Food Review September 2018

SOUTH AFRICAN

www.foodreview.co.za

Journal for food and beverage manufacturers SEPTEMBER 2018 Vol. 45 • No. 9

Dairycap

18 years of putting the lid on freshness

Are your safety and hygiene practices up to scratch?

Smart innovations for baked goods Dairy food technology designed for the future

INSIDE:

Beverage Review & Packaging Review

New flexibility through consistent digitalization

Innovative products and solutions make you more competitive Food and beverage manufacturers must consider many factors: a consistently high level of product quality, maximum plant availability, optimum resource efficiency – and, increasingly, the greatest possible flexibility in order to meet more and more individual customer requirements. Mastering all these challenges today and in the future is possible only with digitalization. We offer the products and solutions you need to fully or gradually integrate and digitalize your entire value chain.

Find out more on Siemens innovative solutions for Food and Beverage: www.siemens.com/food-beverage siemens.co.za

CONTENTS SEPTEMBER 2018 | Vol. 45 • No. 9

Company focus

10 Firesuppression PAGE

“Dairycap meets all HACCP and comprehensive hygiene procedures and controls expected by the dairy and food industry”

06

for food processing facilities PAGE

16

NEWS

35 Beverage Review BeverageREVIE SOUTH AFR ICAN

IMCD signs deal with Ingredion Say goodbye to trans fats

“Lanxess is a global provider of liquid purification technologies. The company has almost 80 years' experience in water treatment and purification applications”

Tokara strikes olive oil gold

08

NEW PRODUCT COMPETITION New and exciting innovations in the spotlight

13

September

2018 | Volume

www.foodre view.co.za

SAFETY, HYGIENE & QUALITY CONTROL Put an end to fly infestation Hygiene starts with your hands

How to ensure

boiler doesn’tyour blow Quality fillers

for base wines

Water processing ch allenges debunked

Best breed fire safety systems Digitisation drives value chains Unpacking SHEQ management Functional safety alert

22

BAKERY Easy systems for awesome baguettes

Septem

me 43

| Number

9

VIEW agingRE

Pack

CAN H AFRI SOUT

8 | Volu ber 201

41 Packaging Review

.za iew.co oodrev ww w.f

“Cama engineered a complete system comprising a highspeed MP sleever and an IF robotic loading unit”

ntial of the pote Unlock a k ging

c rigid pa

Rewrite the way you think about bakeries Healthy fibres make healthy bread Ishida’s new range of weighing equipment Sweet sugar substitutes for baked goods Add calcium the easy way Flour made from waste produce

33

ed

helps ity app ng ted Real eiti Augmen counterf

st certifi SA’s fir professional ing packag

t comba

DAIRY FOOD GEA’s mammoth butter making technology Protein solutions in cream cheese

September 2018 | Food Review

3

8 | Number 09

W

EDITOR’S COMMENT

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

Don’t leave

safety to chance

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

Layout & Design: Andipha Nkoloti +27 (0)11 877 6168 andipha.nkoloti@newmediapub.co.za Contributors: Candice Sharp ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmediapub.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmediapub.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmediapub.co.za INTERNATIONAL SALES

T

he food and drink manufacturing industry is broken down into several small sectors, ranging from processing facilities, sugar refineries and grain mills to beverage manufacturers and alcohol distilling. Each has its own set of risks for the employee and products on shelf. Strict health and safety policies must be in place to prevent sickness and injury.

In this edition of Food Review, we investigate some diverse options to deal with this issue. On page 14 we bring you the story of an innovative hand washing machine, which rotates with a soft brush, water and antibacterial soap. The unit tracks the number of washes per employee per day – ensuring total peace of mind. A spate of high profile fires has placed renewed attention on the issue of fire-suppression in buildings. ASP Fire installs best of breed systems, which comply with national and international fire safety standards. Our case study (page 16) looks at the explosive possibilities of leaving this safety issue to chance.

Demand for baked goods is driven by fast-growing urban populations seeking convenient food items. Mintel’s report provides additional insights. It found urban consumers spend an enormous amount of time travelling to and from work – with many returning too late to eat a proper meal. Baked goods often fill this gap and the need to fortify cost-effective products is becoming

critical. We unveil Mecatherm’s new turnkey solution for industrial baguette production on page 20 and track inroads being made by disruptive Rapidojet technology. Turn to page 24 for the full story.

Beverage Review turns technical with an in-depth look on how to identify and remedy reverse osmosis process challenges. Lanxess is a global provider of liquid purification technologies with almost 80 years' experience in water treatment and purification applications. If you are in this area, don’t miss the article on page 38. We also bring you the latest information on how to safeguard your boilers with a new system that conforms to international regulations with a unique front panel installation.

End of line packaging assembly automation is the focus in Packaging Review this month.

Read all the insights from page 44 onwards.

I hope you enjoy this edition. We love to hear from you so please don’t hesitate to contact me at maryke.foulds@ newmediapub.co.za.

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

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

Gail Angela Macleod

4

Food Review | September 2018

Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmediapub.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmediapub.co.za Production Controller: Rae Morrison Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park 2092 Tel: +27 (0)11 877 6111 Fax: +27 (0)11 877 6198 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published on behalf of Media24 by New Media Publishing (PTY) Ltd. MANAGING DIRECTOR Aileen Lamb Bridget McCarney EXECUTIVE DIRECTOR John Psillos NON EXECUTIVE DIRECTOR Irna van Zyl

EDITORIAL ADVISORY BOARD

Dr Aubrey Parsons

Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com

CHIEF EXECUTIVE OFFICER

Happy reading,

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.

Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de

HEAD OFFICE

Managing director of Symrise South Africa; chairman of SAAFFI.

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

Kerusha Pillay

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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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September 2018 | Food Review

5

NEWS

Exclusive distribution agreement announced

I

MCD South Africa, a leading distributor of speciality chemicals and food ingredients has signed an exclusive agreement with Ingredion to distribute its range of starches and functional food ingredients across multiple territories in sub Saharan Africa.

With a staggered roll out approach, IMCD commenced distributing Ingredion Starches in the western Cape, neighbouring SADEC countries and East Africa.

Gauteng and KwaZulu-Natal will come on board 1 October 2018. ‘Our ability to technically drive and add value to Ingredion’s product portfolio has been a key factor in joining forces,’ says Otto Brinkmann, managing director for IMCD South Africa and East Africa. ‘The new distributor partnership is a positive development in expanding Ingredion’s geographic footprint in Eastern and Southern Africa region,’ Kennedy Ouma, Ingredion’s business director for Africa.

Ingredion Incorporated is a leading global ingredient solutions provider specialising in nature-based sweeteners, starches, nutrition ingredients and bio-material solutions. With customers in more than 100 countries, Ingredion serves approximately 60 diverse sectors in food, beverage, brewing, pharmaceuticals and other industries. •

Verder expands network with Nelspruit

distribution partner

T

he company has appointed Flo-Tek as its exclusive distributor in Nelspruit and surrounding areas. ‘Nelspruit and the Mpumalanga province present significant growth opportunities for our business – particularly as key economic contributors to the region fall predominantly within infrastructure development or industrial and consumer market sectors,’ says Darryl Macdougall, managing director, Verder Pumps South Africa.

Mpumalanga is said to have higher than average growth rates.

This is mirrored by tremendous growth in Nelspruit.

Macdougall highlights that Flo-Tek holds valuable market knowledge that supports the pump company’s business growth and expansion plans within this region.

‘We understand that navigating the technical obstacles of selecting the right pumping solutions for specific applications can be complex. Flo-Tek is well placed to understand the local context conditions and needs of their customers. The appointment opens incredible opportunities for Flo-Tek to expand their offerings to their customers further.’

Flo-Tek will initially stock hoses for the VerderFlex range of pumps, and as the portfolio grows strategic stock will be kept in Nelspruit. Flo-Tek will also continue to offer aftersales service support to their customers for quality and performance assurance. •

6

Food Review | September 2018

US bans trans F

ood manufacturers had three years to phase out the ingredient, which the US Food and Drug Administration (FDA) ruled unsafe to eat in 2015.

According to the Washington Post, nutrition researchers and public health advocates found artificial trans fats, a modified form of vegetable oil, raised “bad” cholesterol and contributed to heart disease.

Initially used to extend shelf life and improve the texture of processed foods in the 1950s and 1960s, researchers began to link artificial trans fats to cholesterol and heart disease in the 1990s. As the scientific consensus grew, the FDA required food companies to disclose artificial trans fats on product labels in January 2006. In 2015, the agency ruled that artificial trans fats are not safe in food and set a June 2018 deadline for their removal from food systems.

Between 2015, when the ban was first announced and 2018, food companies removed 98 per cent of trans fats from the food supply.

There is now concern over the ingredients used to replace trans fats in formulations. Some environmental groups have raised concerns that food companies are using palm oil, which alledgedly contributes to deforestation.

There has also been concern that food manufacturers might boost the flavour and texture of newly reformulated products by increasing the fat content overall. •

Tokara strikes gold

at SA Olive Awards T

he producer located outside Stellenbosch has been rewarded across its entire range of cold pressed extra virgin olive oils at the 2018 SA Olive Awards.

Top performer this year, is the 2018 Tokara Mission Single Variety, one of just three contenders to clinch a gold medal in the ‘Delicate’ category.

The Mission variety stems from America and is mild and gentle with a finely balanced grassy, herbaceous character.

It is one of two single variety oils and two full flavoured blends produced from its olive groves on the foothills of the Simonsberg. South Africa produces world class olive oil and every year the SA Olive Awards reward excellence by acknowledging the best of the vintage as judged by a panel of international and local taste experts. •

ADVERTORIAL

Imperial Logistics

enjoys sweet success with premium chocolate deal

A

contract renewal for warehousing and distribution management is the latest development in a significant, seven-year partnership between supply chain and logistics leader Imperial Logistics and premium chocolate producer Lindt & Sprüngli.

Recognised as a global market leader, the Lindt & Sprüngli group offers a wide selection of products in more than 120 countries around the world. Imperial Logistics is proud to have played a role in Lindt’s South African success story since 2011. ‘This contract renewal represents our commitment to constantly meeting our client’s exacting, world class quality standards, and to continuously innovating, improving and expanding our capabilities, in order to better meet Lindt’s needs,’ comments Imperial Logistics chief strategy officer Cobus Rossouw.

‘Our client applies the most stringent standards to everything that goes into delivering the finest quality chocolate.

Its uncompromising quality standards are met along its entire supply chain, by all its suppliers and service providers, from raw materials to the finished product in

the hands of the consumer. Supply chain requirements to ensure the quality of this temperature sensitive product are complex.

We are as invested as Lindt in safeguarding the treasured quality of its products all the way to the homes of consumers.’ The solutions Imperial Logistics provides to Lindt include reefer container inbound handling, warehousing, outbound transport and distribution and reverse logistics. Value added Imperial Logistics capabilities that enhance this partnership include co-packing services such as labelling, unpacking products down to consumer units, kitting, repacking and display building.

Since winning its first Lindt contract seven years ago, Imperial Logistics’ partnership with the confectionery leader has grown from strength to strength. ‘Imperial Logistics proved then that it had the capabilities, infrastructure and commitment to quality to meet Lindt & Sprüngli’s exacting standards.

Since the inception of our partnership, we have not rested on our laurels, and have strived for continuous improvement aimed at delivering service enhancements and cost savings, and ensuring our client maintains its high quality standards and market leading position,’ Rossouw stresses.

Imperial Logistics has

invested in temperature controlled vehicles throughout the supply chain. This ensures the quality of Lindt & Sprüngli’s superior, temperature sensitive products are never compromised. All warehouses, including receiving and distribution facilities are temperature controlled throughout.

Double-rack trailers incorporated into Imperial Logistics’ dedicated Lindt fleet are delivering cost savings.

Imperial Logistics undertakes continuous staff training, to ensure awareness and understanding of the sensitivity of Lindt’s products. The co-packing undertaken for Lindt enhances employees’ knowledge of products, processes and specific requirements. ‘Co-packing was a new business capability that Imperial Logistics was only beginning to explore, but in our partnership with Lindt, it has proved to be a resounding success,’ Rossouw notes. ‘Collaboration, persistence and the establishment of a true partnership between Imperial Logistics and Lindt & Sprüngli is the key to this seven-year long success story, and it continues to deliver positive results.’ •

Imperial Logistics – www.imperiallogistics.com

September 2018 | Food Review

7

NEW PRODUCT COMPETITION

Hip, happening and on trend

2018 JUDGES

This year’s prestigious judging panel comprised Michael Gristwood, Clive Glover, Heidi Grimmer, Cynthia Mabela and Janusz Luterek, who spent a whole day tasting each entrants’ creations.

