, muffins, fruit pies, flans, jam tarts, doughnuts, Danish pastries and many other desserts. Flavours include strawberry, Black Forest, black cherry, red cherry, blueberry, kiwi, pineapple, apple and cinnamon, raspberry, mango, granadilla and mixed berry amongst others. Fruit content is adjusted to customer requirements. Other products in the portfolio include fruit pulp and preparations for yoghurt, drinking yoghurt and smoothies in a variety of different flavours. Vivit Foods manufactures egg-less lemon curd, caramel treats and spread in five kilogram packaging and other packaging options. Syrups for milkshakes, drinking yoghurt, smoothies, ice coolers and slushes can be packed. Jams in 25kg bulk packaging have been developed for bake-stable and spreadable applications. Salad dressings, mayonnaise and savoury gourmet sauces are also available. ‘Whatever topping or filling is used, be generous and have fun adding colour, flavour and that little extra that will place your products ahead of the competition. The astounding array of options in toppings and fillings for food and beverage products provide ample opportunity for bakeries and dairies to unleash their creativity and charge a premium for products with special touches inside and on top,’ Grobbelaar concludes. •

VIVIT FOODS IS: • FSSC22000 certified • A SADC registered exporter • Halaal and Kosher certified • Woolworths and PnP approved supplier. Vivit -


Food Review | September 2017


Chemical hazards – here we go again Although microbiological contaminants often take centrestage in discussions about food safety, chemical contaminants and their residues should not be underestimated. The recent fipronil scandal has once again raised concerns around the use and abuse of chemicals in a food handling facility. By Linda Jackson


ipronil is commonly used to get rid of fleas, lice and ticks but is banned by the European Union for use on animals destined for human consumption, such as chickens. It is thought that Fipronil was used in chicken farms to combat red lice, thus affecting the eggs of laying hens which were destined for human consumption. Although the FSA (UK) have advised that the risk to public health is “very low”, the WHO has warned that the pesticide is moderately toxic. Dutch food standards agency NVWA warns that fipronil can cause "nausea, vomiting, abdominal pain, dizziness, and epileptic seizures" although its effects are reversible. Three primary sources of chemical contaminants affecting food processors are chemicals entering the plant with the raw materials or ingredients; chemicals used in the plant to support manufacturing processes; and chemicals used for cleaning and sanitation purposes. One could add pest control processes to this, since fumigation is a common practice in many sectors. Food safety programmes should clearly identify what may be used, how must it be applied, where may it be applied and the associated legal requirements. This incident also raises concerns regarding the ability of food safety programmes to identify this kind of contamination. Chemicals users can ensure they control the potential for contamination. Identifying and managing chemicals that may be in raw materials and ingredients is more challenging for recipients, since control measures are out of their control. Contamination of raw materials or ingredients remains a problem across the

entire food supply chain. Contamination and adulteration both involve the presence of a substance that is not intended to be in a product. Adulteration is the deliberate and intentional replacement or dilution of the expected ingredient for economic gain. Contamination is unintentional and may be “technically unavoidable” due to some sort of shortcoming or lapse in control systems. Contamination is generally predictable. Higher residues of arsenic can be expected in plants grown in soil that is itself high in arsenic. The application of pesticides may result in pesticide residues in plants, and risks from contamination are generally easier to manage or limit because they involve hazards that manufacturers should be aware of. The challenge is to be prepared for the unexpected incidents, such as the fipronil saga.

"Contamination is generally predictable. Higher residues of arsenic can be expected in plants grown in soil that is itself high in arsenic" According to Markus Lipp, senior director for food ingredients at US Pharmacopeia, testing for the unknown to discover the unexpected, is a real challenge for analysts and risk managers. One of the best approaches to detect the presence of an unknown substance is to verify the identity


of an ingredient rather than test for the presence of potential adulterants. In other words, account for what a product is - rather than what it isn’t. In addition to the mandatory requirement to test raw materials (something we don’t do nearly enough of), food manufacturers should establish robust supplier processes, including visiting and inspecting supplier sites. While not wanting to create unnecessary audit bureaucracy, relying on proof of certification and raw material specifications may not be enough. Lipp reminds us, even audits may have shortcomings if suppliers deliberately hide unethical practices. ‘All food safety and food quality systems rely on the ability to predict and manage reasonably foreseeable risks and hazards. Prediction is very difficult when you don’t know what your substance is—and in the case of adulteration, only the adulterator has that knowledge,’ he explains. Fipronil is a reminder that we should be vigilant and perhaps not as trusting of suppliers for the right reasons. •

Fibronil is a broadbased insecticide that belongs to the phenylpyrazde chemical family.

Food Focus - About the author: Linda Jackson is a director at Food Focus

September 2017 | Food Review



Don't become a contamination statistic Consumers are concerned about what is in the food they are eating and how ethically it was produced. There is a growing pressure from the manin-the-street for food producers and retailers to be more transparent about the origins of their products. This calls for technology that can deliver such an important task.



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Food Review | September 2017

121.FOOD-REVIEW-W88.5 xH268-FA6.indd 1

2017/04/11 4:47 PM


homas Robbertse, CEO of traceability experts IQ Logistica says there has been a gradual power shift from the supply side to the consumer. This has been brought about by consumers becoming more knowledgeable about food products. ‘Consumers are anxious about food safety and want to know the truth about a food product they buy; what exactly they are eating; its origin; product attributes; how it was produced and its environmental friendliness,’ Robbertse explains. The advent of the Internet and social media has increased the consumer’s knowledge base, with platforms like Facebook and Twitter giving people a voice that can spread news on contaminated food like wildfire. ‘The tide has turned and there is no going back. The demands of consumers are on the up, whilst compliance regulation is also becoming stricter. Stakeholders in food supply chains are left with little choice but to ensure that real traceability of their supply chains is implemented.’ Robbertse believes proper traceability is a win-win situation for the supply chain and the consumer. Traceability gives the supply chain increased certainty because greater operational visibility is established. This in turn builds trust with consumers, which should lead to increased preference towards the specific products. Earlier this year, Doug McMillon, president and CEO of the international retail conglomerate Wallmart with majority shareholding in the local Massmart group with brands like Makro and Game, predicted customers will demand increased transparency around pricing and the supply chain in the future. He said they will have less time to research the products they buy, but will care even more about how they are sourced. ‘They’ll choose to shop with retailers who provide that transparency so they can feel good about the items they purchase. This will require retailers to work with manufacturers to source items responsibly and sustainably. Retailers who do this

"It means the final food product on the shelf can be traced back to the farm on which it was produced”


DID YOU KNOW? * IQ Logistica has an ISO 9001:2015 certification from TÜV Rheinland 
 *The company complies with the GS1 global standards for business communication designed to improve efficiency, safety and visibility of supply chains * Has a Level 2 B-BBEE status.

and share the information will further earn customers’ trust.’ Hennie Ras, principal specialist of traceability and operations visibility at IQ Logistica, notes that its IQ Thentic technologically advanced communication system ensures proven traceability and sustainability within a supply chain. ‘IQ Thentic can integrate a supply chain that deals with different commodities – from the raw product in its original state to the finished item on the shelf – that all need to be tracked differently, all using the same system and within the same database,’ Ras enthuses. What makes the IQ Thentic technology remarkable is it can handle all the

transformation and value adding processes that a raw product undergoes in a value chain. In simple terms, it means the final food product on the shelf can be traced back to the farm on which it was produced. ‘When it comes to quality issues, the system can drill down to a specific event to identify the problem or to recall products.’ Traceability is tracked by way of a unique identifier. In IQ Thentic’s case, this is a QR code that identifies each individual item within each product line. It also establishes an audit trail within and between different organisations in the supply chain. When fully implemented throughout the supply chain, the product information is available immediately.





