SOUTH AFRICAN
www.foodreview.co.za
Journal for food and beverage manufacturers SEPTEMBER 2019 Vol. 46 • No. 09
20 Years of Partnerships
Exceeding Expectations Smart bakery innovations
Future proof your water processing
Unlock packaging’s lightweight potential
Fibre up your world with JRS The innovative JRS organic fiber technology With the innovative JRS organic fiber technology, we make the many functions of these valuable natural substances available to industry. This includes functional products made of cellulose, cereal and fruit fibers or wood fibers, processed as required into ultra-fine fibers, compactates, granules, blends or special dosage forms.
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Applications in Bakery: · Bread · Cake · Wafers · Pizza · Cookies · Muffins · Bakery Blends · Tortilla & Wraps
CONTENTS
SEPTEMBER 2019 | Vol. 46 • No. 09
PAGE
12 Multi-Fine Products is a locally grown, national food ingredient supplier 08 NEWS
Yoghurt category continues to evolve
Keep your floors hygienic and safe
Beer locks in the cold this summer
How green are PET alternatives?
28 DAIRY FOOD
The latest in effective cheese shredding solutions
30 SAFETY, HYGIENE & QUALITY ASSURANCE
Is your food labelling up to scratch?
Pest management and the law
34 WATER PROCESSING TECHNOLOGY
A game-changer in water treatment
Ensure the best water quality
Substantial savings with anaerobic wastewater treatment
PAGE
10 INDUSTRY TALK
SK Chemtrade and Barentz join forces
Maximise your ERP investment
26
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A perfect flow for wrapped biscuits
12 COMPANY FOCUS
Multi-Fine Products celebrates two decades of success
Convey • • • •
14 NEW PRODUCT COMPETITION
Who will be the next NPC winner?
16 BAKERY
Vegan pastry gets a makeover
What makes toast great?
Use steel belts for highquality baking
Chain technology that beats the heat
Deliver taste and texture with free- from ingredients
Safe lubrication during baking
A perfect flow for wrapped biscuits
Conveyor Rollers Modular Conveyor Platform Belt Curves Drum Motors
38 PACKAGING
Sort
Preform cooling technology for shorter moulding cycles
The world's lightest bottle
• Horizontal Sorter • Vertical Sorter • High Performance Diverts
Pick
41 EVENT
Metpac-SA hosts successful AGM
• Carton Flow • Pick Tunnels
Store • Modular Pallet Conveyor Platform • Pallet Flow
September 2019 | Food Review
3
Visit interroll.co.za for more information
EDITOR’S COMMENT
EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmedia.co.za Layout & Design: Andipha Nkoloti +27 (0)11 877 6168 andipha.nkoloti@newmedia.co.za
Food for thought
A
press release popped into my inbox recently from the Tiger Brands Foundation. What an eye-opener! The editorial dealt with a report released by The World-Wide Fund for Nature South Africa entitled Food Loss and Waste: Facts and Futures. The commentary indicates that 10 million tonnes of food or one third of the 31 million tonnes of food produced in South Africa is wasted with a large proportion occurring at production level. Two years ago, South Africa ranked number 44 of 133 countries when it came to the affordability, availability, quality and safety of food. This information is based on the Economist Intelligence Unit's 2017 Global Food Security Index report. It also mentioned that an estimated 12 million South Africans go to bed hungry every night, while scores are facing gross food insecurity. In South Africa, it remains illegal to sell or donate perishable food beyond its use-by dates even if the food is still safe for human consumption. Perhaps we need to re-look current legislation, which regulates the use-by and sell-by dates of food. In a country where millions face food insecurity, we must appeal to the government to amend these laws to allow food manufacturers, distributors and even the ordinary man on the street to donate food to those in need. Food Review is passionate about the issue of food waste and supports the drive towards sustainable production. It is a recurring topic within the magazine and this month is no exception. We kick off this edition with a look at SK Chemtrade’s announcement of a joint venture with global ingredients supplier Barentz International (page 10). It is expected
that Barentz’s global network of application laboratories, coupled to SK Chemtrade’s product-development laboratory will create synergies and value for all customers. We also celebrate Multi-Fine Products’ 20 years as a locally grown, national food ingredient supplier. Turn to page 12 now for the full story. It is predicted the market for free-from ingredients will see growth of up to 43 per cent by 2020. On page 22 we look at how formulators can overcome challenges when creating free-from products that still deliver on taste and texture. Food labelling is a critical component to ensure safe and quality food products. Don’t miss the article on page 30 where Wouter Conradie of NSF discusses the dos and don’ts when labelling food and beverage products. We also touch on the installation of an Econvert Eco Digester at one of the country’s largest beverage processors. Find out just how much money can be saved by implementing this sustainable technology. Lastly, don’t forget to read all about the Food Review/Symrise New Product Competition judging day, which took place recently - more on page 14! I hope you enjoy this edition. If you have any comments or suggestions, please contact me at maryke.foulds@newmedia.co.za.
Contributors: Doug Hunter, Rudy Wouters and Wouter Conradie ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmedia.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmedia.co.za Sales Executive: Daleen Filbey +27 (0) 83 409 3119 daleen.filbey@newmedia.co.za INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmedia.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmedia.co.za Production Controller: Mandy Ackerman Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park 2092 Tel: +27 (0)11 877 6111 Fax: +27 (0)11 877 6198 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published by New Media, a division of Media24 (Pty) Ltd MANAGEMENT TEAM MANAGING DIRECTOR: Aileen Lamb COMMERCIAL DIRECTOR: Maria Tiganis
Happy reading!
BRAND STRATEGY DIRECTOR: Andrew Nunneley CHIEF FINANCIAL OFFICER: Venette Malone HEAD OF HR: Camillah West
EDITORIAL ADVISORY BOARD Two doctorates in chemistry; leader in the field of palm oil; SAAFoST president 1993-2001 and honorary life member; past president, Society of Cosmetic Chemists SA.
Dr Aubrey Parsons With a PhD in biochemistry, an MBA and a Institute of Brewing and Distilling diploma Heidi also serves on the Innovation Hubs BioPark and UNISA’s Life Science advisory board.
Dr Heidi Grimmer CEO of Stratcom Branding, founding member of the glba (Global Local Branding Alliance)
Gail Angela Macleod
4
Food Review | September 2019
CEO: MEDIA24: Ishmet Davidson
Managing director of Symrise South Africa; chairman of SAAFFI.
Rudy McLean She is a qualified food technologist with an honours in Bachelor of Commerce in Business Management and a PMD at the Gordon Institute of Business Science.
Kerusha Pillay
HEAD OFFICE New Media House, 19 Bree Street, Cape Town 8001 PO Box 440, Green Point, Cape Town 8051 Tel: +27 (0)21 417 1111, Fax: +27 (0)21 417 1112 www.newmedia.co.za
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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Food Review | September 2019
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NEWS
Innovation is vital in a changing consumer environment
C
onsumers’ yoghurt habits appear to be evolving with convenience themes becoming important. An Innova Market Insights survey indicates that 17 per cent of consumers named this as a significant factor in 2018 - twice as many as in the previous year. This can be explained by a shift in eating occasions, evidenced by recent data. Breakfast is still the number one occasion for yoghurt consumption, but it has lost ground over the past few years. Consumers are turning to yoghurt as a convenient snack, while dinner is a growing niche. ‘These shifts highlight the
importance of ongoing innovation in the sector,’ Lu Ann Williams, director of Innovation at Innova Market Insights explains. ‘Convenient formats are important for many consumers, while the rise of dinner usage suggests interest in more indulgent, dessertstyle yoghurts.’ Health remains an ever-present theme within yoghurt development. The percentage of consumers who cite health as a significant choice factor has dropped. Most yoghurts now occupy at least some kind of health platform so healthiness is being accepted as standard. •
Janet Trotskie and George Jolly export sales team at Goscor Cleaning Equipment
Scrubbing AB InBev’s Nigerian brewery clean
G
oscor Cleaning Equipment supplied two Tennant M20 combination sweeper/scrubber/driers to Sagamu Brewery in Nigeria. The equipment is being used in the warehouse to sweep and scrub floors. The Tennant M20 can help reduce cost of ownership with optional innovative technologies that can clean harsh environments in a single pass. System technology improves productivity by combining sweeping and scrubbing functions - reducing the need for multiple machines. The optional innovative ec-H2O technology reduces
costs associated with chemical purchases and reduces water usage. The optional scrubbing side brush increases productivity by expanding the cleaning path up to 1 370mm. The machine also comes with innovative features for simplified operation and ease of maintenance. The Touch-n-Go control module featuring a one-step start button reduces training needs by simplifying operation. Solution and recovery tanks allow for complete visible inspection and cleanout. The easy-to-identify yellow maintenance touch points and no-tool squeegee and brush access simplify maintenance. •
Castle Lite locks in the cold this summer The all-new Cold Lock is the only lab-tested, secondary packaging in Africa that keeps beer extra cold for three hours with no ice and after pre-refrigeration. Set to reshape the consumer’s drinking occasion and experiences, the 16X500ml can capacity Cold Lock represents a new era in the brand’s long history of paradigm-shifting innovations. Fans of the brand will be familiar with the 2-Stage Cold Indicator, which was introduced in 2013; the Ice Core cooler in 2014; Quick Chill which cooled your beer quicker and the first-ever resealable 910ml returnable pack in 2018. Cold Lock has received the seal of approval from SGS South Africa, global authorities in inspection, verification, testing and certification.•
LET’S THINK DIFFERENT Together for Business and Environment
Grape Seed Extract Liquid Tartaric Acid www.brenn-o-kem.co.za
8
Food Review | September 2019
WE SUPPLY • Natural Tartaric Acid (L+) • Liquid Tartaric Acid • Natural Cream of Tartar • Oxiprovin • Grape Seed Oil • Nutraceutical Extracts and Contract Manufacturing
SALES Elzabé Swiegers t 023 231 1060 e exports@b-o-k.co.za
NEWS
Are PET alternatives green?
A
study from environmental think tank Green Alliance shows that bottled water alternatives are not as green as they claim to be. The comparative study examined aluminium, glass, cartons and plastic against three criteria: production waste, carbon emissions and end-of-life. Using red, orange or green traffic lights as a device, it defined each material's overall score. Plastic bottles scored marginally the worst (with amber for production waste and carbon emissions, and red for end-of-life). Critically, all alternative materials received one amber and one red light each. Locally, the South African National Bottled Water Association (Sanbwa) has been advocating caution when it comes to responding to the wave of anti-plastic sentiment rippling around the globe. Executive director, Charlotte Metcalf, doesn’t dispute the fact that plastic in all its forms is one of the major pollutants of our water bodies and landmasses. Nor does she argue against the fact that ways must be found to curtail that pollution. She maintains it is time to find a balance in the myriad calls for plastics to be replaced with alternatives or degradable versions. ‘If we don’t, we risk setting policies, formulating regulations, enacting legislation, investing in technologies and encouraging people to take on certain products that will do more harm than good,’ she explains. ‘The findings of this study must be taken seriously. It shows that switching to aluminium will generate toxic waste; glass would generate additional carbon emissions and carton create hundreds of tonnes of low-quality waste.’ Trucost, an American organisation helping companies and investors to achieve success by understanding environmental issues in business terms revealed its study finding. It estimates that substituting plastic in consumer products and packaging with alternatives that perform the same function would increase environmental costs from US$139 billion to US$533 billion. Metcalf points to a ‘flaw’ she considered in the Green Alliance premise. She says it is a mistake to regard plastic water bottles as singleuse. ‘Greenbusiness.com concluded its review of the study highlighting that ‘the only truly sustainable solution to staying hydrated on the go is to ditch single-use containers altogether and use a refillable bottle. ‘Like other containers, bottled water bottles are reusable and recyclable – they are not single-use products. By recycling them after reusing them, you reduce their environmental footprint by 25 per cent. This is a major step in the right direction to reducing plastic waste. People, everywhere, just have to change their behaviour and take that step,’ Metcalf concludes. •
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September 2019 | Food Review
9
I N D U S T RY TA L K
Joint venture benefits local food industry Global ingredient distributor Barentz International, is continuing its expansion in South Africa with the recent announcement of its joint venture with SK Chemtrade Services. The latter is a leading supplier of high-quality raw materials to the life sciences industries in South Africa and neighbouring countries.
