Food and Drink Business Europe Nov/Dec 2012

November/December 2012

Britvic and AG Barr agree ÂŁ1.5 billion merger

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C o n t e n t s

- 39 C ONFECTIONERY & S NACKS

- 2 M ERGERS & A CQUISITIONS

ProSweets Cologne 2013 – 27th-30th January, 2013.

Coverage of British and international deals.

PAGE 2 Agust Gudmundsson, ceo, Bakkavor Group.

- 7 C OVER S TORY Britvic and AG Barr agree £1.5 billion merger.

R EGULARS

P AGE 8 John Gibney, ceo, Britvic.

Bottling & Packaging . . . . . . . . . . . . 12 & 29

Materials & Ingredients . . . . . . . . . 22, 40-45 Red Arrow hits the target with innovative flavour systems . . . . . . . 43 Iprona – The fruit company . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

- 10-11 S EAFOOD

PAGE 15 Bill King, ceo, Baxters Food Group.

Processing & Manufacturing. . . . 23-27, 31, 46

Ten million chefs to use Scottish seafood.

UK seafood consumption remains buoyant.

PAGE 2 Paul Walsh, ceo, Diageo.

Pizza . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 & 24 Finis Food Processing Equipment delivers complete projects. . . . . . 31

Materials Handling . . . . . . . . . . . . . . . . . . . 33-37 Schenck Process – The global expert in materials handling. . . . . . . 33 Conveyors, Belts & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-37

- 15 A MBIENT F OODS

Energy & Environment . . . . . . . . . . . . 4 & 48

PAGE 17 Audrey Baxter, chairman of Baxters Food Group.

Tradition and ambition at Baxters Food Group.

Managing Director: Colin Murphy Editor: Mike Rohan Sales Director: Ronan McGlade Advertising: Susan Doyle and Sylvia McCarthy

PAGE 3 Stephen Glancey, ceo, C&C Group.

- 19 B AKERY

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M E E R R G G E E R R S S M VION to Sell UK Food Operations Dutch-based food producer VION is to sell its UK food businesses to concentrate on its core markets in the Netherlands and Germany and the development of its global ingredients business. VION UK produces and processes beef, lamb, pork, bacon and chicken in addition to convenience products such as sausages, cooked meats and added value cooked chicken across its 38 sites in Scotland, England, Wales and Ireland.

The group’s extensive facilities across the UK range from farms and hatcheries to primary production, processing and packing.

VION is confident that it will successfully sell its UK pork, red meat and poultry business units as ongoing viable businesses.

VION entered the UK in the late 1990’s with the acquisition of Key Country Foods, followed

by Tranfield and subsequently Grampian Country Food Group in 2008 and currently employs 13,000 people in the UK. In addition to its food activities in the UK, VION is also divesting a number of non-core activities, including Banner Pharmacaps and Oerlemans Foods (frozen vegetable and potato products).

& &

A C C Q Q U U II S S II T T II O O N N S S A

The combined group will possess an attractive portfolio of strong and differentiated brands (including Irn-Bru, Robinsons, Fruit Shoot, J2O and Rubicon), with its portfolio well represented in key sub-segments of the soft drinks market. Britvic shareholders will own 63% of the combined business with and AG Barr shareholders the remaining 37%.

Bakkavor Group to Sell French and Spanish Businesses Bakkavor Group has agreed to sell its French and Spanish produce businesses for Eur33 million to Agrial, a leading European food co-operative.

The businesses being sold comprise Cinquieme Saison SaintPol, Cinquieme Saison Macon, Bakkavor France, Crudi and Sogesol.

Completion of the transaction is subject to competition authority clearance, which is expected by the end of the first quarter of 2013.

Agust Gudmund-sson, chief executive of Bakkavor, comments: “The sale of our French and Spanish businesses marks an important step in our strategy of reshaping our portfolio to focus on our core fresh prepared markets. The transaction will be beneficial from a leverage perspective and net proceeds will be used to reduce our term loan.”

Bakkavor is the UK’s leading provider of fresh prepared

Britvic and AG Barr to Merge UK soft drinks producers Britvic and AG Barr have agreed to merge to create Barr Britvic Soft Drinks, one of the leading soft drinks companies in Europe, with annual sales of over £1.5 billion, a portfolio of strong brands and significant prospects for future growth.

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Agust Gudmundsson, chief executive of Bakkavor Group.

foods. The group has an annual turnover of £1.68 billion, of which £290 million is generated from international sales.

Diageo to Acquire Stake in Leading Indian Spirits Company Diageo has agreed to acquire a 27.4% stake in United Spirits Limited (USL), the leading spirits company in India for INR57.3 billion (£660 million) from United Breweries (Holdings). Diageo will also now launch a mandatory tender offer to the public shareholders of USL to acquire further shares, equating to 26% of the enlarged share capital of USL. If the tender offer is fully subscribed, Diageo will hold 53.4% of the enlarged USL share capital at an aggregate cost of INR 111,665 million (approximately £1.285 billion). This represents a 20x multiple of USL’s EBITDA for the year ended 31 March 2012.

Paul Walsh, chief executive of Diageo.

Dr Vijay Mallya will continue in his current role as chairman of USL, and UBH and will work with Diageo to build the USL business as the current consumer trends for premiumisation accelerate in India.

Paul Walsh, chief executive of Diageo, comments: “USL’s number one position in local spirits together with our growing international spirits business of leading brands will enable us to grow across the consumer space as India’s increasing number of middle class consumers look to enjoy premium and prestige local spirits brands as income levels rise.”

He adds: “The acquisition of our shareholding in USL is fully

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

aligned with our strategy to build our presence in the world’s faster growing markets and enhances our position as the world’s leading premium drinks company.”

Bright Food Completes Weetabix Acquisition Bright Food, one of China’s largest food groups, has completed its acquisition of 60% of Weetabix Food Company from private equity firm Lion Capital for an enterprise value of £1.2

billion. The remaining 40% of the shares will continue to be held by Lion Capital and management. Weetabix is the second largest branded manufacturer by value of ready-to-eat cereals and cereal bars in the UK and exports its products to over 80 countries.

In addition to its strong presence in the UK, the company has operations in North America, South Africa, Germany and Spain and exports to more than 80 countries around the world. Weetabix employs about 1,800 people worldwide and in 2011 generated sales of over £460 million.

Bright Food’s landmark acquisition is an exciting move by the company, signalling its entry into both the UK and global food markets through the iconic Weetabix brand. The transaction is the largest overseas acquisition by a Chinese company in the food and beverage sector. The purchase also supports Bright Food’s strategy of buying famous international brands, developing advanced technology and taking strong competitive positions in each of its markets.

New Irish Dairy Processing Joint Venture Established Following approval by both sets of shareholders, Glanbia Ingredients Ireland, the joint venture between Glanbia plc and Glanbia Co-operative Society, has been established.

The joint venture incorporates

N N E E W W S S the business and assets of Dairy Ingredients Ireland, a business unit of the Dairy Ireland segment of Glanbia plc, including its 45% share of the Corman Miloko Ireland joint venture and its 23% shareholding in the Irish Dairy Board. The new joint venture, to be known as Glanbia Ingredients Ireland, will be 60% owned by the Glanbia Co-operative Society and 40% owned by Glanbia.

The existing DII business is the largest dairy ingredients processor in Ireland, assembling a milk pool of 1.6 billion litres and processing it into about 180,000 tonnes of dairy ingredients largely for export to over 50 countries worldwide. In 2011, DII generated revenue of Eur738 million and operating profit of Eur33 million.

addition of an extensive distribution network and the creation of an attractive, multi-beverage brand platform,” comments Stephen Glancey, chief executive of C&C Group. “Over the past three years, we have progressively diversified the group’s brand portfolio in Ireland from the single premium cider brand Bulmers to a broader LAD range including Tennent’s, Caledonia Smooth and a number of beer agency brands. The acquisition of the Gleeson Group accelerates the re-shaping and diversification of C&C in Ireland.

United Coffee Expands in the UK Total coffee solutions provider, United Coffee UK & Ireland, has grown its market share

C&C Group to Acquire Gleeson Group in Ireland Irish and international branded cider and beer producer C&C Group has conditionally agreed to acquire the Gleeson Group, a leading supplier and distributor of beverages in Ireland for Eur12.4 million in cash. Existing debt of Eur45.6 million implies an enterprise value of Eur58 million.

The Gleeson Group is the largest distributor of packaged long alcohol drinks (LAD) to the licensed on-trade in Ireland.

On a pro forma basis the business generated EBITDA of Eur10.2 million for the 12 months to June 2012 implying a multiple of 5.7x 2012 EBITDA before synergy benefits.

“The acquisition has the potential to transform our existing Irish business through the

within the independent sector with the acquisition of Andronicas. Based in Corby, Andronicas is a premium roastery specialising in gourmet coffees for independent coffee shops, delicatessens and highend retailers.

United Coffee UK & Ireland is part of UCC Holdings, Japan’s largest producer of coffee with a turnover of Eur2.5 billion. United Coffee UK & Ireland owns British brand Lyons’ coffee, which relaunched in 2011 to the UK retail sector. UCC Holdings acquired United Coffee, one of Europe’s largest coffee roasters, in 2012 to become one of the top five biggest independent coffee companies in the world.

Raisio Expands in Continental Europe

Stephen Glancey, chief executive of C&C Group.

Raisio has acquired Czech confectionery manufacturer Candy Plus for an enterprise value of Eur20.5 million. The acquisition complements Raisio’s existing confectionery activities in the UK trading as Big Bear

B B R R II E E F F Confectionery.

Founded in 2000, Candy Plus is owned by private investors. In 2011, the company’s net sales totalled Eur23.3 million, EBITDA was Eur2.9 million and EBIT was Eur2.1 million. Assets on 31 December 2011 totalled Eur17.6 million, liabilities Eur9.1 million and equity Eur8.5 million. The company’s two production sites are located in the eastern part of the country, in Rohatec and Petrvald u Karvine.

Carbery Group Enters Brazilian Joint Venture Carbery Group, the Irelandbased dairy ingredients manufacturer, has announced the formation of a 50/50 whey processing joint venture with one of South America’s leading food companies BRF Brasil Foods. The venture, which involves a shared investment of $50 million will use Carbery’s innovative technology to process whey generated at Brasil Food’s cheese making operations in one of the foremost milk producing regions in Brazil.

BRF, which employs around 115,000 people and has an annual turnover of $13.7 billion, is the second largest collector of milk in Brazil. Together with significant pork and poul-

ences company, has agreed to acquire US-based food ingredients blends producer Fortitech, in an all cash transaction for a total enterprise value of $634 million (Eur495 million). Subject to customary conditions, the transaction is expected to close before the end of the year.

Fortitech, a privately held company, is a leader in customised, value added food ingredient blends for food and beverage, infant nutrition and dietary supplements industries. Fortitech has six production sites located in New York (USA), California (USA), Campinas (Brazil), Kuala Lumpur (Malaysia), Gastrup (Denmark) and Poznan (Poland), with sales offices in China and Mexico.

Net sales for 2013 are expected to be about $270 million with an EBITDA of about $70 million, including synergies and excluding exceptional items, resulting in an EV/EBITDA multiple of about 9.

Premier Foods Disposes of Hain Celestial Share for £32.0 Million

try operations, the company has fourteen dairy processing sites in Brazil together with one in Argentina and processes in excess of 1.6 billion litres of milk per annum.

DSM Strengthens Human Nutrition Business Royal DSM, the global life sciences and materials sci-

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

On 27 October 2012, Premier Foods completed the disposal of its Sweet Spreads and Jellies business to The Hain Celestial Group. for an aggregate consideration of £200 million, satisfied by £170 million in cash and the issue of shares in Hain Celestial with a value of at least £30 million on completion. Premier Foods has now completed the disposal of the Hain Celestial shares for a total cash consideration of £32.0 million. The total gross proceeds from the disposal, which amount to £202.0 million, will be used to pay down debt.

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I ENERGY MANAGEMENT

Counting the Cost of Energy ith the food industry facing a ‘green W image’ issue, many manufacturers are investigating ways of operating efficiently, flexibly and sustainably, in a bid to reduce carbon emissions and utility consumption.

This is coupled with increasing demands on the industry to quickly provide innovative new products to market. Therefore, taking an holistic approach and combining energy management with production management capabilities, will go a long way towards creating a manufacturing environment that is cost effective and energy efficient with a high ‘Overall Equipment Effectiveness plus Energy Management’ or OEE+E rating. Mark Staples, food and beverage segment manager of the Industry Business division at Schneider Electric - a global specialist in energy management – explains.

Food manufacturers have been tasked with reducing their energy consumption by 2020, in line with government targets. By the same year, it is predicted that the earth’s population will have swollen to around 8 billion people, meaning that food and beverage manufacturers are facing a significant challenge of increasing their output to produce enough food to meet the world’s growing need, while lowering overall energy consumption. This means that it is imperative that food and beverage manufacturers seek innovative solutions that will help them to overcome both of these challenges.

Overall Equipment Effectiveness plus Energy Management Within the industry, the term ‘Overall Equipment Effectiveness’ or OEE, is a recognised key measurement of efficiency and is based on three main factors: performance, availability and quality. With an increasing focus on reducing energy consumption, energy management specialists 04

such as Schneider Electric, believe that there is an argument to take a more holistic approach and now include energy within the equation – resulting in Overall Equipment Effectiveness plus Energy Management (OEE+E).

In today’s tough economic climate, endusers need and expect control systems to go beyond functional and regulatory performance. Control systems have become a tool to manage the plant while reducing energy and overhead costs, cutting carbon emissions and providing quick and precise information that moulds both production and business strategies. Additionally, increasingly complex software, such as Schneider Electric’s Ampla Express, can now be introduced to a plant, enabling end-users to collate all of their energy related data onto a single platform, offering them an easier way to analyse energy consumption.