The Food Review/Symrise New Product Competition celebrates new product innovation of tasty, authentic, healthy and increasingly ethically sourced food and beverage items. By Maryke Foulds

T

his year's product line up showcased most of these trends focusing on healthier ingredients, very clever packaging, sugar reduction solutions and meal kits. This ties in with global trends in the broader global industry where real food, convenience and lifestyle are starting to dominate.

Judging took place at the well-appointed and trendy PnP Good Food Studio located in Sandton, Johannesburg on 23 August.

Now In its 24th year, a sensational and pioneering mix of 33 products were entered. The grand prize is a fully paid trip to Anuga 2019, held in Cologne, Germany.

Judges were extremely happy with the professional presentation and tasting arrangements.

Taking all of the entries into consideration, there seems to be a noticeable theme in the direction of health, wellness and reduced sugar and salt.

Of particular interest to judges Michael Gristwood and Dr Heidi Grimmer who judged the organoleptic and sensory category, were products reformulated with lower salt and sugar.

These pushed taste boundaries and answered the call for consumers’ desire for healthier items on shelf.

Brand owners and manufacturers are required by law to comply with food and beverage labelling legislation. It became evident in this category that even though a product might have won the sensory vote, it often fell short on labelling and packaging.

This was true for both bigger brand owners and smaller manufacturers. As the day progressed it became clear a number of products were not R146 compliant.

‘It is good to know the enthusiasm surrounding new food products is still such an upbeat feature of our daily life.

There was evidence of several awesome creative ways in terms of reusable packs and innovative closures,’ enthuses Clive Glover. ‘In the end, there must be a balance between packaging and the product to

8

Food Review | September 2018

Janus z Luterek an d Clive Glover en sured that all packaging lab elling and regula tions were complied

secure brand loyalty in the future. We must accept the fact brands clamour for innovative ways to engage with shoppers.

Differentiation plays a big part in securing a portal of opportunity to make the initial purchase.’

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 aspiring image. Remember there are many products competing for the same market.

Your success comes from the ability to cut through the noise and clutter,’ she notes.

The competition’s award ceremony took place on 13 September at The Bay Hotel in

di Grimmer, Clive Glo Cynthia Mabela, Dr Hei Gris twood Luterek and Michael

ver, Janusz

Cape Town. Don’t miss the October edition of Food Review where we will pay tribute to the manufacturers and producers who are leading the way in fostering innovation in the food and beverage sector. •

NEW PRODUCT COMPETITION

FAST FACT

Samples to be judged

More than 50 per cent of current revenues in food and beverage comes from products introduced to 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.

Rugani 100%

Juices

2018 Entrants: ABINBEV | Castle Free Aqua Rush | Aqua Rush Vitality - AGUA RUSH Big Brands | Seltzer Essence Clover | Tropika Slender Clover | Cream O’Naise Diageo | Storm Berry Twist Ella | Ella Cappucino Malange Fit Chef | 21-Day Challenge Fry’s Family Food | Crafted Range FRYS Fry’s Family Food | Kasha Range Kellogg Tolaram | Kellogg’s Instant Noodles Lohocla Beverages | Lochocla Messina Verpakkings | Green Banana Flour Nutriseed | NuME “Not so Naughty” Parmalat | Steri Stumpie Lite Strawberry Flavoured Milk Pesto Princess Foods | Hummus the Classic PESTO PRINCESS Pioneer Foods | Moir’s Mug Cake Rechos Food & Beverages | Cape Apple

Rugani Juice | Rugani 100% Juices SOGA Organic | Soga Organic Frozen Lemon Juice SOGA Southern Oil | B-Well Sandwich Spread Southern Oil | B-Well Olive & Canola Mayonnaise Unilever | Aromat Naturally Tasty Woodlands Dairy | First Choice Full Cream Flavoured Milk “Milki” Woolworths | Carb Clever Noodles Woolworths | Double Cream Ayrshire Yoghurt Woolworths | Fresh Soups - FRESH SOUPS Woolworths | Fruity Numbers and Fruity Alphabets Woolworths | Giant Cutie Pie Woolworths | Global Menu Woolworths | Gluten Free Pretzels Woolworths | Marshmallow Flower Woolworths | Squeezed & Pressed Fruit Juice

About our sponsors: Symrise is a global supplier of fragrances, flavourings, cosmetic active ingredients, raw materials and functional ingredients, sensorial and nutritional solutions. Clients include manufacturers of perfumes, cosmetics, food and beverages, the pharmaceutical industry and producers of nutritional supplements, pet and baby food.

The company comprises three segments: flavour, nutrition, scent and care. The flavour division consists of beverages, savoury and sweet business units. This division develops, produces and sells flavours and functional ingredients for use in food, beverages and health products.

The nutrition division consists of the Diana division and its various business units. Diana develops tailor-made solutions from natural raw materials, which help to improve the sensorial and nutritional performance of its

customers’ products. This includes sensorial and nutritional solutions to reinforce its customers’ benefits in the food industry, as well as natural and functional food solutions and palatability enhancers for pet food.

Another area is plant cell cultures dedicated to active synthesis for the food, health and cosmetics industries.

This year MCC Labels joined the NPC as co-sponsor for the packaging award.

Multi-Color South Africa has grown to become the most awarded premium label printer servicing company in southern Africa. Its facilities hold leadership positions in the wine and spirits and food and beverage markets.

MCC South Africa provides pressuresensitive and cut and stack labels through its primary print technologies of UV exo, rotogravure and UV offset, and also offers a complete in-house prepress service.

Fr y's Family

food range

September 2018 | Food Review

9

C O M PA N Y F O C U S

Lidding solutions, service and quality for the food industry

Cape Town-based Dairycap was established in 2000. The company’s launch coincided perfectly with South Africa’s emerging yoghurt boom. Food Review met with one of the founders Robyn Adamou at her office in Cape Town to chat about how the company became a trendsetter in the supply of high quality, innovative and striking lids for the food industry.

F

ounders Adamou and Tony Dignam realised there was a gap in the marketplace for an alternative source of decorative lidding. This packaging trend was rapidly increasing in Europe.

‘We found the ideal manufacturing partner in Europe,’ Adamou explains.

‘They had the right credentials for high print quality and design excellence, and produced lids with a unique firm seal and easy peel.

'Quick and flexible lead times and responsible pricing sealed the deal.’

EUROPEAN QUALITY GUARANTEED Dairycap’s manufacturing partner is located at a purpose-built factory in Europe.

The company is an industry leader in the manufacture of pre-cut lids and heat sealable lidding with an impressive reputation for quality, service, flexibility and innovation.

Its products are used across a variety of markets, including dairy, food and beverages. The

Dairycap delivers first shipment of corner pot lids for Woolworths

2000

Dairycap cc formed with Tony Dignam, Robyn Adamou and Zaino Dramat managing the office

2001 Suppliers to Mayo and Darling Dairies

2002

2012

Expanding the team with Bryan Morkel, Willy Holt and Liz Hudson

2016

Focus on cost-saving alternatives by offering a lid with a five gramme heat seal lacquer in addition to the popular extended life lids of eight gramme lacquer

2018 10

Food Review | September 2018

C O M PA N Y F O C U S

latest manufacturing techniques are used to maintain market share in an increasingly competitive and crowded space.

The European facility was upgraded in 2006 to meet the standards and requirements of the international dairy and food industry. ‘Hygiene standards are watertight. The company meets HACCP and comprehensive hygiene procedures and controls expected by dairy and food packaging suppliers.’

The company also has ISO 9001:2000 and latest BRC certification. It can handle runs from as little as 20 000 to millions of lids, while flexible service allows for shorter lead lids – meaning your product can get to shelf first.

DAIRYCAP SUPPLIES: • Standard aluminium foil lids with PP/ PS heat seal lacquer 37 or 47 micron, with either a five or eight gramme lacquer depending on required shelf life • Die cut or reel fed, printed two to six colours (more if required) • MetPET and plain PET lidding, reel fed and die cut - single lids, and perforated multi-pack lids • CAF lidding for extreme conditions and long life products • A range of co-ex lidding for acidic products like mayonnaises and dips • Semi-rigid aluminium foil lids with rim embossing • Lids with print on reverse side with food safe inks • Specialised lidding with unique openings can be ordered • Six grammes or higher heat seal lacquers are ideal for keeping your product factory fresh on the shelf.

‘Our material is checked reduce prices,’ she notes. Long twice. First at the raw standing clients include foil manufacturer Danone and Clover, on and again after the books since 2004 printing and die and 2008 respectively.

Dairycap’s proactive approach to cutting at the the marketplace includes a monthly Mailchimp reminder about stock ENSURING SUPPLY supplier. There is levels, as well as a quarterly There will be several full traceability newsletter illustrating new ideas, new products available from raw material products and packaging from through Dairycap throughout the around the globe. soon, with a view to supply chain. 'We are current cost constraints focused on supplying in the market, and also some the latest materials and innovative lidding and ideas to our client base. 'We print techniques. continue to buck rampant inflation in Foil is becoming the benchmarked South Africa and maintain our responsible product for freshness and its positive pricing policy. impact on extended shelf life and flavour Where possible we try to reduce integrity. ‘We specialise in precut six costs to our client. That said, we will pack lids in mainly Met PET, which is never compromise on quality purely to

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September 2018 | Food Review

11

C O M PA N Y F O C U S

“Product quality and service remain our focus. We want to ensure our customers come first. Our proactive approach ensures we remain one of the industry leaders in South Africa. ” – Robyn Adamou

visually very appealing to consumers. We also offer products with an extended shelf life. Dairycap is a direct supplier to dairies in Zimbabwe, Botswana and Mauritius among other African countries.

'Our export lidding is of a premium integrity and one of the highest specifications worldwide with few equivalent products available internationally,' Adamou explains.

Printing quality is also superb.

The company rationalises the number of cylinders and is very creative with combining colours.

Its studio produces flexographic printing cylinders such as UV printing, embossing patterns and bespoke designs in response to customer demand.

Clients can choose from a wide range of materials to suit all applications and container types. Finished products and services are backed up by the supplier's technical expertise.

The production environment is uniquely managed from a health and quality point of view. New reverse print lids have successfully completed migration tests and are printed with a top international food grade ink. ‘Our greatest strength is our flexibility to clients – whether they need small volumes of 60 000 to runs of five million. We are also very proactive in helping manage stock.

We have warehousing facilities in Cape Town, Port Elizabeth, Durban and Johannesburg and we deliver to order.

‘In terms of export from South Africa, our extended shelf life products are great.

Local dairies can now venture further afield during processing.'

Transit times are quicker, which results in better opportunities as no one wants to create a situation where risk management is affected. ‘We would like to confirm our dedication to our amazing customers and the South African industry whose loyalty for the past 18 years we appreciate every day,’ Adamou concludes. •

Dairycap – www.dairycap.co.za

12

Food Review | September 2018

S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E

Boost your pest control

Up to 45 per cent of businesses that suffered fly infestations in the past five years report a high or moderate concern about loss of income

Rentokil spent three years analysing LED technology and testing new units against market. The company announced the launch of its new y killer range, Lumnia, early in 2017.

T

his was the first electric fly killer range in the world to use LED lighting rather than traditional bluelight fluorescent tubes. The switch from traditional fluorescent tubes allows for an estimated energy consumption reduction of 60 per cent. Rentokil has 12 patents across the unit.

In addition to energy saving benefits, units have different lighting settings to suit the specific requirements of your location. An active lighting mode adapts output according to ambient lighting levels on premises, further reducing energy costs.

Lumnia units have improved serviceability, reducing the number of times fly killers need to be serviced at heights, and offer several energy modes: high, medium and low. They also offer an active mode which adapts to UV levels,

adapting continuously to the conditions of the customer premise.

LUMNIA STANDARD Launched in 2017, Lumnia Standard is suited for all businesses operating within the food service, food retail, and hospitality and healthcare sectors. Units have a modular design and can be used as a glue board or encapsulation unit.

It offers a control or monitor option depending on infestation levels.

LUMNIA ULTIMATE The latest addition to the Lumnia family.

This unit has been designed for high dependency environments, including food processing, hospitals, pharmaceutical and general industry sites. It boasts three black LED lamps which are proven to be 30 per cent more effective at catching

flies. Encapsulation technology means the risk of contamination from fly fragments is eliminated.

LUMNIA COMPACT The Lumnia Compact will be available in South Africa in January 2019. It is suited for small-to-medium, low-risk businesses that are prone to the hazards of fly infestations, especially where food is being prepared, stored, packed and served. Compact is highly effective and one of the lowest energyconsuming units on the market. •

Rentokil - www.rentokil.co.za

September 2018 | Food Review

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S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E

Hygiene practices – do or die Food and beverage production facilities and general industries understand the importance of hand hygiene in securing a safe and healthy facility.