The QR code on the final product is also how the consumer can track the evolution of the product from its origin. ‘We can do this regardless of the number of participants in the chain because the traceability platform is cloud-based – therefore it covers the value chain as an umbrella and links into each role-player’s own system,’ Ras concludes. •

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Traceability is a win-win situation in the food industry

7/08/2017 10:58:19 AM

September 2017 | Food Review



Angeline Nel , Mpumi Malindi, Santie van Niekerk and Vinay Moodley

Dynamic solutions in health and hygiene

After spending 12 years in the medical, food and environmental industry, Santie van Niekerk had a clear vision of what unique services were needed to address new and existing opportunities in the local food and beverage industry. By Maryke Foulds


n 2014, dynamic and goal driven entrepreneurs Santie van Niekerk and Vinay Moodley, launched MiChem Dynamics. The pair are qualified microbiologists, South African National Accreditation System (SANAS) and Southern African Development Community Accreditation Services (SADCAS) assessors and management system experts. Their primary focus was to create a link between the laboratory and manufacturing industry by means of interpretation of results, root-cause analysis and implementing corrective actions. Additional services were introduced later. These include training, consulting, auditing and recruitment. This makes MiChem Dynamics a comprehensive provider of all services in the laboratory, food and beverage manufacturing, health and safety industries. ‘MiChem Dynamics offers professional and experienced consulting, auditing and training services, to ensure laboratory, food safety and hygiene compliance, related to ISO 17025, ISO 15189, FSSC 22000, ISO 22000, SANS 10330, SANS 10049, R962, ISO 9001, ISO 18001 and ISO 14001,’ Van Niekerk enthuses. ‘It is our aim to ensure MiChem Dynamics becomes one of the most trusted and respected professional services firms in South Africa. We want to be recognised by all our stakeholders for delivering excellent service that focuses on providing the highest quality services that address their specific business needs. We strive to attract, recruit, and retain the most knowledgeable and passionate professionals, and provide a cooperative culture that enables them to thrive professionally and personally,’ Moodley concludes.


reasons to choose MiChem Dynamics

• Trained staff that partner with the best in the industry. The company assists in identifying new opportunities, and ensures you have the best of breed software in place. This provides peace of mind that processes are based on the best industry can offer. • A one stop shop for all client challenges and needs. Its extensive network enables employees to find solutions to the most difficult and complex questions faced by the industry. • Innovation lies at the core of the company ethos. Bespoke solutions are provided to ensure key frustrations are addressed in unique ways.• MiChem Dynamics –


Food Review | September 2017


September 2017 | Volume 7 | Number 9

Every drop counts Lifting the stigma of water reuse

Sugar tax still in limbo

“Long4Life has concluded a share purchase agreement to acquire 100 per cent of Inhle Beverages”


Every drop of Brian Joffe

Inhle Beverages in targeted acquisition

Long4Life has concluded a share purchase agreement to acquire 100 per cent of Inhle Beverages (Inhle), subject to the completion of a due diligence and obtaining certain regulatory approvals. INHLE IS A well-established contract packaging business located in Heidelberg, Gauteng. It specialises in the canning and bottling of carbonated soft drinks, energy beverages and natural mineral water using cans and PET. The company was established in 2003 with one production line. Today it is the second largest beverage co-packaging business in South Africa, with seven production lines and considerable scope for expansion. The company employs around 300 staff and undertakes co-packaging on behalf of an established client base. Long4Life chief executive Brian Joffe comments, ‘This acquisition fulfils the broad definition of our investment criteria in the leisure space. It presents a strategic opportunity from which we can build a beverage business of scale, through both organic growth and bolt-on acquisitions. Immediate access to the largest market in the country as well as its proximity to surrounding territories, positions Inhle extremely well from an expansionary point of view.’ Inhle recently secured a liquor licence (for packaging purposes), which represents

another industry opportunity for Long4Life to expand its interests in this sector. The co-packaging on behalf of Inhle’s clients will initially be focused on canned, already-mixed beverage products, which has seen strong growth over the last few years. Inhle director Chris Botha explains, ‘The overriding benefit of this acquisition is that it positions Inhle for its next exciting growth chapter. As a family-owned business we have certain constraints, but by partnering with Long4Life we can access its funding capability, and the vast entrepreneurial knowledge and experience of its team. This allows us to better position ourselves and take advantage of the significant opportunity that exists in the rapidly growing beverage industry in South Africa.’ The concept of co-packaging on behalf of beverage manufacturers is a growing international trend, which ultimately reduces risk for the packaging supplier. Long4Life’s chief operating officer, Kevin Hedderwick concludes, ‘We recognise the value of entering a market with a partner that is already well-known and highly regarded in the industry.’

water counts

THE WESTERN CAPE has been declared a disaster area as South Africa experiences its worst drought in 30 years. ‘Corporate South Africa, government and the public need to make a collective effort to safeguard this essential resource,’ says Nico Moloto, stakeholder and sustainability manager at Pioneer Foods. To mitigate against potential water-related risks, Pioneer underwent a group-wide basic water assessment in October 2015. The geographical and catchment area risks for each production plant were assessed and site-specific water consumption figures recorded. By the end of 2016, Pioneer managed to save approximately 86 million litres of water in total across all its sites. The company identified the potential to improve water consumption across the production process, particularly in beverage plants. In addition to the supplementary use of borehole water at the Ceres Beverages site backwashing water is recovered and reused, while new pumps regulate water pressure more efficiently. The Ceres Beverages factory in Gauteng is close to achieving a 20 percent saving in the amount of water per one litre beverage produced. This is thanks to more efficient processes and the capture and re-use of water used on the seals and pasteuriser pumps. Up to 80 per cent of the water used in each backwash is now recovered and reused since an improvement project was recently completed. •

No agreement of sugar tax yet, says BevSA

THE BEVERAGE ASSOCIATION of South Africa has dismissed reports that there was an agreement on the Health Promotion Levy at the National Economic Development and Labour Council (Nedlac). BevSA is opposing the introduction of a 20 per cent tax on sugary beverages, or what has been referred to as sugar tax, which government wants to implement in a bid to curb noncommunicable diseases. Mapule Ncanywa,


Food Review | September 2017

BevSA executive director, said the industry still believes that the levy in its current form would have serious negative impacts on the economy, and have no impact on the non-communicable diseases problem. He reiterated that the primary aim of the industry was to avoid any job losses particularly under the current economic conditions, which is faced with a technical recession and credit rating downgrades

and have an impact on health. ‘BevSA welcomes the continuation of the engagements and hopes that all efforts will be explored on finding a solution that addresses concerns raised by industry and other stakeholders,’ Ncanywa said.