C
ommenting on the announcement, Mark Ferrao, managing director
ABOUT SK CHEMTRADE
of SK Chemtrade explains, ‘As a strong strategic partner based in
SK Chemtrade Services supplies high-quality raw materials to
Europe, Barentz is an excellent fit. Both companies have the same
manufacturers of food, beverages, pharmaceuticals, dietary
ethos: delivering high-quality products coupled with technical support where
supplements, household detergents and personal care products in
required. We are very enthusiastic about constant product development that
South Africa and neighbouring countries. The company was established in 1992 as a distributor
will ultimately benefit the industry.’ For Barentz, this new collaboration is a logical step. Barentz’s chief
of flavourings and fragrances from International Flavors &
executive officer Hidde van der Wal explains, ‘SK Chemtrade and Barentz are
Fragrances (IFF). The company is headquartered in Meadowdale,
both active in the rapidly growing life sciences industry. We were naturally cut
Johannesburg and new product development and warehousing
out to be partners.
facilities were opened in 2010 in Montague Gardens, Cape Town.
‘As a joint venture, we will have quicker access to the market in southern Africa. SK Chemtrade is well-known and managed with a
ABOUT BARENTZ
strong and ethical reputation. This partnership will provide a solid base
The company is a global provider of ingredients for the life
for creating robust business opportunities here and in neighbouring
sciences industries. Barentz represents world-class suppliers and
countries,’ Van Der Wal highlights.
offers customers a comprehensive portfolio of products.
It is expected that Barentz’s global network of application laboratories,
The range includes speciality ingredients and blends from
coupled to SK Chemtrade’s product-development laboratory, will create
Barentz-owned production companies, coupled to the best
synergies and value for all customers.
technical teams and top-of-line application laboratories. Barentz operates in more than 60 countries and has a turnover of around 1.1 billion Euros. It currently employs just over 1 100 people globally. •
Offering value added product Offering value added product development, compounding, flavours, development, compounding, flavours, vitamin premixes, sucralose, colourants, vitamin premixes, sucralose, colourants, botanical extracts and nutraceuticals. botanical extracts and nutraceuticals.
n Fer Mark Ferrao, Collee Hidde van der Wal
Email: info@skchemtrade.co.za Website: www.skchemtrade.co.za
Kees Schepers, vice president overseas territories, Colleen Ferrao, Mark Ferrao and Hidde van der Wal
JHB : 011 974 1124 CPT : 021 551 0681
concept to launch Barentz - www.barentz.com SK Chemtrade - www.skchemtrade.co.za
10
Food Review | September 2019
rao, and
I N D U S T RY TA L K
How to maximise your ERP investment Implementing an Enterprise Resource Planning (ERP) system without understanding how it can benefit your business is a bit like owning a gold mine without knowing where to dig. If you’re not experienced in the application of ERP, it can be difficult to pinpoint exactly what solution your business needs. By Doug Hunter
T
o get the most out of your ERP system, you need to draft a predefined list of goals tailored to your business’ specific needs. Align yourself with an ERP services organisation that understands the scope of your business and its processes. Important features you should be discussing with your consultant include: business processes, relevant functionality, cost of ownership plus qualified consulting resourcing.
BEYOND BASIC FUNCTIONALITY Optimisation starts with examining your current processes and identifying operations that could be simplified by enabling and automating them through the ERP. Getting true value from your ERP is about much more than simply enabling more efficient processes and generating transactional data. The data the system produces is the competitive advantage your business needs to grow. You should be assessing elements such as the type of reporting packs your business produces, questioning whether they will ultimately give you the information you need. The usability of your ERP system also requires significant consideration. For example, mobile options like Syspro
Espresso afford employees the ability to access real-time business information anytime, anywhere. If your ERP system currently produces printed reports, consider whether it would make more sense to implement dashboards to give employees greater scope to refine the information they view.
PLAN FOR GROWTH It’s important your ERP system grows alongside your company, and an effective ERP partner should help you optimise and innovate across your business. This means they should be encouraging you to consider new avenues of growth, such as ways to harness the depth of big data, for example. Advanced ERP systems can leverage technology like IoT to broaden data capture throughout your supply chain. AI coupled to ML (machine learning) analyses and learns from data providing predictive insights before and not after you need them.
KEEP EMPLOYEES UP TO DATE Optimising the implementation of your ERP system includes making sure employees understand how it operates. A once-off implementation of the system won’t be enough to help them derive maximum value from it.
The system will be evolving constantly to meet changing business needs, therefore employees’ knowledge of how to operate the system must be updated continuously. Syspro Professional Services facilitates onsite customised education plus online eLearning (via the SLC - SYSPRO, Learning Centre). This allows users to brush up on their current knowledge and investigate what other Syspro ERP functionality is available, which could help them move the business forward. It’s important to make sure your ERP system will continue operating smoothly into the future even when problems occur. You should make sure your business has access to professional consulting and support services via a Contact Centre that can make sure operations continue while complex issues are resolved. You must extend the ERP system to new relevant functions or areas of the business as you grow. At the end of the day, your ERP system can offer you massive returns on investment, but only if you have a clear roadmap as to how you should implement and leverage your system appropriately. •
Syspro – www.za.syspro.com
Getting Things Done: Our Recipe for Success Food Manufacturing ERP for Movers and Makers of the world. At SYSPRO, we support people who get things done – people like you. It’s why we’re committed to delivering specialist ERP software that can help you track allergens, streamline production across your entire supply chain, improve forecasting and reduce waste. Because we believe that the Movers and Makers of the world are the ones who move us forward. Learn more at www.syspro.com
September 2019 | Food Review
11
C O M PA N Y F O C U S
Cheers to 20 years! Multi-Fine Products is a locally grown, national food ingredient supplier. The company specialises in sourcing and supplying commodities and specialist ingredients to the food and beverage manufacturing industry in South Africa and on the continent.
T
his year, the company celebrates its 20 th anniversary. Maryke Foulds sat down with Sonja Erasmus to discuss how the company managed to
grow in a challenging industry by focusing on its core abilities: providing innovative solutions; on-trend products; reliable service and sound technical advice.•
Q: HOW DID THE COMPANY START AND HOW HAS IT EVOLVED? A: We are excited to be celebrating our 20th anniversary this year. When the company first opened its doors in 1999 our initial aim was to provide specialist ingredients to the South African food and beverage industry. During this time, we’ve encountered some challenges. The biggest changes experienced include the evolving regulations landscape and the increase in stringent food safety requirements. We’ve experienced extreme volatility in major exchange rates; the impact of transparency requirements stipulated by customers and harsh economic trading conditions in South Africa and our neighbouring
Q: PLEASE EXPLAIN THE ACCREDITATION AND CERTIFICATION OF YOUR PRODUCTS AND FACILITY? A: To ensure the ingredients and commodities stored and delivered by us are safe and of the best possible quality, we have the following certification in place: R962, which is the general hygiene requirement for a food premises and the transport of food. A food safety and quality programme implemented using the guidelines as prescribed by HACCP (SANS 10330); PRP Systems (SANS 10049); GFSI (guidance document) and ISO principles (SABS 9001:2008) are also in place.
countries. We are very proud that we could maintain focus and grow our business and grateful to our customers, suppliers and personnel. We couldn’t have done it without them.
Q: WHAT ARE YOUR BEST SELLERS? A: Dairy commodities, specialised fats, maize derivatives, MSG & I+G and various other commodity ingredients. We are an appointed distributor and
Q: WHAT IS THE “MULTI-FINE WAY”? A: Our ethos is to exceed customer expectations
agent for international and local producers.
by under-promising, but over-delivering. We have established partnerships with approved raw material suppliers. This ensures quality products are supplied at a competitive price. These products must comply with global health standards. Efficiency and exceptional service remain at the heart of our business. We drive this goal through our friendly and well-trained staff. We pursue targeted, valuecreating growth opportunities, locally and with neighbouring countries.
12
Food Review | September 2019
COMMITTED TO:
• Compliance with all relevant food safety legislation and regulations • Define and implement appropriate standards and systems for raw material sourcing and distribution • Train, develop, support and recognise employees to take responsibility for quality improvements • Focus on embedding relevant HACCP principles at all stages of product handling, storage and transportation • Ensure full traceability of products • Seek to become the preferred supplier through the sustained improvement of quality and service in all aspects of the business.
Dwayne and Sonja Erasmus
C O M PA N Y F O C U S 1
SPECIALISTS IN THE FOLLOWING MANUFACTURING INDUSTRIES: • • • • • • • •
2
Ice-cream Bakery Confectionery Nutrition & health Meat Dairy Spices, seasonings and flavours Juices.
1: Company headquarters in Johannesburg 2: The team behind the success of Multi- Fine Products
“We are committed to collaborating with customers to develop and source value-added products. By combining personal customer service with a flair for developing new ideas and strategies, we can build constructive partnerships that benefit our customers" Sonja Erasmus, managing director, Multi-Fine Products
Q: HOW WILL THE COMPANY ENSURE TRADING IN A DIFFICULT ECONOMIC CLIMATE? A: We focus on calculated, managed growth within our specialised field, whilst maintaining service levels and relationships with customers and suppliers. We run a tight ship by focusing on cash flow, diversified growth yielding investments and managing known external risk factors. As with any well-managed company, our personnel are of utmost importance. They are key to our growth and play a pivotal part in strategising and managing risk while maintaining service levels.
Q: GIVE ME SOME INSIGHT INTO YOUR STOCK HOLDING CAPACITY AND WAREHOUSING. A: Our head office is based in Johannesburg with warehousing and distribution facilities in Durban and Cape Town. We distribute more than 30 000mt of ingredients to the food industry
Q: WHERE DO YOU SEE YOURSELF IN 20 YEARS? A: Maintaining the same service and quality standards as we have over the last 20 years. We aim to remain a family-owned business and to continue exceeding expectations through strategic partnerships.
every year. We are planning to increase our distribution capacity in 2020.
Multi-Fine Products – www. multifineproducts.com
Q: WHAT DO YOU PREDICT AS THE NEXT BIG THING IN THE FOOD INDUSTRY? A: With the ever-increasing awareness and demand for natural and sustainable food products, we predict the focus will shift to functional food, which can be traced to their origin. We also think that access to these foodstuffs will become readily available to all consumers in the future.
September 2019 | Food Review
13
NEW PRODUCT COMPETITION
Are you ready for the next NPC winner? This year’s Food Review/Symrise New Product Competition saw a resurgence of traditional, luxury products with a novel twist. The indulgence factor showed some crossover, even in products that pushed the free-from and health agenda. By Maryke Foulds
J
udging of the event took place at the
‘Tasting so many products is always
PnP Good Food Studio in Sandton,
challenging,’ explains Lorainne Geel who
Johannesburg. With the continued
judged sensory and organoleptic section
support of leading sponsor Symrise, a
with fellow judge Gerrie du Rand. ‘What
sensational mix of 29 products entered this
makes it easier is that the facilitators and
year. The grand prize is a fully paid trip to
the venue were very organised and carefully
SIAL Paris – arguably the most definitive
regulated. This made the process a very
show for the retail food and beverage trade.
pleasant and insightful exercise.