T

his requirement was one of the driving forces in the design and creation of a hand wash machine as a standalone unit, which guarantees clean hands. Scrubzone’s hand wash machine has been designed for a variety of food and beverage production facilities, as well as those locations where hand hygiene is nonnegotiable. Explains Frits Burger of Scrubzone, ‘The machine gets activated when a person

“Scrubzone’s hand wash machine has been designed for a variety of food and beverage production facilities, as well as those locations where hand hygiene is non-negotiable”

inserts both his hands into the unit. A soft brush starts rotating and 400ml of water and two millilitres of anti-bacterial soap gets dispensed onto the brush and hands.

‘In a nine second cycle, the hands while being rotated are scrubed clean.

Thereafter, a blower dries the hands with the machine in a further six second cycle.

When the unit is not being used, two strong UV lights sterilise the slowly rotating brush and wash chamber on a continuous basis.'

This ensures a clean environment. ‘Our hand wash machine gives companies piece of mind, regarding random inspections for

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Food Review | September 2018

TESTIMONIAL most common bacteria and ensures a top class hygienic standard throughout the company.’ An electronic counter keeps tabs on the number of washes per day - allowing strict control by the production manager of the number of washes per employee per day. The scope of the new Scrubzone hand wash machine is almost endless.

‘There should not be a food or production facility in South Africa that is not protected. Entrances to hospitals, gyms, schools and forecourts all benefit,’ Burger concludes. •

Scrubzone – www.scrubzone.c.o.za

Hans Westhof, owner of Supafoods in Durban says, ‘For the past five years we’ve been using traditional Scrubzone Hand Wash Machines at our production facility. We find our staff are more inclined to use the machine, rather than a traditional sink. We’ve had a zero-failure rate with unexpected swabs of employees’ hands during this period. It gives me peace of mind that we are fully compliant with HACCP requirements.

We are looking forward to installing the improved units, which includes a new hand drying function within the next few months.’

S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E

Fire-suppression for food processing facilities ASP Fire has completed rational designs for two solvent extraction plant clients operating sunflower and soya-seed processing facilities in the North West Province and Mpumalanga.

These units meet the challenge of installation in existing and functioning structures.

T

he company installs best-of-breed systems, which comply with national and international fire safety standards.

‘In creating a bespoke system for any new or operational business, we look at each risk area, and ask what it is we need to do to mitigate this particular risk,’ CEO Michael van Niekerk explains.

Both clients extract oil from seeds by creating an initial mash, then extracting oil using hexane, a highly-flammable solvent that separates the oil content from the meal. From there, hexane is removed from the oil through a drying process.

‘We have heat, pressure and flammable liquid – not a combination anyone can take lightly,’ Van Niekerk cautions. While heating is indirect, vapours that arise from the mix can ignite. ‘In the solvent plant where hexane is used, you have a volatile product that loves to burn and flammable vapour that can explode. This area requires extremely careful management,’ he highlights.

The last part of the process is storage of dried meal, where there is a significant quantity of dust. Airborne dust creates an explosive atmosphere that can be ignited by a single spark, implying a far greater fire risk than the hexane plant itself.

There’s also crude oil storage to take into consideration, which is not flammable but

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Food Review | September 2018

combustible. This requires a different set of solutions to mitigate fire risk and potential damage.

Fires in solvent-extraction plants can be managed by means of ventilation, where the concentration of flammable vapours is never allowed to reach a point of combustibility.

This requires forcing air into the environment to prevent build-up of flammable vapours below hexane’s lower explosive limit (LEL), as concentrations under the LEL are too lean to burn. In an open structure, there is no vapour build-up, as this is vented to atmosphere.

In an enclosed structure, solvent vapours are heavier than air and can accumulate on the ground, building up to the LEL. All that is required for a potential catastrophe is an ignition source.

‘The key risk is a hexane leak and resultant miscella, which is the volatile mix of the oil and solvent,’ Van Niekerk points out. To protect equipment, high-velocity foamspray systems are installed. The steel structure itself is protected by a foamsprinkler system. If there is a spill from a ruptured vessel that starts to burn a layer of the spillage on the floor, this can then be enveloped in foam.

All of these risk-mitigation systems from ASP Fire comply with the strict NFPA 36 standard for solvent extraction plants, which provides stringent guidelines for fire suppression and aversion. Compliance is vital for saving lives, reducing the costs of

fire damage and protecting equipment and buildings from major damage.

One of the biggest risks in industries that use solvents such as hexane is the so-called BLEVE phenomenon, an acronym for boiling expanding liquid vapour explosion. A hexane tanker could be up to 42m3 in size, so an incident such as brake failure can quickly turn into a tanker fire.

To mitigate the overall fire associated with tankers and refinery structures in particular, fire-protection facilities include a highvelocity deluge system over the solvent tankers at the refuelling point. This is critical because the solvent is flammable so the fire has to be put out before a BLEVE can result. ‘It’s all about identifying then mitigating Michael the associated fire risks,’ van Niekerk Van Niekerk stresses.

Another fire risk associated with hexane plants is an unconfined vapour cloud explosion (UVCE).

A hexane tank that ruptures results in a pool of alcohol that evaporates rapidly. A litre of hexane can result in a 300m3 building explosion. Hexane forms an odourless, invisible vapour cloud, and the prevailing wind causes it to drift off the premises. This can cause a deflagration, an explosion in which the speed of burning is lower than the speed of sound in the surroundings.

This can have devastating effects. The deflagration can impinge on the pool of hexane, which can cause the vessel itself to explode, resulting in a catastrophic chain reaction. ASP Fire experts take each of these risk areas into account in terms of mitigation.

‘The factors are many and varied,’ Van Niekerk acknowledges, as these need to encompass the building, equipment and personnel. •

ASP – www.aspfi re.co.za

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Innovations that deliver superior equipment and performance

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S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E

How digitisation affects technology value chains Demonstrable benefits of new technologies speed adoption as companies realise failure to do so will be detrimental to long-term prospects.

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hat are the most important technologies, and how will they affect your business going forward?

CLOUD Syspro Cloud is an Infrastructure as a Service (laaS) offering, which seamlessly and securely takes care of all core technology, storage and networking capabilities.

Full functionality of Syspro ERP is available through this system, which delivers an always-available, fully-managed ERP infrastructure.

This allows you to focus on your core business without worrying about managing IT. Additional benefits include: • No upfront capital outlay • Data centres are audited to ensure compliance with ISO 27001 information • Monthly subscription pricing based on number of users • Strict security standards • Always-on availability • Highly scalable • Using high-density servers in shared services environment reduces carbon footprint.

MOBILITY

• • • • •

Syspro Espresso is a mobile ERP application that gives you access to your business information wherever you are, 24/7. It works seamlessly on any popular mobile device or desktop. Use of this service results in: Increased productivity and better decisions Empowered employees Improved customer engagement Streamlined supply chain Tailored experience

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Food Review | September 2018

• Accessibility • Library of applications.

LIVE MONITORING OF IoT DEVICES Enables you to use applications that will work any time, any place, and on any popular device. It offers instant and secure access to information about customers, suppliers, inventory items and other key business information.

IoT AND IIoT The concept of connecting any device with an On/ Off switch to the internet and/or to each other.

This creates a network of physical devices, vehicles, home appliances and other items embedded with electronics, software, sensors, actuators and network connectivity, enabling these objects to connect and exchange data.

ANYPLACE ANYWHERE Unprecedented level of visibility throughout the supply chain. The system uses devices to extend existing manufacturing and supply chain monitoring and management systems to provide broader, more detailed visibility and enable automated controls and increasingly accomplished analytics.

SOCIALISATION Social ERP provides collaboration capabilities to follow and track key data, take action and communicate relevant information to internal and external stakeholders. Bringing social media aspect into the core of ERP, Syspro Harmony answers the needs of the modern-day workforce by incorporating a familiar social media-type interface on which to do business.

Embedded within software, Harmony is designed to simplify user experience and increase engagement.

ARTIFICIAL INTELLIGENCE AI and Predictive Analytics harness the power of algorithms to surface business trends across value chains. Predictive searching makes sure you get that information quickly and effortlessly.

Big picture insights across your business instantly surface anomalies, trends, patterns and developments.

BIG DATA AND ANALYTICS Driven by specialised analytics systems and software, big data analytics point the way to various business benefits, including new revenue opportunities, effective marketing, better customer service, improved operational efficiency, and competitive advantages over rivals.

Harnessing big data with predictive analytics, provides a means of analysing data sets and drawing conclusions about them to enable strategically informed decisions.

BOTS One offshoot of Artificial Intelligence is an intelligent and human-like chatbot that can answer, analyse and predict queries quickly and accurately.

Chatbots are fast becoming a broad technology initiative for many organisations. This emerging platform has unlimited potential for business applications. It can analyse information from various sources to create efficiencies, improve processes and increase revenue, all with limited human intervention.

Significantly improved customer service by providing customers and suppliers within your supply chain with an alwayson and consistent self-service; predicting and responding to queries quickly and accurately and freeing up resources within business. •

Syspro – www.zasyspro.com

S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E

Demystifying SHEQ management The term SHEQ refers to a technical field that applies to several disciplines. It includes compliance and continued improvement of occupational safety, health, environment and quality factors that could impact an organisation. Food Review talks to Lungile Mkhize, group SHEQ manager of Servest on how understanding the basics can make or break compliance.

M

khize describes her first job out in the field, as literally being out in a field. She was tasked with overseeing a client that feeds safe daily meals to workers. ‘The experience was humbling.

I had to ensure when workers got to camp at five am their meal was ready. The tricky part was serving it to them at the right temperature in the middle of a forest. This had to be done in compliance with all food safety standards,’ she explains.

Now managing the complete SHEQ portfolio, her challenges are greater than ensuring a meal is served at the right temperature. The risk of colleagues not being able to work due to ill health or injury can hit hard on a company’s production. If a work environment is safe, employees will be more productive. When looking at the safety aspects of SHEQ, it is important not to look at injuries or fatalities as a measuring stick.

It is critical to understand the hierarchy of incidents and how to prevent them. The focus should be placed on preventing incidents.

This means aggressively addressing the three base levels of the pyramid illustration to prevent the top three levels from happening.

Ensuring standardisation of safety, health environment and quality assurance is not easy. It must reach everyone with the correct interpretation of their role.

‘The way you impart knowledge and information to top level managers, is different to how you do it for the manager on the ground and the colleague who is fulfilling the role of implementer,’ she notes. Legislation must be translated simply for people on the ground, to ensure they understand the importance of the function. Communication chain of command is fundamental in affecting duties. You need to strike the right balance between what the law requires and how colleagues will interpret it, to not only ensure they understand what to do, but why they need to do it.

‘When it comes to SHEQ, we know we are effective when our teachings are taken home. SHEQ is not an organisational issue, but rather a community issue. It

influences people’s behaviours.’

She uses the example of safe driving. If there is a safe driving programme at work and colleagues are monitored and possibly rewarded, the chances of them driving the same way with their personal vehicle and educating others on what they’ve learnt at work, are very high. ‘Education at work, infiltrates into a community through a ripple effect. We cannot change a culture without changing behaviour.’ SHEQ offers assurance, rather than policing.

‘People should not have to scatter erratically when quality checks or inspections are done. We need to assist management in ensuring sufficient and correct training, supervision and support is provided, so that colleagues monitor themselves.

Only then is the cycle effective. You need to trust the process is there to protect you and your environment, daily - not just when there is a crisis, like the recent Listeriosis outbreak,’ she concludes. •

Servest – www.servest.co.za

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September 2018 | Food Review

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S A FE T Y, H YG I E N E & Q UA L I T Y A S S U R A N C E

The cost of functional safety A variety of regulations for food processing plants relate to safety. Most countries, including South Africa, have strict safety regulations in these potentially dangerous environments.

Employers who fail to meet adequate safety considerations could face large fines.

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n Europe, the Machinery Directive 2006/42/EC requires machinery to be designed and built for safe use.

In food processing plants, there are many dangerous machines for which plant managers should implement safety regulations. Machines such as decanters operate at high centrifugal forces, sometimes running with g-forces reaching more than 2 000 times gravitational force.

This presents a dangerous environment for employees to work in. Comprehensive risk management becomes the best method to prevent accidents and ensure plants do not face the threat of closure or high fines.

In the 1970s, many companies started to approach workplace safety differently when a surge in heavy machinery forced an increase in safety guards. Safety conscious companies undertake a risk analysis in the initial stages of machine development to determine what risks exist and what measures need to be put in place to mitigate that risk and meet regulatory safety requirements.

As regulations become more stringent, the need to retrofit old equipment with additional safety measures may occur. In the food processing industry, companies

should consult functional safety experts who have experience in this sector. They may, for instance, suggest equipment such as light grid, which performs an emergency stop on a machine when a light grid is broken by an object. These types of safety devices are more appropriate for the food processing sector as they allow easier access for maintenance and washdown, which is essential for hygiene.

With safety regulations constantly evolving, managers of food processing plants should consider safety a priority.