Limit water risk It is estimated that an average of 3.5 to five litres of water is used per litre of beverage production. For many operations the risk of water shortages and poor water quality is costly due to resultant operational shutdowns, which negatively affect a business' bottom line.


ot only is the beverage industry vulnerable to continued water scarcity, but escalating water costs, stringent regulations, and extreme weather events are all real risks. A lack of water has a direct effect on production, which in turn leads to significant revenue loss. The amount of water required to produce beverages accumulates along the value chain. Contributors include agricultural production of ingredients, water utilised in product processing, as well as product packaging and beverage consumption. Risks associated with the beverage value chain vary. Industrial processing of beverages are susceptible to risks

including regulatory (legal noncompliances), reputational (pressures from clients and customers), physical (water availability and quality), and financial risks (costs associated with water consumption and discharge such as water and energy tariffs and infrastructure upgrades). The significance of these risks is largely dependent on the manufacturer’s geographical location, which is characterised by differing water availability, local infrastructure and governing legislation.

POSSIBLE SOLUTIONS The key to managing water risk in the beverage industry is to identify and

"The stigma surrounding water recovery is lifting as water recovery becomes an increasing necessity"

evaluate site specific risks associated with water supply, utilisation and discharge. Once water related risks are evaluated, tailored risk and opportunity management solutions can be developed. Opportunities can potentially extend beyond wastewater treatment to biogas production and wastewater recovery.

September 2017 | Food Review



How to choose the right strategy for your business

Water used accumulates along the value chain in the beverage processing industry

BIOGAS PRODUCTION Due to the high sugar content of wastewater within the beverage industry, potential opportunity exists in the generation of biogas through biological wastewater treatment. Biogas can in turn be used in boilers, reducing operational energy expenditures and reliance on external energy suppliers.

WASTEWATER RECOVERY This is a concept which is becoming increasingly popular. The stigma


Food Review | September 2017

surrounding water recovery is lifting as water recovery becomes an increasing necessity. The apprehension of using recovered water is founded on the idea that it is below standard. Water recovered through a well-functioning wastewater treatment process is often of an equal or higher quality than that supplied by the local service provider. Measures can also be taken to ensure areas utilising recovered water are ring-fenced to avoid contact with product if required.

Beverage manufacturers can start by unpacking their water footprint through identifying current water intake, usage and discharge. This is critical in the process to identify potential opportunities for water efficiencies, savings and reuse. The next step is to identify opportunities to reduce water use in processes and use wastewater in the business itself. Water and wastewater solutions experts, Talbot & Talbot’s multidisciplinary team of professionals endeavour to provide solutions to water resource management needs and challenges. This runs from understanding water-related risks and ensuring optimal supply to maximising performance efficiencies, reducing effluent discharge and ensuring environmental compliance. Services extend from assisting clients to identify key water risks and opportunities and develop optimised strategies to manage those, to designing, building and managing water and wastewater treatment and associated water and energy recovery facilities. •

Talbot & Talbot –


Industry specific water treatment Local companies are currently feeling the full impact of the water shortage, but industry is fast following on the footsteps of its European cousins.


vailability of sufficient, quality intake water is the biggest threat for the South African food and beverage industry. In terms of effluent, a large percentage of industries are not discharging at the correct discharge standards. Redox Water Technology, supplied locally through DFS Process Solutions (DFS) offers a wide range of products to assist. Large amounts of effluent water can be reused, reducing the reliance on municipal water and utilities costs. Industry can reuse up to 40 per cent of its effluent. If legislation in the food industry allows, this could be increased to between 80 and 90 per cent. According to Walter Mengel of DFS there are a number of systems that could offer benefits to local industry. ‘The strongest and most effective piece of equipment would be the dissolved air flotation (DAF) system. This

process clarifies wastewater by removing suspended matter such as oil or solids. Removal is achieved by dissolving air in water or wastewater under pressure and then releasing the air to atmospheric pressure in a flotation tank basin. Released air forms tiny bubbles which adhere to the suspended matter, causing it to float to the surface of water where it is removed.’ Additional technology is FBR biological wastewater treatment systems. ‘Wastewater after primary treatment is pumped into the aeration basin, filled with an activated sludge/water mixture. Activated sludge is flocks of bacteria, called biomass. In the presence of oxygen pollution will be decomposed by these bacteria. The oxygen supplied by the aeration system supplies optimal condition to decompose main pollutants, mainly carbon, hydrogen and nitrogen.

Redox biological treatment plant

‘Eventually most pollutants will be converted to carbon dioxide, nitrogen gas, water and excess sludge. Water flow is continually pumped out of the aeration basin, processed by a special flotation unit which separates activated sludge from clean effluent. This flotation system is capable of handling high solids loading, and thickening activated sludge to about five per cent dry solid content. Microscopic air bubbles adhere to the sludge, reinforced by the dosing of polyelectrolyte. The sludge floats to the surface where it is then mechanically dewatered and skimmed,’ Mengel concludes. •

DFS Process Solutions – Redox -

September 2017 | Food Review



Partial deionisation

in water processing The Gemü Group has been instrumental in facilitating the optimal working of a water facility. Beverage Review spoke to managing director Brian Allingham, on how the process works.


o begin with, raw water is filtered in the facility over the course of various preparation phases using ultrafiltration. It is softened using an ion exchanger and then sanitised via UV disinfection. 300m³ of water is treated every hour at the plant: this equates to 2.2 million m³ every year. The plant’s most notable feature is the ion exchange using the carbon dioxide regenerated ion exchangers also referred to as the Carix® procedure. The system features low operating costs and is environmentally friendly.

ULTRA-FILTRATION After coarse filtration, water requiring treatment is fed under pressure (0.1 - 0.8 bar) through porous diaphragms with a pore size of approx. 0.01μm. This enables the finest solids, turbidity and pollens, as well as germs, to be retained. The water, dissolved ingredients such as hardening salts or minerals, and small molecules can pass through the diaphragm.

PARTIAL DEIONISATION AND REGENERATION Using ion exchange (mixed-bed filter), the hardness components calcium and magnesium, and undesirable substances – such as nitrate, sulphate and chloride - are approximately halved in the sanitised but still hard water. Carbonic acid is generated as a by-product, and it breaks down into water and carbon dioxide (CO2). This is then removed in the secondary pure-water degasifier before the treated water is transferred to a pure water container and is fed into the water supply following UV sterilisation. During the sub processes, water hardness is reduced from 27° dH to the optimal level of 13 to 14° dH (from hard to medium). Raw water is used as a regeneration agent for the mixed-bed filter, which has been enriched with CO2 – the direction of the exchange reaction is therefore reversed during the regeneration process. Under pressure, CO2 is then dissolved in water and this creates carbonic acid. The carbonic acid is then channelled in the counter current over the mixed-bed, which is regenerated as a result. The exchanger resins are therefore returned to their initial state. Most of the CO2 required for regeneration is recovered (approximately 95 per cent) and fed back into the process. This regeneration principle and recovery of CO2 is the key element of the Carix® procedure and turns it into a particularly environmentally friendly and resource-saving procedure to partially deionise water. Alongside pneumatically and manually operated Gemü butterfly valves in nominal sizes up to DN 400, ball valves and plastic butterfly valves are also used in all treatment processes for the distribution of raw water and treated at the facility. •