The event will be held in Paris, France from 18
‘The main themes for me were essentially around authenticity, vitality, control and
to 22 October 2020.
indulgence. Various types of products
WHAT’S NEW ON THE MENU?
covered included baking ingredients, dairy
Plant-based concepts and products featured
products, ready to drink beverages, beers
pioneering flavours, clever ingredient
and wines. In the main, products were of good quality, well formulated and tasty.
concepts and innovative packaging. A big
Innovation was, however, not as extravagant
trend keeping its place in new product
as one would expect from a platform like
development is craft indulgence. This year
confectionery. Entrants also included artisanal, sustainably-produced cider and beers that pushed the hops factor. An innovative twist on mainstream products saw
DID YOU KNOW?
Apple Spritzers, sweet yeasted buns and unashamedly luxurious yoghurts and ice cream. Even Wagyu beef biltong was on the judging list this year… The free-from and health sectors were well represented with sugar-free options and plant-based products leading the charge. The judges were exceptionally excited about our only cannabis-infused beer entry. This is a sector that is sure to show excellent growth in the coming months and we look forward to seeing what new products formulators come up with for next year’s competition.
More than 50 per cent of current revenue comes from products introduced into the market in the past five years. This makes swift and successful innovation critical to the long-term strategy and success of food and beverage organisations.
14
new ingredients or flavour directions was less
The competition, now in its 25th year, remains an excellent gauge to see how the industry is adapting to the latest food and beverage innovation trends.
FAST FACT
Food Review | September 2019
Symrise creates and develops flavours and fragrances for nutrition and cosmetics solutions. The company continues to refine its traditional flavour and fragrance ingredients while pioneering multifunctional benefits that respond to emerging market trends. Its strategy encompasses a growing presence in complementary, adjacent markets such as pet and baby food. The company is committed to innovation, creativity and sustainability. It achieves these qualities by understanding key trends, working with the finest people and securing the best in raw materials.
this. Innovation in terms of
saw gin and beer making a crossover to other traditional products like
ABOUT THE SPONSOR
than I would have liked to have seen, but branding and labelling approaches delivered some surprises and attraction,’ she points out.
country, particularly around “designing for recyclability”, I think our packaging compares favourably with what can be found on the shelves in most first world countries. It is a pleasure to see that we are able to rate ourselves among the best,’ Charles Müller points out. Brand owners and manufacturers are
In terms of marketing,
required by law to comply with food and
Cynthia Mabela was impressed
beverage labelling legislation. Important
with products entered this year. ‘A brand
aspects of the competition criteria are
needs to appeal to its audience. They
that the products must taste good, offer
must find it attractive on the shelf first
an innovative solution for consumers and
before they even taste it. The packaging,
must be presented in pioneering packaging.
logo, design and messaging must all tie-
Coupled to this, the product must also be
up to create an image worth aspiring to.
compliant with all relevant regulations. So,
It is always important to remember that
while your products might taste great and
many products are competing for the same
do well on the sensory and marketing vote,
market. Your success will come with the
it might fall short on the packaging or might
ability to cut through all the noise and
not be 146 compliant or conform to liquor
clutter and stand out.'
legislation requirements.
‘As a 40-year veteran in the plastics and
The Food Review/Symrise competition
packaging space I still find it interesting to
awards ceremony took place on
appraise and have a look at the excellent
19 September at the Venue in Sandton,
quality and innovative designs that South
Gauteng. Keep an eye out for the October
African brand owners, designers and
edition of Food Review, where we pay
industry professionals are coming up with
tribute to the manufacturers and producers
to package and merchandise their products.
who lead the way in fostering innovation in
Whilst we still have some way to go as a
South Africa’s food and beverage industry. •
NEW PRODUCT COMPETITION
1
ABOUT THE JUDGES:
• Charles Müller: Appointed executive director of Packaging SA (previously Pacsa) in 2013. He was instrumental in preparing the groundwork for the Federation of Plans (Paper & Packaging Industry Waste Management Plan) • Cynthia Mabela: Marketing guru • Gerrie du Randt: Associate professor Department Consumer and Food Sciences, University of Pretoria • Janusz Luterek: Custodian member of SAAFoST and sits on the Food Law Advisory Group of the Department of Health. He is a chemical engineer and patent attorney • Lorainne Geel: Researcher at Consumers in Focus.
THIS YEAR’S ENTRANTS AB In-Bev/SAB - Brutal Fruit Ruby Apple Spritzer Beyers Chocolates - Craft Range Beyers Chocolates - Panned Range Danone – DanPro Yoghurt Range Darling Brew - Bone Crusher Hoppy Darling Brew - Pixie Dust Deli Spices - Seven Colours Grill Seasoning Delite Foods - Dash of Flavour Range Fry’s Family Food Co - Seafood Range Loxtonia Ciders – Loxtonia Cider Range Nomu - Sweetly Baking Sugar Substitute Nomu - Sweetly Chocolate Protein Shake Powder Nomu - Sweetly Sugar Substitute Pesto Princess Foods - Pesto Princess 100% PlantBased Fresh Soup Range Pioneer Foods - Wellington’s Sweet Jalapeño Sauce Poison City Brewing - Durban Poison Cannabis Lager Soga Organic - Certified Organic Frozen Ruby Grapefruit Juice The Big Beef Company - Angus & Wagyu Beef Cured Range Woolworths - Cheese Nibbles Woolworths - Double Cream Strained Yoghurt Range Woolworths – Kombucha Range Woolworths - Long Life Iced Tea Range Woolworths - Mini Chocolate & Caramel Ice Cream Bars Woolworths – Premium CSDs Woolworths - Raw Cocoa Treats Range Woolworths - Rusks Range Woolworths - Sweet Yeasted Buns Woolworths - Tonic Water Range Woolworths - Cape Wine Range
3
2
1: Charles Müller 2: Janusz Luterek and Gerrie du Randt 3: Cynthia Mabela and Lorainne Geel making notes 4: Kicking off a hard day’s judging 5: 2019 NPC judges
4
5
September 2019 | Food Review
15
B A K E RY
Pastry gets a vegan makeover Consumers are on the hunt for a well-balanced diet that goes hand in hand with healthy, convenient and sustainable products.
A
significant trend in this area is the development of vegan food. These diets have become mainstream and a ‘greener’ alternative to conventional food. As
a movement, it pushes global awareness of environmentally friendly production and consumption. For formulators of food products, this is an area that is continuously growing and well worth keeping an eye on.
NO EGGS, PLEASE Pastry manufacturer JP’s Pastry is following this movement and decided to reformulate its gluten-free pastry recipe to respond to consumer demand. Located in the US, the company is an online provider, specialising in baking gluten-free, artisanal cupcakes and pastries. They asked Brenntag to find a plant-based alternative to eggs, which could perform a similar role - without affecting taste or texture. ‘Our Food & Nutrition (F&N) team at Brenntag North America assisted JP’s Pastry in mastering this challenge by applying our passion for great food, the experience of our partners Vegan style pastry that ticks all the boxes
and our credentials to meet its needs,’ notes Graham Hines of Brenntag. ‘Leveraging the expertise of our application specialists, we used alpha-cyclodextrin. This is an effective emulsifier and foaming agent that can mask unpleasant flavours and aromas. It can even reduce cholesterol.’
A KEY TO SUCCESSFUL INNOVATION IN VEGAN FOOD Brenntag’s solution to use alpha-cyclodextrin as an alternative to eggs proved to be the right fit for the pastry processor. ‘With close and trusting cooperation with our partners and a wide range of specialist teams, we can elevate the vegan movement to a higher level at a lower price,’ Hines concludes. •
FAST FACT
Brenntag assisted JP's Pastry in all stages of research and development at its laboratories. With this solution, JP's Pastry could start manufacturing its proposed glutenfree, vegan pastry with a costeffective impact on production.
Brenntag – www.brenntag.com/south-africa
16
Food Review | September 2019
B A K E RY
Identifying sensory descriptors can assist in translating freshness criteria in bread
What makes toast so great? Bread has a positive effect on the economy, creating a wide range of opportunities for farmers, millers, independent and industrial bakers. Food Review spoke to Emeline Commun, marketing manager for Bakery EMEA at DuPont and asked her what sways consumers when choosing their bread.
A
ccording to the Food Advisory
Brown toast bread is perceived by consumers
Consumer Service (Facs), the baking
as healthier and preferred by those interested
industry produced a whopping
in nutrition although it is thought to be
2.278 billion loaves of bread between
expensive. White bread is thought the most
October 2017 and September 2018. White
delicious: softer, sweeter and more appealing
is important to the baking
bread accounted for 49.06 per cent of total
to children, even though it could have an
industry and consumers. One
production; brown and whole-wheat bread
improved nutritional profile.
of the key objectives of the study
equalled 50.78 per cent and the balance was made up by speciality bread. Packaged bread is the largest bread
The study suggests that fans of brown
consumers mean when talking about
Approximately 35 per cent of participants
freshness. Identifying the different freshness
stated they read the ingredient listing when
in volume by a CAGR of 2.3 per cent from 2013
deciding what bread to buy. Only six per cent
to 2018 . Toast bread makes up the bulk of the
of white bread consumers read the ingredient
packaged bread category. To gain a deeper
listing. This suggests a high degree of trust
understanding of the industry and consumer
in industrial bakeries. It is also a potential
needs, Consumers in Focus2 conducted
opportunity to educate consumers about what
proprietary market research commissioned
goes into bread.
descriptors, from a sensory perspective could assist in translating freshness criteria into lab measurable criteria. This could work on specific solutions to help industrial bakers achieve exactly what their consumers want. The study offers new insights into what South African consumers mean when talking about freshness in toasted bread. Freshness
by DuPont.
and preference are closely linked while
FRESHNESS REIGNS SUPREME HEALTHY AND CONVENIENT
Irrespective of brown or white, there are
In 2018, most bread launches focused on
key challenges facing industrial bakers in
convenience and health. High in fibre,
South Africa. One of the biggest is how to
wholegrain, vegetarian or low GI are among
keep products fresh and delicious - despite
the most popular product claims3.
logistics and transportation challenges.
The study shares insights into South African
was to better understand what
toast bread are more health-conscious.
category consumed in South Africa, growing 1
We know freshness
the texture of the bread i.e. softness and elasticity versus hardness indicated how fresh the bread was. The team at DuPont used this information to define an optimal texture range for white and brown bread. •
The study found that freshness was the
consumer preferences when it comes to
most important criteria for consumers when
selecting their favourite toast bread. Almost
choosing toast bread. Price and taste also
85 per cent of all participants eat bread every
influenced their decision. Many consumers
day, with some buying several loaves when
admitted to squeezing the bread through the
shopping and freezing for extra convenience.
packaging and smelling it to gauge freshness.
Euromonitor 2019 Conducted December 2018 3 Innova Market Research 1
2
DuPont - www.food.dupont.com
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
September 2019 | Food Review
17
B A K E RY
High-quality baking, low-cost operation The unique advantages of a steel bake oven belt lie in its physical form: no other material can compete when it comes to a steel belt’s baking qualities.