Automation As a way of improving efficiencies, manufacturers should consider ‘bridging the technology’ gap and automating processes that currently operate manually. By doing so, it is possible to streamline and integrate production methods to manage energy consumption from a single control point. This also not only reduces human error and makes significant cost savings for the company, but allows for better repeatability, so both the recipe and the actual production process can be controlled – ensuring that products look and taste the same every time.

Over the past decade, the adoption of Ethernet-based control networks and commercial off-the-shelf hardware, components

and operating systems have paved the way for automation and improved the way the systems communicate. This provides endusers with the flexibility, choice and predictability – all of which are necessary to achieve a truly energy efficient plant. By upgrading to a fully integrated plant, incorporating both the energy management and automation system with the operation management applications, it is possible to make vast improvements to a site’s OEE+E. An integrated plant helps companies deal with external factors which are outside of their control, by making the most of their energy. A flexible automation system is capable of reacting to increasingly changeable energy costs. The price of energy can vary significantly at different times of the day, as well as geographically by region and an integrated plant provides users with the transparency to ensure they aren’t using too much energy at the wrong times of the day.

As a manufacturer in the food and beverage industry, the prospect of migrating to an automated, fully interoperable system such as this may seem like a daunting prospect – particularly with the current budget constraints and the high costs of raw materials. However, by addressing the issues in detail and with a little help from the experts, system migration to an open, energy efficient and collaborative production environment is achievable and logical.

PlantStruxure In response to market demand for a collaborative system, Schneider Electric introduced PlantStruxure - a process automation system which includes a range of production management software solutions. Once implemented, a solution such as PlantStruxure can help to keep unexpected downtime to a minimum, lower production costs, and help to ensure that energy reduction targets are met.

This effectively reduces waste and helps companies comply with the heavy environmental regulations which govern today’s food and beverage industry. Businesses that operate an open and collaborative production environment that embraces standards can enjoy significant energy efficiency benefits. It is time for manufacturers to look to a top-down approach to achieve a high OEE+E rating, to ensure that their systems are flexible, sustainable and energy efficient to withstand the test of time. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

COVER STORY

Britvic and AG Barr Agree £1.5 Billion Merger UK soft drinks producers Britvic and AG Barr have agreed to merge to create Barr Britvic Soft Drinks, one of the leading soft drinks companies in Europe with annual sales of over £1.5 billion and bright prospects for future growth.

A

G Barr and Britvic are highly complementary businesses in terms of brands, sales channel presence and geographic spread within the United Kingdom. Britvic shareholders will own 63% of the combined business with AG Barr shareholders the remaining 37%, reflecting the relative market capitalisation of the two companies prior to the merger agreement.

“I believe this business is stronger than the sum of its parts and gives us a fantastic opportunity to create a truly outstanding growth platform,” says Roger White, chief executive of AG Barr, who will head Barr Britvic Soft Drinks. “By combining Britvic, which is a large scale business with genuine market leading national brands and well developed systems, with AG Barr, a smaller, agile business with strong execution focus and growing brands, we have the opportunity to take the best of both businesses.”

He adds: “This will create a business that is not only bigger but most importantly better, with complementary presence across a number of channels, geographies and overall enhanced market access.”

Britvic is one of Europe's leading soft drinks companies. It is the largest supplier of branded still soft drinks in Great Britain and ranks number two within the branded carbonated sector. Britvic is also a leading player in Ireland and in France, and has extended its reach into other international territories through export, licensing and franchising.

Employing approximately 3,300 people, the group reported revenue of £1.29 billion and an operating profit pre-exceptional and other items of £135 million, with profit before tax pre-exceptional and other items of £105 million for the 52 weeks ended 2 October 2011. For the 28 weeks ended 15 April 2012, Britvic's revenue was £641 million (2011: £633 million) and it made profit before tax of £25 million (2011: £28 million).

Established in 1875 in Scotland and currently employing about 980 people, AG Barr sells soft drinks primarily in the UK but has a growing

Roger White, chief executive of AG Barr, will head Barr Britvic Soft Drinks.

level of international sales. The drinks producer ach-ieved revenue of £237 million and a profit before tax of £35 million for the 52 weeks ended 28 January 2012. For the six mon-ths ended 28 July 2012, revenue was £130 million (2011: £124 million) and profit before tax was £15 million, down from £16 million in the corresponding period in 2011.

Integrating Britvic with AG Barr is expected to yield annual cost synergies of approximately £35 million

Management Team through savings in overheads and procurement While Roger White will and enhancements to the supply chain. be chief executive of Barr Britvic Soft Drinks, John Gibney, the current chief financial officer of Britvic, will hold a similar position within the combined group.

Gerald Corbett, the current Britvic non-executive chairman, will become the non-executive chairman of the enlarged business, and Ronald Hanna, the current chairman of AG Barr, will become the non-executive deputy chairman of Barr Britvic Soft Drinks.

Both companies have strong track records of successful new product launches, new flavour introductions, new packaging formats and enhancements alongside innovative and differentiated marketing campaigns, and will contribute significant expertise in soft drinks innovation to the enlarged group.

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

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Formidable Brands Portfolio Barr Britvic Soft Drinks will have a formidable portfolio of brands providing it with strong positions in all key subsegments of the soft drinks market. Britvic's portfolio of owned international brands, such as Robinsons, Robinsons Fruit Shoot and Teisseire, alongside strong national brands such as J2O, Tango, juicy drench, Britvic, R Whites, Fruite, Moulin de Valdonne, Ballygowan, Club and MiWadi, will be combined with AG Barr's brands, including Irn-Bru, Rubicon, KA, Barr and Strathmore.

Britvic enjoys a strong relationship with PepsiCo, which is supportive of the merger with AG Barr. Britvic has exclusive bottling and distribution agreements with PepsiCo in Great Britain for a number beverage brands including Pepsi, 7UP, Gatorade, Mountain Dew and SoBe, and for Pepsi, 7UP and Mountain Dew in Ireland. AG Barr also has a partnership with Pepsi, which operates the Irn-Bru franchise in Russia.

Barr Britvic Soft Drinks’ franchised brand portfolio is further complemented by AG Barr's licensed brands including Orangina and Rockstar and by Britvic's exclusive agreement with Pepsi Lipton International for Lipton Ice Tea. The enhanced portfolio will allow Barr Britvic Soft Drinks to offer consumers a wider choice of products and brands and to meet changing

consumer preferences and purchasing patterns. Barr Britvic Soft Drinks will have a significant international presence in France and Ireland, and growing distribution of proprietary brands in markets such as the USA, Australia, Netherlands and Russia.

Well Balanced Busines Barr Britvic Soft Drinks will be a well balanced business between still drinks and carbonates and across the take-home and drink now channels.

The stills segment accounts for 38% of sales and carbonates 62%.

Approximately 71% of the group’s combined revenue of £1.5 billion is generated in the UK with 16% in France, 11% in Ireland and the remaining 2% from other international markets.

“Operationally, the combined group has a geographically well balanced national footprint,” Roger White points out. “In trade channel terms, Britvic’s position in clubs, pubs and grocery is complemented

by Barr’s strength in the convenience channel.”

Roger White continues: “The combined group is committed to maintaining and developing Britvic’s successful relationship with Pepsi and the group will benefit from the additional long-term partnerships with Rockstar and Orangina. John Gibney, current chief financial officer of We have the opportu- Britvic, will hold a similar position within Barr nity to build and Britvic Soft Drinks.

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FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

improve our market positions in France and Ireland as well as the significant international growth potential which exists in markets such as the USA.” Barr Britvic Soft Drinks’ strategy will focus on creating value by driving both the availability of its brands and operational efficiency.

“In my view, this is the most natural and compelling combination within the European soft drinks market today – two businesses, which are strong in their own right with fantastic owned brands, strong franchise partnerships and great people,” says John Gibney.

Synergies of £40 Million Integrating Britvic with AG Barr is exp-ected to yield annual cost synergies of app-roximately £35 million through savings in overheads and procurement and enhancements to the supply chain. The merger offers the opportunity to optimise the combined operational footprint, increasing manufacturing capacity utilisation to enable better leverage of fixed production costs.

The combined gr-oup will be able to benefit from a reconfiguration of the supply chain. For instance, it is likely that the new facility that AG Barr is currently constructing in Milton Keynes will provide additional cap-acity which will offer greater flexibility for Barr Britvic Soft Dr-inks.

Barr Britvic Soft Drinks will also benefit from a strengthened sales and distribution network and, in particular, Britvic's focus on the national grocery chains and its contracts with licensed on-trade outlets

as well as AG Barr's Direct Store Delivery model that supplies small retail convenience stores.

In addition to these cost synergies, the merger is expected to provide an opportunity to achieve a contribution of at least £5 million from annual net revenue synergies through utilising the combined distribution channels, brand portfolios and geographic presence.

The savings will be delivered progressively – £3 million in the first 12 months after completion of the merger, rising to approximately £16 million in the second year - to achieve aggregate synergies of £40 million in 2016.

One-off exceptional costs of about £40 million are anticipated, of which £11 million would be incurred in the first 12 months and the remainder in the second year. Capital expenditure of £8 million will be required in the first twelve months after completion of the merger to realise the synergies.

Robust Capital Structure “The business will have a robust capital structure and strong free cash flow which is already underpinned by the significant synergies of £40 million per annum,” points out John Gibney. “This will deliver a strong de-leveraging profile and in turn will enable us to maintain levels of strategic investment in the business, predominantly in the areas of marketing, innovation and capital expenditure, and pursue organic growth initiatives and potential future acquisition opportunities.”

The merger is conditional on the approval of AG Barr shareholders and Britvic shareholders and OFT clearance. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

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I

SEAFOOD

Ten Million Chefs to Use Scottish Seafood en million chefs are set to cook with T Scottish seafood following a landmark deal with the World Association of Chefs’ Societies (WACS). As a result of the agreement, Scottish Salmon and Langoustines will also be used exclusively by more than 100 world-class chefs in the 2012-14 Chefs Global Challenge, which includes regional competitions in locations such as Singapore, Italy, Las Vegas and Hong Kong.

Seafood Scotland, Scottish Quality Salmon and Scottish Salmon Producers’ Organisation - in partnership with Scottish Development International – have concluded the deal, which will see only Scottish Salmon and Langoustines featured in the WACS global chef competitions over the next two years - culminating in the 2014 final in Norway.

The World Association of Chefs’ Societies has more than 10 million members world-

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wide and members will be encouraged to use Scottish Salmon and Langoustines in their restaurants and a series of inspirational recipes will be produced to show how Scottish seafood can be used to create delicacies from around the world.

“This landmark agreement will give unprecedented global exposure to Scottish produce and the link with the World Association of Chefs' Societies is an extreme-

ly prestigious accolade for Scottish food and drink,” says Richard Lochhead, Scotland’s Cabinet Secretary for Rural Affairs. “Our Salmon and Langoustine are already ingredients of choice in many restaurants around the world and this deal will further boost the global profile of the premium seafood that hails from Scotland’s larder.”

He adds: “Scottish fish and shellfish are internationally regarded as being some of the most delicious and high quality seafood anywhere in the world. Not only that, but our seafood is fresh, healthy and sustainably sourced – all standards that the world’s top chefs look for. This deal will give huge worldwide exposure to Scottish seafood but we also hope as a result chefs around the globe will explore Scottish produce more generally and in turn this will provide a boost to our other premium products too.” J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

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SEAFOOD

UK Seafood Consumption Remains Buoyant UK fish consumption is expected to continue to expand as lesser-known fish species grow in popularity. ver half of all fish products sold will be outside of the UK’s most popular ‘big five’ species (Cod, Haddock, Tuna, Salmon and Prawns).by 2030, predicts the Our future with fish report, commissioned by Sainsbury’s and produced by the Future Foundation. The major study into fish consumption and attitudes in the UK shows a marked shift in consumer buying habits as an increasing number of consumers purchase lesser known, alternative fish, such as Pollack, Seabass, Coley and Tilapia, which are more abundant in the oceans.

Indeed, following a year of high profile awareness campaigns for sustainable fish, such as Sainsbury’s own Switch the Fish initiative, a change in fish buying habits has resulted in sales increasing across species including Seabass up by 57%, Fresh Pollack up15%, Trout ahead by 29% and Tilapia growing by 117%.

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Increasing Consumption The report also reveals that the UK population will be eating more fish in future, with UK adults set to eat twelve extra fish meals a year by 2030, increasing their weekly consumption by 17% (from under 8 million kilograms today to 9.23 million kilograms by 2030).

The primary driver for increasing UK fish consumption is personal well-being, with 51% of people surveyed stating that health concerns have encouraged them to eat more fish over the last year. However

the report also identified some of the key barriers to current fish consumption levels in the UK, these include a lack of recipe knowledge (35%), lack of availability of fresh fish in local shops (28%) and lack of time to prepare fish from scratch (28%).

Fish is the Dish Seafish, the body which supports the UK seafood industry, has been running a campaign entitled ‘Fish is the Dish’, targeting parents and encouraging them to introduce fish as a main part of their children’s diet. This will make them more likely to continue to eat fish through adulthood, which will be good for their health and the health of the industry.

slower rate than between 2008 and 2010.

The number of sea fish processing units now stands at 325, a decrease of 15% on the 384 units recorded in 2010.

Employment in the industry has also reduced by 17% to 11,864 full-time equivalent (FTE) jobs since 2010.