Gemü Group -


Beverage Review | September 2017


September 2017 | Volume 43 | Number 9

Streamline your approach to

end-of-line packaging

Building blocks to

Propak Cape 2017 set to reign

smart packaging


An explosive


mindful recycling


HE END OF the year is just around the corner; spring is in the air and the highly anticipated Propak Cape 2017 exhibition will open its doors soon. The event takes place next month and promises demonstrations on the latest advancements in equipment, products and materials by various industries. It will also offer daily seminars, a Sustainability Pavilion and more. Please pop by our stand in Hall 1 Stand E66 to meet the team. This month’s packaging section, jam-packed with content, is one of the largest editions since I took over as assistant editor. Don't miss the Propak preview on page 44. Enjoy the read

Assistant Editor Aarifah.Nosarka@ PPK023-3-2.pdf













Packaging Review | September 2017

11:38 AM

METPAC-SA, THE newly formed industry body representing the interests of the local metal packaging industry, joined forces with various packaging streams during September. This was to encourage households to practice mindful recycling as part of Clean-up and Recycle SA week, which took place from 11 to 17 September. ‘More than one third of aluminium currently produced globally originates from old, traded and new scrap. The high intrinsic value of metal scrap has always been the main impetus for recycling, independent of any legislative or political initiatives. In addition to this obvious economic dimension, growing environmental concerns and heightened social responsibility have served to boost recycling activity to conserve resources and avoid littering,’ says Delanie Bezuidenhout, CEO of MetPac-SA. The industry body is a product recovery organisation bringing together the entire metals packaging value chain

in South Africa. It provides the aluminium, steel and tin can industries with a unified voice when presenting views, making recommendations or voicing opinions. These industry leaders work together to ensure that they support the greater packaging industry’s vision of zero waste to the environment. Although South Africa boasts an already impressive recovery rate of about 72 per cent for used beverage cans, the association believes more can be done to divert other metal packaging such as aluminiumfoil, containers and empty tin cans from landfill. ‘Our waste management partners such as WastePlan and The New Reclamation Group confirm that they also readily accept and recycle metal food cans and aluminium food packaging at their commercial sites. They also have sorters on site to separate the different recyclable commodities,’ Bezuidenhout concludes. •


Innovation centre IPEX MACHINERY (IPEX), the South African representative of Wittmann Battenfeld, hosted an open house from 21 to 23 August. This was to mark the official opening of its new technology centre at its Johannesburg premises. ‘The reason for opening the centre was two fold. It allows customers the opportunity to see their moulds running on the most technically advanced IM machine in SA and serves as a training facility,’ says Sean Kleingeld, Wittmann Battenfeld product manager at Ipex. Presentations at the open house included a demonstration on robotics and automation more specifically, an IMM (110t) with an integrated robot, loading and dosing equipment. This included a demonstration on the full integration of all the auxiliaries into the HMI of the machine, using Wittman 4.0 software. Kleingeld says settings to the

takes off

components that make up the complete workcell can be implemented from the Human Machine Interface, which is the IMM control panel. ‘These are technologies that communicate with each other. All its devices are integrated with a full overview of the complete working cell provided to the operator. Since all parts are easily changed, the system makes life easier,’ explains Siegfried Köhler, sales director at Wittmann Battenfeld. In celebration of the sale of Ipex’ new machinery, it hosted a cocktail and dinner event at the Gold Reef City Theme Park hotel on 22 August. The event honoured six customers who have invested in new machinery. Bruce Allen, MD at Ipex says the dinner is anticipated to become a regular event,

which allows current and potential customers to network in a relaxed environment. ‘With a turnout of 60 people from all over South Africa, we welcomed our first members into the exclusive Wittmann Battenfeld owners club and look forward to seeing this number grow at future events,’ he concludes. •

New bottles

are a clear winner RPC PROMENS CONSUMER Llantrisant has launched a series of PET bottles suitable for all types of sauces, condiments and toppings. The new Mercury range combines high shelf impact with outstanding consumer convenience. The stylish curved design and glass-like clarity of the PET ensure that products are displayed to their best advantage, while the lightweight, easy-to-handle and squeezable bottles are ideal for home use. The bottles are fully FDA approved and can be recycled after use. They are available in five sizes from 300 to 920mℓ with a wide choice of standard closures, including headstand options. RPC Promens Llantrisant also provides full technical support including assistance with filling trials. •

September 2017 | Packaging Review



Are you ready

to switch on your brand’s packaging? In this age of information, even packaging can tell us valuable things about its contents. Active or intelligent packaging provides information on practically everything, from monitoring freshness of a product to displaying information on the quality of the product and more. By Gail Macleod FAST FACTS ON INTELLIGENT APPLICATIONS


s the world is getting smarter, so is packaging. Exciting technologies such as Augmented Reality (AR) enable a humble box to entertain or inform consumers in ways that are both magical and pragmatic. Not only can the artwork appear to come alive, the nature of this new engagement also creates a sense of interaction far more immediate and profound than that of traditional on-pack promotions. Although AR may sound like a futuristic term, it is not new and companies are increasingly making use of this revolutionary digital technology. It connects reality with the virtual world. AR is a mix of the reality with a virtual addition or enrichment. In practice, it means that digital content is added to your range of vision. It’s about creating content that is genuinely engaging, which consumers naturally share because it is so good. It involves content that invites people to have a conversation, interact, or even co-create new ideas. This is what transforms consumers into fans or, better still, a community. Experts enjoy debating which magic ingredients make up the secret sauce of shareable content. The packaging can provide a bigger multimedia canvas to showcase this creativity. It can provide the same interaction or ability to recognise consumers that a web-browser does. AR packaging design can do these things and all you need to know is how to blend the digital and physical worlds together.

ASK YOURSELF, WHAT SHOULD PACKAGING DO? A bigger question than how to go about this is ‘what extra content should the packaging provide’? This is a tricky one but, like every other new channel created in the digital gold rush, brands need to think hard about the ideas that add genuine value for the consumer, and what is frivolous, intrusive, or plain irrelevant. It’s not enough to jump on a bandwagon because rivals are doing so. More than anything, an interactive packaging experience must relate to the rest of a brand’s values and be produced with


Packaging Review | September 2017

• Freshness indicators display the quality of the product. These not only detect volatile, but also nonvolatile compounds or changes in the product itself. • Tracking services monitor the quality of perishable goods during transportation, storage and sale. They are also able to alert the end-user if the product has been stored or transported at an optimal temperature.

the same care as that of any other marketing material. Great things can be achieved quickly and with modest budgets. Yet it’s far better to not do anything rather than launching something with limited functionality just to say ‘you’ve done it’. To get this right and add real value, initially you need to understand the specific needs and contexts of consumers when interacting with packaging, and then build on this thinking. The technologies that constitute interactive packaging are fairly new; they all have pros and cons. Before I get into the specifics, it’s important to understand what these represent. Interactive packaging can connect consumers in deeper and richer ways to the brand and other consumers. It is a huge opportunity to foster genuine engagement rather than build a huge number of likes on a Facebook page nobody ever reads. However, it must be part of a unified story with a clear role of the consumer as a participant, not a punter. While AR may not be a widely-known concept locally, forward thinking brands have shown they are not afraid to take a leap into the virtual. •

About: Gail Macleod, founder and CEO of Stratcom, a strategic packaging design agency providing commercially successful solutions for brands. Smart, seamless, professional problem solving and clever thinking have been the hallmarks of the company’s philosophy. MacLeod studied graphic design at the University of Witwatersrand and is one of the founding members of the Global Local Branding Alliance.