From the safety of single pieces of equipment to line safety and plant safety, plant managers need to be aware of what they can do to mitigate risks at all points along the production line.

According to the South African Department of Labour, ‘an employer or user of machinery shall ensure that every person authorised to operate machinery is fully aware of the dangers attached thereto and is conversant with the precautionary measures to be taken or observed to obviate such dangers.’

Plant managers have a responsibility to put in place an accurate safety strategy to protect their employees. They also need to protect their businesses from costly infringements of worldwide safety regulations. As the pace of technological innovation increases so do machinery capabilities and necessarily, safety regulations. Many companies will find

“In the 1970s, many companies started to approach workplace safety differently when a surge in heavy machinery forced an increase in safety guards”

it difficult to manage the complex and changing world of safety regulations.

In these cases, a professional services organisation that can advise on the best course of action will prove to be a high value investment to your business. •

ABB - www.abb.com/Africa

Neglecting functional safety can have serious consequences

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Food Review | September 2018

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B A K E RY

Inside the baguette factory Mecatherm has unveiled its turnkey solution for industrial baguette production on the African continent. The company specialises in the manufacture of automation production lines for the industrial bakery sector.

Food Review met up with the team at a customer seminar held in conjunction with Eurogerm in Gauteng recently.

K

nown simply as The Baguette Factory, this ingenious and profitable turnkey solution is aimed at African clients looking to move into industrial baguette production.

Mecatherm handles many projects around the world – particularly in Africa. This market, with traditional production methods offers attractive opportunities for investors, but has its own idiosyncrasies.

The key lies in gaining an understanding of these and incorporating these into new ranges.

THE TURNKEY SOLUTION CONSISTS OF: • A 100 per cent automated production line • Various features including boiler, compressed air production and water cooler • A small, three-person team can achieve production rates upwards of 4 000 freshly baked baguettes per hour • Project management with a dedicated team (study phase, implementation and after-care) • Installation and start-up of the production line managed by Mecatherm technicians

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Food Review | September 2018

• Training and assistance provided by trained bakery technicians • Additional services are available to ensure each project is a success. These range from support during the feasibility study phase and help with recruiting factory managers capable of handling these types of projects, through to assistance in sourcing finance, plus a multitude of after-sales services.

The Baguette Factory is supported by a network of reliable, well-respected partners such as the French public investment bank BPI France, which helps provide finance solutions.

Within the range, investors can be sure to see

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B A K E RY

FAST FACT Founded in 1964, Mecatherm is a French industrial company in the industrial baking sector. It currently operates three production sites in France with commercial offices in three other countries. It is headed

by Olivier Sergent and employs more than 400 staff.

It specialises in the design, production and installation of equipment (make-up lines, ovens and handling systems) and automated production lines for industrial bakeries.

More than 780 automated production lines are currently operating in 69 countries on five continents. They produce the equivalent of 30 000 tonnes of baked goods every day.

Hourly production rates range from 700kg to over five tonnes of dough, outputting a variety of products optimally suited to a client’s industrial requirements and distribution method.

a return on investment in three to five years, even with limitations and specific economic factors of the region.

A global approach allows investors to move into the industrial bakery sector, regardless of their level of familiarity with the industry or with managing large-scale projects.

Technology is aimed not only at investors seeking a quick return on investment, but also at manufacturers looking to diversify activities; millers who would like to invest in the processing of flour and bakery professionals with several sales outlets wishing to boost capacity.

This solution will enable them to centralise production to effectively tackle the shortage of skilled labour and control quality and uniformity of day-to-day bread production.

‘Industrialisation of the bread making process makes it possible to achieve high production volumes, optimal hygiene conditions in production and finished products of uniform quality. ‘Experience proves that simply supplying a ready-to-use production line is not always enough to guarantee a project’s success. Working closely with specialist partners and local representatives, we develop turnkey solutions to support clients during every stage of their project to ensure

they can easily overcome obstacles they may encounter along the way,’ explains sales director for Africa, Jean-Yves Bruckert.

‘Developing the African market and providing on-site support for our clients are among our key priorities. The Baguette Factory embodies our vision for industry and our expertise in the African market. An initial project is currently approaching completion.

The factory is scheduled to open in the spring,’ concludes chief executive officer Olivier Sergent. •

Mecatherm – www.mecatherm.com

The Baguette Factory is a turnkey solution for industrial baguette production

September 2018 | Food Review

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B A K E RY

Simple solutions are often the best

Disruptive Rapidojet technology is set to change the way traditional bakeries do business. Instead of utilising mixing tools, it works by forcing high pressure liquid into dry ingredients. Inventor, Dr Bernhard Noll explains how this innovative technology works.

A

patent pending mixing chamber replaces the normal mixing bowl.

Even with a single machine, bakeries can instantly hydrate or mix most dry ingredients. Complete flexibility means one unit can produce the following: • A 65 per cent flour and water Biga • A 115 per cent liquid sponge • Hydrated bran at 225 per cent • 400 per cent hydrated vital wheat gluten • Hydrate items such as potato flakes to make mashed potato.

Due to the lack of mixing tools, Rapidojet’s range is about 5000 per cent in baker’s per cent. A normal mixer has a hydration range of about 30 per cent. Mixing potential is about 1.5Kw hour/tonne of output as opposed to a normal mixer, which consumes about 15Kw hour/ tonne of output.

Extremely hydroscopic ingredient vital wheat gluten, requires a 400 per cent hydration level to be fully functional. When pre-hydrated via Rapidojet, usage rate for this expensive ingredient is reduced by 20 per cent. When added to a normal mixer as a dry powder, it is never fully hydrated or functional.

You no longer need to soak bran for three hours and find places to store it around the bakery to achieve only 80 per cent hydration. The result of instant hydration at 225 per cent via Rapidojet is higher dough yield, longer shelf life, higher loaf volume, reduced mix time in your legacy mixer and better final product consistency.

Whole grain blends are cleaned of exterior DON and fully hydrated in 10 minutes instead of the normal four hours of soaking. Flour millers find the normal eight to 26 hour tempering time is cut to three hours. Sprouting time is also radically reduced.

Rapidojet is currently being operated as a continuous mixer for masa used in tortilla chips and potato flake hydration/ mixing. Machines are normally installed

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Food Review | September 2018

above the masa hog or depositor thereby eliminating normal mixer and mixing bowls.

Benefits in product consistency, worker and product safety, sanitation and energy use are assured. When all your ingredient flour is pre-hydrated with Rapidojet for dough with about eight per cent more water, and minors are added at the legacy mixing bowl, mix time is reduced by 85 per cent. This is because the system instantly develops gluten structure.

It can also be used as a continuous mixer for gluten-free products. A traditional mixer normally takes 12 to 15 minutes to develop gluten structure. A tremendous amount of heat via friction is generated – requiring glycol and ice, often hard on wear and tear of equipment.

Rapidojet achieves the goal of gluten development in a fraction of a second without the need for cooling and a stronger and homogeneous bond is instantly created by the system’s high pressure.

Rapidojet is a high hydration system for quick dough production

Approximately eight per cent more water must be used to attain the same level of machinability, dough feel, extensibility and rheology. Slower starch retrogradation also results in longer shelf life.

‘We’ve found that our ability to substantially reduce normal dough tail out is one of our greatest benefits in a full range of applications. It’s become clear that tail out is not primarily caused by oxidation, but rather when using a metal mixing tool.'

'Normal surface tension barriers are impossible to penetrate immediately. It takes about 30 minutes for full hydration to occur. Our patented use of high pressure liquid addition to dry ingredients instantly defeats this resistance. We eliminate almost all free water instantly,’ Noll concludes. Rapidojet is represented in South Africa by Courlanders. •

Courlanders – www.courlanders.co.za

B A K E RY

Healthy bread with healthy fibres When dietary fibres were characterised initially, they were considered as dispensable: dead weight with no function for the human body. It is well known that these ingredients have physiological properties such as improvement of digestion, impact on satiety and reduction of blood glucose rise and cholesterol levels.

T

hey play an important role in the prevention of various lifestyle diseases such as obesity, diabetes, or diseases of the gut. A meta-analysis, published in the British Journal of Nutrition on dietary fibres indicates the intake of cereal fibres seems to protect against cancer, cardiovascular disease and overall mortality.

The German Society for Nutrition (DGE) in its guideline paper on carbohydrate intake, indicates a high consumption of fibres from cereals lowers the risk of Type 2 diabetes. The last aspect is particularly interesting, considering the continuous rise of diabetes and heart disease. It is well known that the average person does not take in enough fibre in their daily diet. Most researchers agree that a daily intake of between 20 and 40g is sufficient. With fruit and vegetables, bakery products are foodstuffs primarily associated with dietary fibres.

Hit all your inspection targets

“The consumption of whole grain products is decreasing. The trend is moving towards refined grain products as consumer preference is a bread that is light in colour with a soft crumb”

As a comparison, one slice of whole grain bread contains approximately 4.4g of dietary fibre and one slice of white bread around 1.6g. The consumption of whole grain products is decreasing. The trend is moving towards refined grain products as consumer preference is a bread that is light in colour with a soft crumb.

‘With the use of Vitacel dietary fibre concentrates (up to 98 per cent content) from our producer JRS Germany, it is possible to create bakery products rich in fibre, but light in colour, with no impact on taste and appearance,’ notes Graham Hiam of Brenntag.

‘Vitacel does not need further adaptations in the recipe, with the advantage of being able to create tasty products with higher fibre content with the same indulgence of standard products.’ •

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www.heatandcontrol.com | info@heatandcontrol.com Cape Town +27 21 948 5934

September 2018 | Food Review SAFoodReview_Jul18_88.5w x 262h_CEIA.indd 1

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B A K E RY

Weighing solutions ideal for fragile products

Ishida Europe has introduced its range of 10 and 14 head multihead weighers.

These units were designed to deliver fast and accurate weighing of fragile products including biscuits, wafers and frozen items.

P

roducts that break easily pose a challenge for automated weighing systems. The design of Ishida’s new units incorporates gentle slopes and reduced angles throughout. This is to ensure that product passes through the passage easier. Bancollan inserts for the hoppers and a discharge chute provides effective cushioning, while unique curved pool and weigh hopper designs deliver controlled deceleration.

This further minimises the potential for breakages. A ring shutter also helps prevent breakages due to product collisions in the discharge chute during transfer of product into the packaging machine.

For fragile frozen products, such as pasta, seafood, fruits, vegetables and bakery items, the GS model can be specified in a WP waterproof version. This provides industry

leading protection for the weigher in challenging factory environments. The IP69K test rating means the weigher offers the highest levels of water and dust resistance, making it perfectly suited to applications where equipment must 10 and 14 head be thoroughly sanitised. multihead weighers The CCW-RV 10 and 14 heads GS offer all the proven benefits of the Ishida RV range with its reputation for unsurpassed accuracy and efficiency.

All heads are capable of being used in a single combination calculation. Unique triple combination calculation software can calculate three optimal weight combinations, double

INDUSTRY SECTORS FOOD INGREDIENTS

More than just a chemical supplier.

Tel: 011 821 3300 | 021 550 8100 | 031 468 5424 | 041 403 1000 Website: www. proteachemicals.co.za | Email: info@proteachemicals.co.za

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Food Review | September 2018

check them and then select the one nearest to the target weight in a single cycle. This minimises error discharges and increases efficiency, while enhancing weighing accuracy and consistency.

Anti-floor vibration removes background vibration from the load cell output signal, improving signal stability and machine accuracy.

Speeds of up to 65 per minute for the 10 head and 90 packs per minute for the 14 head model can be achieved, depending on product characteristics and required target weight. •

Ishida – www.ishida.com

Find the smallest objects before they cause the biggest problems Our quality control systems leave no stone unturned.

Or shard of plastic or glass. Or piece of rubber or bone.

If there’s a foreign body in your product, our machines will find it. Reducing product recalls and protecting your brand.

Work in harmony with Ishida.

ishidaeurope.com

B A K E RY

Sweet substitutes for the future

Sugar reduction affects the food industry and regulatory requirements. Demanding consumers are forcing manufacturers towards a clear direction: Sugar content must be reduced without any impact on taste or sensory properties.

F

unctional ingredients manufacturer Beneo has found a way of implementing sugar reduction in a high quality, nutritionally advantageous way. Stringent regulatory requirements and demand for these products are increasing, prompted by consumer concern about weight gain and health consequences.

The type of reduction matters. Healthconscious consumers want to avoid chemical ingredients such as artificial sweeteners. Products of natural origin are the preferred choice.

CONTEMPORARY SWEETENING CONCEPTS Food manufacturers are working hard to meet consumer needs

and regulatory requirements. They are dispensing with unpopular ingredients, setting value on meaningful nutritional profiles and improving on-pack labelling.