N
ot only does it deliver reliable operation in applications where temperatures can reach as high as
400ºC, but also provides excellent thermal conductivity for good baking performance and consistent product quality. Available in solid or perforated form, steel belts are suitable for baking products as diverse as bread, biscuits, brownies, crackers, pastries, sponges, allbutter cookies and pizza bases. It can also be used in finishing operations such as cutting, creaming and chocolate enrobing.
CHANGING MARKETS DEMAND SOLID BELTS The qualities of a steel belt have made it essential to the production of a worldwide favourite: American-style cookies. As these products use real butter and often chocolate chips, they must be baked on a solid belt to eliminate the risk of melted product dripping and causing a fire, or simply drying out. The use of a solid steel belt also produces an attractive crisp base. The globalisation in taste has led several bakery operations to look at how to capitalise on opportunities available. This has resulted in a switch from wire mesh to solid steel systems. For some, this means investing in new production lines. For others, close cooperation
Ipco’s wide bake oven belt
standards of hygiene to be maintained while minimising water and chemical/ detergent costs. In addition to a long working life and low maintenance requirements, the relative lightness of a steel belt can result in lower operating costs. Marko Leber, global product manager for Ipco’s food business explains, ‘The heavier the belt, the more energy is required to heat it. Solid steel belts are lighter than wire mesh and perforated
between Ipco and original equipment
steel belts lighter still – costing up to
manufacturers (OEM) makes it possible
30 per cent less to heat.’
to upgrade the conveyor system, while retaining existing ovens.
ECONOMICAL OPERATION AND LOW ENERGY COST While initial investment cost might be higher than for mesh belt, the figures look different when lifetime costs are compared. Steel belts are strong and stable. They offer excellent resistance to stretching and can deliver a working life of 20 years
Each time the belt exits the baking chamber, it begins to cool and has to be
from 800mm to 3 500mm. This makes it possible to achieve significant improvements in productivity
As much of 25 per cent of an oven’s energy
without investing in factory extensions
consumption is needed to heat the belt, so
or new facilities. An oven with a
these savings can be considerable.
1 500mm wide belt offers almost twice
This weight advantage also means
the productivity of one with an 800mm
less energy is needed to drive the belt
belt without any increase in the line
through the oven.
length. Upgrade to an oven with a
or more - half a century is not unheard of. Their hard, flat, smooth surface also
Ipco’s range of steel belts has been
means they are easier to clean than wire
used for bake oven conveyor lines since
mesh belts. This enables the highest
the early part of the last century. The
Food Review | September 2019
company can produce belts in widths
heated again so savings are continuous.
WIDE BELTS FOR MAXIMUM PRODUCTIVITY
18
Belt with American style cookies
3 200mm belt or larger and throughput is increased by a factor of four. •
Ipco – www.ipco.com
Solid and perforated steel belt conveyors for the food industry IPCO is a world leader in the manufacture and supply of solid/perforated steel belts and associated process systems for the food industry, with application-specific expertise that extends across baking, cooling, forming, freezing, drying, casting, meat cutting, conveying and more. Our belts and systems are used to handle literally hundreds of different food types, from cookies, chocolate and coffee to strawberries, sugar and seafood. And in every area they offer efficient, reliable and durable operation together with fast, easy cleaning for maximum hygiene. Whatever your requirement – belt-only, process support or system solution – our global coverage and technical expertise means we deliver the level of service that’s right for your business, whatever its size or location. • W orld leading steel belt technology: solid/perforated, carbon/stainless, wide belts, choice of grades. • Process solutions including our proven Rotoform FD pastillation system. • G lobal service and spare parts support, new installations, upgrades, planned maintenance, belt replacements. • Experienced engineers offer consultancy on all aspects of process design.
ipco.com
B A K E RY
Chain technology can drive your business to new heights The food and beverage industry has particular requirements in terms of health and safety. These specifications are set by industry standards, with the main focus on hygiene and legal requirements.
B
earings International (BI) supplies a range of innovative chain solutions from Kobo. The range includes maintenance-free, acid-resistant or stainless steel chains. Food Review met with Frikkie Ras, national product manager chain and drives on how this technology can impact the value chain. ‘For industrial bakeries such as pizza and bread manufacturers, a range of made-to-order solutions Frikkie Ra s is available - from tunnel ovens to proofing cabinets or pre-baking ovens,’ Ras enthuses. Kobo carries out research and development in conjunction with OEMs and end-users to develop innovative designs such as special carbon components with an extended lifetime. These units are also
maintenance-free. Rollers are mounted outside the chain and can be replaced with minimum downtime, reducing maintenance and production losses. BI supplies the Kobo prover chain for specific applications such as bakery ovens and provers. In South Africa, the standard prover chain is a 100mm pitch chain with custom-dimensioned rollers and inner hollow pin diameter. BI can also customise its prover chains. A recent project in Botswana saw a bakery prover chain catering for a different pitch. The secret to the high quality of the range is a combination of quality metals and heat treatment to optimise the strength and wear resistance of chains during operation. The prover chain design includes an anti-twist safeguard in the plates and on the pin. A bush arrangement
Kobo chain technology
ensures no turning in the plates for maximum efficiency. Heat treatment is specific to the temperature and humidity requirements of the application, as well as the consistency in tolerances between the working parts. This will ensure smooth running and correct alignment between parallel running chains. The bakery industry is under pressure to increase production volume as demand increases due to population growth. Kobo has designed higher-capacity chains based on a range of alternate materials and heat treatment processes, thereby nearly doubling chain capacity. •
Bearings International - www.bearings.co.za
Get what you need, when you need it, with our nationwide network. IȒȒƳ JȸƏƳƺ nɖƫȸǣƬƏȇɎɀ ۴ ƺƏȸǣȇǕɀ ۭ ³ƺƏǼɀ ۴ !ǝƏǣȇ ۴ 0ǼƺƬɎȸǣƬ xȒɎȒȸɀ ۭ (ȸǣɮƺɀ ۴ ƺǼɎɀ ۭ ¨ɖǼǼƺɵɀ
�e�� � �� �� ��� ���� � ��ai�� in�o��earin��.�o.�a � www.�earin��.�o.�a
20
Food Review | September 2019
B A K E RY
Free-from innovation creates opportunities It is predicted the market will see growth of up to 43 per cent by 2020 with the free-from trend. Rudy Wouters discusses how to overcome challenges when creating free-from products while still delivering taste and texture.
Put Urschel to the Test
A
key way to harness the power of free-from is to create cleaner label formulations that taste just as good as standard market equivalents. Beneo’s consumer research
indicates 60 per cent of European consumers often consider
As a valuable service to you our customers, Heat and Control AND Urschel offer sample test cutting. This may assist with R&D, help explore different machines to decide on a capital purchase, or discover additional cutting capabilities for your existing Urschel machinery. Urschel machinery produces precise cuts at high capacities within your designated parameters – meeting your production goals, improving your end-products to reduce waste, and maximising your profits. Schedule a visit with the Heat and Control South Africa team to test cut your product, or simply send samples so we can test for you.
Set-up a free test cut of your product with Heat and Control South Africa!
ingredient listings, nutritional information and claims on pack. While consumers look at food packaging labels to check that it does not contain trigger ingredients, they are also checking the number of artificial ingredients in a product. Clean label ingredients are often a key driver for purchases. Research findings support this. It indicates that more than half of consumers consider the ingredient list and nutritional information and claims on pack. The other half looks at food with no artificial additives (colours, flavours, etc.). Figures also indicate that ingredients added for a health benefit (such as added calcium or fibre) are extremely important attributes for consumers. MAKE THE MOST OF IT Manufacturers that can combine
DID YOU KNOW?
Research conducted in 2017 indicates that gluten-free food is frequently higher in fat, sugar and salt, while lower in fibre to comparable mainstream products that contain gluten.
free-from ingredients with clean label credentials are at an advantage. Product reformulation does not come without its challenges, particularly in areas of taste and texture. Consumers want to be assured that products with fewer additives will appeal to their taste and other senses in terms of visual and textural appeal. If manufacturers can balance the technical issues to create cleaner labels, good taste and textured food, then there is great market potential for such products. By working with experienced food ingredients’ companies, it is now possible to clean up most products to deliver in terms of taste and texture. GLUTEN-FREE PRODUCT DEVELOPMENT
www.heatandcontrol.com | info@heatandcontrol.com Cape Town +27 21 948 5934
Beneo has developed a way to combine its rice flour and rice starch ingredients to create the perfect gluten-free, yeast-raised pizza crust. It also significantly reduces the complexity of the product’s ingredients list. This ensures that food looks as good
The Global Leader in Food Cu ng Technology ÂŽ Comitrol, Urschel, Urschel logo symbol, and The Global Leader in Food Cutting Technology are registered trademarks of Urschel Laboratories, Inc. U.S.A.
22
Food Review | September SAFoodReview_Sep19_88.5w x 262h_Urschel.indd 1 2019
8/5/2019 2:56:51 PM
on a label as it does on the plate. The global number of pizzas launched with a gluten-free claim soared by 58 per cent between
B A K E RY Gluten-free pizza bases are formulated using rice ingredients
Beneo’s gluten-free pizza crust achieves
rice flour, modified rice starch, potato starch, olive oil, evaporated cane sugar, tapioca flour,
taste and texture
potato flour, fresh yeast, salt, xanthan gum
perfection by using
and calcium sulphate to a considerably shorter
two of Beneo’s
list: rice flour; water; rice starch; oil; sugar;
speciality flours:
salt; guar gum and yeast.
wet-milled rice flour
Reformulation can be challenging. Beneo’s
(Remyflo R7 90 T CP)
speciality rice ingredients and the technical
and brown rice flour
expertise of the Beneo Technology Centre
(Remyflo C 200), instead of standard white flour. Wet milling allows the production of much finer flour particle sizes in Remyflo
ensure that free-from and cleaner label credentials are achievable, without any impact on taste or texture. This is not just good news for consumers, but manufacturers. •
R7 90 T CP without severely damaging starch granules. This allows starch granules to
“The global number of pizzas launched with a gluten-free claim soared by 58 per cent between 2012 to 2015”
hydrate more easily and results in better dough handling. The fine particle size of this
1Source: Consumerntenbond, Netherlands consumer association, August 2017 2Source: Beneo Consumer Research 2015
flour also improves mouthfeel, texture and crispiness of the gluten-free pizza crust. Remyflo C 200 is used as well to promote the short bite and palatability of the crust. Beneo’s unique rice flour/starch mix
2012 to 2015. Pizza launches containing rice
enables the ingredient’s listing of a standard
flour as an alternative ingredient to wheat is
gluten-free pizza to tick clean label boxes.
showing a rapid increase.
Ingredient listings are reduced from water,
Specialty rice ingredients for healthy, delicious food. Gluten-free – naturally! These days, an increasing number of consumers deliberately chooses a gluten-free diet because they consider it to be better for them. Nonetheless they expect alternative options to be just as delicious and nutritious as conventional foods. Apart from their natural origin and their wellbalanced nutritional composition, BENEO rice starches, flours and blends provide a sensorial experience matching the “original”. Add BENEO specialty rice ingredients for better taste and texture, the healthy way.
Follow us on:
ABOUT THE AUTHORS RUDY WOUTERS is head of the Beneo Technology Centre.
Beneo – www.beneo.com
Our Sales Network Partner in South Africa:
sfc-info@savannah.co.za
www.beneo.com
September 2019 | Food Review
23
B A K E RY
Lubrication for safe food processing
Oven chains must operate freely and smoothly in food manufacturing facilities. Lubricating chains in this environment can be tricky, given intense operating temperatures.