Stratcom –

Official INX distributors for South Africa Constantia Printing Inks are proud agents for INX International, Salchi and CTI. INX Low Migration inks and coatings for non-food contact surfaces are created in a dedicated, state-of-the-art facility to meet stringent government regulations and compliance requirements. First impressions do make a difference, and one way for a brand to break through the clutter is with the use of special effects in the printing process. INX inks and coatings in this category include soft touch, pearlescent, raised glitter and spot gloss coatings; reticulation varnish; and fluorescent, foil stamp and metallic inks. With BiocopacPlus Salchi Metalcoat is developing the first bio-based varnishes for food packaging obtained from agro-industrial waste from the tomato industry. CTI’s food safety technologies are on the cutting-edge of ensuring proper pasteurization, heat-sealing, and transportation. CTI provides technology that alerts consumers if a product’s quality has been compromised in various stages within a supply chain. Options from CTI include; Thermochromics , Photochromics , Glow-in-the-dark , Reveal inks , Trigger inks,HPP indicators and Colour changing Plastic.

Tel: +27 011 524 0715 / 0716 Email: Web:


An array of

anti-counterfeiting technologies Using foils to enhance the look and feel of products, add security features and add variable information such as expiry dates to products. Established in 1995, United Foils is a supplier of quality hot and cold foils, thermal transfer ribbons, date –coded foils and date –stamping machines for a wide range of clients, including printers, the food and beverage and pharmaceutical industry. We also assist advertising agencies, graphic design companies and publishing houses with concept development. Innovative products, knowledge and experience and trusted delivery form the essence of what we offer. Our ability to solve problems by providing innovative foiling and date-stamping solutions translates into smart solutions, cost effectiveness and convenience for you. • •

Packtech Tooling is a specialist tooling supplier to Africa’s printing, packaging and narrow web label and related industries. Our services include metal tooling, woodbase tooling, general engineering and packaging design. We invest in sophisticated machinery and in the expertise of our staff to offer you quality tools, quick turn-around times and competitive pricing. Our research and development Department helps to ensure that we stay on top of the latest local and international tooling techniques and trends. For you as a client, this relates into the ability to rely on quality tooling, relevant advice and friendly service. Packtech conducts its business in a socially responsible way, taking into account the development of people and the sustainable use of resources. • •


Packaging Review | September 2017

Companies invest heavily in building brand equity. It is important to protect your brand and minimise revenue loss from threats such as counterfeiting and substitution. Consumption of counterfeited food and beverages can also pose health and safety risks. By Carol Zweep


o help minimise these risks, packaging can be designed with anti-counterfeiting features. Classic solutions have been tamper-resistant/evident packaging. More sophisticated packaging technologies that have been developed to combat counterfeiting include track and trace technology and authentication technology. • Radio frequency identification (RFID) technology is an example of track and trace technology. They consist of an antenna connected to a microchip, which can be applied to the product using a selfadhesive label. • Authentication technology uses holograms, watermarks, specialised ink and dyes, and taggants. Three-dimensional holographic labels and watermarks are difficult to replicate but end users are able to easily identify and confirm the authenticity of the product. • What is a taggant? A taggant is a chemical or physical marker added to materials. Physical taggants come in different forms but are usually microscopic, used at low levels for simple and fast detection in a non-destructive manner. Taggants are uniquely encoded and virtually impossible to duplicate and can only be verified with specialised but inexpensive readers. • DNA markers can be used to authenticate products. DNA sequences can be custom created and embedded into inks, varnishes, thread, laminates and metal coatings. • The combined use of overt, covert and forensic features can deliver enhanced security and protection. The manager of Packaging, Food and Label Compliance for NSF Overt technology provides International, Carol Zweep has been instant visual authentication at the company since October 2002. (e.g. holographic devices). She manages a department that performs both packaging and shelf Covert techniques (e.g. RFID, life studies. taggant) use microscopic tagging with special readers to confirm authenticity. Forensic features include molecular and biological tracers that are difficult to reproduce and detect. Anti-counterfeiting technology development has been driven by brand protection and economic loss. Although there is general lack of awareness and affordability of these technologies, recent campaigns by anti-counterfeit trade organisations and interventions from government NSF International – have increased their use. •


Think ink for quality produce A newly developed heat activated ink technology is believed to improve food quality standards by means of notifications.


hromatic Technologies Inc (CTI) recently announced the introduction of Tamper Alert, a new irreversible, heatactivated ink technology. The technology was designed to identify tamper evidence in labels and packaging for chemicals, food, electronics and other products usually targeted for theft and counterfeiting. The company’s newest technology is a breakthrough in tamper evidence. It provides a tight activation window where the alert transitions from colourless to full colour within a range of 10°C. Traditional irreversible technologies require a transition window between 30 and 50° Celsius, which often results in weak colour activation and detection at lower temperatures. The colour change is indicative of products that have gone through changes that affect their quality. Examples include the product being removed from a refrigerator for a significant amount of time, or if it has been tampered with. Tamper Alert is available in target activation temperatures of 50°C,60°C, 70°C and 80°C. ‘For much of our 24 year history, CTI has produced inks that change back and forth based on temperature or sunlight. This was demonstrated in our ink used recently for the US Postal Service 2017 solar eclipse stamp,’ says Lyle Small, CTI’s founder and CEO. He says the company has perfected ink that is irreversible. The Tamper Alert invention incorporates CTI’s Turbo colour technology,

which creates the strongest colour alert in tamper evidence in blue, green, black and red. ‘CTI receives 30 calls every year from across the world seeking improved tamper evidence technology,’ he adds. The company is constantly asked whether it has a technology that activates in a tighter temperature window and has stronger colour. Small explains, ‘It was a very tough chemistry to figure out, but the team finally did it.’ Currently, Tamper Alert is currently only available in water-based applications. CTI is a producer of thermochromic ink and manufactures other environmentally reactive technologies such as photochromic, pressure-activated, irreversible, reveal and glow-in-the dark.