Suppliers with in-depth knowledge of ingredients are in high demand, actively supporting customers in development of

“Sugar provides pleasant sweetness and performs important functions within the food matrix in terms of appearance, stability and texture�

www.braganchemicals.co.za

Durban Office Tel. No.: +27 (0) 83 252 4826 Cape Town Office Tel. No.: +27 (0) 78 780 9976 Port Elizabeth Office Tel. No.: +27 (0) 71 213 9288

WE DO WHAT IT TAKES

Food Review | September 2018

FOCUS ON HEALTHY FIBRES Prebiotic functional fibres such as oligofructose and inulin are perfect

Johannesburg Head Office Seven Warehouse Complex 3 Bernie Street, Unit 3, Kya Sands Tel. No.: +27 (0) 11 708-0007 Fax No.: +27 (0) 11 708-7311

28

suitable recipes. This is a big challenge.

Sugar provides pleasant sweetness and performs important functions within the food matrix in terms of appearance, stability and texture.

Simply reducing or eliminating sugar works in the rarest of cases. Manufacturers must select alternative ingredients that improve nutritional profiles, maintaining a high level of taste and appearance.

Contemporary sweetening concepts are the solution. Beneo offers the right choice for many product concepts. These innovative ingredients provide not only technological functionalities but health benefits.

B A K E RY

for healthy sugar reduction.

Both have a mild sweetness - ideal for sugar reduced food such as baked goods and dairy products. Partial sugar reduction, with Beneo’s fibres, has several effects at once: it reduces calorific content and glycaemic effect.

Natural dietary fibres obtained from chicory root are not metabolised in the small intestine and its constituents don’t enter the bloodstream – unlike sugar. A diet rich in fibre, as recommended by the WHO, contributes to healthy digestion.

TECHNOLOGICALLY ADVANTAGEOUS The think tank at Beneo’s Technology Center developed a sugar reduced chocolate chip cookie. In this product sample, Orafti Inulin allowed for 30 per cent reduction in sugar, with no significant differences in sweetness, taste or texture compared to reference products.

A second

product sample demonstrates how dietary fibre can be used to reduce sugar. This ingredient was cut by almost 30 per cent in a cereal bar by Orafti Oligofructose.

In addition to positive effects on intestinal health, fibre scored high in this application because of technological advantages. Compared to the reference bar, there were no significant differences in chewability and taste. There was however an improvement in haptic properties and shelf life.

The bar also shows more stringiness when it breaks and is less hard compared to the reference product during storage.

Soluble fibre is a suitable alternative to artificial humectants.

REPLACING SUGAR COMPLETELY If sugar is not simply reduced, but completely replaced, Isomalt is the ingredient of choice. It can replace sugar totally in a ratio of 1:1 in many applications. In most cases, there is no need to change either the recipe or production parameters.

Polyol is only partially metabolised and provides about half as many calories as sugar. It is tooth-friendly and features

a low glycaemic index. Most popular applications are sugar-free hard boiled candies and tooth-friendly chewing gums.

In terms of taste and technology, the only sugar substitute obtained entirely from sugar beet has comparable properties to sucrose. As a bulking and texturising ingredient it can be used in baked goods.

This was demonstrated during a test run at Beneo’s Technology Center. Isomalt was used to replace all sugar in a shortbread biscuit, reducing calorie content. The resultant biscuit tasted as good as the sugar-containing product, with an awesome crunch as Isomalt does not draw moisture from the surrounding air, thanks to low hygroscopicity. •

Savannah Fine Chemicals – www.savannah.co.za

Matching today’s expectations.

Smart ingredients for healthy lifestyles.

As part of their modern lifestyles, consumers expect their food to be tasty, healthy, convenient and functional at the same time. BENEO offers smart ingredients that help you meet these expectations. Our products cater for energy and weight management, improved digestion and healthy ageing as well as better taste and texture, just to name a few. Beyond that, your product development will be inspired by our insights and expertise!

Follow us on:

Our Sales Network Partner in South Africa:

info@savannah.co.za

www.beneo.com

September 2018 | Food Review

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B A K E RY

Future-proof fortification As the principal component of bones and teeth, calcium is the most abundant mineral in the human body. Yet a South African review of dietary intake surveys documented nutritional deficiencies are still highly prevalent in the adult population, especially in rural areas.

S

ix surveys published between 2000 and 2015 report the mean calcium intake of men and women is far below recommended amounts of 1 000mg1 per day (based on Dietary Reference Intake).

This is often caused by high prices and a lack of availability of certain food such as fruit, vegetables and dairy products. There is a growing population segment with raised calcium requirements like lactoseintolerant people or the elderly with the

Wheat totilla with added calcium

Omya Consumer Goods omya.com

Bakery goods, naturally improved Omya high-purity natural Calcium Carbonate in bakery final formulations provides bioavailable calcium, while improving final product characteristics.

lisadk@cjpchemicals.co.za

Official Distributor for RSA

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Food Review | September 2018

B A K E RY

risk of osteoporosis. Consuming fortified food is a viable approach to ensure proper supply of this essential nutrient.

Natural high purity calcium carbonate is a perfect match for bakery products.

Switzerland-based company Omya is a leading global supplier of naturally derived calcium carbonate. Inorganic calcium salt has no allergenic potential and no taste drawbacks. Thanks to pureness of its sources, any heavy metal is kept to an absolute minimum.

It is significantly below legal thresholds.

The ingredient fulfils even the strictest specifications. Good bioavailability makes calcium carbonate an ideal fortification source, which additionally simplifies production processes and improves formulations. In the field of baking, it can be used to enrich tortillas, breads, bread rolls or fine baked goods.

HEALTHY TORTILLAS With expert knowledge of more than 130 years, Omya offers mineral particles bundled under the brand Calcipur that suits all kinds of bakery applications. The natural, cost-efficient ingredient offers considerable benefits.

With a calcium content of approximately 40 per cent, it is the calcium source with the highest concentration of all existing salts. Compared with other available technical solutions, up to five times less Omya Calcipur is required to obtain the

Recipe: Fortified wheat tortilla • 873.6g wheat flour (Type 550) • 25.2g Omya Calcium Carbonate • 156g oil • 17.2g salt • 0.8g baking powder • 452.4g water

“With a calcium content of approximately 40 per cent, it is the calcium source with the highest concentration of all existing salts”

same calcium dose in an end product.

Baked goods, such as wheat and corn tortillas, can be easily fortified with calcium by replacing the corresponding amount of corn or wheat flour with Omya Calcipur. Test panels prove the addition of calcium carbonate in both products has a positive influence on taste, described as less sour and more round sensation. There is no impact on mouthfeel, as particle size grade is controlled.

It only takes less than two per cent in a recipe to visibly increase the size of tortilla doughs. Mineral particles also make dough more plastic and less elastic, so it becomes more kneadable and easier to process. With only 1.7 per cent of Omya Calcipur added to the formulation, a single 35g tortilla can be fortified in a way to contain 600mg of calcium carbonate what corresponds to 240mg of elemental calcium. Tortillas are an everyday product for many people.

Fortification with Omya Calcipur can help to achieve 25 per cent of the optimum daily calcium dose with just one piece.

Omya is represented locally by CJP Chemicals. • Mchiza, Z. J. et al. (2015): A review of dietary surveys in the adult South African population from 2000 to 2015.

Nutrients 7.9, 8227-8250.

1

CJP Chemicals – www.cjp.co.za

We offer creative and innovative solutions through in-house research, customised products and packaging

Our Promise is inside Phone - +27 (0)11 4526730 Email - info@vivit.co.za Web - www.vivit.co.za

Manufacturer of cake pie fillings, toppings, yoghurt fruit pulps,caramel treat, milkshake syrups, salad dressings,mayonnaise and sauces.

FSSC 22000 Certified Halaal and Kosher

September 2018 | Food Review

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B A K E RY

Bridging the gap between functionality and innovation Fruits and vegetables are widely utilised horticultural commodities in the food and beverage industry. They are extremely versatile and consumed in many forms - from raw and minimally processed to fully processed products, writes Candice Sharp.

A

s consumer awareness increases on what people want to eat, there is growth in demand for manufactured goods from these products.

As with other commodities, the production of fruit and vegetable products results in waste and losses. In the fresh produce industry, the term ‘losses’ refers to the unintentional result of the way food is processed. It occurs throughout the supply chain from harvesting to consumption.

Waste on the other hand, refers to fruit and vegetable components that do not conform to quality and food safety requirements. It is usually graded in this category because it is unfit for human consumption. It does not conform to customer specifications like weight, size or colour. These products are intentionally discarded. When considering the economic and environmental challenges our world faces, it is important for all members of the supply chain to be as cautious as possible to prevent losses and waste.

In 2015, there were approximately 800 million people in the world without access to ample food. This could potentially be alleviated by reworking or converting food waste into safe, consumable food. It will also ensure the quality of food consumed is improved. There is a definite need for industries to decrease and utilise their waste, generated on a day-to-day basis, in a manner that supports sustainable development. Manufacturers are obligated by food safety requirements to implement

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Food Review | September 2018

Banana flour is high in oligosaccharides.

responsible waste disposal practices that contribute to additional capital expenditure with no extra income.

Making use of non-conforming fresh produce components such as skin, peels, seeds and pomace could possibly assist in generating new, functional ingredients with significant nutritional properties.

Fruit and vegetable waste inherently contains several bioactive compounds, such as vitamins, minerals, and dietary and novel fibre. Waste is susceptible

“There is a definite need for industries to decrease and utilise their waste generated on a day-to-day basis, in a manner that supports sustainable development”

to spoilage, and should be sanitised by some means before use. The production of powders from drying the waste is one way of achieving a safe product that still exhibits a large number of nutritional and functional capabilities.

The use of fruit and vegetable powders in food opens the door for many new products and the improvement of existing products.

Another example is the drying of bananas to create a flour that is high in oligosaccharides, which food producers will be permitted to claim on their labels, if the draft Regulations Relating to the Labelling and Advertising of foods (R.429/2014) are passed unchanged.

Banana flour has several functional benefits: it can be used as a thickening agent and imparts a creamy mouthfeel to a product, while having a neutral effect on the flavour of the end-product.

Carrot and beetroot peels and other by-products are Candice high in carotenoids Sharp and anthocyanins, which act as natural colourants. If R.429 is passed this too could be declared on a product label as natural colouring. Depending on the proportions used, carrot and beetroot powders can impart nutritional benefits to products in terms of vitamins and minerals.

There are many applications not yet considered. The possibilities for the use of fruit and vegetable waste are endless.

As a company Facts is interested in developing concepts to do with preventing waste, and creating new and interesting categories of food.

Facts is involved in assisting companies with new product development, along with the journey of testing and other regulatory requirements such as product labelling. •

CANDICE SHARP has an

honours in B.Sc Food Science.

Facts –www.factssa.com

DA I RY F O O D

The perfect solution for large scale butter production GEA recently sold its first BUE 6000 buttermaking machine type to an Indian dairy producer-Creamy Foods Limited, located in the state of Uttar-Pradesh.

T

hese units have a processing capacity of up to 6 000kg/h making it the largest buttermaking machine in India. It will start operation in February 2019.

Creamy Foods Limited is one of the largest global producers of ghee - the Indian equivalent of clarified butter in Europe and the primary cooking oil in every Indian household. In Europe, ghee is also popular among people who embrace ayurvedic medicine. ‘GEA’s equipment will enable us to produce ghee and other milk fat products to the highest global quality standards,’ say Amit and Anurag Aggarwal, directors at the dairy processor.

The machine allows for the continuous

production of butter from sweet or sour cream according to the Fritz continuous butter making process. A unique feature is the I-Churn, which makes it possible to automatically control the speed of the churning cylinder. The result is an optimally churned butter – independent of fluctuating feed parameters. GEA offers quick and reliable supply of spare parts as an additional benefit.

In addition to the BUE 600, the scope of the order includes a GEA MSI 600 separator for separating cream from skim milk; GEA MSE 60 separator for concentrating butter oil and a Ecoclean clarifier for removing solid components from clarified butter.

With this new equipment, the dairy can

Creative Flavors International offers the National and International market with quality flavours and emulsions Designed to add various degrees of cloudiness and flavour to beverages, our emulsions form the foundation for efficient beverage manufacturing. We offer consistent high quality products with a perfect balance of cloudiness, flavour and colour stability. We offer flavours for all beverage applications e.g. alcoholic beverages, fruit juices and soft drinks.

All of our flavours are Kosher- and Halaal suitable and manufactured under strict hygienic conditions with the necessary Good Manufacturing Practices in place. We are also ISO 22000 certified.

Tel: +27 11 760 1830 • Fax: +27 11 760 1829 • www.creativeflavors.co.za

September 2018 | Food Review

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DA I RY F O O D

process up to 190 tonnes of cream, turning it into 76 tonnes of ghee per day with minimised product losses.