W
ithout good lubrication, chains harden due to exposure to heat and moisture. This causes corrosion and
oxidation – leading to the premature failure of oven chain pins and brushings. Robust lubricant formulations can perform in this application. These must be food-grade lubricants - approved for incidental food contact (category H1 of food-safe lubricants). Roan van der Walt, sales technician at Lubrication Engineers (LE) SA explains, ‘Most lubricants melt under the extreme heat of the ovens and don’t stick to hot oven chains.
that is suspended in a carrier fluid. Both options are designed to stop metal surfaces from coming into direct contact with one another. This cuts down on friction and wear and tear,’ he notes. ‘The LE Ovenworx H1 Syn
Lubricants used in the food industry must be approved for incidental food contact
especially when over-applied,’ he points out. The LE 4061 lubricant is designed to penetrate all moving parts of the oven chain, enabling them to move freely. It can be applied to hot oven chains without interrupting operation. It also meets NSF H1 and Kosher Pareve requirements. LE now supplies the revolutionary RotaLube
Chain Lubricant (4061) has been formulated
chain lubricator. ‘This automated chain
to combat the demanding conditions required
lubricating system disperses lubricant at
by oven chain applications. It is approved
predetermined and controlled intervals,’ Van
for incidental food contact and contains no
Der Walt enthuses. ‘The design means it will
artificial dyes, making it a good choice for food
not clog and maintains accurate lubrication,
manufacturing plants such as bakeries or meat
whatever the condition of the chain and pins,
processing plants.’
loads and usage. New on the market, it benefits
LE’s 4061 lubricant is liquid as lubricants
automated systems by accurately lubricating
designed to stay on the oven chain. This
with solids suspended in a carrier fluid must
each chain link irrespective of chain speeds”
minimises application intervals and increases
be stirred to keep solids distributed within
he concludes •
chain longevity.’
the carrier to prevent it from falling out of the
It's necessary to use a specialised lubricant
There are two main ways to lubricate oven chains. ‘You can use a liquid or a solid lubricant
suspension. ‘Solids can build up over time, creating residue around the application area,
Lubrication Engineers www.lubricationengineers.co.za.
Superior Lubricants for food and beverage processing facilities Lubrication Engineers (LE) South Africa is proud to represent the LE brand in Southern Africa. We hold the rights to Southern Africa on the LE brand, recognised internationally as a specialist in lubrication. No matter what your industry, if you use high-quality lubricants to protect your valuable production assets, and keep the lubricants clean and dry, you will see positive results on your bottom line. Our products, including our proprietary additives, are world-class. They are designed to achieve the highest possible levels of performance and to deliver greater value into our customers’ businesses. LE’s food grade oils and greases play a key part in reducing maintenance and operating costs for food and beverage facilities. Our high-performance H1 and H2 products include solutions for heat, cold, moisture, rust and oxidation (R & O), and wear.
LE has a food machinery lubricant solution for the majority of applications and operating conditions. Lubricants that are NSF H1 certified have been cleared for use in USDA-inspected food processing plants and can be used where incidental food contact may occur. All LE H1 lubricants – except for H1 Machine Oil – are also certified Halal and Kosher Pareve by the Orthodox Union. H2 lubricants meet USDA H2 criteria for non-food contact areas of food processing plants. H1 grease, H1 oils and H2 lubricants: Performance under pressure LE’s selection of H1 and H2 food machinery lubricants provides superior performance under a range of conditions. Depending on the particular food grade oil or food grade grease, benefits and features vary.
H1 Grease LE’s H1 grease provides extreme pressure performance and resistance to water, heat, impact and mild acids and alkaline fluids. It is white, nonstaining and environmentally safe. H1 Oils LE’s H1 oils exhibit superior anti-wear, rust and oxidation resistance, low-temperature performance, excellent EP characteristics, and loadcarrying ability. They also feature a pleasant odour and are pure, translucent and non-staining. H2 Lubricants LE’s multipurpose H2 lubricants provide compatibility, wide temperature range, excellent water separation, and an ability to withstand heat without oxidizing. They reduce friction and wear, and provide corrosion resistance.
Contact: 011 464 1735 https://lubricationengineers.co.za
24
Food Review | September 2019
beverages
dairy farming
dairy processing
utilities
transport
food
core technologies
Milking & Cooling
Seperators
Decanters
Homogenisers
Valves
Spray Drying
Aseptic Filling
Brewery & Dairy
Compressors
Packages & Skids
Ice Machines
Freezers
GEA Southern & Eastern Africa 48 Reedbuck Crescent, Corporate Park South, Midrand 1682, RSA Tel. + 27(0)11 392 7114, Fax. +27(0)11 392 7000 info-sea@gea.com
www.gea.com
engineering for a better world
B A K E RY
A perfect flow for wrapped biscuits Cama’s latest delivery comprises equipment that will enable the customer to increase output, while improving flexibility. It is ideally suited for the bakery’s wide product range. “The system consists of a loading unit with two Cama Triaflex Delta robots feeding a CL series highspeed continuous motion side-load cartoner”
1
continuous motion side loading section of the machine. Products are positively transferred into pre-glued cartons using an overhead mounted pusher system.
2
Cama’s standard productivity features incude the following: no product, no carton; pusher overload protection; and open flap detect and reject. These configurations contribute to maximising
1: Cama FW Case Packers are capable of packing a variety of products into a one-piece wrap-around or two-piece display case for Shelf Ready packaging solutions 2: Example of a wrap around case for wafer cubes
output for the customer. Production speed varies according to the product configuration. This could range from 60 to 110ppm in this application. The CL series machine is capable of more than 300ppm for the relevant configuration.
D
esigning sustainable packaging
Machinery uptime and ease of use are
means considering the
facilitated through quick and easy size
production system and disposal
changing procedures.
of the pack. There is also a second phase
The versatile Cama packaging system
- linked to recovery, recycling and reuse
receives flowpacks from upstream
of packaging. This will reduce volume,
equipment. These are accurately metered
while minimising the use of new
into a multiple pocket vertical racetrack.
raw material. The secondary packaging line (supplied by Cama) has been engineered for flow wrapped biscuits, coming from two upstream flow-wrapping machines at 360ppm. The system consists of a loading unit
Triaflex robots pick a group
DID YOU KNOW? Cama is certified according to UNI EN ISO 9001, UNI EN ISO 14001 and OHSAS 18001.
with two Cama Triaflex Delta robots. This feeds a CL series highspeed continuous motion sideload cartoner. This combined system has been
of collated products depending on the format to be packed. The collation is then placed into a continuously moving
• Improved hygiene and easier cleaning • Accessibility and modularity
The flexibility of the robot loading solution allows products to be grouped, rotated and/or stacked in different loading patterns. It is now possible to produce multiple different formats with minimal change parts.
26
Food Review | September 2019
BENEFITS OF CAMA’S BTG SYSTEM:
relevant orientation.
for flexibility. It can handle a variety of and production efficiency is guaranteed.
Cama’s latest breakthrough generation (BTG) packaging systems. All Cama’s new BTG systems incorporate the latest advances in packaging research and development for the secondary packaging machinery market. The innovative technology defines a new standard in the world of secondary packaging for paperboard or corrugated packaging machinery with improvements in all areas of machinery design and implementation.
bucket chain in the
designed to meet customer demand products and packaging configurations
This high output line has been desi gned and realised according to
Once the required collation is made in the bucket chain, this passes to the
• Operability and zero retention • Open profile and ergonomic access • Energy saving engineering and cabinet free technology • User-friendly controls and graphical interfaces for data and performance. •
Cama – www.camagroup.com
Retail ready. Smarter, faster, together.
Every business has challenges; ours is to help you overcome yours. Ishida can help you get your product to market quicker, without compromising quality or compliance. From foreign body and leak detection through to checkweighing, working smarter, faster, together, we can achieve higher standards at every stage of your quality control process.
Smarter Faster Together
To set the wheels in motion visit ishidaeurope.com
DA I RY F O O D
Fabulous cheese shredding solutions Cheese characteristics vary widely in terms of fat, moisture content and hardness. These factors must be considered when assessing the desired end-product. Urschel dairy solutions provide size reduction technology for a variety of cheese.
T
he Affinity Dicer is the largest cheese dicer manufactured by Urschel. The unit
offers a sanitary design, optimal high capacity output and precision cuts. The dicer can process high fat, cold temperature products with additional feed assistance via a feed roll and drum. These units are delivered as a product transitions through the cutting zone. The Urschel family of CC/CC-D series shredders delivers precise cuts at high yields required by the cheese industry. Each model offers continuous operation for uninterrupted production and can handle input product size up to 89mm. Models include the longstanding, production-proven CC and CC-D. These units are available in conjunction with the newer CC-DL and CCX-D series. These high capacity, versatile machines feature interchangeable quick-locking double rings. Single adjustment cutting heads enable processors to change the type of shred in minutes. Specially designed knives do not require sharpening and are
product passes each knife in a smooth and
inexpensive to replace. Types of cuts include the following varieties: • Full shred
uninterrupted manner. Length is controlled by input product size. Urschel is distributed locally through Heat and Control. •
• Oval shred • Crescent shred • Wide oval shred
High fat and cold temperature products are an ideal fit for Urschel’s range of dairy equipment
• Strip cuts • Granulations • Flat slices. The thickness of the shred can be adjusted to suit specific production environments. A key strength of these CC models machines is their operating principle. Products delivered to a feed hopper enters the rotating impeller and is held against the inner surface of the cutting head assembly by centrifugal force. The cutting head assembly consists of several stationary and individual cutting stations. Slices or shreds are produced as the
Heat and Control - www.heatandcontrol.com
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
28
Food Review | September 2019
Manufacturer of cake pie fillings, toppings, yoghurt fruit pulps,caramel treat, milkshake syrups, salad dressings,mayonnaise and sauces.
FSSC 22000 Certified
Innovation In Action
Complete turnkey solutions for Potato Products Systems
Heat and Control is the leading single source supplier of complete processing and packaging systems for the highest quality potato chips, french fries and other potato products, Heat and Control offers truck unloading and raw preparation through to frying, seasoning, packaging and inspection. With manufacturing facilities and sales offices worldwide, Heat and Control supports manufacturers with experience, expertise and resources to develop the most value driven and efficient solutions for any food production challenge.
Put our innovation to action in your plant today!
Preparation | Cooking | Coating + Conveying | Inspection | Weighing + Packaging | Controls + Information
www.heatandcontrol.com | info@heatandcontrol.com | Cape Town +27 21 948 5934
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
A quick guide to guaranteed, safer food Food labelling is regulated in South Africa by guidelines relating to the production, marketing and labelling of foodstuffs. Wouter Conradie of NSF International talks us through some of the important do’s and don’ts when labelling your product.
THINGS NOT TO DO • Pictorial representation may not be false,
o No claims of ‘complete’ or ‘balanced’
misleading or deceptive or create an
[Reg 13(f)].
erroneous impression regarding character,
o The words ‘cure' or any other medicinal
‘Wild caught’ which is permitted [Reg 47(3)]. • Frozen foods thawed for subsequent sale cannot label these as ‘Fresh' unless qualified
origin, composition, quality, nutritive value,
claim including prophylactic and
as ‘Previously Frozen’ in bold, uppercase,
nature or other properties in any respect.
therapeutic claims [Reg 13(g)].
minimum of three-millimetre height on the
It is no longer necessary to use “Serving Suggestion” [Reg 34].
• No negative or nutrition-related claims allowed for packaged water [Reg 14(3); 51(3)].