Supporting the UK Fishing Industry UK Fisheries Minister Richard Benyon has called on the British public to make 2013 the most successful year ever for the UK fishing industry, by making fish a central part of their

The seafood industry was worth £5.6 billion to the UK economy in 2011. The UK imports most of the seafood it consumes. In 2011, a total of 718,000 tonnes of seafood worth £2.55 billion was imported into the UK. This includes Cod, Haddock and other whitefish from Iceland, Norway and Denmark; warmwater Prawns from India and the Far East; Tuna from Mauritius and the Seychelles; and Salmon from Faroe Islands and Norway. The average price of imported seafood increased by 9% from 2010 to 2011.

Indeed, a recent report based on a census of the UK seafood processing industry carried out

by Seafish between March and August 2012, shows that the number of UK sea fish processing units has continued to fall over the last two years, albeit at a

diet.

The Minister is also keen to promote different types of species that are not normally found on dinner plates but are plentiful in the UK’s seas, such as Saithe, Hake, Whiting, Ling and Gurnard that also make excellent meals.

By making different species of fish a key component of people’s diet this will allow British fishermen to target and land these more plentiful species, to discard less fish and for our seas to be managed sustainably.

“Fish not only has many nutritional benefits but also supports many local communities up and down the country,” he says.

“Currently four out of five households eat fish at least once a month – I want to see that increase to twice a week. By trying different types of fish and buying British we can help ensure that this industry can thrive for years to come and boost the economy at the same time.” J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

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National Flexible ‘Wraps Up’ Fairtrade leading manufacturer of chocolate and confectionery for the A UK market has been working with film specialists National Flexible to develop the packaging for a new range of chocolate bars.

Available in selected retail outlets, the bars are flow-wrapped in a premium-effect matt laminate film to enhance shelf-appeal and value to the consumer. National Flexible’s print team were able to minimise the outlay on origination costs for the manufacturer by way of clever work at repro and on-press.

“Our ‘Zero-Zero-One’ approach is different in the packaging industry as it allows us to pipeline bulk quantities of base materials for printing, slitting and lamination,” says National Flexible’s Marketing Manager Andy Smith. “This allows us to offer our customers greater flexibility in terms of cost, lead times and order quantities.”

National Flexible operates from a state-of-the-art facility servicing its customers with flexible packaging in the food, confectionery, bakery, snack, contract packing and pharmaceutical industries. The company has become established at the forefront of quality, procedures and best practice in the packaging industry.

Independently audited, the company has become well-known as the preferred supplier of packaging films to a growing number of high profile UK manufacturers and brands. For further information contact National Flexible on Tel +44 (0)1274 685566 or visit www.nationalflexible.co.uk. J

Packaging Automation’s New Website ackaging Automation has launched a completely redesigned P website (www.pal.co.uk). The site extends PA’s recently launched fresh new image to PA’s internet presence. The website launch coincides with the company’s first communication via Twitter which it is intended will provide a useful source of information to customers and contemporaries in the food and packaging industries worldwide.

Packaging Automation provides innovative filling and tray sealing solutions. Operating from state-of-the-art premises, the business employs 100 people and produces a wide range of equipment from simple manual units and semi-automatics through to in-line fully automated systems. J 12

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

I PACKAGING DESIGN

Win with Eye-Catching Retail Ready Packaging ompetition on the shelf has never C been so intense, says DS Smith Packaging - the company which ser-

its primary value is its ability to take out cost and carbon in the supply chain through effective pack design.

Simply, by making better use of space more can be loaded onto pallets, reducing the number of lorries needed for deliveries.

For DS Smith Packaging customers, what happens in store is a big part of the conversation. RRP has to be easy to identify, simple to open, the right size to fit the shelf and help to make replenishment quick to achieve optimum sales rates. Waste reduction and time efficiency in store, says DS Smith Packaging, should not be underestimated.

vices thousands of food and drink customers ranging from large international brands to small businesses.

But a huge advantage in the fight for the attention of the shopper can be delivered through Retail Ready Packaging (RRP).

By complementing the primary and secondary pack to positively influence shoppers at the point of purchase, RRP can ensure that the product is presented in the best possible way in that final contact point.

Visual Disruption The power of RRP is perhaps best described as ‘visual disruption’. Whether reinforcing brand positioning, driving impulse sales, visual disruption in an increasingly confused category or making new promotions succeed; RRP has the power to deliver value from the factory floor to retail store. In short, more sales, lower supply chain costs, efficient packaging operations and less waste.

With its first patent in RRP registered

16 years ago DS Smith Packaging, whose customer portfolio includes the likes of Cadbury, Seven Seas and Nestle, has led the way in RRP from the beginning. The company has become a hub of innovation in the industry with its Impact & Innovation Centre in Ely showcasing

continuing advances in the market in response to trends and customer needs without using any more packaging material than necessary.

Recent examples include Tiltmaster, which displays products on a backwards tilt enhancing visibility on shelf, the ShelfMaster range which can be packed on equipment intended for traditional cases and R-Flute®, a type of corrugated fluting offering an excellent print surface and protective performance in transit. The latter has seen leading FMCG brands experience a significant reduction in handling and storage costs since board thickness is 20 per cent less, resulting in more packaging being able to be delivered per pallet and per vehicle and a need for less warehouse space. Kellogg’s, for example, on just one product line, received 911 fewer pallets of inbound packaging, equating to a massive 24 full loads per year.

Effective Pack Design Effective RRP pack design tackles many themes, among them look and feel, helping shoppers navigate a fixture, controlling colour and identification, using sales space for optimum range, reducing stock outs and driving availability. But for many manufacturers

The Future So, what does the future hold for RRP and DS Smith Packaging? The company envisages enhanced integration between RRP, primary pack design and POS. Early participation in planning and concept work with marketers is crucial in the delivery of well-scheduled and cost effective campaigns that effectively use every aspect of customer promotion.

Investment in innovation will also stay top of the agenda as shopper marketing evolves, says the company, with cost and

carbon reduction a key requirement for all new products.

Increasingly it seems that what used to be the humble brown box has now become part of the brand. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

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I AMBIENT FOODS

Tradition and Ambition at Baxters Food Group Baxters Food Group, one of Scotland’s best known food manufacturers, is making steady progress with its strategic plans to expand in the UK and internationally by focusing on its core strengths. stablished in 1868, the family business spans four generations and has successfully developed one of the UK’s best known food brands, due to the quality of its products based on traditional recipes, such as Baxters Royal Game, Cock-a-leekie and Scotch Broth soups, coupled with the ability to adopt to changing consumer tastes and trends. In addition to soups, the Baxters brand also encompasses jams, marmalades, condiments, chutney and beetroot.

Baxters Food Group recently diversified into canned meat production following the acquisition of Fray Bentos last year for an undisclosed sum, to add another well known UK heritage brand to its portfolio. Fray Bentos produces a range of canned pies and puddings as well as corned beef and meatballs.

Mainly a private label operation, it also makes Jack Daniels sauces, Pizza Express dressings and a variety of other products.

E

Fray Bentos “The Fray Bentos brand is iconic and has a similar history to the Baxters brand and is loved by UK consumers. For a company like Baxters who are comfortable managing iconic brands with long histories, Fray Bentos is a good fit,” points out Bill King, who has been chief executive of Baxters Food Group since 2008, when Audrey Baxter, great granddaughter of the founder and who had headed the company since 1992, became chairman.

“The acquisition has taken us into a category that we have long wanted to enter – canned meat. It gives us a lot of scope to apply our skills and innovation in the category. We are now operating in the UK with another major

Bill King, chief executive of Baxters Food Group.

brand in our portfolio.”

The Baxters brand is well respected in many overseas markets. The company exports about 150 SKUs to 30 different countries and this business represents about 10% of turnover.

Manufacturing Base In addition to a thriving export business, Baxters Food Group has also established food manufacturing operations abroad and now operates fives factories on three continents, having acquired businesses in Canada in 2004 and Australia and Poland, both in 2007.

The main factory and company headquarters are still based in Scotland at Fochabers in Moray. The Fochabers factory, which is the largest industrial site in the north of Scotland, can produce about 300 million cans of soup, 40 million jars of beetroot and up to 10 million jars of jams, marmalades and chutneys a year. The site is also being developed to accommodate Fray Bentos production and will be capable of making 60 million meat pies a year.

The Scottish food company has a second site in Britain, located at Colchester in England. Manufacturing salad dressings and sauces, this small facility has a production capacity of about 20 million bottles a year.

Overseas Operations Baxters Food Group’s Canadian site, based near Montreal, is a canning factory with the capacity to produce 200 million cans of soup a year. It also produces some pouch products for the Canadian Army. Apart from the Baxters brand, the Canadian business incorporates two local brands – Aylmer and Primo – and is also a major private label manufacturer, producing about 80% of the private label soup consumed in Canada. Since its acquisition, turnover has increased from C$16 million to close to C$90 million and now represents about a third of total group turnover.

The factory in Poland, near Poznan, produces pickled onions and has a capacity of 45 million jars a year. Almost all of the site’s output is produced under the Garner’s brand

Baxters Food Group now operates fives factories on three continents.

FOOD & DRINK BUSINESS, NOVEMBER/DECEMBER 2012

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The major launch last year was the Stay Full range of healthy, functional soups designed to satisfy hunger for longer.

and shipped to the UK. In Australia, Baxters Food Group operates a food service facility, just outside Melbourne. This business accounts for about 10% of Baxters Food Group. Indeed, the business in Australia was purchased to allow Baxters Food Group to diversify its core business into food service.

Adjusting to Change Baxters Food Group has developed and adjusted its product range to meet changing customer and consumer demands. “When I joined in 2003, soup and beetroot dominated our portfolio with jams, marmalades and chutneys a poor third. Soup represented about 60% of what we produced, beetroot 30%, and jams, marmalades and chutneys 10%. It was all produced in the UK,” explains Bill King.

He continues: “Now soup globally, which is produced in the UK and Canada, represents about 40% of what we produce, beetroot is about 15%, jams, marmalades, onions etc account for 10% and the balance is made up of the Fray Bentos pie range.”

Financial Performance Despite the tough trading environment characterised by the practice of low margin promotional activity in the UK grocery market, Baxters Food Group has shown resilience in its last reported financial year ended May 28th 2011. Although turnover slipped by 2.5% to £125.8 million, pre-tax profit increased by 6.9% to £7.1 million as the company reported double-digit growth in overseas sales.

“This year both those figures will be up by about 10%,” says Bill King. While much of this increase reflects a contribution from the acquisition of Fray Bentos, “it was also driven by a solid performance in the UK and Canada, which are our two main markets,” he adds.

Guiding Principle Although best known for its branded products, Baxters Food Group is also a private label manufacturer. Private label currently generates about 10% of group turnover.

“When the company was founded back in 1868, the family adopted the strapline - ‘Be different, be better’. Cheesy though it may be, the company has stuck to that over the years.

This is the guiding principle we operate to when we are developing new products or considering moving into new categories. It is also

the rule we apply to our private label business.”

The Baxters Food Group chief executive elaborates: “Our objective is to operate in private label categories at the premium end of the market where Baxters can add value and differentiate out products from competitors because of the taste. We want to protect our operating margins and make it clear to the retail trade that Baxters remains a premium and quality manufacturer, and we don’t play at the low end of the market.”

Innovation A key factor in Baxters Food Group’s longevity has been its ability to adapt to meet changing market demands, while adhering to the company ethos of ‘Be different, be better’.

The current developments in product innovation are being driven by the present consumer preoccupation with taste, health and convenience. “Our ambition is to try and make all our products as close to homemade as we possibly can, in line with our ‘different and better’ philosophy,” Bill King remarks.

The major launch last year was the Stay Full range of healthy, functional soups designed to satisfy hunger for longer. The soups are prepared with a selection of high protein vegetables, meats and pulses, are low in fat, contain less than 300 calories, and have no artificial colours, flavours or preservatives.

“Stay Full has taken off well and will be the first in a range of soups that are all about enhancing people’s diets and addressing some of the health issues as well,” says Bill King.

Baxters plans to launch a range of interesting products next year, centred on the strong health properties of beetroot.

“The other area we are focused on is convenience. We have a range of microwaveable products in bowls and that range will be substantially expanded over the next year or so.”

He adds: “On top of that we have a range of interesting products we are going to launch next year, centred on the strong health properties of beetroot.”

Baxters Food Group also plans to develop the Fray Bentos range over time. “We are obviously starting off with Fray Bentos pies and meat balls but we do intend to expand the range of products and play a much more positive role in the canned meat category, which will complement our activities in the soup category,” he comments.

Audrey Baxter, chairman of Baxters Food Group.

£24 Million Capital Investment Baxters Food Group is currently investing £20 million at its site in Fochabers to accommodate Fray Bentos production. This entails transferring equipment from the original Fray Bentos site in England, introducing new machinery and substantially extending the factory at Fochabers. Integrating Fray Bentos production at the Fochabers site will achieve economies of scale and improve factory efficiencies significantly. Fray Bentos production at Fochaber is scheduled to commence in January 2013.

A further £2 million is being invested this year on upgrading the soup lines at Fochabers. The Canadian operation will also benefit from a £2 million capital investment programme.

Future Development As part of its long-term development plan, Baxters Food Group is aiming to increase turnover to £300 million by 2017. “We are halfway to the target and are quite confident that we will reach the £300 million mark in the next five years. We will achieve this by continuing to expand by acquisition, by expanding geographically and by growing the brands in their core markets.” Bill King concludes. “We have protected the core UK business during the recession by focusing on the quality of our products and maintaining their margins. We have also expanded our private label business into other premium retailers, to consolidate during the period of recession.”

