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June 2012

TOP 100

Food and Drink Manufacturers in the UK and Ireland

Food & Drink Business Website:

www.fdbusiness.com


C o n t e n t s

- 3 M ERGERS & A CQUISITIONS

- 40 M ARKET F OCUS

Coverage of British and international deals.

UK vegetarian foods market to expand further in the future. P AGE 11

- 5 C OVER S TORY The Top 100 food and drink manufacturers in the UK and Ireland.

PAGE 3

Patrick Coveney, ceo, Greencore.

- 40 M EAT P ROCESSING

Nigel Dunlop, ceo, Moy Park.

Linden Foods named 2012 UK manufacturer of the year.

R EGULARS - 17 F OCUS ON I RELAND

Control & Automation . . . . . . . . . . . . . . 19

Ireland – The food island.

Processing & Manufacturing . . . . . 20-27, 39 Green Factories . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24

Top 50 food and drink manufacturers in Ireland

PAGE 5

Simon Baldry, md, Coca Cola Enterprises.

PAGE 11

Stella David, ceo, William Grant & Sons.

Quality & Safety . . . . . . . . . . . . . . . . 33-38 Health & Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Food Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-39

Bottling & Packaging . . . . . . . . . . . . 41-47

- 23 G REEN FACTORIES

Retail Ready Packaging . . . . . . . . . . . . . . . . . . . . . 41-45

Carbonostics - Improving sustainability and efficiency, from farm to fork.

Logistics & Distibution . . . . . . . . . . . . . . 49

PAGE 29

Materials & Ingredients . . . . . . . . . . . . . . 56

Graham Mackay, ceo, SABMiller.

- 29 B REWING Leadership changes at SABMiller.

Managing Director: Colin Murphy Editor: Mike Rohan Sales Director: Ronan McGlade Advertising: Susan Doyle, Neela Desai, Mark Davies and Sylvia McCarthy

PAGE 7

Paul Grimwood, ceo, Nestle UK & Ireland.

. Senior Sales Executive: Paul Lees Production Manager: Susan Doyle

Food & Drink Business Europe is published by Premier Publishing Limited, 51 Parkwest Enterprise Centre, Nangor Road, Dublin 12. Tel: + 353 1 612 0880 Fax: + 353 1 612 0881 E-Mail: info@prempub.com Website: www.fdbusiness.com London Office: Premier Publishing Limited, CTS, 34 Leadenhall Street, London, EC3A 1AT Tel: 0171 247 3238 Fax: 0171 247 3239

- 30 D ISTILLING

Premier Publishing Limited can accept no responsibility for the accuracy of contributors’ articles or statements appearing in this magazine. Any views or opinions expressed are not necessarily those of Premier Publishing and its Directors. No responsibility for loss or distress occasioned to any person acting or refraining from acting as a result of the material in this publication can be accepted by the authors, contributors, editor and publisher. A reader should access separate advice when acting on specific editorial in this publication!

Diageo to invest £1 billion in Scotch whisky production.

- 33 H EALTH & S AFETY

PAGE 8

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Accident prevention in the food and drink industry.

Michael Clarke, ceo, Premier Foods.

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FOR SALE BY PRIVATE TREATY Following the closure of their Gierle Factory, Belgium On behalf of Kempico cvba, Cheese Manufacturing Equipment, Stork Evaporator & Associated Dairy Process Equipment & Services.