OVERALL IMPROVEMENTS Earlier this year, CTI revealed its patentpending, high pressure indicator ink for food packaging. This ink indicates high pressure pasteurisation (HPP), also known as high pressure processing, has been applied to food products. The HPP machines are specially designed to inactivate pathogenic bacteria and thereby extend shelf life. Conventional pasteurisation uses high temperatures, which degrade the taste and nutritional value of food and beverages. One advantage and disadvantage is that the product subjected to HPP looks identical to products that have not undergone HPP treatment. It is impossible

to know by visual inspection, whether or not a product has been treated, which creates a challenge for everyone in the supply chain. CTI’s technology addresses this challenge. •

Chromatic Technologies Inc

Food & Beverage Manufacturing Advanced Automation Solutions

As a partner in all your automation requirements we offer personal solutions, knowledge and expertise. • Vision Inspection • Machine Controllers • Database Connectivity • Pick & Place • Temperature Control • Components & measurement sensors

Omron Electronics ZA 011 579 2600

September 2017 | Packaging Review



Flexing with the trends In end-of-line packaging, flexibility is an important consideration. Primary packs have to be placed in easy to handle secondary packaging before products are placed in an appropriate tertiary outer pack. To keep up with constantly evolving trends, these systems must incorporate maximum flexibility in the changeover process.


MD Packaging Systems’ (PMD) MD, Michael Spencer says compared to Europe and the USA, flexibility is especially important in South Africa. ‘In this country, we have lower line speeds on endof-line machines whereas in other countries there are dedicated lines designed for use.’ This year, the company celebrates a major milestone – its 50th anniversary. In 1967 PMD manufactured its first vertical form, fill and seal technology, the PM100. After the launch of this machine, the company’s sales gained momentum throughout the continent. ‘These machines packed beans, rice, lentils, sugar and many other products. Not long thereafter, we introduced the ice pop machine for ice pops or popsicles, as

they were known by pupils from Algeria and Zimbabwe,’ says Spencer. Two Johannesburg-based companies are still using the machines PMD supplied to them when it first started operating; both machines are still fully functional. ‘We continue to supply spares for machines as old as the company is,’ he proudly adds. Spencer says the company has had significant growth in spite of the country’s difficult economic climate. ‘We predict the coming year will yield record sales and profits.’ Apart from supplying end-of-line technologies, one of its popular systems is the robotic palletiser. The machine caters to a wide range of products including rice, beans and sugar. It can also be used for

corrugated cartons and woven polypropylene sacks. ‘The robot’s key feature is its innovative nature and flexibility of the pickup heads that can be supplied with pallet feed systems. Another well-known machine is the cartoning technology. This particular technology includes systems from the UK for high speed and specialised end and top loading.’ PMD manufactures locally developed end systems for end loading. These are suitable for packing cereals, ice creams and coffee creamers. Historically, the company primarily focused on dry products but has recently become active in providing machines suitable for slurries and liquids.

A PMD cartoning machine


Packaging Review | September 2017


It continues to be a major supplier to all leading food producers in South Africa and other parts of Africa. A major measure of the company’s success is attributed to the fact that most of its personnel are long serving with more than 10 years’ service. Based in Krugersdorp, PMD is in the process of introducing modern end-of-line systems that involve the addition of laminate materials on form, fill and seal technologies. According to Spencer, this will enable producers to differentiate brands from its competitors’ with the additional advantage of no spillages.


heat pipes, sealing technology, fast temperature control and high-pressure sealers. These machines also offer extended product shelf life and provide longer dwell-time, which enables sealing of thick packaging materials, making them particularly suitable for handling tall or heavy products. All Alpha VII horizontal flow-wrapping machines, including the FW3710BS and FW3410BS models are capable of producing standup block bottom gabletop packs. The stainless steel construction simplifies cleaning and both machines have standard bottom film infeeds

Goldpack’s director, Bevan Challenor is upbeat about Fuji Packaging Machines’ Alpha VII horizontal flow-wrapping machine range, which includes the Alpha VII back seal flowwrapper FW3710BS and FW3410BS models. Celebrating its 50th anniversary, PMD started by designing ‘These machines are popular and building fully automatic bagging systems in Africa. Its for packaging a wide range of name became ubiquitous in the world of packaging. Although products,’ he says. The Alpha it is no longer the sole provider of bagging machines in the VII horizontal flow-wrapping region, it has become a leader in Africa for state of the art range is a low maintenance, packaging systems. The company has installed packaging easy to use and energy efficient machines at customers across the African continent. system. They feature advanced

Onward and upward


1967 - 2017 Suppliers of Packaging and Processing Machinery | Tel: +27 (0)11 795 1994

September 2017 | Packaging Review



The KZV-111

enabling an easy and positive transfer of products from the conveyor to films. These models comprise touch panel operations, with simple to understand instructions. Mosca's KZV-111, another Goldpack principal is a fully automatic pallet strapping system. Its key component, according to Challenor is an industrial application that enables users to track orders using a mobile device. The system reliably handles challenges posed by bulky, frequently changing packs. It uses a single basic frame and is easily integrated into existing

The Krones Varioline solution

production lines. The KZV-111has a sturdy design, automatic vertical strapping, robust single column steel construction and is ideal for rigid products. The machine features an optional balance system that distributes strap tension evenly across the pack and ensures reliable stability. A movable sealing top platen equipped with Mosca's SoniXs ultrasonic technology facilitates strapping packs of different heights. Constructed from sheet metal, the lightweight platen promotes energy efficiency. Meanwhile, Mosca's MS-6 side-seal strapping machine features an Evolution Standard-6 strap path with SoniXs ultrasonic technology. It allows full network communication and meets industry 4.0 requirements. It is able to run diagnostics via an online remote control, which makes for fast maintenance and reduces downtime. Its ergonomic strap threading, optional folding frame and automated double strap dispenser are additional features. All the MS-6 series machines have upstream and downstream feeding mechanisms and are easily integrated into existing production lines. They process PP, PET and PLA straps with widths of five to12mm or nine to 12mm.

A COMBINED SOLUTION FROM ONE SOURCE Krones has developed a Varioline flexible solution with the basic idea of a single machine replacing up to six conventional individual machines linked by conveyors. The Varioline combination conjuror enables packaging processes, which involve up to three stages handled by a single machine. The logical consequences are space savings, reduced overall maintenance work and fewer operators. The architecture of this system consists of three modules, each individually configured to suit the particular requirements of the client concerned. The combination of a cartoning module for multipacks and of another for carton blanks, plus a standard module for special tasks can provide a process output of up to 52 000 containers per hour. In addition, these machines can be block-synchronised with other machines such as a Variopac Pro shrink-wrapper. This is so the pack, which excludes the carton package, can also be wrapped in film. •

Fuji’s Alpha series wrapping machine

Krones – Goldpack – PMD Packaging Systems –


Packaging Review | September 2017

Intelligent Packaging Systems

Goldpack is dedicated to supplying the Southern African market with the latest technology in end-of-line packaging systems, machinery and related consumable products. Goldpack is able to consult in the layout, design, installation, commissioning and maintenance training on all systems supplied. After sales technical support is provided through Goldpack’s various branch offices strategicaly located in the major industrial centers.

Installed and GUARANTEED by

CAPE TOWN Tel: 021-534 0215 DURBAN Tel: 031-569 4199 JOHANNESBURG Tel: 011-312 4976


Counting down the days Exhibitors at Propak Cape 2017 will demonstrate their latest innovative technologies. PACKAGING REVIEW provides a sneak peak of the international and national packaging trends to be expected at one of the biggest regional packaging events.