• No references to the Department of Health, government or related officials [Reg 6]. • Words, pictorial representations, marks,
• Any word, statement, phrase, logo, pictorial
label of pre-packed food or poster near bulk food offered for sale [Reg 47(4)]. • Forbidden wording for nutrient content
representation which implies healthy/
claims including rich in; excellent source;
healthier/ additive-free/veterinary
good source; enriched; enriched with X;
logos or descriptions,
medicine-free/more humane
with added X; contains X; Y per cent X
which create an
treatment or rearing of animals
free; packed with X; or similar wording
impression that the food is supported by, endorsed by, complies with or has been manufactured in accordance with: o Health practitioners (individually/ professional association
DID YOU KNOW?
unless linked to specific
Laws that deal with the marketing and advertising of food in South Africa include the Consumer Protection Act; the Foodstuffs, Cosmetics and Disinfectants Act; the Agricultural Products Standards Act; National Health Act and the regulation that fall under each Act.
/consumer advisory organisations) [Reg 13(a)(i)]; o Organisations, associations, foundations or other entities unless approved by the
protocols registered under the Agricultural Products
[Reg 52(4). • No claim may be made on the label that the food has acquired nutritive value
Standards Act (APS Act)
from nutrients or substances added for
or National Regulation
technical or sensory reasons. Example: A
for Compulsory
product may not claim to contain Vitamin
Specs Act. Examples: ‘Grainfed/ ‘Grass-fed'/‘Karoo
Lamb'/‘Natural lamb’/‘Country reared’/‘Free range’/ ‘Pure’/ ‘Organic’ [Reg 47(1)]. • Any word, statement, phrase, logo,
C if vitamin C is added as an antioxidant [Reg 50(10) (a)]. • Claims cannot refer to anything, not in the package.It must be clearly indicated and nutritional information can only be for what is in the package. Example: A cereal product may claim to contain calcium if
director-general and can prove generic
pictorial representation, which convey
health promotion supported by evidence-
or implies similar concepts as expressed
based nutrition and do not contradict these
below which are not regulated in terms
• No claims for novel fibres [Reg 51(10) (a)].
regulations in terms of nutrition claims and
of APS Act or National Regulation for
• No sugar added / No added sugar
criteria. This excluded religious certifying
Compulsory Specs Act unless complying
claims are not allowed for any food
organisations, fauna and flora certifying
with criteria in Guideline 7. Examples:
containing any one or combination of
or endorsing bodies and organisations
‘Fresh’/ ‘Natural’/‘Nature ‘s’/’ ‘Pure’/
the following sugars: xylose and mono-
accredited by SANAS to certify certain
‘Traditional’/‘Original'/‘Authentic'/‘Real'/
and disaccharides such as corn syrup,
quality aspects of foods and the safety
‘Genuine'/‘Homemade'/‘Farmhouse’/
deionised, deflavoured fruit concentrates
thereof [Reg 13(a)(ii)].
‘Handmade’/‘Selected’/‘Premium’/‘Finest’/
and juices, dextrose, dextrose syrup,
‘Quality’/‘Best’ [Reg 47(2); Guideline 7].
fructose, fructose syrup, glucose, glucose
o The words ‘health' or ‘healthy' or ‘wholesome' or ‘nutritious' or words or
• ‘Wild’ for fish and other marine food
it is clearly indicated that milk has been added to the cereal [Reg 50(11)].
syrup, invert sugar, lactose, maltose,
symbols implying health-giving properties
(regulated by National Regulation for
maltose syrup, sucrose and sucrose syrup
[Reg 13(d)(e)].
Compulsory Specs Act) unless qualified as
[Reg 52(13)].
30
Food Review | September 2019
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
THINGS TO DO Include the following: • Information must be provided in English [Reg 7(1)(a)]. • Pictures or graphics may not obscure or affect visibility, legibility or indelibility of the information on the label [Reg 7(1)(b)].
• Batch identification to ensure traceability of food through production, processing and distribution [Reg 11]. • Date marking or coding must be used as follows: “best before”, “BB” and/or “use by” and/or “sell by”. Products labelled with a “best
• Labels may not be separate from the container holding the food
before” do not become unsafe to consume after the indicated date.
stuff [Reg 7(2)].
A typical example would be a bakery item. "Use by” indicates that
• Specific letter sizes are prescribed [Reg 8].
the product could be microbiological sensitive and unsuitable for
• Name of the Food: CODEX1 descriptions for established names to be
consumption after the “use by date”. An example of such a product
used where these exist [Reg 9(a)]. • Manufacturer, importer or seller’s name and address to appear [Reg 9(b)]. • Storage instructions before and after opening [Reg 9(e); 32]. • Net contents in SI units [Reg 9(f)]. • Country of Origin: either “Product of [country]” or Produced/
would be a prepared meal. “Sell by” indicates to the retailer that the product should be removed from display and that it is still suitable for consumption. An example would be potatoes. [Reg 12]. • List of ingredients [Reg 9(d)]: Must be listed in descending order at the time of manufacture under the heading "Ingredients" [Reg 17]. Seasonal ingredients can make use of ‘and/or’.
Manufactured/Processed/Made in [country]” and “Packed in [country]
• Added water must be declared except:
[Reg 10(a)(b)(c)]. (For imported, single ingredient agricultural
o If it is used solely to wet a dry ingredient or additive;
commodities in bulk, which may change due to climatic, seasonal
o If it is part of brine or syrup and declared as such;
or other contingencies, there is an option to label the names of the
o If the water added is less than five per cent of the finished product.
countries concerned [Reg 10(d)].).
This does not apply to raw processed meat [Reg 18; 28].
PROCEED WITH CAUTION Allergen-related claims [Reg 45; 46]:
• Naturally gluten-free/Special dietary/Special dietetic claims not
Precautionary labelling:
permitted for cereals which by nature are free of gluten, but may
• Where there is a risk of cross-contamination then ‘Not suitable
use ‘This cereal product is by its nature gluten-free'. Example:
for people with (allergen) allergy' at the end of or under the ingredient list can be used. • Where an allergen control policy (CAP) is in place and allergen testing is carried out regularly, but cross-contamination risk is still possible then ‘May contain (allergen)’ may be labelled ‘Allergen control programme in place’ at end of or under the ingredient list [Reg 45; Guideline 2].
Rice [Reg 46(1)(b)]. • Hypoallergenic/non-allergenic/allergen-free only allowed if: • Hypoallergenic’ or ‘Non-allergenic’ or similar wording - Only if chemically or genetically modified to a level not detectable by suitable testing [Reg 46(2)(a)]; • Free from (allergen)’ or ‘(Allergen) Free’ or similar wording – Only if tested to confirm the absence of allergen using suitable
• Gluten-free only allowed if the food does not contain:
testing [46(2)(b)].
o Ingredients derived from significant cereals;
Although this is a long list, it is not exhaustive and you are advised
o Ingredients from significant cereals with gluten not removed
to ensure your labels are checked, before printing, to ensure you do
via processing;
not make costly mistakes. •
o Ingredients from significant cereals with gluten removed but the presence of >20mg/kg in the final product; o >20mg/kg gluten determined by ELISA5 or Codex methods
[Reg 46(1)(a)];
NSF – www.nsf.org
September 2019 | Food Review
31
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
Will your facility pass the grease traps test? Hygiene in commercial kitchens and processing facilities is important. A commercial manufacturer is not an environment where you would ever want to see pests, especially not flies and cockroaches. Both are carriers of a host of serious illnesses.
S
everal factors can lure pests into a
Industrial cooking facilities and kitchens
processing facility, but the obvious
produce large volumes of waste grease -
culprit is food and food waste. The
present in drain lines from various sinks,
grease and sludge in your grease trap
dishwashers and cooking equipment. The
are hugely attractive to flies and other
law* requires that all premises engaged
cockroaches.
in the cooking and preparation of food must install and maintain adequately sized
WHAT IS A GREASE TRAP? This is a plumbing device designed to slow
grease traps.
down the flow of greasy wastewater by
WHAT HAPPENS TO THE WASTE?
separating grease and solid waste before
Fats, oils, grease and starch (Fogs)
it enters the sewerage system. Water
separated by a grease trap forms a scummy layer, which must be disposed of
flows into the sewer and
DID YOU KNOW?
grease floats to the top and is retained in the trap. The design has remained largely the same since its invention in Victorian times. South Africa’s sewerage system is geared to accept toilet,
regularly. If the grease trap is not regularly cleaned out, the
The first patent for a grease trap was obtained by Nathaniel Whiting from California in the late 1800s? The design has remained largely the same since then, and utilise the same laws of physics: that grease and oil are lighter than water and will rise to the top when the mix is allowed to stand for a time.
sink, basin and bath waste, while the stormwater system is only geared to accept
accumulation of Fog’s and foodstuffs will start to rot and give off the characteristic rotten egg/drain smell. This rotting sludge is extremely attractive to pests. Proper maintenance of
grease traps is critical. A biological dosing system offered by
rainwater. Anything else puts a severe
Initial is an environmentally friendly, non-
strain on the system, causing blockages.
chemical maintenance programme. The
32
Food Review | September 2019
Grease traps should be kept in pristine condition for optimal functioning
WHAT THE LAW SAYS… * Legislative Requirements for the Maintenance of Grease traps:
The General Hygiene Requirements for Food Premises and the Transport of Food (R.918/1999) corrected by Government notice No 638 of 22 June 2018 specify that food premises must have a wastewater disposal system approved of by the local authority and that the duties of a person in charge of food premises include ensuring that wastewater on the food premise is disposed of to the satisfaction of the local authority. * Provincial Wastewater By-Law: 1 Sep 2006. Section 3: Protection of Municipal Sewers No person shall discharge, permit to enter or put into any municipal sewer - any petrol, oil, greases, waxes, fat or pesticides, insecticides or paints any liquid that has a pH value of less than 5.5 or greater than 12.
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
FAST FACT:
· Tests on German, American and Brownbanded cockroaches showed that 70 per cent were contaminated with Salmonella spp. (Fathpour H, Emtiazi G, Ghasemi E (2003) Cockroaches are reservoirs and vectors of drug-resistant Salmonella spp. Fresenius Environmental Bulletin, 12: 724 - 727). · It is estimated that US$1billion is spent on professional services in the US each year to control cockroaches (Bonnefoy, X., Kampen, H., and Sweeney, K., Public Health Significance of Urban Pests, World Health Organisation, 2008). · Female German Cockroaches can produce 25 000 to 50 000 units of allergens, males 2 000 to 3 000 (Denmark JJ, Bennett GW (1995) Adult German cockroach (Dictyoptera: Blattellidae) movement patterns and resource consumption in a laboratory arena, Journal of Medical Entomology, 32: 241 - 248).
Rotting sludge is extremely attractive to pests
“A biological dosing system offered by Initial is an environmentally friendly, non-chemical maintenance programme for grease traps”
municipal sewerage system is improved. Importantly, pest problems are eliminated by reducing the available food source. The elimination of bacteria means the characteristic bad drain smell is controlled. ‘When aiming for a spotless facility it’s
bio-dosing unit pumps a measured dose
critical to remember that your dirty trap
of bio-enzymes into the trap. This starts
could be attracting pests to your kitchen.
a biological process, which digests and
Initial can assist with information on its
liquefies solid organic waste, fasts starch
bio-dosing service and Rentokil can
and grease.
assist with pest control,’ concludes Nathalie
Organic waste remains free-flowing. The quality of the effluent released into the
Leblond, marketing communications manager - Rentokil Initial. •
Rentokil Initial - www.rentokil-initial.co.za
Financial loss:
Stored Product Insect larvae was found to cause serious financial impact, with 60% of respondents reporting annual revenue
losses of between 1-9%
as a result of infestation.