Viewing strictly by appointment only, contact Malcolm Wilkinson (Managing Director) on +44 (0) 7970 947155 or E-mail: malcolm.wilkinson@moodyplc.com or contact: Justin Lacey (Operations Director). +44 (0) 7971 671897 Fax: +44 (0) 1777 709086 E-mail: justin.lacey@moodyplc.com


M E E R R G G E E R R S S M Kellogg Completes $2.7 Billion Acquisition of Pringles Kellogg Company has completion of its acquisition of Procter & Gamble's Pringles business. The $2.69 billion acquisition further strengthens Kellogg Company's competitive position in global snacks, making Kellogg the world's secondlargest savoury snacks player. "The addition of Pringles to our portfolio significantly advances the company's strategic goal of building a global snacks business on par with our global cereal business, and expanding our global footprint," says John Bryant, Kellogg Company's president and chief executive officer. The Pringles acquisition nearly triples the size of Kellogg Company's international snacks business, and adds a complementary product to the company's high-quality snacks brands including Keebler, Cheez-It and Special K Cracker Chips. Pringles is the world's second largest player in savoury snacks, with $1.5 billion in sales across more than 140 countries.

& &

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

world’s leading cider maker, based on its number one position in the UK - the world’s largest cider market - and market positions in countries such as Finland, the Netherlands, Hungary, Italy, Canada and the US. The strategic acquisition of Stassen comes at a time when the international cider category is gaining momentum. Heineken is positioning itself to benefit from this trend through innovative new product offerings.

Greencore Selling Chilled Desserts Plant to Muller UK Greencore is disposing of its chilled desserts facility in Minsterley to Muller Dairy UK for £4.3 million. Under the terms of the disposal, ownership of the facility will transfer to

Patrick Coveney, chief executive of Greencore.

John Bryant, president and chief executive of Kellogg.

Heineken Strengthens Cider Business With Belgian Acquisition Heineken has acquired Stassen, a leading international cider company located in Aubel, Belgium, from its current management. In addition to its strong research and development (R&D) capabilities and facilities, the acquisition of Stassen provides Heineken with cider making capacity in continental Europe. The terms of the transaction were not disclosed. Heineken is already the

Muller and the co-packing arrangement for Cadbury chilled desserts will terminate. The disposal is expected to complete at the start of January 2013, by which time the transfer of production of other premium desserts lines and related manufacturing equipment to Greencore’s Evercreech facility will have been completed. This would then conclude the restructuring of the chilled desserts business, which Greencore acquired from Uniq in September 2011.

Kevin Lane, chief executive of IDB.

year ended 31 December 2011. The transaction which is subject to regulatory approval is expected to be completed by 31 July 2012. Proceeds from the transaction will be invested in furthering the IDB’s strategic growth plans and in international acquisition prospects. Kevin Lane, chief executive of IDB, says: “The sale of our continental cheese packing business to Royal FrieslandCampina is another significant strategic step for IDB. The divestment will unlock additional capital to develop more focused routes to market for Irish product at a time when IDB Belgium’s future potential can best be realised with the support of a local dairy partner.”

Premier Foods to Dispose of Vinegar and Sour Pickles Business Premier Foods is selling its vinegar and sour pickles business, including the Sarson's, Haywards and Dufrais brands, to Japan-based Mizkan, for a cash consideration of £41 million.

The sale is expected to complete by the end of July 2012. The disposal represents a further step in Premier Foods’ strategy to prioritise investment behind its eight ‘power brands’ and divest selected, non-core businesses. For the year ended 31 December 2011, the vinegar and sour pickles business had reported revenues of £34.0 million and EBITDA of £6.2 million. The gross assets of the business being sold as at 31 December 2011 were £31.7 million. The proceeds of the sale will be used to pay down debt. The Sarson's and Haywards brands are the leaders in their respective categories of malt vinegar and pickles in vinegar while Dufrais is the number two brand in speciality vinegar. The brands are predominantly manufactured at the group's Middleton factory, near Manchester, and all employees at the site are expected to transfer to the buyer. The transaction includes the production, distribution, sales and marketing of the Sarson's, Haywards and Dufrais brands, the associated private label business, the Middleton site and the pickled beetroot and piccalilli lines at Premier Foods’ Bury St Edmunds factory. Mizkan is one of the leading vinegar manufacturers in the world with operations in Japan, the US, the UK and other Asian countries. It has a stable of wellknown international brands under the ‘mizkan’ umbrella brand and is a leader in the liquid condiment category.