Further acquisitions of complementary food brands in the UK will be considered while private label businesses will be targeted in North America. Baxters Food Group has started to expand into the US where it is importing from both Canada and the UK. The group expects to complete an acquisition in Australia in early 2013 to move into the sauce market. J

FOOD & DRINK BUSINESS, NOVEMBER/DECEMBER 2012

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I BAKERY

The Continuing Rise of Wrights Pies Wrights Pies, the Crewe-based family bakery business, is continuing to develop into a fully fledged food group. stablished in 1926 when Jack Wright and his first wife Lizzie started selling pies to their neighbours, Wrights now employs over 450 people across three production units, a frozen distribution centre, a dry goods warehouse and 18 retail outlets, and has a turnover of about £40 million.

The product range has developed from pies to encompass other savoury products, sandwiches and sweets. Using the combined capabilities of its three manufacturing facilities, Wrights blends traditional cooking methods with the latest manufacturing technology to offer its food service, bakery and retail customers a constantly expanding portfolio of ready meal solutions, as well as party food, snacks, cakes, desserts and traditional pasties and pies.

The company ethos is to ‘Produce Quality Food using the Best Ingredients, The Best Equipment and The Best People’.

Reflecting this approach Wrights uses fresh vegetables delivered every day and focuses on small but important details such as hand crimping its pork pies. Indeed, the founder’s famous Meat and Potato pie still contains the same eleven ingredients as it did in 1926.

“It is all about quality – in raw materials, products and services – and giving people what they want,” says chairman and chief executive, Peter Wright. "That involves second-guessing markets, emerging trends and changing tastes, not just here but in the 26 countries we export to. We are constantly trying to predict, and planning at least two

retail and quality foods. The dry goods warehouse will serve more than 200 food suppliers to the business, handling in the region of 400 tonnes of raw materials each week which are used to produce a range of pies, savouries, confectionary and ready meals across the company’s three manufacturing sites.

E

Wrights is committed to continual investment in the latest food manufacturing technology.

Pictured in the new central distribution warehouse are from left Alison Harding, Wrights retail operations director, Martin Watson, managing director, and Peter Wright, chairman and chief executive.

years ahead, which is increasingly complex as we are now a wide-ranging food group, rather than a company simply making pies.”

Latest Technology Wrights is committed to continual investment in the latest food manufacturing technology. All equipment is manufactured to the company’s exact specifications in order to achieve the consistency and quality of products its customers expect. Indeed, the business holds higher level Grade A BRC accreditation, confirming that its quality and technical systems are cutting edge.

Wrights recently finished a £4 million expansion program which has just seen the completion of the refurbishment of the ready meals production area, within the £20 million Crewe bakery complex that is capable of producing over 5 million savoury products every week. The Wrights facility in Stoke concentrates on the production of sweets.

The enterprising family business also recently opened a new state-of–the-art central distribution warehouse close to Wright’s main food processing factory in Crewe. The £1 million 20,000 sq ft warehouse development features a fully a computerised stock control system and the latest warehouse handling equipment incorporating magnetic guidance sensors for the safe operation of fork lift handling equipment.

The new facility has further improved logistics operations and is designed to support the company’s expansion plans across its three main operating divisions – bakery,

Retail Investment Wrights has also been investing in its retail business across the Potteries and North Staffordshire, under a £1 million refurbishment program. This has entailed the installation of new contemporary fittings and distinctive Wrights orange branding and counter displays.

According to Alison Harding, Wrights retail operations director and the founder’s granddaughter: “Following each branding refurbishment the new look store has recorded an up lift in sales of around 20% and our Potteries shops continue to trade well as we have a loyal following from customers looking for high quality, locally produced products at affordable prices,” Innovation Innovation and creativity have been the foundations upon which the company’s success has been built. The Wrights team of development chefs constantly create new ideas and bespoke products for customers to keep their menus fresh and individual, so maintaining the company’s reputation for innovation, quality, service and competitive pricing which been built up over 80 years.

The new product development team can help customers create, design and deliver bespoke products - whether a brand new concept or an adaptation of an existing range. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

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No matter what we do, we can’t stop thinking about food.

To us, innovative thinking is what makes a leader, not a follower. It’s what drives us to understand our customers and inspire them to create new products.

It’s why every Dawn Farms facility operates a best in class Meat Science & Innovation Centre to develop winning ideas.

It’s another ingredient that sets us apart.

GREAT INGREDIENTS, GREAT FOOD.

Visit www.dawnfarms.ie

I PIZZA

UK Frozen Pizza Market Has Firm Base For Growth The Eur636 million frozen pizza market in the UK is showing resilience despite the challenging economic environment, which is squeezing chilled pizza sales. emand for convenience foods, including pizza, has been increasing due to the rise in the number of single person households. Pizza sales have also benefited from being marketed by food manufacturers and retailers as an alternative meal to dining out during the present recessionary times, which have prompted hard pressed consumers to cut back on trips to restaurants. Efforts by manufacturers to reduce salt and fat levels have also helped to promote a healthier image for pizza.

Despite the uncertain economic climate, the UK pizza market is also characterised by a willingness by consumers to ‘trade up’ to higher quality products like stone baked pizzas. A further new market development is the introduction of ‘stuffed crust’ pizzas.

Another feature of the market has been the growth of ‘thin & crispy’ pizzas, such as Dr Oetker’s Ristorante and Goodfella’s Delicia.

This sector now accounts for about 54% of the UK market with ‘deep pan’ pizza holding a 40% share.

D

Frozen Outperforming Chilled Within the overall UK market, sales of frozen pizza have been growing faster than those of chilled pizza, which have been harder hit by the squeeze on consumer spending. Frozen products now account for over half of total UK pizza retail sales by value.

Frozen pizza manufacturers have revived sales by intensifying new product development activity to offer consumers a wider choice of bases and toppings. Specific consumer groups such as women, children and single person households have also been successfully targeted. Indeed, frozen pizza manufacturers are expected to continue to place an increasing emphasis on quality and value for money to compete against their chilled counterparts European Market In terms of volume consumption, the UK is the second largest pizza market in Europe, behind Germany but ahead of third ranked Spain. Ireland has the highest per capita consumption in Europe, pushing Germany and Belgium into second and third places respectively.

The relative strength of the frozen and

chilled pizza segments varies enormously throughout Continental Europe. In Germany, for instance, frozen pizza is dominant with a market share of about 95%, and likewise in Italy and Ireland where frozen pizza accounts for 85% of total sales in each country. However, in Spain the chilled segment is preeminent with a market share of over 80%.

UK Frozen Pizza Market According to Food For Thought, total demand for UK frozen pizza was Eur636 million in 2011 with the retail market worth Eur560.8 million and food service valued at Eur75.2 million. Expenditure per capita at Eur10.13 has risen by 2.7% in the 2006 to 2011 period.

Unlike the UK chilled pizza market where retailer own label dominates, branded products enjoy the lion’s share (68.7%) of frozen pizza sales.

The three leading players – Oetker, 2 Sisters and Sudzucker – control 72% of the market (see Table). 2 Sisters Food Group is a relative newcomer having only entered the frozen pizza market in 2011 following its £342 million acquisition of Northern Foods, including its Green Isle Foods pizza business.

Food For Thought expects the UK frozen pizza market to have increased in value to Eur666.2 million in 2012 and to reach sales of Eur739 million by 2014. Expenditure per capita is projected to grow by 3.5% during the period 2011-2014. J

Top 10 UK Frozen Pizza Manufacturers By Market Share, 2012 Holding Company

Key Subsidiary

Market Share

by Value

Major Brands

1. Oetker

Oetker

33.0%

American Club, Boboli, Freschetta, Freschetta Bakes & Rises, Gino Ginelli, Marietta, Mighty White, Pizza Restorante, Pizza Wedges, Sombrero, Sunrise Singles, The Chicago Town Pizza, Tony's Pizza

2. 2 Sisters Food Group

Green Isle Foods 28.6%

Deeply Delicious, Delicia, Goodfella's, Goodfella's Deeply Delicious Minis, Goodfella's Friday Fever Square, La Bottega, Ross, San Marco, Solos

3. Sudzucker

Freiberger Lebensmittel

10.5%

Freiberger, Strickler, Tolona

4. McCain Foods

McCain

7.0%

Deep 'n' Delicious Pizza, Five Cheese, Master Pizza, McCain, Meat Supreme, Micro Pizza, Pizza Delivery, Pizza Fingers, Pizza Perfection, Pizza Rolla, Pizza Slices, Rising Crust, World of Pizza

5. Heinz

Heinz

4.0%

Heinz, Weight Watchers

6. Nestle

Crosse & Blackwell

3.0%

Buitoni, Crosse & Blackwell, Lean Cuisine, Shanghai Pizza, Toasties

7. AAC Capital

Perkins Foods

2.0%

North Country Foods

8. Pizza Canadian

Pizza Canadian

2.0%

Abe Lincoln, Pizzaman

9. Tendafrost

Scotfresh

2.0%

Scotfresh

10. Country Style

Country Style

1.0%

Banghan, Campbell's, Fleur de Lys, Tiffany's Upper Crust

Source: Food for Thought (FFT)

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

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I MEAT INGREDIENTS

Dawn Farms Wins Prestigious Export Award awn Farm Foods, the leading European D supplier of cooked and fermented meat ingredients, has won the Food and Drink ‘Exporter of The Year’ Award in Ireland.

The company, based in Naas, County Kildare, supplies cooked ingredients to the food service and manufacturing sectors throughout Europe, exporting more than 80% of its output to 30 countries worldwide.

Larry Murrin, Chief Executive of Dawn Farms, says: “Dawn Farms is heavily export-focussed and prides itself on growth through long term investment and strategic alignment with blue chip international brands in both food service and food manufacturing sectors.”

Dawn Farms submitted a case study highlighting the work of its food innovation service in the development of a new product for one of its global restaurant cus-

22

tomers. Using its stage-gate innovation process NECTAR (Need, Explore, Create, Test, Action, Review), the company identified a shortlist of new products for their lunch menu, leading to a successful new product launch in the UK and Ireland.

“The power of NECTAR lies in identifying and converting marketplace trends into innovative new products which puts Dawn Farms ahead of the competition as a valueadded partner – and keeps our customers on top of their respective categories,” says Larry Murrin.

The company’s trademark NECTAR new product development service operates from its state-of-the-art Science and Innovation Centre in Naas. The 20-strong team of technologists and meat service experts works

in a value-added partnership with customers to develop innovative new products.

The Dawn Farms group of companies includes two stateof-the-art production facilities in Ireland including International Meat Ingredients (IMI), TMI Foods in the UK, producing cooked bacon, protein-based snacks and roasted vegetables and a partnership with Minerva Foods SA in Brazil, the foremost cooked meat ingredients specialist in South America.

The company’s two facilities in Naas employ 450 people and cover a 14,500 sq m area and together have the capacity to produce 75,000 tonnes of cooked meats per annum. It is one of the most modern meat technology operations of any cooked meat factory in the European Union. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

Rademaker Pizza Production Lines – Where Tradition and Innovation Meet ademaker develops and makes the proR duction lines to efficiently produce whatever pizza product customers need.

From Italian-style pizza, American pan pizza to pizza baguette, they can all be made using Rademaker’s high-precision, high-capacity, flexible and hygienic sheeting lines. In addition to the pizza production lines, Rademaker also provides complete system integration solutions that may include mixing, proofing, cooling and baking equipment.

Rademaker has developed two different pizza production lines: a Pizza Base line (with or without proofing) and a Pizza Topping line.

Pizza Base Line

Rademaker’s Pizza Base line is dedicated to the production of exactly those types of pizza crusts customers want to manufacture. In developing a solution, Rademaker will therefore keep customer specifications and requirements in mind. When sheeted pizzas are produced, Rademaker will incorporate either one of their extruders or a low stress pre-sheeting system. When pressed pizzas are required, the line will include a blocking dough forming system. Either way, pizzas in any shape or form can be generated.

Customer Satisfaction is Key

Pizza Topping Systems

Rademaker Pizza Topping solutions are automated systems that can create topped pizza with tomato sauce, vegetables, grated cheese, ham and/or pepperoni cubes, etc. Rademaker has developed two different Pizza Topping systems to top pizzas exactly the way customers want them. Both Topping systems feature a variety of depositors and applicators. The modular design of the lines ensures flexibility and fast product changeovers. With respect to cleaning, maintenance and operation, the Rademaker Pizza Topping systems are designed to meet the latest technical, hygiene and technological standards.

Waterfall Pizza Topping system

The Rademaker Pizza Base line has a working width that varies from 600 to 1.600 mm, with capacities that depend on the product and the thickness of the dough.

The line is designed such that all parts are easily accessible for cleaning purposes and only a minimum of maintenance is required.

Rademaker is able to produce and place a proofer into the Pizza Base line. It can be placed in-line to proof continuous dough sheets prior to the product stamping and/or cutting, it can also proof individual dough products.

The Rademaker Waterfall Pizza Topping system is suitable for pizza topping of various shapes and diameters as well as for pizza-related products like pizza baguettes, pizza sticks etc. High accuracy, high output and flexibility are the characteristics of the Waterfall Pizza Topping system. To achieve maximum efficiency, the system can be equipped with a re-circulation system that feeds both re-circulated Individual Quick Freezing (IQF) materials and fresh materials onto the applicator. An optional weighing conveyor for a controlled infeed of materials ensures that accurate amounts of topping are deposited.

Target Pizza Topping System

With this system pizza bases can be introduced manually or automatically by means of a pizza base dispenser. The system is equipped with target applicators for strewing various ingredients using fixed shaped travelling hoppers set for ‘indexed’ pizza topping systems, leaving the rim of the pizza free of topping.