Get in touch with us!
0800 736 86545 or www.rentokil.co.za
September 2019 | Food Review
33
WAT E R P R O C E S S I N G T E C H N O L O GY
A game changer in water treatment The Carix process is used during water processing. The technology consists of carbon dioxide and regenerated ion exchangers. Gemü offers a range of valve solutions for water management during this procedure.
GEMÜ 481
GEMÜ 807
GEMÜ R690
T
he system is currently implemented at a water treatment plant, which treats close on 5 000 l of water per minute. After coarse filtration, the water is fed
to an ultrafiltration system. Here it passes through porous membranes with a pressure drop of two to 12psi. Ultrafiltration retains fine solids, turbidity, pollens and germs. Water
Valve Solutions for Water Processing Industry
containing dissolved ingredients such as hardness components, minerals and small molecules can pass through the membrane. PARTIAL SOFTENING AND REGENERATION Using ion exchange, the concentrations of hardness components (calcium and magnesium carbonates) and undesirable substances i.e. nitrate, sulphate and chloride are reduced by 50 per cent in the sanitised water.
• Wide range of valve types • Manually, pneumatically operated or motorized • Measurement and control systems • All from a single source
Carbonic acid is generated as a byproduct and dissolved to water and carbon dioxide (CO2). Excess CO2 is removed in the pure water degasifier before the treated water is transferred to a pure water container. This is then fed to a municipal water supply sanitised by UV sterilisation. During the process, water hardness is reduced from 480ppm CaCO3 to a medium level of 240ppm CaCO3.
GEMÜ VALVES AFRICA (PTY) LTD Cnr Olympic Duel Avenue And Angus Cresent Northlands Business Park (Stand 379) New Market Road · Randburg Phone: (0)11 462 77 95 · info@gemue.co.za
www.gemue.co.za
Raw water enriched with CO2 is used as a regeneration agent for the mixed bed filter. This reverses the direction of the exchange process. CO2 is dissolved in water with high pressure, creating carbonic acid. The carbonic acid is fed to the mixedbed in counter current, regenerating the ion exchanger resin. Most of the CO2 required for regeneration can be recovered (approximately 95 per cent) and fed back into the process. to page 34
34
Food Review | September 2019
WAT E R P R O C E S S I N G T E C H N O L O GY
Achieve the best quality of water Water is the lifeblood of South Africa’s processing sector. As a commodity, it is becoming scarcer and a significant and expensive component to the food and beverage industry.
A
Guth SA can assist the local industry to
hygienically install Keofitt valves using our
cost is the general deterioration
produce world-class products to compete
coded trained technicians. This will ensure
of South Africa’s water quality -
in the global market. Its four strategically
your sample integrity remains intact,’
specifically municipal supply. South
placed branches in South Africa offer and
Marshall concludes. •
Africa also suffers from ageing
distribute equipment and consumables
infrastructure and additional demand from
to take and retain samples for testing.
a burgeoning population.
This will enable laboratories to accurately
contributing factor to its rising
Guth skid-mounted pasteuriser
identify harmful pathogens and bacteria
It is mandatory in the food and beverage industry to test all incoming
present in our water, incoming ingredients
and outgoing wastewater. It is
and outgoing final product.
particularly important to test all products
‘Should you not be using the Keofitt sampling valve system or Whirl-Pak sterile
manufactured using water.
aseptic sampling bag in your industry,
The Listeria outbreak in South Africa placed a strong focus on sampling and
contact us. We will arrange for our
testing water during processing. ‘A more
trained staff to conduct a factory audit
holistic approach will ensure that samples
at your premises. We will advise you on
taken are uncompromised by inferior
the correct placement, operation and
sampling taps. It would also ensure the
utilisation of the Keofitt sampling system
vessels used to convey the samples to the
along with the correct and cost-effective
lab are sterile,’ notes sales engineer
Whirl-Pak bags. ‘Guth SA not only supplies
Ricky Marshall.
sampling and testing systems, it can also
Guth - www.guth.co.za
WITH YOUR SAMPLE Connecting Processing & Sampling To Ensure Better Results
KE(}FITI:
J4WHIBL-PAK results you can trust
WORLD LEADERS IN STERILE SAMPLING"'
Johannesburg: +27 (0) 11 477 4923
®
Cape Town: +27(0) 21 555 8300 info@guth.co.za
Eastern Cape: +27 (0) 41 451 2155
Pinetown : +27 (0) 31 709 5444
www.guth.co.za
STAINLESS STEEL EQUIPMENT FOR PROFITABLE PROCESSING
September 2019 | Food Review
35
WAT E R P R O C E S S I N G T E C H N O L O GY
Meet Africa’s smart and sustainable energy solution Water and wastewater specialist Talbot is in the process of installing Africa’s first Econvert Eco Digester. The anaerobic wastewater treatment plant will be active at a production facility belonging to one of the continent’s largest food and beverage companies.
T
he Eco Digester was supplied by
traditional AD installations.’ The system
Talbot’s technology partner, Econvert
effectively manages effluent, improves
Water and Energy - specialists in the
environmental compliance, enhances water
delivery of innovative anaerobic digestion
recovery opportunities and generates notable
(AD) and biogas water treatment solutions.
savings through reduced wastewater disposal
Talbot has the exclusive rights to the
and energy costs.
technology across Africa and the Indian Ocean
‘Anaerobic micro-organisms break down
Islands. The company believes the technology
organic matter in effluent while producing
holds significant potential for the continent's
energy-rich biogas. This gives companies the
fast-moving consumer goods (FMCG) sector.
option to channel renewable energy back into
‘AD and its many benefits have traditionally
Talbot has installed more than 10 biogas boilers on anaerobic digesters across the continent through its exclusive agreement with East Coast Steam
their production processes,’ Haycock points
90 per cent COD removal, requires low capital investment and is well-suited to applications on the African continent.
been the preserve of larger effluent
out. The Eco Digester is skid-mounted
producers with high chemical oxygen demand
and can be installed in less than four to
ECONOMICALLY VIABLE, ENVIRONMENTALLY SUSTAINABLE
(COD) loads,’ notes Talbot CEO Carl Haycock.
eight weeks.
The Eco Digester provides an economically
‘This development is a game-changer for
It is ideal for smaller wastewater
smaller wastewater producers who were
producers with COD loads of up to
previously unable to justify the cost of
5 000kg per day. It achieves more than
viable and environmentally sustainable alternative to traditional wastewater treatment. This, at a time when the global
from page 34
GEMÜ PRODUCTS IN USE • Gemü 480 Victoria metal butterfly
The 480 Victoria metal butterfly valve offers an advanced seal design, even for
valves - up to DN 600, manually or
larger diameters. The design allows a low
pneumatically operated;
torque and savings through lower actuator
• Gemü D450 plastic butterfly valves;
costs. Further valve types like plastic
• Gemü 717 plastic ball valves;
butterfly valves and ball valves are available
• Gemü LSC limit switch box for quarter
in various actuator and material versions.
turn actuators.
‘All butterfly valves and ball valves in the range are completely assembled in Gemü’s
KEY PROCESS DATA:
assembly centre - even with the appropriate
• Media: Raw water, CO2, acid/caustic/
accessories on request.
sodium hypochlorite as
'You will receive our pre-assembled
cleaning agents
solutions preset and tested. As well as
• Operating pressure of 90psi.
receiving all components from a single source, you save time and effort in logistics
1: Carix is an environmentally friendly process 2: A cost-effective water treatment system
WHY GEMÜ?
and installation of the system on site, as
The company offers technically
well as in documentation,’ concludes Brian
sophisticated solutions for water
Allingham, managing director of Gemü
treatment. With a wide range of valves
South Africa. •
and accessories, the complete valve selection, measurement and control instrumentation are supplied from a single source.
36
Food Review | September 2019
Gemü – www.gemue.co.za
WAT E R P R O C E S S I N G T E C H N O L O GY
industry faces increased regulatory pressure
distilleries, bottling plants, dairies and
and rising consumer expectations for the
sugar mills.
• The system is completely automated and has low maintenance requirements
adoption of transformative processes that
• With a footprint of just 60m2, installations
help minimise carbon emissions and protect
ECO DIGESTER FACTS AND FIGURES
and conserve scarce natural resources.
• Ideal for smaller wastewater producers with
The client is one of Africa’s largest listed
daily COD loads of up to 5 000kg
manufacturers of FMCGs. It opted to install
• More than 90 per cent COD removal
the Eco Digester at its Johannesburg-based
• Significantly cheaper than conventional
soft and sports drink production facility to
AD solutions
South African Food Review, 132 mm, ensure consistent compliance with municipal • Potential savings of R400 000xa200 month discharge bylaws.
through reduced wastewater disposal and
‘The manufacturer selected the unit as it
energy costs
can be completed in less than four to eight weeks • Talbot provides ongoing operations and maintenance support • A rental option is available. •
Hydronomic, CC-en34-AZ190 04/17 Talbot – www.talbot.co.za
was the most energy-efficient solution available, saving around 2 500kWh a day at peak production levels when compared with conventional aerobic solutions,’ Talbot technical director Grahame Thompson points out. This equates to a monthly saving of R 75 000. ‘Comparing the product with other anaerobic designs, the Eco Digester delivers a capital saving of 15 per cent. It is also expected to reduce discharge and energy costs by around 80 and 65 per cent, respectively, while producing a daily 22GJ of energy equivalent to around 400 tonnes of coal a year,’ says Thompson. The client will initially make use of the system’s built-in buffer and flare. There is also potential to use biogas to generate steam, thereby offsetting additional fossil fuel-based energy costs. Concorp, a large sweet manufacturer in the Netherlands adopted the technology as a sustainable way of purifying wastewater arising from its production process. The biogas produced is comparable with natural gas in respect of calorific value and used in the factory to generate heat. The process meets between 20 and 25 per cent of the company’s annual energy requirements. ‘Sustainability-minded food
Hydronomic #GermanBlingBling #Hydronomic
producers are redefining the definition of waste. They’re starting to look at wastewater as a valuable by-product rather than a liability in a world where water and energy are becoming scarce and expensive,’ Haycock concludes.
We do more.
The technology has a ready market in multiple sectors, including food processing, confectionery and snack manufacture; beverages, CC-en34-AZ190_05-17.indd 1
08.05.18 08:37
September 2019 | Food Review
37
PAC K AG I N G DID YOU KNOW?
Zero Cooling benefits productivity and efficiency
Zero Cooling can assist in reducing overall energy consumption per bottle; allows further opportunities for weight reduction and covers a range of material specifications.
Nissei ASB Machine Co. is a highly regarded manufacturer of injection stretch blow moulding technology for PET and other plastics. It utilises a one-step injection stretch blow moulding process for general food packaging.
A
3. Optimized Preform Stretch / Blow
SB’s revolutionary advances
The shorter & thicker Zero Cooling preform is quality optimized for higher stretch / blow ratios resulting in higher stiffness, topload strength and improved visual quality.
in preform cooling technology increases product quality. It
Zero Cooling Preform
also results in significantly shorter moulding cycles.
4. Product Eject
Higher stretch ratios = increased strength & improved visual quality.
What makes the technology unique is ASB’s proprietary four-station, one-step moulding system. The shift from a second
1. Zero Cooling at the Injection Station
conditioning station dramatically reduces
By virtually eliminating cooling time, a direct saving on overall molding cycle is achieved.
injection cycle times. Zero Cooling moulding enables short cycle times and avoids the need for thin, compromised design preforms. These are often susceptible to quality-related problems, most notably fisheye.