Irish Dairy Board to sell Belgian Cheese Subsidiary The Irish Dairy Board has agreed to sell its Belgian continental cheese packing operation, IDB Belgium, to Royal FrieslandCampina. IDB Belgium operates from Genk in Belgium and has a turnover of about Eur100 million for the

The disposal represents a further step in Premier Foods’ strategy to prioritise investment behind its eight ‘power brands’ and divest selected, non-core businesses.

FOOD & DRINK BUSINESS EUROPE, JUNE 2012

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COVER STORY

The Top 100 Food and Drink Manufacturers in the UK and Ireland Food & Drink Business Europe presents its seventeenth annual ranking of the top one hundred food and drink manufacturers in the UK and Ireland, while highlighting some of the key corporate developments within the industry during the past twelve months.

T

he Top 100 companies are ranked according to their most recently available turnover figures and pretax profits are also listed. Headed by Unilever’s refreshment and foods business with sales of Eur22.8 billion (£19.4 billion) last year, the 2012 Top 100 incorporates companies ranging in scale down to brewer SA Bain & Co, which achieved sales of £113.6 million in 2011. Diageo is the largest beverages group and companies with turnovers in excess of £1 billion occupy the top 24 places within the 2012 listing. Increasing M&A Activity Merger and acquisition activity, which was relatively subdued throughout 2009

Simon Baldry, managing director of Coca Cola Enterprises.

and 2010, has been steadily increasing. According to sector experts Grant Thornton UK, overall M&A deal numbers in 2011 rose 22% on the previous year reaching almost pre-recession levels. Diageo was the most active company within the Top 100 in terms of acquisition spend. During the year it completed its £1.3 billion acquisition of Mey Icki, the leading spirits company in Turkey. Diageo has also now received regulatory clearance to acquire the outstanding shares of Sichuan Shuijingfang Co, one of the largest super premium Chinese white spirits brands in China, for £630 million. On the brewing side of its business, Diageo also completed the acquisition of Meta Brewery, a leading beer company in Ethiopia, for a cash consideration of $225 million (£143 million). The acquisition represents a key milestone in achieving Diageo’s strategy of participating at scale in beer and spirits in growth markets in Africa. The largest deal within the UK food sector involves the sale of the iconic Weetabix brand. Bright Food, one of China’s largest food groups, is acquiring 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. Completion of the transaction is expected in the second half of 2012. Weetabix is the second largest branded manufacturer by value of ready-to-eat cereals and cereal bars in the UK. The company’s portfolio of household brands features the market-leading brand Weetabix, and also includes Weetaflakes, Oatibix, Oatiflakes, Seriously Oaty, Ready Brek, Weetos and Alpen, the leading UK muesli brand. Weetabix is also the second largest manufacturer of own FOOD & DRINK BUSINESS EUROPE, JUNE 2012

Major consolidation within the UK dairy industry has been a feature of the past six months.

label cereals for retailers in the UK. In addition to its strong presence in the UK, Weetabix 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. The acquisition marks Bright Food’s first entry into both the UK and global food markets. Overseas Interest Another overseas company showing a strong interest in UK and Irish food businesses is Hain Celestial Group, the US-based organic food and drink producer. During the past year, Hain Celestial has acquired Daniels Group, the UK chilled and fresh food and beverages manufacturer, from Singapore Airport Terminal Services for $230 million. Daniels Group has a turnover of £177 million and its portfolio includes soup producer New Covent Garden Food, Johnsons juices, Farmhouse Fare desserts and International Cuisine ready meals. Hain Celestial has also extended its international presence into Ireland with the acquisition of Cully & Sully, a manufacturer of natural chilled soups, savory pies and hot pots. 5


venience food group Northern Foods in an all share deal of equals to create Essenta Foods, a £1.7 billion turnover business. However, Boparan Holdings, controlled by Ranjit Singh Boparan, who is head of major British chicken processor 2 Sisters Food Group, thwarted Greencore’s plans with a successful £342 million cash bid for Northern

Foods. Greencore has since furthered its ambitions to develop a convenience food business of real scale in the US with the acquisition of Marketfare Foods for $36.0 million. Greencore has now listed on the London Stock Exchange. The move reflects the fact that despite its Irish ori-

TOP 100 Food and Drink Manufacturers in the UK and Ireland

Paul Grimwood, chairman and chief executive of Nestle UK & Ireland.