Rademaker’s technology-driven research has resulted in Pizza lines that are unmatched anywhere in the world. Some of the benefits, the production lines offer include: * High quality at significant capacities: Perfectly controlled dough treatment from the very beginning to the end of the process. Rademaker knows how to shape dough and respect its unique properties.

Capacities depending on the product and dough thickness. * Well-controlled processing: Consistent output and product quality for any type of pizza. Easy operation due to random speed changes that are automatically re-calculated and changed (cascade). Recipe management system. * Flexibility & line-efficiency: Modular design for a wide variety of products, enabling quick and easy change-overs.

Low downtime, high efficiency and high product yields, resulting in a good return on investment (ROI ). * Safety & hygiene: Rademaker production lines are designed using all relevant norms and regulations for safety. The Rademaker Pizza lines are suitable for wet cleaning and build according to CE -regulations. It meets IFS , BRC, and GFSI standards.

Rademaker’s goal is to meet and exceed the latest hygiene and safety standards and provide also on these topics full customer satisfaction. * Customer requirements are met: Rademaker offers technical support. Test facilities are available and custom-built solutions will be developed when necessary

When bakers choose Rademaker as their partner in Pizza production lines, they choose the very best. Rademaker listens to customers, keeps close track of market developments and treasures the feedback of its service engineers. This enables the Research & Development department to develop innovations customers can face the future with. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

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I PIZZA

International Pizza Parade In-house at AliMec izza-makers from across the world P recently visited AliMec’s Italian factory to view the company’s in-house demonstra-

requirements quickly and without the need for operator intervention.

tion of a complete Pizza Topping and Make-Up line.

Designed for 4 rows across of 250mm and 275mm pizzas, this 1200mm line has the capacity to run at 60 rows/minute using the waterfall principle or 25 rows/minute where the application of toppings is targeted.

From the oven, the pizza bases are elevated to a 6 minute ambient spiral cooler and returned, cooled, parallel to the oven and through 2 tomato sauce applicators, a herb cream sauce metering system, two high speed slicers and 2 dispensers for cheese, ham, or vegetables with the option for targeted application border-free or waterfall application. There is an Oregano dispenser followed by a water spraying unit, and a clever row reduction unit prior to entry to a Frigoskandia spiral freezer.

Individual belt weighing systems.

Sauce depositor.

Six minute ambient cooling spiral.

Sales Manager Paolo Regolini and Andrea Roso, son of the founder, on hand to answer questions, were gratified by the perceptive comments from the experts from around the world who quickly identified the innovative design changes which would make life in their factories more productive and more profitable.

When targeting tomato and cream sauces, consistency of weight accuracy is substantially enhanced by multiple pistons each handling only three nozzles, an optimum ratio to guarantee no blockages and perfect weights. Automatic stroke length adjustment programmable through the plc deals with different customers’ weight 24

neered into the line to confirm to a makeup operator whether a product is under weight. The system has all the mechanism overhead to avoid contamination and uses very simple graphics directly over the requisite pizza to show the operator the information required.

The high-speed band slicers can accommodate 2 or 3 pendulums for different numbers of slices per pizzas. A very well directed oil nozzle and air blowing system keeps the pendulum clean of excess material.

The single belt waterfall cheese distributor works over a very small diameter terminal, to eliminate inaccurate feed rates associated with larger diameter terminals.

When used for individually quick frozen ingredients, a heating system prevents frost build-up. The single belt can be removed endless for maintenance within minutes without tools.

Proprietary continuous belt weighing systems from Siemens were cleverly engi-

Cheese applicator and return.

But the two elements winning the greatest praise were the simple row reduction system, 4 rows into 2, and the design of all the product contact conveyor systems. Robust but uncluttered framework with the heavy duty belts supported by a series of serpentine structured 8m diameter stainless steel rods made access for cleaning a priority. Pre-programmed pneumatic cylinders, centrally controlled from the main panel ensured a consistent belt tension throughout the plant, safely released for cleaning and retensioned before the plant is allowed to run again.

This means calm transfer of product from belt to belt with no risk of shaking the expensive ingredients off the pizza base.

The narrow width product reclaim and return conveyors were voted perfection in respect of their ergonomic design and ease of removal for cleaning.

ALIMEC design turn-key installations with all field wiring and cable trays completed before despatch. This ensures a swift installation phase which is amply reflected in ALIMEC’S costing of the line.

Alimec is represented in the UK by Sollich (UK) Ltd Nassington Peterbor ough, telephone 01780 784007 or by email james.bainbridge@sollich.co.uk J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

I LUBRICANTS

New PURITY TM FG Sprays From Petro-Canada Help Plant Managers Protect Hard to Reach Places etro-Canada Lubricants, the makers of P PURITY FG lubricants, have launched a new line of sprays. PURITY FG Sprays provide a solution for lubricating hard to reach areas, allowing food processors to apply the same high standards of food safe, plant tough lubrication throughout their facilities.

These new PURITY FG Sprays were developed to spray as effectively when the container is held upside down as right side up, making application easier and more thorough “With the introduction of sprays to our family of PURITY FG lubricants, we're able to offer manufacturers a full line of food safe, plant tough lubricants to protect their machinery safely and effectively from top to bottom,” says Petro-Canada's Christie Longhurst , Category Manager Food Grade Lubricants.

The PURITY FG Spray line up features three new products: PURITY FG Penetrating Oil, PURITY FG Silicone Spray

and PURITY FG2 with Microl MAX Spray grease. Many of the PURITY FG lubricants start with Petro-Canada’s 99.9% pure base oils and all are specially formulated to deliver industrial strength protection in even the

most severe operating conditions.

Collectively, PURITY FG lubricants provide longer lasting protection, excellent wear performance, and when it comes to greases, high resistance against water washout. And like all PURITY FG lubricants, the new sprays fit perfectly into the HACCP system (Hazard Analysis and Critical Control Point) and GMP plans (Good Manufacturing Practice).

“Employing food grade products like PURITY FG lubricants and sprays across their full facilities provides manufacturers with peace of mind, knowing their equipment is properly protected, and products are safe for consumers,” says Christie Longhurst.

“At the same time this level of protection also helps them to meet or even exceed today’s growing regulatory demands.”

Food manufacturers can get more information about the new PURITY FG Sprays and the full PURITY FG product line at www.purityfg.com. J

I WATER SERVICES

Water Switching the Key to Asset and Environmental Performance, Say ACWA ntil recently only the very largest commercial water users U could switch water supplier. Now with the threshold for switching very substantially reduced the potential market has expanded from just 2,000 to almost 30,000 businesses. For many this new-found ability to choose a single water retailer could bring benefits which extend well beyond billing, as new entrants to the supply market will also offer bundle deals to include comprehensive water management packages.

Leading process water specialists ACWA Services believe that outsourcing the operation and maintenance of their water and wastewater assets makes perfect sense when the potential to deliver improved operational efficiency and environmental per-

formance is factored in.

Bob Hastings of ACWA Services, explains: “We see his as an opportunity to do more of what we Bob Hastings of ACWA Services. are doing directly with customers already. Our cost-effective, optimised technologies can help drive down costs and help commercial customers meet legislative responsibilities.” For further information visit www.acwa.co.uk. J

Innovation to Deliver a ‘Win-Win’ for Business peaking at the Water 2012 conference recently, Severn Trent Costain Managing S Director, Wayne Earp called for a more innovative approach to water and wastewater services for businesses. Stressing the need for added value ‘behind the stop tap’, where the services of traditional water utility companies often terminate, Wayne Earp said, “Companies can save significant amounts by reducing their water footprint, driving down water use with the help of experts who can assess the full cycle and all the opportunities it holds makes very good business and economic sense.”

Mr Earp urged the adoption of a holistic approach to water and wastewater services and praised the benefits of the developing competitive market, noting that businesses increasingly want to outsource their water and wastewater activities to a single, expert provider allowing them to concentrate on their core business, and bringing them cost savings in the process. For further information visit www.severntrentcostain.com. J 26

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

I WATER SERVICES

There is More to Sustainable Operations than being Green ith growing legislation and industry W pressure, the past few years have seen a need for the food and drink industry to become more sustainable and reduce its impact on the environment, particularly in relation to water use and effluent treatment.

Nowadays, the term 'sustainable' is most commonly associated with the environment and despite the high levels of peak rainfall we have seen in the past few months, reducing overall water use remains a priority, particularly as water stress in many areas across Europe becomes a growing concern.

Becoming 'sustainable' is not just about minimising the impact industrial operations have on the environment, it is about improving operational efficiency and cost effectiveness for it to be viable long term.

Ondeo Industrial Solutions, part of

Degremont Industry, operates and maintains process and effluent treatment plants on behalf of its customers throughout the industry. The company understands the pressures its customers are under and how to operate a plant’s water cycle most efficiently and effectively.

Simple operational changes can make a considerable difference to the overall management of an effluent treatment plant.

However, many factors have to be evaluated first including operational changes and financial investment if required.

By understanding your water cycle and making the appropriate improvements, your plant can reap the benefits in relation to operational efficiency, profitability, plant reliability, health & safety performance, water use and overall environmental impact. J

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Eastlink Business Park, Ballysimon Road, Limerick, Ireland T: + 353 61 400035 F: + 353 61 400036 E: info@lmkpkg.ie W: www.limerickpackaging.ie

I TOTAL SOLUTIONS

Shelf Ready Packaging – ‘On Time Everytime’ discount retailers in Ireland.

ackaging is changing because the way P products are displayed on Supermarket shelves is changing rapidly and profoundly.

As a result corrugated packaging has responded to this challenge with the development of Shelf-Ready Packs (SRP’s).

One of the best placed Packaging companies to assist customers in this regard is Limerick Packaging. Renowned for their ‘On Time Everytime’ delivery, they are now a market leading company in the design and supply of Shelf Ready Packs.

Speaking with Mike Boland, Sales Director, you can’t help notice that this whole new concept of packaging is not just embraced by Limerick Packaging, it is being enhanced and driven forward by them. Because of their close association with the UK’s leading packaging manufacturer they are well versed in this type of pack and very well placed to offer a large range of options to any customer seeking SRP’s. In fact they are one of only three companies approved to supply SRP’s to the

Extensive Product Range Looking down the range of products provided by Limerick Packaging it appears as if every eventuality is covered. The lion’s share of what they supply is corrugated boxes in some form, but it doesn’t stop there.

The product range includes: * Corrugated Boxes in regular slotted and die-cut format; 1/3/4/6 point-glued, corrugated sheets, pads and divisions. * Litho-Printed cartons and LithoLaminated outer boxes and trays. * High quality Post-Printed corrugated boxes; * Polythene bags, sleeves, sheets and palet hoods; * Palet-Wrap, Edgeguards, Strapping and accessories, Pallets and Tapes; * Protective Foams, Foam/Corrugated/Wood composite packs; * Labels, Loose-Fill and BubbleFilm.

According to Mike Boland: “Ten years ago if a customer asked for a litho tray glued to a half slotted case and they wanted to use it as a regular slotted case would be used, we would have said it can’t be done. Today, however, we will offer our customers a six colour plus var-

nish litho-printed tray with an automatic crash-lock base, and spot glued to the tray we will have a three colour flexo printed half slotted case, wh›ch our customer will pop up, fill and tape the top in a conventional end-of-line box taper.”

So this pack is easy, fast and economical for the product manufacturer to use, it is easy for supermarket staff to open, shelf and break-down the lid for recycling, and it is easy for the shopper to shop.

Customer-focused Mike Boland continues: “We at Limerick Packaging are at the forefront of Shelf Ready Packaging because we understand what it means to the product manufacturer, the retailer and the shopper. We understand how rapidly a purchasing decision is made by a shopper and so ease

of identification is absolutely essential.

The pack must also make it easy for the shopper to shop and our printing technology and range of substrate materials makes all of these requirements achievable and repeatable.”

As you look across Limerick Packaging’s range of products, it appears their ability to combine Litho-Laminated trays with conventional corrugated box technology is the secret to their success in SRP’s but this is probably too simplistic. The range of SRP boxes they supply can be as simple as a flexo-printed regular slotted case with perforations r›ght up to a two-piece multipoint glued pack where the tray is printed to almost photographic quality.

“Bringing all this technology to the table is very attractive to our customers,” says Mike Boland, “but the comfort of knowing we will consistently deliver quality products, ‘on time everytime’ is what gets us customers for life.” J

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I TOTAL SOLUTIONS

Finis Food Processing Equipment Delivers Complete Projects includes the training of customers’ staff.

“Finis is not just a supplier of peeling machines. Finis ing process solutions, rangis committed to meeting the ing from stand alone changing processing needs machines to complete proof its clients,” points out duction lines, for the international vegetables and fruit Wouter van Raaij. “The industry. emphasis today is on reducSince being founded in ing labour costs, improving 1924, Finis has developed yields and saving costs on peeling and cutting cleaning and maintainance. machines for all kinds of With our new peeling products. The enterprising Complete onion line from storage to packaging capable of producing 60 tons per day. machines and our complete company’s machines are projects expertise we are now used across the full spectrum of the of adjustment possibilities we have raised meeting all these requirements.” international agricultural products industry the bar in potato peeling,” says Wouter van For instance, Finis has just completed a from small family farmers to large industri- Raaij, Marketing and Commerce, Finis. turnkey project entailing the installation of al concerns.