We specialise in value adding re-closable bags, because they give consumers more features and benefits, which essentially is value for money. • Zipper bags – we offer 2 ranges , Standard and Premium Range.

Each has a comprehensive range of sizes from small to large. We custom make any size and offer special custom printing as well. • Double Zipper Bags – we have a zipper bag with double locks for enhanced product protection. • Self-sealing glue strip bags – we have A4 and A5 standard sizes Ex stock. We custom make specific sizes and cater for small runs on BOPP bags.

EXCITING NEW DEVELOPMENTS!!! 1. We now offer BOPP and Blown Polyprop ZIPPER bags! Even Modified Atmosphere BOPP and Anti-mist films can be used to supply a re-closable Zipper bag in BOPP! Awesome for fresh produce, confectionary and bakery products to mention a few! 2. Protective Liquid packaging – A zipper bag with absorbent liner to protect your luggage during air travel. The bag contains the liquid and the liner absorbs 750mls liquid so your clothes won’t get wet!

Proficient Packaging CC Phone: 021 703 8016 Unit 2 , No 145 Bamboesvlei Road, Email: Ottery, Cape Town, South Africa, 7800


Packaging Review | September 2017



ttendees will have an opportunity to see the latest advancements in machinery, equipment, products, materials and services offered by the packaging, food processing, plastics, printing and labelling industries. The Western Cape trade exhibition will take place at the Cape Town International Conference Centre from 24 to 26 October. The event will also include a focus on sustainability, eco-sensitivity and recycling in packaging. Expert advice from technical specialists will be available in person to provide the correct solutions for business growth. For the first time, bringing wine and olive oil production and supply into the spotlight, the newly launched Wine and Olive Oil Production Expo is set to take place alongside Propak Cape.

African customer’s request of handling flowrapped coated marshmallow eggs at the production speed of 350 pieces per minute on a single lane. The packaging also had to be handled in different configurations. This is when Cama realised a Break-Through generation upgrade of its IT 281 two-axes loading unit was due. The technology, which will be showcased at Propak, provides a high accessibility level for an operator. The machine also has the ability to accept different packaging configurations by means of its ‘foolproof size-parts’ recognition.

CAMA’S BREAK-THROUGH GENERATION LOADING UNIT Specialists in the engineering and production of high technology secondary packaging systems, the Cama group’s Packaging and Robotics divisions, have combined knowledge with the expertise to produce a ‘unique machine range’, the Break-Through Generation. A machine, which part of the range was specially designed to meet a South

Cama's IT281 new BTG unit

September 2017 | Packaging Review



The recently launched Break-Through generation range comprises units that have been designed to minimise factory footprint. This makes the machines ideal for compact manufacturing facilities in South Africa. Cama will be exhibiting in Hall 1, at its South African agent, USS Pactech's stand B26 and C26.

Steel belts remain stable, are suitable for excellent baking performance and consistent product quality

PROFICIENT PACKAGING ILLUSTRATES BAGGING AT ITS BEST The company is a manufacturer of bags, pouches and sheets. It specialises in resealable and re-closable bags. Its products offer convenience for freshness, ease of use, re-usability and recyclability. Zipper bags, Boutique Bags, Self-Sealing BOPP bags, selfseal glue strip bags, separating sheets and discs are among the diverse range of products to be showcased at the exhibition. Among the items on display, will be the company’s new range of BOPP zipper bags, Anti-mist BOPP zipper bags, modified atmosphere bags and wine protection zippers that serve as protective packaging for travel bags.

INNOVATIVE STEEL BELTS AND PROCESS SYSTEMS Sandvik, a manufacturer of steel belts and processing systems for the food industry, has a portfolio extending to the inclusion


Packaging Review | September 2017

of bake oven belts, cooling lines and conveyors. The entity also supplies steel belts for high precision printing as well as belts in carbon or stainless steel to suit the needs of a variety of food processing applications. They can be manufactured to virtually any length or width, and supplied in solid form, or perforated to provide a longer lasting, lighter alternative to wire mesh belts.

A key advantage of processing on a steel belt is the assurance of maximum hygiene. The strength, flatness and durability of a solid steel belt enable easy, effective cleaning and sanitising. This makes them particularly suited to applications such as meat processing. The belts are versatile, maintaining their strength and flexibility at operating temperatures from minus 80°C to +750°C, which also makes them suitable for freezing, drying and baking.

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


The company’s bake oven belts represent its largest food-related market, and can be produced in widths from 800 to 3 500mm. The thermal properties of a steel belt are ideal for an application where temperatures can reach as high as 400°C. The belt remains stable, provides excellent thermal conductivity for suitable baking performance and consistent product quality. It also delivers clean product release, ensuring high product quality standards are maintained. Sandvik also produces its own process systems and is a supplier of forming/ solidification equipment. These include the Rotoform FD, a foodgrade pastillation system used to turn molten chocolate into pastilles for remixing as an ingredient or as chocolate chips for use in cookies and cakes. The process is simple and efficient. Molten chocolate is fed into the Rotoform unit and deposited in droplet formonto a continuously running steel belt . The heat of the chocolate melt is transferred to cooling air blown onto the product and to the belt itself. The excellent thermal conductivity of the belt delivers

fast, controlled solidification and the chocolate pastilles are discharged cleanly at the end of the system.

LIGHT AS PET AND GOOD AS GLASS KHS introduces its Plasmax coating process, which combines the advantages of PET with those of glass bottles. FreshSafe PET ensures long-lasting freshness and a crystal-clear look. To achieve this, the inside of the PET bottle is finished with an ultra-thin layer of pure glass that not only reliably protects the

KHS introduces its FreshSafe PET technology

You are invited to join SMC Pneumatics at ProPak Cape 2017! Wherever packaging machines are required, you can be sure that SMC offers quality pneumatic and industrial solutions to suit your needs! Join SMC at ProPak 2017 to meet our team of experts and learn more about our hygienicdesign, washable components, corrosionresistant materials, special seals, non-toxic materials and niche solutions such as ionizers, dryers and chillers. Dates: 24 – 26 October 2017 Times: 09h00 – 17h00

SMC is a proud sponsor of ProPak Cape 2017!

Venue: Stand D1, Cape Town International Conference Centre (CTICC), 1 Lower Long St, Cape Town, 8001

Meet SMC’s automation heroes designed specifically for the packaging industry Whatever your need, whatever your application – we have you covered. Vacuum • ionizers • dryers • chillers • air preparation units • fittings for special and general environments • tubing • solenoid valves • cylinders (ISO, stainless steel, hygienic, compact) • safety equipment • electric actuators • grippers and controllers and more! Contact your nearest SMC sales representative or RSVP to Note: Registration is free.