A good deal of domestic deal activity has centred upon Premier Foods as the UK’s largest indigenous food manufacturer continued to make disposals to reduce its debt mountain. Premier has recently sold its loss-making Brookes Avana business, comprising RF Brookes chilled foods and Avana Bakeries, to 2 Sisters Food Group (part of Boparan Holdings) for £30 million in cash, and sold four Irish brands - Chivers, Gateaux, McDonnells and the Erin licence - to The Boyne Valley Group for Eur41.4 million. Premier Foods’ vinegar and sour pickles business, including the Sarson's, Haywards and Dufrais brands, are currently being sold to Japan-based Mizkan for a cash consideration of £41 million. A key deal within the UK convenience food sector during the past year was Greencore’s £113 million acquisition of Uniq. The deal significantly improves Greencore’s standing in the food to go and chilled desserts sectors in the UK. Of course, Greencore had earlier in 2010 attempted to merge with UK con-

Ranjit Singh Boparan, chief executive of Boparan Holdings.

Company 1 (1) Unilever (Refreshment & Foods) 2 (3) Associated British Foods 3 (2) Diageo 4 (5) Kerry Group 5 (6) Tate & Lyle 6 (8) Glanbia 7 (7) Premier Foods 8 (11) Irish Dairy Board 9 (10) Coca-Cola Enterprises

Turnover

Pre-tax Profits

Ownership/Status

£19.37b £11.07b £9.94b £4.51b £3.09b £2.27b £2.00b £1.68b £1.67b

£2.90b* £757.0m £2.36b £369.9m £348.0m £117.9m -£259.1m £17.8m £254.7m

10 (9) Heineken UK

£1.66b

£730.9m

11 (13) Bakkavor Holdings

£1.64b

£21.4m

12 (12) Dairy Crest 13 (14) Arla Foods UK

£1.63b £1.59b

-£10.1m £31.1m

14 (16) Nestle UK 15 (15) InBev UK

£1.50b £1.46b

£1.7m -£29.1m

16 (32) Boparan Holdings

£1.38b

-£23.7m

17 (17) MolsonCoors Brewing

£1.37b

£53.0m

18 (19) Britvic 19 (-) Igloo Foods Holdings 20 (47) Vion Food UK

£1.29b £1.22b £1.21b

£79.9m -£69.9m -£20.2m

plc plc plc Irish co-op/plc plc Irish co-op/plc plc Irish dairy co-ops Coca-Cola Enterprises, US Heineken, Netherlands Bakkavor Group, Iceland plc Arla Foods, Denmark/Sweden Nestle, Switz. Anheuser-Busch InBev, Belgium Incorporating 2 Sisters Food Products – Independent Molson Coors Brewing, US plc Permira Vion, Netherlands

Source: KEY NOTE, company accounts. * operating profits. Eur = £0.85. Figures in brackets indicate previous year’s rankings.

FOOD & DRINK BUSINESS EUROPE, JUNE 2012

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gins Greencore generates the majority of its turnover and operating profits in the UK, where its key production assets are located. Some of the smallest companies within the Top 100 have been on the acquisition trail during the past year. R&R Ice Cream, Europe’s largest own label ice cream manufacturer, expanded its French business with the Eur27 million acquisition of Pilpa, and acquired Durigon Gelato of Germany for an undisclosed sum. Baxters Food Group, the Scottish

Paul Walsh, chief executive of Diageo.