“This fully automatic system, which has a complete production line from storage to low peeling costs and very low maintenance packaging for a major potato processor in Innovation and cleaning costs, can turn rejected pota- the Czech Republic. The new production Finis invests continuously in developing toes into ‘A’ grade potatoes.” line, which incorporates a combination new machines and systems to improve the To complement this, Finis supplies peeler, an optical sorter and a Finis operational efficiency of its customers and extremely accurate potato quartering KGSCH machine, can produce 2.5 tons of the quality of their end products. Recent machines using vision technology and an finished product per hour. Finis was chosen innovations include a new way to peel root audio detection unit to reject stones, lava for the project because of the capabilities of vegetables and a completely automatic rock, wood, glass etc from process flows. its new potato peeler and because the comonion peeling and processing line, using Finis has also developed the world’s first pany’s proposed solution provided other vision technology.

Automatic Orientation System for onions. operational benefits, such as the use of The KGSCH is a world-class continuous The new innovation can feed a peeling line water transport instead of belts to make the peeling machine for potatoes and other without the need for manual labour. The process more hygienic, and also resulted in root vegetables. Due to the machine design, system not only reduces labour costs but an end product with a better appearance. it uses less water and the product’s cell also significant increases yields. The fully structure is kept intact, resulting in an end automatic onion peeling machine can ori- Family Company product with a longer shelf life and a hand entate 8 onions in less then 1.5 seconds and Finis is still a family-owned and run compeeled look. It is perfect for any fresh peel- has a total peeling capacity of 12,000 pany. Current director Ton van Raaij is the ing process and an extremely useful addi- onions per hour. grandson of the company founder and he tion to any high volume steam peeling line has now been joined in the business by his as a reject peeler where it has been proven Complete Turnkey Projects sons, Wouter van Raaij and Bastiaan van to provide major yield advantages in the In addition to developing new machines, Raaij, one involved in marketing and comFinis is also an acknowledged worldwide merce and the other in engineering and process.

The Finis developed special potato peeler leader in providing complete end to end development.

As a family business Finis believes in for the rejects of steam peeled potatoes has processing projects. Using Computer Aided now been installed by the world’s leading Design (CAD), Finis is able to visualise and mutual co-operation and good communicaFrench fries producers. “With a large range deliver bespoke solutions. Through its part- tions with both staff and customers. With nerships with other world renowned the fourth generation of the family now machine manufacturers, Finis can draw on involved in the business, Finis remains its considerable expertise to provide committed to providing its clients with turnkey projects designed to meet the spe- outstanding equipment to support them in cific needs of clients creating added value in food processing.

The scale of projects handled range in “We are a real family company. Trust, capacity from a few hundred Kg to more experience and honesty is important for us than a hundred tons per day. Finis takes and that is how we build our relationships care of the entire planning, execution, with our customers,” says Wouter van installation and commissioning and this Raaij. J

etherlands-based Finis N Food Processing Equipment specialises in engineer-

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MATERIALS HANDLING

I

TOTAL SOLUTIONS

Schenck Process – The Global Expert in Materials Handling nown globally for the quality of its K products and capabilities, Schenck Process provides food manufacturers with total engineering solutions in the areas of bulk materials handling, feeding, weighing, conveying and filtration.

Schenck Process’ client list includes blue chip companies across most sectors of the international food and drink industry. The Schenck Process name is synonymous with expertise in the fields of weighing and feeding technology but the group is similarly well regarded in the areas of mechanical handling with the Redler brand and pneumatic conveying and filtration with the Clyde Process range of products.

Schenck Process’ expertise and systems also extend within the food processing plant with its core range of feeding and weighing systems, such as mass flow meters, belt weighers, and gravimetric and volumetric screw feeders – all controlled by its cutting edge software solutions.

Since acquiring Clyde Process (including Clyde Materials Handling and Mac Process) in 2011, the equipment range has been extended to encompass pneumatic conveying including dense phase conveying, lean phase conveying along with modular short range vacuum conveying systems.

This technology is supported by a wide range of filtration products for process equipment and to meet environmental requirements.

Schenck Process Pneumatic conveying system.

In addition the Redler range incorporates chain conveyors, chain and bucket elevators and other equipment necessary for high volume bulk material handling of products such as grain and malt.

“We offer the complete package of services including design, build, installation, commissioning and then look after the plants for their life cycles. We are a very experienced company, which has the scale and provides security of long term supply and ongoing aftercare of the products on

site. It is all about providing an overall package,” explains Martin Thomson, Director of Light Industries, Schenck Process’ international business segment that specialises in the food industry.

Scope of Supply Schenck Process undertakes food industry work ranging in value from around £100,000 to multi-million pound projects.

For example, it is currently involved in a large bulk materials handling projects for State-owned flour and grain terminals in the Middle East and also currently installing a big bag discharging system for a chocolate crumb manufacturer in Europe.

“As a company, we try to own the key process steps. So rather than being an integrator, like many suppliers in the food industry who integrate other people’s equipment, we look to own the key critical process steps,” says Martin Thomson.

“There are not many players in our industry with both mechanical conveying and pneumatic conveying technologies to the depth that we have. We are able to handle a wide variety of raw and processed materials using mechanical or pneumatic conveying methods or a combination of both, depending upon the application. Therefore, we can act as an ‘ombudsman’ for clients to advise on the most suitable system for their requirements.”

He adds: “The other factor that distinguishes us from rivals is our global footprint. We have 33 locations across the globe and it allows us to have competence locally to each project.” Schenck Process’ ethos is to ‘think globally and act locally’.

Global Footprint With its global footprint Schenck Process is well placed to cater for the trend by large multinational clients to establish centralised engineering technology hubs to oversee new plant and process development throughout their worldwide operations.

Indeed, its expertise and track record of delivering customer satisfaction ensures repeat business and Schenck Process has built its business on establishing long standing relationships with its clients.

“We can draw on the expertise from the full Group to solve specific problems for clients. We can take a solution that has been developed and used in America and apply it in Germany, for example. We are very customer specific but can call on capa-

Schenck Process MCF Air Filtration unit.

bilities that many competitors would not have access to,” points out Paul Markwell, Marketing Manager of Schenck Process UK. Innovation Schenck Process is committed to continual investment in innovate R&D. One of the Group’s major breakthroughs in the food industry has entailed the development of a dense phase pneumatic conveying solution for moving sugar over long distances whilst still maintaining the crystal shine. The Schenck Process pneumatic conveying system also offers health and safety benefits over traditional mechanical handling methods by eliminating dust in the work environment and with it, the associated risks.

Schenck Process is currently upgrading its filtration range, originally developed by Mac Process in the US, and adapting it for the European market which will be CE and ATEX compliant. This product development process, which will result in lower running costs and easier maintenance for customers, is expected to be completed in January 2013.

“Customers are looking to the longer term and investing in systems that will last, have low maintenance and will help reduce future operating costs. So it is not just capital cost but the lifecycle cost that is important,” says Martin Thomson. J

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MATERIALS HANDLING

I CONVEYORS, BELTS & HOSES

Steel Belt Cooling, Conveying and Bake Oven Belts andvik Process Systems is a company S whose relationship with the bakery, confectionery and ingredients industries stretches almost 90 years. Its core products are found at the heart of process systems in operations the world over and its name is synonymous with systems of the highest quality.

Sandvik is the company behind the solid steel conveyor belt, a deceptively simple but highly engineered component that enables efficient, continuous production of literally thousands of different food products every day.

A steel belt is prepared for delivery at Sandvik’s headquarters in Sandviken, Sweden.

The steel belt – carbon or stainless, depending on the application – is an extraordinarily versatile conveying medium, being employed in freezer tunnels, cooling/solidification lines, ambient conveying systems, dryers and bake ovens.

This ability to maintain its inherent strength and flexibility through years of operation, often involving constantly changing temperatures, is one of the main reasons behind its widespread adoption across so many different areas of the food industry, but another key factor is its ease of cleaning.

The flat surface of a steel belt means there are no joints or crevices in which germs can hide and this in itself makes a steel belt more

Ease of cleaning and sanitizing makes steel belts ideal for hygiene-critical conveying operations.

hygienic than other transportation media.

And the durability and inertness of steel means it can be subjected to any method of cleaning – steam, pressure, detergents, brushes, chemicals, even aggressive scrapers – to ensure the lowest levels bacteria.

This ease of cleaning brings with it other benefits, not least being lower costs due to reductions in water consumption, cleaning materials, and cleaning time.

Innovative Cleaning Solution Sandvik has just launched an innovative new cleaning system of its own, the Quick Cleaner. While specifically developed for removing the carbon residues that build up on bake oven belts, it can actually be used on any belt: solid, perforated or wire mesh.

The cleaning medium, a combination of sodium bicarbonate and calcium phosphate, is blasted at high pressure onto the belt surface, removing the bulk of the residue without damaging the steel. The chemical action then attacks the organic residues at a molecular level, further enhancing the cleaning process.

“The result is a clean, completely degreased belt,” explains Fabio Conti, Global Products Manger, Food. “It’s a dry process, so there’s no risk of rust, no need for waste water treatment and significantly lower energy consumption than other cleaning methods.”

Wide-ranging Applications Bake oven belts represent a major market for Sandvik, and is an area in which market changes in the emerging nations – in particular the BRIC (Brazil, Russia, India, China) nations – are driving more bakeries to upgrade to solid steel belts.

This is partly to do with increased affluence; higher disposable incomes mean people are buying snack products in greater volumes, leading bakeries to look at moving from batch production to more efficient continuous baking.

But the shift to steel belts is also being driven by changing market tastes and an increasingly global appetite for Americanstyle cookies. As these products use real butter, and often chocolate chips too, they need to be baked on a solid belt to eliminate the risk of melted product dripping a causing a fire, or simply drying out.

“A solid steel belt provides the perfect base for this kind of product,” explains Conti. “It also stays flat, keeps its shape and offers

Bake oven belts have been providing reliable service in continuously operating bake ovens since 1925.

excellent thermal conductivity.”

These qualities bring unparalleled versatility in terms of the products that can be baked on one line: brownies, pastries, pizza bases, bread, cookies, granola, meringues, patisserie and sponge cakes are all produced on Sandvik’s solid or perforated steel belts.

Controlled Cooling and Solidification Cooling is another major application, and one in which Sandvik can supply not only the steel belts but also feeding, cooling and associated control equipment. These systems are widely used for solidification, with applications including chocolate, sugar mass, caramel, gelatine, hard melt candy, nougat, nut brittle and more.

The company also manufactures the Rotoform FD, a steel belt-based granulator used for the pastillation of a wide range of food products including chocolate, emulsifiers and fats.

For many though, the main application is straightforward conveying of products like sugar and cocoa mass, and Sandvik can supply conveyors for existing systems, steel belts for OEMs, or complete installations including drums, supports, tracking controls and cleaners/scrapers. J

Continuous production of solid chocolate pastilles on the Rotoform system.

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MATERIALS HANDLING

I

CONVEYORS, BELTS & HOSES

Realising Cost Savings With Gates Solutions orldwide engineering group Gates is W meeting the needs of food manufacturers by offering a variety of products, including V-belts, synchronous belts and hydraulic hose assemblies and industrial hoses, for use across a wide range of applications. However, all Gates products have one thing in common – they solve a wide range of problems to help customers meet production and efficiency goals and save money.

Gates engineers have first-hand experience of the daily impact on food production lines of product contaminations, regular wash-downs, extreme temperature operations, emergency maintenance stops, etc.

They know that, when these conditions cause equipment to halt operations, literally every minute of downtime costs huge amounts in lost production. This experience has lead Gates to develop a product range that perfectly meets the challenging operating conditions of the food manufacturing industry.

Green Approach Furthermore, Gates is also committed to reducing its ecological footprint and driving

down energy use and cutting waste. It is helping its customers do the same by supplying products which help to improve energy efficiency and provide a long, reliable and trouble-free service life. By opting for Gates, customers can not only generate a return that positively impacts their bottom line but also enhance their reputation as a sustainable company.

Gates has developed solutions to the key challenges facing food manufacturers – hygiene, extreme temperatures, production continuity and energy conservation.

Hygiene Cleanliness and hygiene to eliminate product contaminations is vital to food manufacturing operations, yet it adds no value to the product. This paradox poses a challenge for management. To remain competitive, plants must operate with maximum efficiency, eliminating downtime whenever and wherever possible.

It goes without saying that manufacturers can extend the period between clean-ups and minimise downtime more easily when their equipment is easy to clean and maintain to begin with. Gates offers products that are compatible with wash-down environments and are low maintenance.

Extreme Temperatures Temperature has a big influence on the life span of machinery components, especially in very hot or very cold environments which are typical of food manufacturing processes.

When machines operate at extreme temperatures, users are often willing to accept decreased component performance. This is unfortunate considering that, with the right product, you do not have to compromise on performance. Gates offers products that provide superb resistance to heat and cold.

Production Continuity Every minute of downtime is directly reflected in a manufacturer’s bottom line. Getting the production system up and running again increases the costs through time consuming interventions of expensive maintenance staff.

A smart investment is an investment in products with longevity. Gates products provide a long, reliable and trouble-free service life with significantly reduced downtime and virtually no maintenance.

Energy Conservation Manufacturing companies in Europe spend

billions of euros on the electricity powering their production system. Many of these are not running at optimum efficiency, and loss of power is a loss of money.

Simple steps can lead to significant waste reduction. Improving durability, eg extending every component’s useful life, reduces waste, and that is exactly where Gates’ long-life products come into the picture.

Adding Value When rising energy costs, high maintenance or frequent replacement of components becomes the norm, it is time to reassess your production system. Gates high-quality products, industry-leading technologies and unmatched support have been developed to meet all the needs of the food industry.

According to Gates, food manufacturers should consider not only the purchase price, but also the total cost of ownership and satisfaction rate when selecting new equipment and products. A system that minimises maintenance and replacement of components and maximises energy efficiency will not only save money in the long run, but also increase uptime, productivity and sustainability.