Packaging Review | September 2017


The KHS solution for more sustainability: New avenues in packaging technology. We are continuously improving our packaging. By applying innovative technologies and switching over to mono-material packaging we have halved our packing materials over the last ďŹ ve years. And we are soon to take another big step forward in using new, thinner types of ďŹ lm.


contents but also has a brilliant appearance. The Plasmax process ensures that the glass layer is bonded firmly with the PET under all conditions and stays where it belongs – on the inside of the bottle. It protects the product and keeps it fresh with the same high quality , vitamin and flavour protection as glass. The handling of this packaging remains the same as that of glass bottles. It maintains the advantage of PET, which is being light and unbreakable. Turkish beverage producer, Doğanay was the first company to market a protective glass barrier within its PET bottles. ‘For a long time, our company and the R&D department have been looking for a packaging system to keep our beverages safe and fresh,’ says Rafet Doğanay, company CEO. ‘We found the perfect system with FreshSafe PET which we call CamPET (glass PET). Now, we are serving the market with packaging, which is as light as PET and as good as glass. The Turkish market has welcomed this with enthusiasm and demands more and more beverages in CamPET every day.’

Don't miss Yamato’s weighing technology display


Packaging Review | September 2017

INSTALLATION OF YAMATO’S MACHINE BOOSTS EFFICIENCY Big Bear Confectionery (Big Bear), a subsidiary of the Raisio Group, boosted its new packaging line’s production by 7 000 packs per shift with the investment of a multihead weigher and checkweigher from Yamato Scale Dataweigh, UK.

The company has achieved considerable improvements in its weighing and checking of chocolate and sugar coated products by boosting not only its speed but also the operational flexibility of the line. After identifying inefficiencies in its previous solution, as well as seeking a layout change to resolve congestion issues, Big Bear contacted Yamato for new weighing machinery. This undertaking marks a new level of aspirational investment by Big Bear. ‘It looks fantastic and will provide an exceptional standard of packing for our clients. The new Yamato weighing and packing line is a professional and modern solution that gives us world-class capabilities,’ says Sandra Fawcett, operations manager at Big Bear’s Blackburn site in the UK. Space was at a premium and the company wanted to expand its capabilities while also streamlining its product handling process. The decision was made to merge the two lines into one. This was conducted through the purchase of a Yamato multihead weigher and an end-of-line Yamato Checkweigher. For portioning and feeding to the bagging machine, an Omega multihead weigher was proposed and installed. This 14-head machine

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with six litre capacity is capable of reaching speeds of up to 110 packs per minute on retail packed Big Bear products. Its abilities extend to 12 packs per minute on larger 4.5kg packs. Additionally, an end of line I Series Checkweigher was provided, with a maximum pack weight of six kilograms, allowing Big Bear additional flexibility with future operations and processes. ‘Yamato is proactive and offers excellent customer service,’ Fawcett adds. The company is exhibiting at the upcoming Propak Cape where it will showcase its diverse offering.

EXPANDING PORTFOLIO AND FOOTPRINT Geiger & Klotzbücher, a family owned business since 1967, is one of southern Africa’s suppliers of an exclusive range of packaging material and equipment required for the packaging of perishable food products. The company services the meat, seafood, poultry,

dairy and convenience food industries, from small to industrial enterprises. ‘We offer modern, in-house, BRC certified printing and converting facilities underlining our commitment to product quality, safety, hygiene and process standards as well as being proactive regarding packaging related economical and environmental issues,’ says Christian Schiess, sales manager at Geiger & Klotzbücher. The company will highlight BOSS Vakuum, a new partner for its vacuum machines made in Germany, and PaperLike, an exciting new packaging printing technology, which will soon be launched for the first time in South Africa. The Geiger & Klotzbücher team will be at stand C52 in Hall 1.

FEAST ON AN ASSORTMENT OF PRODUCTS Polyoak Packaging will be exhibiting at this year’s Propak Cape at stand B32 where

Geiger & Klotzbücher’s Titan x480 double chamber vacuum packaging machine



Packaging Review | September 2017

attendees are welcome to explore its new division, Dairypack Cartons. This division specialises in aseptic packaging systems for southern Africa, in exclusive partnership with IPI, a Coesia Group company headquartered in Italy. Dairypack Cartons offers the market new and interesting carton shapes, to push the boundaries of the standard carton brick. Its broad range of aseptic pack sizes from 100 to 1 000mℓ, constitutes 28 innovative options in different shapes. The complete system service includes integrated filling machines, multilayer packaging and matching closures, as well as downstream equipment for secondary packaging, to produce a finished product of the highest quality. The Dairypack Tubs division will also share some innovative food applications for its

2017/07/10 10:03 AM

P R O PA K C A P E P R E V I E W Printed closures from Polyoak Packaging

range of vibrant colours for impactful branding on the shelf.

SMC ENGINEERS SOLUTIONS TO SUIT ALL NEEDS A first-time exhibitor at Propak Cape and a proud sponsor of the event, SMC Pneumatics (SMC) will showcase an array of solutions that are tailored to industry’s needs and built to meet the most demanding applications. Having opened its production facilities last year, the company offers locally manufactured solutions and the assembly of select items such as cylinders, valve manifold assemblies, FRL assembly and more recently a pneumatic/ electro-pneumatic panel offering. Its pneumatic panel offering and several new products will be demonstrated at the stand. The company promises to enlighten and excite by showcasing a broad and comprehensive range of machinery. SMC’s expert team will be available to discuss the latest developments and technologies at stand D1.

DEDICATED CONFERENCES retortable barrier plastic tubs, which enable products traditionally packaged in glass or tin such as baby food, purees and soups, to be packed in cost-effective, lightweight plastic. The oxygen barrier extends shelf life, and its quality decoration is possible on all of its surfaces. Dairypack Tubs has earned its reputation for outstanding in-mould labelling, by bagging its most recent gold award for Best Thin Wall Package 2017 from the In-Mold Decorating Association in the USA. The award was for the division’s Dairymaid Ice Cream Tub. According to Dairypack Tubs, this is the first tub in South Africa with IML across the entire surface area of the packaging and lid. The African Closures division will be showcasing technologically advanced three-colour offset printing on its 28mm CSD closures. These are available in a

Propak Cape’s daily free-to-attend seminar programme will include an array of interesting topics covering plastics, packaging, processing, printing and wine and olive oil processing. The South African National Bottled Water Association (SANBWA) will also have a dedicated afternoon of enlightening talks on 25 October. A bottled water market review will be presented by BMI and PETCO to engage the audience on how they are driving the transition to a circular economy in South Africa. The Packaging Indaba will be running alongside Propak Cape on 24 October. Industry insights from across the packaging value chain will be highlighted in a comprehensive one-day agenda. The Sustainability Pavilion will enable visitors to view the various industry initiatives


raw materials processing equipment bottling packaging plastics printing labelling logistics warehousing recycling waste management.

that have been successfully implemented by the sector’s producer responsibility organisations. Many of South Africa’s leading associations will be amongst those exhibiting in the Sustainability Pavilion and industry experts will be available for discussions on sustainability, the environment, recycling and related issues. Propak Cape is organised by Specialised Exhibitions Montgomery, a member of the Montgomery Group. •

Cama – Geiger & Klotzbücher – KHS – Polyoak Packaging – Proficient Packaging – Sandvik – SMC Pneumatics – Yamato –

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September 2017 | Packaging Review


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Food Review | September 2017

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Food Review September 2017  

This month’s edition of Food Review investigates a broad range of pioneering technology, ingredients and new food and beverage products. The...