GEA is a leader in buttermaking technology, especially when it comes to large processing capacity requirements under hygienic and fully automated conditions. Global sales of BUE continuous buttermaking machines has grown drastically over the last few years.

The sale of a new butter churner in the Indian market is particularly exciting due to the large number of second-hand

buttermaking machines available in this price-sensitive market.

‘Receiving the first order for a new BUE buttermaker in India – one of the world’s largest milk producing countries – is a strategic win and will no doubt be the basis for future sales. With the GEA BUE 6000, Creamy Foods Limited will have the latest technology for buttermaking in place. We are sure the benefits will interest other Indian dairy producers and we are happy that we can use this as a reference for other customers,’ says Kianusch Javadinejad, product sales manager – dairy at GEA. •

GEA – www.gea.com

GEA BUE 6000

Protein solution cuts costs

Arla Foods Ingredients has launched one of the world’s fastest cream cheese manufacturing processes.

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ream cheese production is a complex procedure that can take up to 20 hours. It generates significant amounts of acid whey. This makes it inefficient and expensive, occupying valuable space on production lines. The new whey protein ingredient solution, Nutrilac CH-7694, allows dairies to reduce their cream cheese manufacturing process to just 30 minutes, while increasing yield.

Developed in its application centre in Buenos Aires, Argentina, Nutrilac CH7694 creates a new product that delivers excellent flavour and texture. It is easy to handle and highly versatile, making it suitable for further processing into products such as cheesecakes and sushi.

The key to a speedy production process is the elimination of fermentation and separation processes. This reduces manufacturing times, eradicates acid whey production and requires less investment

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Food Review | September 2018

in machinery. Aparecido Silveira, the company’s global marketing manager for dairy explains, ‘Our new high-yield solution is a great way for cream cheese makers to cut costs and increase profits.

It is suitable for first time entrants to this category. It requires no extra investment in the manufacturing plant and has the potential to revolutionise processes for existing manufacturers.’

INNOVATIVE SOLUTIONS IN YOGHURT Arla Foods Ingredients’ new solution for high protein drinking yoghurt delivers great texture and mouthfeel throughout its shelf life.

In tests, a 7.5 per cent protein drinking yoghurt made with Nutrilac YO-5088 had more desirable levels of viscosity than a similar product made with a standard milk protein concentrate. It also retained

a pleasant, drinkable texture for much longer. Results show Nutrilac YO-5088 is ideal for creating on-the-go drinking yoghurts that offer great taste and high levels of satiety to today’s busy and health conscious consumers.

Nutrilac YO-4575 is a low-pH, heatstable protein ingredient for creating delicious, fresh-tasting, healthy longlife yoghurts. Sensory evaluation demonstrates these yoghurts scored high on mouthfeel, delivering a pleasant and soft texture with zero dryness or sedimentation. Tests indicate long-life yoghurt will not develop syneresis even after six months' storage at 30°C. •

Arla Foods Ingredients – www.arlafoodsingredients.com

BeverageREVIEW SOUTH AFRICAN

September 2018 | Volume 8 | Number 09

www.foodreview.co.za

How to ensure your

boiler doesn’t blow Quality fillers for base wines

Water processing challenges debunked

NEWS

BevSA appoints general manager M

pho Thothela has been appointed World Cup local organising committee. He general manager for corporate held leadership positions at Deloitte where services at Beverage Association of he served clients such as the Western Cape South Africa with effect from 1 August 2018.

Department of Education, Mpumalanga An admitted attorney of the High Court of Land Restitution and the Companies and Intellectual Property Registration office.

South Africa, Thothela is a former director of corporate ‘BevSA is delighted to affairs at Muhari Logistic. welcome Thothela. We He will now be responsible believe his capabilities will for BevSA’s marketing continue to build BevSA as a and communications, formidable voice of the South brand positioning and African beverage industry. We reputational management, are looking forward to tapping financial management, into his vast knowledge, experience and expertise he revenue growth, budget has acquired over the years,’ management, IT BevSA executive director and related Mpho Mapule Ncanywa enthuses. functions including Thothela ‘His knowledge and unique support services. skillset in understanding the He joins BevSA from Proudly South Africa, where he served laws governing the country, will help BevSA as chief officer: membership, legal and in its vision to develop a thriving business compliance and company secretary. In 2010 environment for South Africa’s non-alcoholic Thothela was legal manager for the 2010 FIFA beverage sector.’

New grape solution for wine industry

G

rape juice supplier Welch’s Global Ingredients Group (Welch) has embarked on a foray into the wine industry. The company launched a Niagara grape juice solution, designed to be a cost-effective but high quality filler or base wine for a broad variety of wine styles. The Niagara is a white grape with a golden hue. It delivers a sophisticated flavour profile that is crisp, sweet, light and refreshing. Its juice is a popular ingredient in the juices and soft beverages category.

Research and development specialists at Welch’s developed a de-characterised version of the juice that is perfect for fermentation and blending with wine made from more traditional wine grape varieties and even other fruits. Juice grapes typically sell at a significantly lower price when compared to wine grapes. This means the new de-characterised Niagara is a perfect option for winemakers looking to reduce raw material costs without impacting quality. The company also supplies Concord grape juice to the wine production sector. The Concord grape is a distinctive dark purple grape variety with a sweet bold flavour, suitable for making Concord wines or as a filler in select red wines where the unique Concord grape’s flavour and aroma notes are desired. Kevin Kilcoyne, vice president and general manager says, ‘We’re excited to be expanding our capabilities to provide a cost-effective ingredient solution for the winemaking industry. This will be an important market for us going forward, and we have further winery-specific innovations in the pipeline.’

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Beverage Review | September 2018

Johan Van der Eeken, Eeva Heeman and Stephan Hohenadl

Support development in Africa

L

eybold, part of the Atlas Copco group handed over a donation cheque for €5 930 to the employee initiative, Water for All. Since 1984, the enterprise has supported projects that provide people in need with access to clean drinking water, sanitation and hygiene.

It is Atlas Copco's most important non-profit initiative and is funded through employee volunteer contributions. In total, more than two million people have gained access to clean drinking water. In the long term, the focus is on supporting sustainable water supply and hygiene projects, especially in Africa.

‘When we presented the concept to the sales department, I was very pleased with the immediate support for this project,’ says Stephan Hohenadl, who is responsible for this campaign. ‘To reduce inventories, we launched a so-called 'Red Tag' campaign. This offered corresponding products on the market at special conditions. The articles were then sold at a very attractive price and our warehouse was cleared.’

That alone was nothing special - but the sales team's highlight was a percentage share if the minimum sales price was exceeded. The second highlight was when the sales team made a percentage contribution to the renowned social project Water for All of parent company Atlas Copco.

‘Our cooperation with Welthungerhilfe makes it possible for institutional donors to double the donation and ultimately raise €17 790 for our joint aid projects. Eva Heemann and Cemre Altinsoy from the Atlas Copco employee initiative were delighted when they accepted the cheque. I am very pleased this initiative has been so positively received and supported by our staff,’ emphasises managing director Johan Van der Eeken. ‘This campaign is a win-win situation for everyone. It supports sustainability to a special degree and serves to make life easier for those in need in a direct way.’

WAT E R P R O C E S S I N G T E C H N O L O GY

From source to bottle

Algerian beverage producer SARL Nomade has modernised its production facility with technology from KHS.

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growing population and rising living standards mean there is high demand for bottled water in Algeria. Local supplier SARL Nomade has opted for plant engineering from KHS during modernisation of its production facilities.

In 1998, SARL Nomade started operations by filling soda pop in Akbou, a town about 150 kilometres west of the capital of Algiers.

The company now specialises in bottling spring water.

Tap water in the region contains a high amount of chalk and demand for the Ayris brand is increasing. ‘The population now favours water in PET bottles,’ says Yasmine Brahimi, KHS project manager for Africa and the Middle East.

Hamid Chalabi with Makhlouf Boukhata

GROWTH IN DEMAND SARL Nomade decided to extend his production operations with the help of an InnoPET BloFill stretch blow molder/filler block.

‘KHS had us convinced,’ says Makhlouf Boukhata, technical plant manager. KHS also increased its regional presence to cover the whole of the African market. ‘We’re strongly represented locally and know the market,’ Brahimi states. ‘From first making contact, to the commissioning of the system, our work together is characterised by mutual trust and appreciation.’

‘We were chiefly convinced by the reliability of KHS machines,’ Boukhata explains. ‘We also appreciate the compactness of the space-saving system. Connecting the stretch blow moulder directly to the filler, eliminates the need for the air conveyor, feed plate and bottle rinser. The stretch blow molder/filler block from KHS enables up to 81 000 bottles per hour to be produced.

SARL Nomade fills 40 000 bottles an hour containing 0.33, 0.5 and 1.5 litres. ‘We work much more efficiently. Not only have we considerably increased our capacity, we’re also benefitting from fast format changeovers and automatic operation.

‘Since commissioning the line the amount of energy used has also dropped considerably. Together we’ve developed a new, modern bottle design with the help of the Bottles and Shapes™ programme.’ Due to the efficiency of the line installed the processor placed a further order with KHS in 2018 – for a turnkey PET line for the bottling of carbonated and non-carbonated water.

The company aims to diversify and expand its portfolio with fruit juices and carbonated soft drinks envisaged soon. With its new line SARL Nomade will replace an older one. This will complete the programme of modernisation. Other beverage producers in the area have come to view the modern production setup and plant machinery. ‘The response has been 100 per cent positive,’ Boukhata concludes. 'The machines made by the systems provider are of a high quality. We wanted German quality – and this is what we got. That’s what KHS stands for.’ •

KHS – www.khs.com

SARL Nomade fills 40 000 bottles an hour containing 0.33, 0.5 and 1.5 litres

September 2018 | Beverage Review

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WAT E R P R O C E S S I N G T E C H N O L O GY

Identify and remedy reverse osmosis process challenges Lanxess is a global provider of liquid purification technologies. The company has almost 80 years of experience in water treatment and purification applications.

E

N14597 High performance products can treat and purify water to required specifications; purify processing streams and recover valuable ions from a solution. Products include Lewatition exchange resins, Lewabrane reverse osmosis membrane elements and Bayoxide iron oxide absorbers. Reverse osmosis is a standard water treatment technology, which gained acceptance over the years.

This technology is no longer limited to use in industrial water treatment facilities, but also smaller applications such as treating mains water.

Whatever the application, fundamental problems observed in membrane processes haven’t changed and include: - Decreasing rejection efficiency - Reduction in performance (reduced flow or higher pressure).

When problems occur, the first question that needs clarification is: have there been any changes in the feed water quality or temperature? To easily locate problems, it’s important to document basic parameters such as temperature, flow, pressure, yield and conductivity. Measuring pressure loss, preferably between concentrate levels, is also important. Data should be normalised, i.e. expressed in relation to a standard situation so it is possible to assess whether the change in performance is due to the system or changed inflow parameters.

Calculation tables for this purpose are provided by membrane manufacturers, free of charge. It is vital to check that other facility components such as measuring equipment, antiscalant dispensing units and ion exchange systems are running smoothly.

If after normalisation, data deviates as listed below, the reason should be closer investigated.

• 20 per cent higher salt passage (definition: salt passage = 100 per cent rejection) • 10 per cent reduction in flow • 20+ per cent of pressure loss along a pressure pipe.

Frequently, small facilities only record a few measurements. These are generally not normalised. Where this is the case, influence of temperature and variations in salt loads in the water should be considered. The rule of thumb is for each degree the temperature drops, flow is reduced by approximately three per cent.

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Beverage Review | September 2018

INVESTIGATING THE PROBLEM It goes without saying the investigation process depends on problems observed.

If salt passage has increased, i.e. the rejection has declined, this can indicate chemical or mechanical damage to a membrane or element. Reduced flow is generally due to organic, biological or inorganic fouling. The following table provides an overview of the tendencies and potential reasons for a drop in performance.

It is often difficult to localise and then deal with a problematic point in the system.

INCREASED FLOW AND DETERIORATION OF SALT REJECTION When there is an increased flow and a deterioration of salt rejection i.e an increase in the conductivity of the permeate in all pressure pipes must be checked in case any values are significantly elevated. If any single pipe is conspicuous, the element can be identified using the central pipe testing method.

This involves passing a flexible hose into the central pipe of the element to the end of the pressure pipe and then slowly pulling it back out, catching some permeate in the hose. This sample can be tested for conductivity. Should this suddenly rise, the location of a leak can be identified based on the length of the hose that has been pulled out. A leak might indicate damage to the element itself or to the interconnector between the elements.