For further information e-mail inforequest@gates.com or visit www.gates.com/ europe. J

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I

CONFECTIONERY & SNACKS

ProSweets Cologne 2013 – 27th-30th January, 2013 Taking place from 27th to 30th January 2013 in the Cologne exhibition centre, ProSweets Cologne 2013 will offer an overview of the technologies and procedures for the production and processing of confectionery products and snack items

F

rom raw materials/ingredients to process technology and packaging – ProSweets Cologne 2013 will cover the entire supply spectrum of the confectionery industry under one roof.

Secondary sectors – such as factory and auxiliary equipment, refrigeration and air conditioning technology, and fields such as food safety and quality management – will also be represented.

ProSweets Cologne will take place for the sixth time, in parallel with ISM, the International Sweets and Biscuits Fair.

Approximately 350 exhibitors from around 30 countries will present their goods and services in the Cologne exhibition centre.

The entire supplier product range for the manufacture, processing and packaging of confectionery and snack items will be on display, and solutions for the challenges faced at different stages of production will be presented.

Supporting Programme A supporting programme that includes a wide range of themes will complement ProSweets Cologne in January 2013.

Featured events will include the Robotik Pack-Line special show, the ideas workshop ‘Futurelab 2013’ that is open to the public, DLG sensor seminars, an expert presentation about the US confectionery market and the 3rd ProSweets Cologne Conference on Ingredients. The wide range of content will enrich and enhance the information available at the trade fair.

‘Futurelab 2013’ will take place each day of the fair in the centre of the ProSweets

Cologne exhibition space (Hall 10.1, Stand H 080 / J 089).

The Robotik Pack-Line will also be located in Hall 10.1. A fully automated snackpackaging line will provide exhibitors and visitors with a close up look at robotics and automation in action. This event will be presented in cooperation with K-Robotix (Hall 10.1, Stand F 090 / G 090).

As a supplement to the Robotik PackLine, a presentation on the theme "Robots in the confectionery industry" will take place on Tuesday, 29th January 2013 at 10:30 a.m. The presentation is being organised in c-ooperation with the DLG German Agricultural Society (Hall 10.1, Stand B 070 / C 079).

The DLG will also organise two sensor seminars on Monday, 28th January 2013.

These seminars will provide information about sensory methods and their application. (10:30 a.m. and 2:00 p.m., Hall 10.1, Stand B 070 / C 079).

The ProSweets Cologne Conference on Ingredients will take place for the third time at the upcoming fair. This renowned specialised event on ingredients in confectionery and snack items will be presented in co-operation with Herbertz Dairy Food Service. This year, the conference will have the subtitle "Market developments for ingredients in the confectionery industry will the markets be served with adequate quantities and reasonable prices in 2013?"

The conference will take place on Tuesday, 29th January 2013 from 1:00 pm to 5:00 pm in the Congress Centre East,

Congresssaal room, section 1. The conference will be held in English and there is a fee for participation.

"The US American market for suppliers to the confectionery industry. Introduction and market entry strategies for manufacturers from abroad." is the title of a lecture that will be presented in cooperation with the American trade publisher MC (Manufacturing Confectioner / Candy Buyers Directory) on Tuesday, 29th January 2013, (2:00 p.m., Hall 10.1, Stand B 070 / C 079).

For further information visit www. prosweets-cologne.com. J

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Cola CREATE™ by Tate & Lyle – 50% Sugar Reduction With Stevia Sweetener ate & Lyle has achieved that longT awaited beverage – a fizzy cola drink delivering a 50% calorie reduction with a natural origin sweetener, and that’s just as acceptable as a fullsugar one. It’s all thanks to its key ingredient, TASTEVA™ Stevia Sweetener, developed by Tate & Lyle as a great-tasting sweetener from natural origins with zero-calorie in use.

With it, manufacturers can achieve a 50% sugar reduction in products that still taste ‘right’ to consumers – without any of the bitter/liquorice aftertaste that usually occurs when stevia is used at such a high level.

Replacing sugar is particularly difficult in cola drinks, due to the complex balance of flavours that the consumer enjoys and

expects. Natural origin sweeteners have a strong appeal with consumers, but the challenge for manufacturers today is to maintain the taste experience. Tate & Lyle

has brought its ingredients, formulation, consumer and sensory expertise to bear in designing Cola CREATE™ specifically to overcome this challenge.

With its taste profile close to that of sugar, Cola CREATE™ gives manufacturers new opportunities to create cola drinks that offer a great taste experience with fewer calories, and using a natural-origin sweetener too.

Cola CREATE™ is just one of many ready-to-use recipes incorporating TASTEVA™ Stevia Sweetener from Tate & Lyle – all designed to make food and beverage product formulation easy and cost effective for manufacturers. J

Pecan Deluxe Inclusions Inspiring European Ice Cream Diversity ith ice cream sales in the UK topping W the magical £1 billion mark last year, a leading global inclusions supplier is helping fuel the growing demand for this still affordable treat by expanding its portfolio of innovative and delicious products.

Pecan Deluxe Candy (Europe) has invested heavily to help ice cream manufacturers introduce new flavours that are keeping this most popular of desserts so appealing to consumers, whether it comes in containers, on a stick, in old-fashioned tubs, the traditional cone or even as a cake.

Supplying an impressive European customer list of leading quick service restaurants and large numbers of well-known high street brands, Pecan Deluxe is renowned for producing innovative ingredients, tailored specifically for different tastes, which can add value and indulgence to any ice cream of soft serve product. Inspired by different flavours and textures from all over the world, Pecan Deluxe has taken bold concepts such as American cookie dough and pie chips, plus the increasingly popular soft extrusion products, which offer soft textures at low temperatures and great flavour release.

The UK-based operation of the family40

owned Dallas business has recently invested over £200,000 on new equipment and additional space at its manufacturing facility in Sherburn-In-Elmet, near Leeds, as a direct response to the increasing demand for the company’s indulgent food inclusions for ice cream and other sectors such as bakery, confectionery and beverages.

This added capacity will also provide the company with capabilities for further new product development for the ice-cream sector and reinforce its position at the forefront of a highly competitive European inclusions market.

Pecan Deluxe first made its mark in Europe with its authentic praline pecans, which were produced using artisan methods of sugar coating pecan nuts in large copper pans. The types of praline that are now created include almonds, hazelnuts, coconut, and cashew nuts, for applications such as ice cream sprinkles and nut clusters. Developing new product concepts in keeping with different trends and tailoring

flavours to match European palates have been key to the success of expanding the global popularity of Pecan Deluxe’s American favourites like its authentic tasting, gooey chocolate brownie inclusions.

The company now has a product portfolio of over 250 inclusions and plans to continue upgrading and expanding to offer customers more choice, more innovation and an all-round tailored service.

For more information please contact Pecan Deluxe direct on +44 (0)1977 681141. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

The Cargill Cocoa Promise Strengthens Commitment to Sustainable Cocoa and Support For Farmers and Communities argill has strengthened its global comC mitment to cocoa farmers and to building a sustainable cocoa sector through the Cargill Cocoa Promise. The commitment builds on the company’s work over the past 10 years and reconfirms Cargill’s efforts to grow and sustain cocoa farming communities while meeting the growing global demand for sustainable cocoa beans. The reinforcement of Cargill’s commitment was made at the World Cocoa Conference in Abidjan, Cote d'Ivoire.

The Cargill Cocoa Promise reinforces the company’s global commitment to making a difference in three key areas: training cocoa farmers; supporting cocoa farming communities; and investing in the long-term sustainable production of cocoa.

“The Cargill Cocoa Promise underlines our commitment to lead efforts on sustainable cocoa and support the future of cocoa farming around the world,” says Jos De

Loor, President of Cargill’s cocoa and chocolate business. “We have been working closely with cocoa farmers and communities for many years. Our Promise will help strengthen cocoa production – while continuing to improve the livelihoods of farmers, increasing access to education and healthcare in local communities, and providing better access to technology, finance and infrastructure.”

The Cargill Cocoa Promise will reinforce the company’s long-term work – by continuing to partner with local governments, non-governmental organizations (NGOs) and the private sector – to provide farmer training, work in partnership with farmer organizations and positively contribute to local cocoa farming communities.

The program will see Cargill continue to invest and provide financing, training and support to maintain and strengthen a sustainable cocoa supply chain in Cote

d'Ivoire, Ghana, Cameroon, Vietnam, Indonesia and Brazil. Already Cargill is on target to source over 100,000 tonnes of certified sustainable cocoa beans from Cote d’Ivoire by 2015 – making its program the largest of its kind in the country. J

Tate & Lyle’s SODA-LO Salt Microspheres Named ‘Most Innovative Health Ingredient of the Year’

John Stewart, Open Innovation Manager, Tate & Lyle, and Andy Hoffman, Director of Health and Wellness Innovation, Tate & Lyle.

ate & Lyle’s ground-breaking, new T salt-reduction ingredient, SODALO™ Salt Microspheres, was recognized as the "Heart Health and Circulatory Innovation of the Year" and as the over-

all "Most Innovative Health Ingredient of the Year" from the NuW Excellence Awards, which recognise individuals and business for their exemplary work and contribution to the industry.

SODA-LO™ Salt Microspheres is a salt reduction ingredient that tastes, labels and functions like salt because it is salt. SODA-LO™ Salt Microspheres reduces salt levels by 25 to 50 percent in various applications including baked goods and salty snacks. SODA-LO™ Salt Microspheres has been created using a patent-pending technology that turns standard salt crystals into free-flowing crystalline microspheres. These smaller, lower-density crystals efficiently deliver salty taste by maximizing surface area relative to volume.

"The development of SODA-LO™ Salt Microspheres is a true case study in innovation helping to overcome a challenge – in this case reducing salt while maintaining taste – and we couldn’t be happier with the results and the commendation from NuW Excellence Awards," says Andy Hoffman, Director of Health and Wellness Innovation, Tate & Lyle. J

Muhlenchemie Optimises Pasta Production olatile prices and limited supplies of V durum wheat (triticum durum) make life difficult for manufacturers aiming to produce top quality pasta. The new Pastazym Plus combination of enzymes and active ingredients from flour improver specialist Mühlenchemie enhances the quality of pasta made from both hard and soft wheat. This produces appreciable cost savings and makes manufacturers less vulnerable to commodity market swings.

The multifunctional enzyme compound also has the advantage of making the surface of the dried pasta look better and giving it greater mechanical stability. If permitted in the country of destination, colourants and vitamins can be added to the compounds. They can be added safely to the dough in one single, easy operation to produce, for example, a rich yellow shade. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

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Experience the world’s finest Smoke Flavors Grill Flavors Roasted Flavors Browning Made in U.S.A.

EMAIL: international@redarrowusa.com

WEB: www.redarrowinternational.com

I SMOKE, BROWNING & GRILL FLAVOURS

Red Arrow Hits the Target With Innovative Flavour Systems aving pioneered the development and appliH cation of smoke condensates to smoke meat, fish and cheese as well as add flavour to food products, US-based Red Arrow has also become an expert in the development of other savoury flavour systems and browning agents.

Red Arrow’s savoury solutions are not only authentic and healthier for the end consumer but they also provide major benefits for food manufacturers including shorter processing time, increased yields, reduced environmental impact, greater food safety and higher consistency in the final food product.

Red Arrow has been developing products specifically designed to address needs within the meat and food industry for smoke flavorings since the early 1960s, using its Condensed Natural Smoke™ technology, a process developed and patented by Dr Clifford Hollenbeck.

Smoke condensates are now in widespread use globally as flavours and also as a replacement for traditional smoking processes. Used purely as a flavour, smoke condensates are a key ingredient in the production of savoury snacks such as potato chips (crisps), smoked almonds and corn chips, and are also used to add flavour to BBQ sauces, soups and spice blends for grilling.

Smokey BBQ Sauce.

“When using smoke condensates to replace traditional wood smoking techniques, manufacturers gain the consistency, high quality and economic advantages they need to stay competitive,” points out Christopher Gutman, Managing Director of Red Arrow International.

“Over recent years, an additional benefit of smoke condensates, which has become key to both the manufacturer and consumer, is an 80% reduction in CO2 emissions and other pollutants compared to traditional wood smoking processes.”

Innovative Product Portfolio To supplement its Condensed Natural

Roasted Beef Flavor RA07032.

Smoke™ techniques, Red Arrow has also developed its Cooking Method Flavors range that emulates popular cooking methods such as those created during the roasting, frying, sautéing and grilling processes. In addition to its authentic food flavours, Red Arrow also offers browning agents and innovative application technologies.

Red Arrow adopts a scientific approach to providing natural, authentic flavour solutions.

The innovative company is constantly searching for ways to provide superior product offerings to food processors so that they can, in turn, enhance the eating experience for the consumer.

“Red Arrow has been the leader in the smoke condensate market for over 50 years. By constantly looking for new manufacturing processes, new wood species and developing top notch equipment for the application of our products in the meat industry, we continue to provide the industry with the solutions they need to be quality driven and cutting edge,” says Christopher Gutman. “Over time, Red Arrow has learned from our customer base that every region of the world has its own special smoke colour, flavour and aroma. We have spent the time and research funds to develop smoke condensates, grill flavours and browning agents to meet those unique needs.”

Strong European Presence Red Arrow has established a strong presence in Europe. The company has a highly trained distributor network throughout the world and excellent representation in every European market. More than 20 full-time Red Arrow staff are located in Europe.

Furthermore, at Red Arrow’s US headquarters, two employees focus specifically on EU regulatory compliance and three other staff members dedicate their time to research/development and technical fieldwork in Europe to help customers find smoke, grill and browning solutions which will make them successful in the

very competitive and ever changing European marketplace.