38
Food Review | September 2019
Injection / Holding
Cooling
Injection / Holding
Index
Index
Standard Cycle Zero Cooling Cycle
Cycle Reduction
2. Preform Cooling at the Second Station Preforms are cooled on both the inner and outer surfaces. Thicker wall of Zero Cooling preform improves temperature stability and equalization for improved overall quality.
Standard Preform Lower stretch ratios = less orientation, lower strength, increased visual defects.
PAC K AG I N G
FAST FACT:
Nissei ASB Machine Co. will launch its new Zero Cooling technology at K2019. The event will be held from 16 to 23 October in Düsseldorf, Germany. The exhibition retains its place as one of the world’s largest and most influential plastics shows. The 2016 edition saw 230 000 visitors and 82 per cent were directly involved in purchasing decisions.
• Response and communication speed is
The model displayed at K2019 will be fitted
2.5 times faster than dedicated PLC systems
with an optional IU-10L stroke injection
• A PC-based system makes it extremely
unit that provides a 50 per cent increase
flexible to use and is compatible
scope for large containers or materials
factory networking
such as polypropylene, which often have a
• A larger, easy to read panel provides
lower density.
access to relevant information without changing pages • Most manual operation switches are replaced by touchscreen • Improved operator feedback improves troubleshooting response time and
The results from a typical Zero Cooling mould indicates a 15 per cent increase in stiffness and topload strength. It also improves control of material distribution with a marked increase in productivity and visual quality is greatly enhanced. Since container strength has been improved, additional scope to apply lightweighting to container specifications is possible.
SIZE ISN’T EVERYTHING The ASB-12M has established itself as an innovation leader in small, fully automated one-step stretch blow moulding machines. Its diminutive size belies its huge capabilities. Now available with a Version 2 specification, the model brings greater performance and utility to the table. Most notable is its control system that elevates machine capability to a new level. This offers significant advantages to users, such as:
in available shot-size. This expands the
with industry 4.0 for enhanced
minimises downtime. Internal hard wiring is drastically reduced • Major machine functions can be added or updated via software installation
These benefits make it an ideal platform for a start-up company looking to make future-proof investments into an everchanging market. It is also suitable for larger companies wishing to exploit niche markets with higher margins. With its full featured specification, it is an ideal laboratory unit for research and development work and pilot moulding before committing to much larger multi-cavity systems for major projects.
• Easier and faster service support • Standardised interface across the model range assists in operator training. The revised ASB-12M expands the capabilities for production of a vast range of PET containers including lightweight bottles and wide-mouth jars. Key features include: • Ability to process more than 20 resin types in addition to PET • Mould containers from 50ml or less up to
“What makes the technology unique is ASB’s proprietary four-station, one-step moulding system. The shift away from a second conditioning station dramatically reduces injection cycle times”
2.5 l capacity • Variable cavitation for up to 15mm neck diameter bottles in eight cavities through to 83mm neck diameter jars in a single cavity • Servo driven hydraulic pumps installed as standard. This contributes to energy savings and offers smooth and quiet operation • Compatible with existing class mould tooling with minimal modifications • Its small size allows fast mould changeovers with minimal manpower and lifting equipment. The ASB - 12M
The ASB-70DPHv4 is a mid-range one-step injection stretch blow moulding machine that offers extreme moulding versatility with competitive investment costs and low cost of ownership. It utilises ASB’s renowned four-station moulding process to achieve optimum moulding efficiency and stability of a wide range of moulding materials. It has remained a long-term industry bestseller in its class because: • It has an ability to process up to 20 resin types in addition to PET • It moulds containers from 50ml or less up to 10 l capacity • Variable cavitation from 18mm neck diameter small bottles in 12 cavities through to 149mm neck diameter jars in a single cavity • With almost 2 500 units shipped, the design is well proven as solid and ultra-reliable • A wide array of factory options allows buyers to tailor the machine to their own project-specific needs • With no hydraulic components above the moulding, the risk of product contamination is eliminated. •
Nissei ASB – www.nisseiasb.co.jp
September 2019 | Food Review
39
PAC K AG I N G
Introducing the world’s lightest industrial bottle X-Lite Still is Sidel’s latest innovative 500ml PET packaging solution for nonpressurised still water. Due to its extremely light industrial bottle design, it is one of the most cost-effective and sustainable packaging currently on the market.
T
his pioneering solution addresses the still water market for small size PET bottles, in particular producers
looking to optimise packaging and their production costs. With 6.5g of weight and a height of 195mm, Sidel X-Lite Still is one of the lightest 500ml PET bottle for non-pressurised still water. It offers a great level of performance - even at very high production speeds1 with a very light water neck finish. This bottle is perfectly complemented by a Novembal Novaqua RightCAP26 closure.
HIGH PACKAGING PERFORMANCE FOR NON-PRESSURISED STILL WATER Sidel X-Lite Still integrates the proven StarLite Still base solution. The bottle features increased stability and stress resistance, design flexibility and clear lightweighting possibilities. Energy savings enabled by StarLite Still is achieved through a reduction in blowing pressure and heating power. This base design can be adapted to all Sidel blowing platforms and applied to existing production lines to reduce the total cost of ownership (TCO).
X-Lite Still has been optimised by
monetary savings of PET resin and energy
the company’s engineers for the Sidel
can reach up to two million Euros per year.
Super Combi, the single smart solution
‘For our customers, the new preform
integrating five process steps: preform
design and neck finish featured by the
feeding; blowing; labelling; filling/capping;
X-Lite Still packaging solution translates
and cap feeding.
into a very fast payback on their
‘Based on a dedicated preform design
includes a completely new injection stack,’4
latest addition to our packaging portfolio
Naveau says. ‘By switching from a 12g PET
can withstand label application on an
bottle to the X-LITE Still 6.5g bottle, the
empty bottle, in spite of its extremely light
payback time for a line upgrade would only
weight. It allows for the ideal bottle shape
be between two to four months.’5 •
design for nested packs and enables an optimum top-load resistance of 34kg. This matches supply chain requirements in terms of pallet stability,’ explains Laurent Naveau, Sidel packaging expert.
Sidel’s X-Lite Still
investment, even when the line retrofit
for optimal mechanical performances, this
As one of the lightest bottle in the world for still water, Sidel X-Lite Still dramatically reduces the consumption of PET resin. When compared to bottles weighing 12g, the new solution can save a remarkable 1 485 tonnes of PET per year while generating energy savings of up to 335 000kWh/year 2. Combined, these reductions amount to 3 000 tonnes of CO2 saved, which equals 25 round trips between
Based on packaging production lines integrating Sidel Super Combi and running at up to 91 800 bottles per hour. 2 Based on Sidel Matrix Combi handling 2 700 bottles per hour per mould, for an SBO 20, with a yearly production of 5 000 hours, with a PET cost of €1 425 per ton and energy costs of 0.12 €/kWh. 3 ICAO / Environmental Protection / Carbon Emissions Calculator (https://www.icao.int/environmental-protection/CarbonOffset/Pages/default.aspx) 4 Line retrofit includes the adaptation parts to be changed for new preform and new neck diameter and height. Typically, from 29/25 to 26/22 mm. 5 Based on Sidel Matrix Combi handling 2 700 bottles per hour per mould, for an SBO 20, with a yearly production of 5 000 hours, with a PET cost of 1 425 per tonne and energy cost of €0.12kwh, including injection stack. 1
New York and Paris by plane with 200 passengers on board3. For bottled water producers, this means that the cumulated
40
Food Review | September 2019
Sidel - www.sidel.com/x-lite-still
EVENT
Metpac-SA hosts successful AGM The Product Responsibility Organisation (PRO) hosted its second annual general meeting at the Coca-Cola head office in Melrose, Johannesburg. The event was attended by members of the association, representatives of the packaging industry and researchers.
M
etPac-SA chairman, Muhammed Darsot of Dürsots, oversaw the
'We applaud their decision to support
official opening before handing
the local metal packaging industry’s
the podium to CEO Kishan Singh. ‘MetPac-SA
efforts to increase the collection and
supports and represents members on industry
recovery rates of aluminium cold drink
matters related to operational, regulatory and
cans, canned food packaging made
environmental issues.
from aluminium and stainless steel.
'We also promote the benefits of metal
This also includes aluminium foil
packaging and the sustainable attributes of
products, aerosol cannisters, metal
steel and aluminium,’ he enthused.
LOOKING BACK AT 2018 MetPac's resources were primarily dedicated
Ishfaq Safi, Klaus Hass, Dr Casper Durandt, Charles Müller, Riccardo Benedetti, Kishan Singh, Muhammed Darsot and Mark Helfrich
to developing the Industry Waste Management Plan (IndWMP) in partnership with JG Afrika in
Singh said Metpac will continue with its
2018. This was an exhaustive and expensive
public awareness campaign aimed at general
process. The association’s plan was finally
consumers and the metal packaging industry
submitted to the Department of Environmental
to increase collection and recycling rates.
Affairs (DEA) as part of Packaging SA's Confederation of Plans. The process has now been stalled with
support their efforts. The metals recycling body had major successes recently, with
Environmental Affairs, Forestry and Fisheries. It
various new members who have joined and
is likely to be a while before the plan is ratified,
helped to increase MetPac-SA’s influence
approved and becomes statutory.
and footprint. Earlier this year, two of South Africa's largest retailers, Woolworths and PnP, submitted their membership applications. This was followed by Spar, Shoprite, Chill Beverages
The immediate strategy for the coming year will
and Golden Era who also submitted company
be to establish the association as a credible
information,’ he noted.
industry representative organisation that is
an example for their suppliers to follow and are helping to invest in recycling and recovery operations through
contributing to an annual Extended Producer Responsibility (EPR) fee,’ Singh concluded. •
METPAC-SA BOARD OF DIRECTORS
1. Chairman: Muhammed Darsot 2. Deputy chairman: Klaus Hass 3. CEO: Kishan Singh 4. Ishfaq Safi 5. Dr Casper Durandt 6. Riccardo Benedetti 7. Mark Helfrich 8. Louis Wentzel 9. Charles Müller. •
‘On behalf of the MetPac-SA Board and fellow
fully supportive of the PSA Federation of Plans.
members, we would like to extend a warm
It will still encourage new members to sign up.
welcome to all these new members.
WWW.METPACSA.ORG.ZA
members, these companies are setting
‘We want to encourage more role players in the metal packaging industry to sign up and
the appointment of the new Minister of
GROWING MEMBERSHIP AND COLLECTION RATES
caps and closures. By signing up as
MetPac-SA - www.metpacsa.org.za
DEVELOPING A CIRCULAR ECONOMY FOR METAL PACKAGING MetPac-SA brings together the entire metal packaging value chain in South Africa. Although we are still in the early stages of our establishment, we already represent close to 60 % of the local metals industry.
WWW.METPACSA.ORG.ZA
South Africa’s metals packaging collection rate currently sits at an estimated 75.8 %, but the industry has set itself the task of increasing this figure to 79 % by 2021 and 81 % by 2023. Current me mb e rs i nc lud e : ABInBev, The Aerosol Manufacturers Association, Chill Beverages, Coca-Cola, Distell, Dürsots, Heineken, Hulamin, Nampak, Nestlé, Pack Solve, Pick n Pay, Saldanha, Spar, Shoprite, Tin Can Man, Woolworths, West Point and Wyda SA.
August 2019 | Food Review
41
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BUTCHER MEAT PROCESSING EQUIPMENT
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