If all elements demonstrate significantly increased conductivity with higher flow, this could indicate permanent damage. This can be a result of oxidation agents such as chlorine, solvents that have dissolved some polymer membrane, or caused by overpressure in the permeate. The latter causes delamination of the membrane. Upstream elements are more likely to be affected by oxidation than downstream ones. Delamination is more likely

to affect downstream elements, since this is where permeate overpressure are likely to be highest. Final clarification in this case can only come through an element autopsy, as this kind of damage cannot be assessed from the outside.

Increased flow and reduced rejection are clear indicators of a leak in the system that must be remedied. This can generally be achieved by replacing elements or parts (e.g. O-rings and interconnectors).

REDUCED FLOW If there is reduced flow, or if greater pressure is required, there is soiling (fouling). This can also lead to a reduction in salt rejection. Fouling is often associated with increased pressure loss along the entire pressure pipe, as flow channels become blocked.

While organic fouling primarily leads to blockages on the upstream side, higher salt loads on the downstream side is more likely to cause salt precipitation, i.e. inorganic fouling or scaling. Biological fouling can spread throughout an entire system and can be found at various points. It is generally possible to determine the nature of fouling by opening the pressure pipe.

A quick inspection is usually enough to find an organic blockage, white salt crystals or biomass. Removing the element and weighing it after draining will determine the degree of fouling. It must be drained for approximately 15 minutes before determining the weight. If, for example, an element that normally weighs approximately 16kg suddenly weighs more than 17kg, this could be due to severe fouling. In most cases, cleaning the element in good time can restore performance. Alkaline cleaning should be used to clear organic or biological fouling, while acid or complexing agents are used for inorganic fouling in acidic ranges.

Decreased flow is usually caused by fouling. It is essential to determine the degree and nature of fouling to select the appropriate cleaning strategy. If initial examination does not provide clear enough results, an element autopsy can be useful.

It is important to test whether the cause of a drop in performance can be eliminated to ensure a stable process. •

Lanxess - www.lpt.lanxess.com

P R O D U C T WAT C H

A world first in boilers The Safety-TL4896, a world first SIL2 rated temperature measuring device from Martens is now available from GHM Messtechnik South Africa. Units conform to international boiler regulations offering a unique front panel installation.

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ertified to DIN EN14597 and DIN EN61508 the device gives an analogue actual value output for regulators. PLC eliminates the need for additional sensors.

Managing director of GHM Messtechnik South Africa, Jan Grobler, says, ‘The Safety-TL4896 is the first safety temperature measurement device designed specifically for application in industries using boiler technology. It will generate enormous interest from plant operators from sectors such as paper and pulp, food and beverage, pharmaceutical, sugar, cleaning, hygiene and dairy.’

‘The device operates as a direct indicator. It is installed in the control panel instead of on the top-hat rail, eliminating the need for an additional indicator,’ Grobler explains. ‘An additional advantage is the execution of the reset function directly on the device. This removes the need for an additional control element.’

In boiler applications for hot water production, a safety temperature limiter must be provided in addition to the limit value monitor and minimum water level monitor. This will reliably suppress the energy supply in accordance with DIN EN 12828 by means of deactivating the automatic firing device with ignition flame monitoring (gas operation), a safety valve (oil supply) or a heating current interruption as soon as any of the limiters reacts.

Only permissible safety temperature limiters are used for industrial heat generators. This is in accordance with DIN EN 14597 and safety requirement levels of functional safety in accordance with SIL2.

Combined heat and power plants require safety temperature limiters for selfsufficient monitors for hot water, the over temperature of motor preheating, motor cooling water, exhaust gas and calorific value heat exchangers. In hot steam production, additional safety elements must be used to monitor boiler systems equipped with over heaters.

The Safety-TL4896 safety temperature limiter has a safety shut-off contact and an adjustable pre-contact to warn of impermissibly high actual values

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Beverage Review | September 2018

independently of the regulating and control device. Before the forced shut-off is activated, additional alarm messages can be issued and corresponding functional processes can be initiated to achieve a safe stand-by status.

This eliminates errors and avoids timeconsuming, costly complete shut-downs and subsequent restart of a plant. High-quality analogue output of the actual process value offered with the Safety-TL4896 enables further processing in the automation system.

It also eliminates the need to install an additional sensor.

BENEFITS OF THE SYSTEM Electronic safety temperature limiters were often built as top-hat rail devices in switch cabinets. For the first time, the device offers installation in the front panel. In the process, the actual and limit values on the large display can be read conveniently. The reset process after correction of the cause of an error takes place on the front panel in the same manner as all other operating processes.

Separate devices and their wiring can be eliminated, because their functions are already integrated.

With the adjustable pre-alarm, no additional limiters are needed and a redundancy to the automation unit is provided. A second additional measuring chain is eliminated by the analogue output. •

GHM Messetechnik SA – www.ghm-sa.co.za

Only permissible safety temperature limiters are used for industrial heat generators.

SAFETY-TL4896 CONFIGURATIONS

Small and compact systems whose complete automation electronics are contained in the operating device (e.g. with use of the GHM-ONE multi-function device or a compact industrial PC/PLC system), there is no longer a large, conventional traditional switch cabinet. As a selfsufficient front panel unit in slim DIN format 48x96, the new Safety-TL4896 enables a consistently compact design of modern small systems.

This reduces the wiring work and facilitates ergonomic operation in monitoring and observance of safety requirements.

The Safety-TL4896 offers time and cost advantages in wiring and installation. With the easy operation from the front side, the requisite safety functions and ergonomic operation of safety temperature limiters is fulfilled for the first time.

SIL2 conforms to international boiler regulations

PackagingREVIEW SOUTH AFRICAN

September 2018 | Volume 43 | Number 9

www.foodreview.co.za

Unlock the potential of

rigid packaging

Augmented Reality app helps

combat counterfeiting

SA’s first certified

packaging professional

NEWS

A trajectory for industry

S

UCCESSFUL TOOLING companies must differentiate their products from global competitors. To produce great concepts, the quality of tooling is critical. A tool has to be designed and produced with intricate geometry and surfaces of the highest precision.

The productivity of a tool is determined by its efficiency during production. These parameters are highlighted on page 46, where Packaging Review brings you the scoop on a new traybending machine due for completion in 2019 by Renlaw.

This innovation is set to place the company’s tools at the forefront of the global market.

There is a costeffective replacement to aluminium trays just

launched on the food packaging market. Turn to page 48 now to read about these CPET packs, which can be moved directly from freezer to oven owing to their special barrier properties.

Congratulations to MetPac-SA’s CEO, Kishan Singh on becoming the first packaging expert in South Africa to be awarded the designation, Certified Packaging Professional. His achievement is featured.

Enjoy the read.

Assistant Editor Aarifah.Nosarka@newmediapub.co.za

SOUTH AFRICA’S FIRST CERTIFIED PACKAGING PROFESSIONAL KISHAN SINGH, CEO of MetPac-SA has become the first packaging expert in South Africa to be awarded the 'Certified Packaging Professional (CPP)designation. It was presented to him by the international Institute of Packaging Professionals (IoPP).

Singh is a global ambassador of the Kishan World Packaging Organisation (WPO) and Singh national education officer of the Institute of Packaging SA (IPSA). IoPP has been awarding CPP designations to packaging professionals since 1972. There are currently less than 2 500 individuals worldwide to have achieved this coveted status. It requires proof of years of experience, in-depth knowledge of packaging, as well as commitment to the global packaging industry. The CPP programme is now also endorsed by WPO and IPSA. Singh is permitted to use the suffix 'CPP' after his name on business cards and letterheads. He can wear the IoPP/CPP lapel pin and display his CPP Certificate.

‘This designation has become the leading mark of excellence internationally and a must-have recognition of industry proficiency and achievement for packaging professionals. I am very pleased for attaining the CPP designation. It is a commitment to excellence in the global packaging profession and an important investment in my development,’ Singh comments.

Innovative recyclable packs introduced at industry events MONDI WILL PRESENT numerous innovations fulfilling packaging trends and the growing demand for sustainable solutions at three major upcoming industry events. The group will showcase its best-selling products and latest solutions for e-commerce packaging, convenience, premium design and other trends. Sustainability of raw materials, manufacturing processes and products are also an integral part of all of Mondi’s business areas.

‘We will demonstrate the strong position we are in to advise our customers and be their preferred innovation partner.

We see increasing interest in and the demand for sustainable packaging and

paper solutions from customers around the world. Sustainability is not a trend it’s a requirement. This is reflected in the key themes at all trade fairs,’ says Sara Sizer, communication and marketing director at Mondi. The group is in support of sustainability in the industry and sponsors the Packaging Europe Sustainability Awards 2018, which will take place in conjunction with the Scanpack fair from 23 to 26 October.

At this event, a new packaging laminate, the BarrierPack Recyclable, will be featured. This laminate helps reduce plastic packaging waste through recycling. Designed for pre-made pouches and FFS roll stock, it is fully recyclable

11900 - PROPAK AFRICA 2019 VISPROM ADVERT NEW MEDIA 177X65_V2.indd 1

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Packaging Review | September 2018

without any compromise of quality or functionality. BarrierPack Recyclable won the 2018 Plastics Recycling Europe Award for Best Technology Innovation in Plastics Recycling.

‘At Mondi, we work towards a circular economy and these recyclable packaging solutions are good examples of how we will change the conversation about plastic packaging through continued R&D and partnership,’ adds Sizer.

The improved version of Splashbag, initially introduced in 2015

2018/08/22 09:22

NEWS

Sacmi’s packaging solutions on show in Dubai THE GROUP WILL highlight its new ultra-high speed filling solutions at Gulfood Manufacturing’s annual fair in Dubai from 6 to 9 November.

These solutions will be displayed alongside a complete, integrated closure making range.

Consultancy and customisation options from a design standpoint will be illustrated with an even broader plant engineering range focussing on manufacturing, logistical and energy efficiency.

The event is expected to host at least 1 600 exhibitors from 60 countries displaying state of the art technology and plant engineering solutions for the beverage and closures industries. Trade fair visitors can experience Sacmi’s high speed DT011.pdf

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2018/07/18

filling line in hall 56, to learn about the new system, designed to operate at up to 72 000bph.

The group will showcase its new CCM24 cutting-edge cap manufacturing solution.

This machine ensures low consumption and better quality of the entire process, which is based on continuous plastic extrusion.

Sacmi develops complete cap-preform systems characterised by high performance and low weights.

The new CCM24 cap manufacturing solution

INTRODUCING A NEW FLEXIBLE TRAY SEALER PROSEAL HAS LAUNCHED its first tray sealer after winning a Queen’s Award for International Trade 2018. TTe is a small, compact and robust tray sealer ideal for low volume food production and production trials. It has been developed specifically to assist the progression of safe food packaging and shelf life extension to underdeveloped countries where packaging is overused or underutilised.

Proseal TTe is a semi-automatic, draw type, tray sealing machine with a full vacuum facility capable of sealing up to 10 vacuum/gas packs per minute with a two-impression tool. It is the latest addition to the company’s innovative ‘e’ technology range. It is characterised by its flexibility to perform any style of heat seal to a pre-formed tray, whether atmospheric, MAP, VMAP, Skin, Skin Plus or Skin Deep.

Each of these options can be added at the point of purchase, a later date or removed if necessary. This enables customers to future proof their investment by providing the flexibility to change pack formats in line with customer demands and market trends. There is no need to purchase new equipment.

Simple in design and operation, fully portable and castormounted, the TTe is convenient to use. It features a five minute tool changeover and a simple and accurate film feed system with an easy film route. It is maintenance friendly and has a robust construction. With the touch of a button, the ‘Auto-Tool’ feature automatically locates and connects the tooling to machine functions, including all MAP functions. ‘In every new machine launched we aim to take performance and usability to another level,’ comments Steve Malone, director at Proseal.

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September 2018 | Packaging Review

43

S E C U R I T Y FE AT U R E S

FOSTER A CULTURE OF LEGITIMACY VIA AR

Food fraud is a serious industry concern. A new AR application, adapted using an existing solution, is expected to help cease the proliferation of food label counterfeiting. By Aarifah Nosarka

F

oster Packaging has been working on a project over the past two years in search of a method to win the war on fake food and drinks. This follows market research conducted into the level of counterfeit products sold across Asia.

‘Customers in the seafood and fresh cherries markets have noticed a large level of copies of their main stream products,’ says Joe Foster, company director. The project involves adapting an existing mobile Augmented Reality (AR) application on a smartphone. It can be aimed at a label, which recognises and records the image or logo before submitting it to a bureau service or verification centre for inspection. If the food label is genuine an embedded watermark is retrieved.

‘We are close to launching this new version.

The existing application will be used as the trigger mechanism to check and verify the product. This is unique because of the level of security at the backend,’ he adds.

UNIVERSAL SOLUTION The idea is for the company to have access to the print files in order to include the embedded watermark. These files will then be sent to a printer in a secure manner.

Foster says the way in which the files will be encoded will make them impossible to

44

Packaging Review | September 2018

reproduce, even with the original prints.