TOP 100 Food and Drink Manufacturers in the UK and Ireland

Company 21 (20) Princes

Turnover £1.18b

Pre-tax Profits £42.1m

22 (18) Tulip

£1.12b

£37.4m

23 (21) United Biscuits (UK)

£1.06b

£149.5m

24 (26) Greene King 25 (25) Hilton Food Group 26 (23) Carlsberg UK

£1.04b £981.3m £978.8m

£116.8m £24.5m £21.4m

27 (22) Northern Foods

£934.9m

-£12.3m

28 (28) Moy Park 29 (24) Robert Wiseman Dairies

£921.1m £917.5m

£27.8m £34.4m

30 (30) Dawn Meats Group 31 (31) Cranswick 32 (35) Greencore 33 (29) HJ Heinz 34 (33) Mars Chocolate UK 35 (32) ABP Food Group

£850mE £821.0m £804.2m £778.7m £743.7m £740mE

nd £48.4m £11.2m £157.0m £107.8m nd

36 (38) Samworth Bros Holdings £716.2m 37 (40) Marston’s £682.2m 38 (42) Ballina Beverages £680mE 39 (39) Kellogg UK £658m 40 (45) Dairygold Co-op £644.1m

£46.7m £80.8m nd £11.3m £19.2m*

Ownership/Status Mitsubishi, Japan Danish Crown, Denmark Blackstone, PAI Partners & Kraft Foods plc plc Carlsberg, Denmark Acquired by Boparan Holdings Marfrig, Brazil Acquired by Muller Dairy (UK) Irish independent plc plc HJ Heinz Co, US Mars, US Formerly Irish Food Processors Irish independent Independent plc Coca-Cola, US Kellogg Co, US Irish co-op

soup and preserves manufacturer, bought Fray Bentos for an undisclosed sum from Princes Group, which is owned by Mitsubishi Corporation. Princes was ordered by the UK Office of Fair Trading to dispose of Fray Bentos, which produces a range of canned pies and puddings as well as corned beef and meatballs, as a condition of its purchase of Premier Foods’ canned grocery operations for £182 million in July 2011. Dairy Consolidation Major consolidation within the UK dairy industry has been a feature of the past six months. Robert Wiseman Dairies, which processes and delivers more than 30% of the fresh milk consumed in Britain, was acquired by Muller Dairy (UK) for £279.5 million. Part of the Muller Group, a leading, family-owned German and European dairy group with annual turnover of more than.Eur2 billion, Muller Dairy (UK) is the overall market leader in chilled yoghurts and potted desserts in the UK. Robert Wiseman Dairies has since been delisted from the London Stock Exchange. The deal has creating a leading integrated dairy business in the UK with complementary positions in the yoghurt and potted desserts market and the fresh milk market. Further dairy industry consolidation is on the cards. Scandinavian dairy cooperative Arla Foods is now planning to merge its UK operations with those of fellow co-operative Milk Link, the UK’s fourth largest dairy company. The combination of Arla Foods (UK) and Milk Link will create the UK’s largest dairy business. The UK is already Arla’s largest market, generating rev-

Source: KEY NOTE, company accounts. * operating profits. Eur = £0.85. Michael Clarke, chief executive of Premier Foods.

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FOOD & DRINK BUSINESS EUROPE, JUNE 2012


period will be achieved through acquisition. These indicators suggest that the recent upturn in M&A activity in food and beverage will be sustained. The food and beverage businesses that have survived the economic downturn have emerged leaner and many are now looking to grow through M&A deals at home and abroad. Future Deals A number of Top 100 firms are likely to change hands in the near future. US private-equity firm Oaktree Capital Management is reported to seeking to sell R&R Ice Cream after seven years of ownership. R&R Ice Cream was formed Nigel Dunlop, Chief Executive of Moy Park.