Red Arrow has also spent years developing relationships with Universities, Food and Drink Associations and food equipment manufacturers in Europe. “These relationships and partnerships are a great resource for our customer base which can help them generate new ideas or find solutions to current challenges whether those challenges are in thermal processing, flavours, equipment sourcing, marketing or even regulatory,” he adds.

Savoury Solutions “We have spent a lot of time over the past few years working on supplementing our flavour offerings. Besides the vast array of smoke condensates made from wood sources such as hickory, oak, maple, we are now offering a group of complementary flavours such as Chipotle, Fire Roast Vegetable, Fried Poultry, Caramelized Onion and Prime Rib Beef. Many of the companies we partner with produce a wide variety of food products and by offering other flavours we can help them expand or improve their product lines,” says Christopher Gutman.

For instance, Red Arrow is currently working closely with some major meat processors in Europe on the development of cold smoking techniques. Until now, cold smoking has proved challenging for both traditional and smoke condensate smoking. “Working in conjunction with one of our equipment partners, we have developed a new cold smoking system which uses a combination of Red Arrow smoke condensates to help prevent the development of yeast and mold - a common issue in cold smoking - to develop a traditional smoke colour and aroma and also reduce CO2 emissions and clean-up by over 80%,” he explains. J

Red Arrow Smoked Mackerel.

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

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I FRUIT CONCENTRATES

Iprona - The Fruit Company rmed with its state-of-art-factory, A Italian fruit processor Iprona has built an international reputation for the quality of the concentrates and other products its supplies to food and beverage manufacturers globally.

Iprona supplies fruit concentrates to producers of juices and other beverages, jams, confectionery, liqueur, food supplements, milk products and many others. The produce range covers more than forty different types of fruit concentrates, pulp concentrates, puree concentrates of berries and tropical fruits and natural colourings (especially from Elderberries) as well as clientspecific fruit mixes. Iprona has recently added extra capacity to create juice compounds – offering an all-in-one-solution to the complexity required by the beverage industry.

Iprona’s best know product is Rubini®, a natural fruit concentrate of an intense red colour, produced by special processes. Its is especially used to colour foodstuffs such as fruit sauces, ice cream, yoghurt, liqueurs, beverages and confectionery.

Iprona is strategically located to avail of a secure supply of top quality raw materials for processing. The company’s headquarters and factory are based in Lana in the heart of the South Tyrolean Mountains and one of the largest fruit-growing areas in Europe.

Established in 1981 as a joint venture between Henkel and Dragoco Gerberding, Iprona is now a privately owned business.

Fruit Concentrates Iprona’s corporate philosophy is to preserve the natural quality of the fruit. In the production of its concentrates, Iprona extracts the natural water content of the fruit juice

Iprona’s headquarters and factory in Lana.

through vaporisation or freezing. The Brix content of the concentrate varies according to the quantity to be extracted.

“Fruits are very delicate raw materials and we continually strive to preserve their aroma and natural colour by using gentle methods of transformation. The quality of the fruit, which means a lot to us, is preserved and guaranteed by our use of innovative processing methods and the continuous improvement of our production processes,” says Lutz Philipp, chief executive of Iprona.

Iprona’s fruit concentrates are used in the beverage and tea industry for juices, fruit juice beverages, nectars, ice tea, and as additives in alcoholic drinks. Within the confectionery and baking industry, Iprona’s products are used in the production of sweets, fruit jellies, chewing sweets and fillings, and in the dairy and ice cream industry for fruit preparations, icings and desserts.

According to Iprona, its innovative freeze concentration process is unique within the world of fruit juice concentrates. The selective water removal at freezing temperature ensures that all the original flavour, aroma and fruit components are preserved, allowing reconstituted juices from freeze concentrates to compete with ‘not from concentrate’ juices on a sensory basis.

The resulting high quality concentrate can be used for premium end-products, and processors can also benefit from reductions in transport and storage costs.

of new technologies, constant and intense research and development along with the continuous improvement to its production processes.

Following intensive R&D, Iprona has recently extended its portfolio into a new product category. The company is now offering its customers natural aromas from certain fruits. The following flavours are available Strawberry, Blackberry, Blueberry and Plum.

Extracts Working through its BerryPharma division, Iprona also markets functional and nutritional Polyphenol extracts to the food, nutritional, cosmetic and pharmaceutical industry. Iprona develops liquid and powdered Polyphenol products made from red berries, such as Elderberry, Blackcurrant, Bilberry, Chokeberry (Aronia), and Cranberry. The products are standardized to active analytical parameters.

Iprona specialises in the production of Polyphenol products without chemical extraction as well as high grade ethanol extracts. The company works closely with its own growers to ensure the highest quality raw materials in its supply chain. J

Recipe For Success Iprona’s international success has been built on the excellent quality of its products, the experience and expertise of its staff, the use

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

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I CASE STUDY

From Consulting to Realisation – Process Plant For Fruit Concentrates

By Bernhard Scheller, Managing Partner, Ruland Engineering & Consulting or IPRONA AG, RULAND Engineering & Consulting GmbH completed in two steps the equipping of a newly built facility with process plants for fruit processing and refinement.

To find out which course of action would be best for equipping their new production facility, IPRONA decided on a consulting process with a concept phase and a second detailed engineering phase.

RULAND started by recording the current methods of production and generated a block diagram which shows the complete flow of materials, from raw goods reception/storage up to the production lines for the finished products. The immense knowledge of the staff was used to discuss details and concepts.

Based on the block diagram, RULAND developed each area into a PI diagram.

Different automation concepts were elaborated and decided on. To avoid collisions of the pipeline routes, a basic 2D piping alignment planning for all media was included.

F

Bernhard Scheller, Managing Partner of Ruland Engineering & Consulting.

The mother-juice can be concentrated in two different plants: a thermal concentration plant and a cold concentration plant.

At the finished product lines, the main products like pulp-, puree- and juice concentrates, with or without fruit pieces and components, can be mixed according to individual customer wishes in mixing tanks of varying size, pasteurised in diverse heat exchangers and filled aseptically.

Project Realisation

Production Process

IPRONA processes varied fresh fruits as well as frozen fruits, which are processed to ‘mother-juice’. The fruits are pressed and treated to clear or naturally cloudy juices, before they are short-term heated and stored in sterile tanks.

Mixing tank group.

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single batch, switching to another filling system can be done simply.

For the cleaning of the production plants, RULAND built two central CIP plants. Finished product lines and juice generation are strictly separated, carryover is eliminated. The complete 13 cleaning circuits were distributed in such a way, that overlap in the individual areas was minimised and production efficiency maximised.

In addition, RULAND implemented a concept to use energy from water vapours from the thermal concentrate plant.

To control the complex processes the Siemens system PCS7 is used and combined with a RULAND-developed MES system, which bridges the PCs with IPRONA’s ERP system. In addition, all components from subcontractors which have an individual automation, are integrated into the control system via a common interface, developed by RULAND. This allows for a common operation and supervision of all plant units.

More than 50 km of piping was installed on five building levels. The whole project was designed in 3D which allowed for piping installation to be optimised both from a process engineering perspective as well as product loss. For further information visit www.rulandec .de. J

RULAND was responsible for all production areas: the juice generation, the juice tank farm, the existing concentrate plants, the finished product lines and the CIPsupply of all plants.

Coaxial agitators in the mixing tanks ensure a homogeneous batch for the following continuous pasteurisation processes. To allow for maximum flexibility, depending on batch size and product needs, either plate- or scraping heat exchangers can be included in the process. Whichever is chosen, the resulting route is leakage-proof, so in parallel or crossing ways other production or cleaning may take place.

This flexibility is also seen when filling bag-in-box, bag-in-drum or stainless steel transport container by CIP unit. using sterile valve clusters. Within a

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012

OEE Systems From London Electronics ondon Electronics makes easy to use L production monitoring systems, designed to help you get the best out of your plant and team. You can see live data for each of your lines, so that you can act instantly if a problem should occur. This is essential in lean manufacturing environments, where a fast response to any drop in efficiency is critical.

Suited for these applications and more: * Calculating live OEE on your production lines; * Logging reasons for stoppages; * Charting OEE over time, so you can see trends; * Calculating production line down time; * Web-based, you can monitor performance even if you are off-site.

You can simply display the live production data on large overhead boards, or you can save the data in a database, to allow graphing and general data analysis.

Mention that you read about this in Food and Drink Business Europe maga-

zine, to claim an additional festive 10% discount!

See www.london-electronics.com for more details. J

Naturex Reveals Focus on Driving Growth in Indulgence aturex is planning a major new N drive to highlight how its extensive range of fruit ingredients could help manufacturers inject growth into the market for premium quality indulgent products, such as cakes, biscuits, confectionery, desserts and other treats. The Avignon-based company produces a wide selection of processed fruit ingredients in a variety of formats, including powders, granules and crisps, as well as extracts.

Naturex believes its ingredients could help manufacturers gain an edge in the highly competitive market for sweet treats by creating product concepts that meet demand both for enjoyment and quality – as well clean labels and improved nutrition content.

Antoine Dauby, Marketing Director at Naturex, says: “Indulgence is very big business. For example, sales of sweet bakery products such as cakes and biscuits were worth Eur8.56 bil-

lion across Western Europe in 2011, according to Mintel. Clearly it is a very large market indeed, and a great opportunity.

However, it is also a very competitive market and growth opportunities can be hard to find. In fact, Mintel figures show that year-on-year growth in the sweet bakery category between 2010 and 2011 was only 1.3%.

Further, Mintel forecasts that the market will grow just 1.6% in 2012.

He continues: “These market conditions mean it is very important for manufacturers to create excitement among shoppers by finding a point of difference that adds value to their proposition. Our ingredients can help companies do this by improving their recipes in a way that is in tune with the trend for more natural and healthier products, enabling them to achieve standout with indulgent concepts.”

For further information visit www.naturex.com. J

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I SUSTAINABILITY

Cargill’s Leading Sustainable Cocoa Program Boosts Profits For Ivorian Cocoa Farmers argill’s sustainable cocoa program C has helped Ivorian farmers have another profitable year by increasing

projects led by the co-operative.

Thanks to the payments, ECASO’s management has financed the building yields, improving bean quality and of a new school with three classrooms, boosting their incomes. During the the renovation of another three schools 2011/12 crop year, approximately in our communities, and the construc26,500 Ivorian farmers across 43 tion of a shop in Soubre that offers UTZ and Rainforest Alliance certified farm equipment and materials.” co-operatives have received Cargill’s Since the introduction of Cargill’s sustainable cocoa premiums payments sustainable cocoa program in Cote totalling $7.6 million – the highest d’Ivoire, the company has continued ever pay-out for farmers in the region. to scale up the amount of certified Cargill’s annual premium payments cocoa it has available to the market recognise farmers for their efforts to and is now sourcing nearly 20 per increase yields and improve the qualicent of its annual cocoa supply as certy of the beans, such as decreasing tified sustainable cocoa. moisture and mould content – this Cargill is continuing to invest over helps to continue to raise the quality $3 million a year in financing, trainYao N'Dri Pascal, farmer and co-op president (left), with a of Ivorian cocoa beans. This year’s ing and support to the Ivorian cocoa fellow farmer. premium has raised farmers’ direct community to maintain and strengthrevenues by 17 per cent on average. en the sustainable cocoa supply chain.

Cargill’s customers who buy certified cocoa Speaking on behalf of the ECASO co- Its sustainable cocoa program also supports and chocolate ingredients contribute direct- operative, farmer Yao N’Dri Pascal explains communities with education and health ly to these premium payments. As such, what benefits he and his cooperative have programs. As result of Cargill’s sustainabiliover the last three years, Cargill’s premium seen since participating in Cargill’s sustain- ty program 87 co-operatives have been cerpayments to Ivorian farmers have totalled able cocoa program: “By participating in tified and another 25 are starting the promore than $12.2 million.

Cargill’s farmer training, I was given the gram, which is now reaching over 60,000 These premiums were presented to farm- unique opportunity to learn how to best Ivorian farmers. Cargill is on target to ers and co-operatives at an event in Cote manage and maintain my cocoa farm. source over 100,000 tonnes of certified susd’Ivoire on 24th October. The ceremony Thanks to this training, I have been able to tainable cocoa beans from Cote d’Ivoire by was attended by the President of the reduce the number of incidences of black 2015 – making its program the largest of its Conseil Café Cacao and over 500 farmers pod disease while using fewer pesticides – kind in the country. from all of the co-operatives that are partic- creating high quality cocoa beans and a Due to the success of Cargill’s sustainable ipating in Cargill’s sustainability program – healthier rejuvenated farm.” cocoa program in Cote d’Ivoire, Cargill has making this one of the largest gatherings Yao N’Dri Pascal continues: expanded its farmer training activities to for the Ivorian cocoa farming community “Certification premiums have helped boost Ghana, Cameroon, Brazil, Vietnam and this year. my income and also supported community recently Indonesia. J

I WATER METERS

Solar Powered Success evern Trent Costain is successfully pioneering the use of solar panels to power S remotely located water meters for the Ministry of Defence (MOD) in the UK. The environmentally friendly photovoltaic panels provide a neat solution to the challenge of providing electricity to remote sites, which are often a considerable distance from the nearest mains power source.

The units which are suitable for most outdoor locations and require minimal commissioning are being trialed in Severn Trent Costain’s showcase ‘Package C’ contract, under which it provides water and wastewater services to 1,300 MOD sites across England.

Following a highly successful initial trial Severn Trent Costain are to extend the use of the cells to a further 20 sites. If ultimately used to power all 1,100 meters installed within the contract this will enable a saving of some 7,700 conventional batteries and reduce cost by £100,000 a year. For further information visit www.severntrentcostain.com. J 48

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2012