Foster Packaging has customers across Africa facing challenges of fake basic commodities infiltrating the market.

‘Kenya had to import large volumes of sugar recently which is sad considering the country’s good resources. This was due to fake sugar purporting one of the country’s top brands which was sold on the market and contained high levels of mercury,’ Foster highlights.

The value of anti-counterfeit packaging is expected to reach US$154 billion in 2020 rising excessively from US$83 billon in 2014.

The expected outcome is for more robust authentication methods and technologies to be introduced to verify whether or not different food products are real.

Foster Packaging’s solution provides for a universal ‘generic’ watermarked label.

The technology will also be available for customised labels based on customers’ needs. Foster says all the authentication processes will take place with a bureau service or appointed verification centre. This is to ensure the highest possible level of security and maintain control over who has access to the application. •

Foster Packaging – www.fosterpackaging.com

USING CONSUMERS TO KEEP AN EYE ON THE SUPPLY CHAIN Coca-Cola Company has urged consumers to report any suspicions of compromised products directly to the brand. This comes after counterfeit goods and expired food were confiscated during raids in Gauteng. The brand released a statement saying there were recent reports of forged Coca-Cola products in South Africa.

‘Coca-Cola takes every consumer concern seriously. We have procedures in place designed to respond to any matter relating to our products. To date, there has been no official contact made by any consumer who has bought such products’, the statement read.

The company added that all the ingredients and methods used in the manufacturing process of its beverages comply with the health and safety regulations of the country. ‘We are tracking online concerns and urge any person who has had any product they believe might have been compromised, to immediately report it to our customer care line on 0860 11 2526 so we can investigate the matter’, the brand stated.

R I G I D PAC K AG I N G

SPEED MEETS FLEXIBILITY IN PACKING The latest technologies by Cama define a new standard in the world of secondary packaging. They feature ergonomic designs, adaptable modular configurations, user-friendly controls and improved safety levels – all R&D milestones.

O

ne of Cama’s advanced systems has been successfully installed at a popular European company in the dairy industry. The customer initially wanted to invest in a new plant to double production volumes from a single line to reduce operating costs. The line had to provide greater flexibility to run a broader range of formats.

As per the client’s requirement, it also needed to support the production of innovative new pack styles.

Cama engineered a complete system comprising a high speed MP sleever and an IF robotic loading unit. These were designed to pack sleeved glass jars of dairy desserts into shelf ready display cartons. Both machines form part of the company’s new BreakThrough Generation (BTG) systems.

300ppm. This was to match the output of the plant. The jars, received on a single lane, proceed for single layer configurations or are divided into two lanes for double layer configurations.

A motor driven double lateral star-wheel system spaces and phases the jars to the lateral clamping unit, which transfers a preset group into the sleeving station.

A rotary feeder then picks up the carton sleeve and places it onto two lateral flighted conveyors, which drive the sleeve on top of the collated jars. The sleeve is wrapped around the group of jars and the bottom section sealed with hot melt glue. Sleeved packs are transferred to the machine outfeed by a suitable conveyor.

DOUBLE PRODUCTION VOLUMES

With its forming, loading and closing modules, the IF Monoblock Loading Unit has been designed to load cartons or

The sleeving machine was conceived to handle the customer’s existing single jar format at

sleeved glass jars into display cartons.

Using the top load principle, Cama reconfigured the existing wraparound packaging styles. This innovation enabled a significant increase in pack speeds. A two-axis robot loads the collated products into boxes, which are shut by an integrated closing unit.

There is an integrated open flap detection and case reject on the outfeed. These ensure consistent quality outers are delivered to the automated palletising system. •

Cama Group – www.camagroup.com The advanced system designed by Cama for a European client

REDUCE OPERATIONAL COSTS

September 2018 | Packaging Review

45

R I G I D PAC K AG I N G

INDISPENSIBLE UTENSILS MAKE THE CUT

The meticulously crafted tools of Cape Town based industrial cutting tool manufacturer, Renlaw, meet the highest standards of quality, strength and durability.

The company’s precise engineering and investment in new tooling technology has enabled it to create bespoke solutions for diverse requirements.

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he growing middle class in Africa and increased prevalence of single person households continues to drive the demand for more packaging and smaller units.

Devloping urbanisation and booming online sales are some of the key drivers for Africa’s rigid packaging market.

The fastest growing material type in the global rigid packaging market is bioplastic.

This substrate is made from biodegradable materials. It breaks down into water, carbon dioxide and compost in a similar way to other organic matter.

Consumer demand for environmentally friendly packaging has created global hype around the use of bioplastics. Heightened awareness and growing pressures from regulatory bodies for commercial organisations to reduce their ecological footprint have resulted in a surge to replace conventional plastic packs with ecofriendlier alternatives.

Premium blade for rigid packaging cuts

46

Packaging Review | September 2018

Different rigid packaging punches

FULFILLING REQUIRED REQUESTS ‘A few years ago, we noticed an increase in demand for two of our product lines. These were the “trayseal blades” and “high precision punches and dies”. The blades are used to cut the lid skin of pre-made meals whilst airflow holes and hangar holes are punched into rigid and semi-rigid plastic containers by the punch equipment,’ explains Mikko Brunner, director of Renlaw.

To remain ahead, the company recently invested in new technology, which also helps Renlaw meet its customers’ needs for specialised tools. ‘We purchased a state of the art cylindrical grinder capable of holding tolerances of up to five thousandths of a millimetre with high surface finishes demanded in the cutting of warm PET and certain bioplastics,’ he adds.

The company is in the process of developing a CNC tray-bending machine.

This, according to Brunner, will be capable of bending tray-seal blades with thicknesses of between 0.5 and 1.6mm to different OEM specifications.

‘This is a particularly exciting project for us as the machine will be the first of its kind in the country. It will allow us to manufacture tray-seal blades to higher accuracies than before. This will see an improvement in blade quality and, in equal measurement, a reduction of our operating costs. We will be able to keep our prices competitive and place our products at the forefront of the global market,’ Brunner enthuses.

The new CNC tray-bending machine is expected to be

The CNC machinery

by Renlaw

SECTOR GROWTH IN SPITE OF THE ODDS

The global rigid packaging market, valued at around US$550 billion in 2017, is projected to grow at a CAGR of 5.8 per cent year on year over the next four years.

This packaging type’s development is largely driven by the increasing demand for consumer goods, the low cost of rigid packaging and the demand for improved recycling rates. The leading constraint is the rising adoption of more flexible materials. complete in 2019. Renlaw is currently running trials to refine the software parameters of the technology. •

Renlaw – www.renlaw.co.za

Renlaw CUTTING-EDGE TECHNOLOGY

Visit us at stand 158 at the Food & Drink Technology Expo 4 - 6 September, Gallagher Convention Centre, Johannesburg

Africa’s leading supplier of industrial cutting tools

info@renlaw.com

+27 (0)21 701 7917 (C.T.) +27 (0)79 155 7358 (JHB)

www.renlaw.com

R I G I D PAC K AG I N G

THE PINNACLE OF THERMAL EQUILIBRIUM

Rigid packaging, such as trays play a key role in the food industry. Providing a longer shelf life, they offer unique benefits such as high impact strength and unique barrier properties. Aarifah Nosarka reports on rigids making waves in the food packaging segment.

A

Johannesburg-based food packaging alternative to aluminium. These trays do not systems supplier, AGQPE has provide the same freedom of design as CPET introduced an advanced trays. This is because the metallised form of packaging. Company material is too unstable to be owner, Amotz Golan says these used for multi-compartment tray packs comprise trays while CPET is not. Its Crystalline Polyethylene flexibility and strength Terephthalate (CPET) and lie in the production are primarily used for process of CPET,’ Golan Replacing PET with rPET ready meals. highlights. reduces carbon emissions by 50 per cent. All trays containing These high barrier The materials rPET are equipped with packs are produced used in CPET trays are a top layer serving as using crystallised mouldable and allow a functional barrier. polyester, making them for a design with more ideal for freezing to -40°C than one compartment. This and cooking, up to 220°C. proves advantageous if a tray Products in CPET trays can be is designed to hold a ready meal prepared in either conventional ovens or with meat and vegetables, as the quality of microwaves. Their high barrier properties also the vegetables is improved by storage in a help to increase a product’s shelf life. separate compartment.

‘There are many advantages to using FREEZER TO OVEN CPET trays, including being a cost-effective The technology behind the production of CPET trays is a crystallisation process. Regular PET plastic trays are manufactured by heating a film, forming it in unique dimension in a moulding machine and then cooling it. The CPET process is more complicated, which makes the material dimensionally stable and usable at temperatures up to 220°C. If the material is not subjected to the crystallisation

DID YOU KNOW?

The Ilpra Energy tray sealer

48

Packaging Review | September 2018

CPET trays in different colours

process, it can only be used at temperatures of up to 50°C. The production of CPET is based on the esterification reaction between ethylene glycol and terephthalic acid, which makes it opaque. As a result of the partially crystalline structure, the material not only retains its shape but is also suitable for use with products requiring heating. A standard for almost all CPET products is an APET top layer.

This has good sealing properties and gives products an attractive, lustrous appearance.

The solution is sustainable because the primary material used is rPET, which is recovered from plastic bottles and other sources. These are cleaned to ensure the material is suitable for use with food products. AGQPE’s supplier, Faerchplast recently introduced the new CPET Frost which has no top laminate, already in use and available in South Africa.

SEAL TRAYS EFFECTIVELY Ilpra Energy, supplied by AGQPE, is capable of sealing one family style tray per cycle and one to two industry standard sized trays per cycle. This model, along with the correct components, can achieve up to 200cph with MAP and 300 to 400cph without.

It comprises up to four impressions per cycle and, as small as it is, achieves big production volumes. Changeovers are not only inexpensive but also performed in two to five minutes. •

AGQPE – www.foodpackagingsystems.com

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ADVERTISERS’ INDEX SEPTEMBER 2018 ABB South Africa ...............................21 .....www.new.abb.com/food-beverage Atlas Copco .........................................13 .....www.atlascopco.co.za Bragan Chemicals ..............................28 .....www.braganchemicalls.co.za Brenntag...............................................20 .....www.brenntag.com Cama 1 Spa ..........................................45 .....www.camagroup.com Cargo Compass ..................................12 .....www.CargoCompassSA.co.za CJP Chemicals....................................30 .....www.cjpchemicals.co.za Commsure Financial Solutions .......11 .....www.commsure.co.za Creative Flavors ..................................33 .....www.creativeflavors.co.za Dairycap ...........................................OFC .....www.dairycap.co.za Eptech ..................................................50 .....www.eptech.co.za Fairbridges Wertheim Becker ..........10 .....www.fwbattorneys.co.za GEA Africa ..................................... OBC .....www.gea.com Heat and Control.....................17, 22, 25 ....www.heatandcpntrol.com

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METROHM SOUTH AFRICA Metrohm SA is a subsidiary of Metrohm AG, a leading Swiss company. We are a regional support centre for all sub-Saharan countries, including Mauritius and Madagascar.

We are proud suppliers of Swiss-made analytical solutions that greatly enhance the output, efficiency and reliability of your labs and processes.

Our products are widely used in the environmental, pharmaceutical, food, mining, electroplating, petrochemical and water treatment industries as well as tertiary institutions for teaching and research.

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

Tel: +27 (0)11 656 1918/ +27 (0)21 852 0213/ +27 (0)31 265 0067 www.metrohm.co.za

info@entecom.co.za www.entecom.co.za

INNEROUT

MATRIX SOFTWARE

A FoodBev SETA accredited training provider offering training in the: • Bakery NQF 2 + 3 qualifications • Meat and Fresh Meat processing qualifications • Packaging qualification • Food and Beverage Handling qualification

Matrix Software, specialist leading ERP software providers for the Meat and Food industry, offers various solutions to assist the factory floor function in production plants.

In addition to the above qualifications we offer numerous skills programmes that addresses the needs of the Food industry.

Training is offered across all regions in SA and Africa.

Our diverse range of software offerings features a unique module listing of more than 700 modules (program nodes).

Our software solutions are tailored for the Feedlot/Abattoir/ Debone / Production Retail industries. Matrix Software is deployed in 8 countries throughout Africa, Australia, New Zealand and Seychelles.

shirley@iots.co.za www.iots.co.za

www.matrixsoftware.co.za

FORMPAK

FIRMENICH

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

We create Fragrances and Flavours for the world’s most desirable brands. Our aim is to delight billions of consumers around the world everyday.

Innovative Craftsmanship in

Tel: +27 (0) 11 828 8870/1/2 Fax: +27 (0) 11 828 8880 email: haase@formpak.com or service@formpak.com www.formpak.com

Fragrances and Flavours since 1895.

DINNERMATES

QUANTUM COLOURS SA

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

• Dried meat products – real meat real flavour!

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

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

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