enues of almost DKr13 billion (£1.4 billion) in 2011. If the merger is approved, this will increase by just over DKr5 billion. In a similar move, Arla Foods is also planning to merge with Germany’s eighth largest dairy, Milch-Union Hocheifel (MUH). This would make Arla Foods the third largest dairy company in Germany. The planned mergers are in line with Arla’s Strategy 2015, the key objective of which is to improve returns for its farmer owners by, among other things, enhancing their positions in the group’s core markets of the UK and Germany. Indeed, Arla Foods is the result of the merger of two dairy cooperatives – Arla of Sweden and MD Foods of Denmark – in 2000. Continuing M&A Activity The recent acceleration in M&A activity within the food and beverage industry in the UK and Ireland is set to continue, according to Grant Thornton. Research by the business and financial advisor has found that 80% of PE respondents plan to conduct M&A activity in the sector and 80% of corporate respondents believe that sector growth in the same

Stella David, chief executive of William Grant & Sons.

TOP 100 Food and Drink Manufacturers in the UK and Ireland

Company 41 (-) Dunbia 42 (44) Kepak 43 (43) Pepsi Cola International 44 (48) Noble Foods Group

Turnover £620.0m £616mE

Pre-tax Profits nd nd

Ownership/Status independent Irish independent

£595mE £594.7m

nd £11.9m

PepsiCo, US Independent – formerly Deans Foods

Sons Distillers

£586.8m £562.2m £553.4m £526.2m £517.6m £492.1m £470.8m £447.9m

£94.8m £4.8m £154.7m £3.4m £157.6m £28.8m -£28.1m £63.7m

Independent Quadrigo Holdings Independent Kraft Foods, US Pernod Ricard, France Independent Independent Permira

Spirits & Wine (37) C&C Group (61) Lakeland Dairies (60) Heineken Ireland (55) Muller Dairy (UK) (57) Sun Valley Foods (58) McCain Foods GB (59) Farmers Boy

£420.0m £408.0m £401.2m £394.4m £393.0m £378.2m £371.5m £368.9m

£235.0m £94.5m* £5.7m nd £40.0m -£25.2m £40.5m £54.7m

Pernod Ricard, France Irish plc Irish co-op Heineken, Holland Alois Muller, Germany Cargill, US McCain Foods, Canada W Morrison Supermarkets plc

45 (-) William Grant & 46 (41) Gerber Emig Group 47 (52) Edrington Group 48 (46) Kraft Foods UK 49 (50) Chivas Bros 50 (49) Warburtons 51 (62) Bernard Matthews 52 (53) Birds Eye 53 (54) Allied Domecq 54 55 56 57 58 59 60

Source: KEY NOTE, company accounts. * operating profits. Eur = £0.85.Peter Lauritzen, chief executive of Arla Foods UK.

FOOD & DRINK BUSINESS EUROPE, JUNE 2012

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region of £600 million during the past two year in expanding and upgrading capacity in distilling, bottling and warehousing. Indeed, distillers are continuing to invest heavily for long-term growth. For example, Diageo plans to

Mark Allen, chief executive of Dairy Crest.

in 2006 when Oaktree acquired Richmond Foods, Britain's biggest icecream maker and united it with Roncadin, the largest German ownbrand label ice cream manufacturer, which it had bought the year before. The ice cream business, headquartered in North Yorkshire, is expected to attract other private equity firms and is likely to fetch around $1 billon. United Biscuits, one of Europe’s leading biscuits and savoury snacks manufacturers, has been put up for sale by joint owners, private equity groups Blackstone Group and PAI Partners. United Biscuits is being separated into two distinct businesses – one focused on biscuits and the other on bagged snacks – prior to disposal of the two units. United Biscuits was offered for sale in 2010 with a price tag of about £2 billion but the auction process was unsuccessful. Blackstone Group and PAI Partners acquired United Biscuits for ?1.6 billion in 2006. Another well know British company, Birds Eye, is also up for sale as part of the auction of Iglo Foods, the European frozen foods group, owed by private equity firm Permira. Premier Foods is also expected to dispose of other assets. Capital Investment In response to the continual growth in export sales, Scotch whisky distillers, including major players such as Diageo, John Dewar (Bacardi), Glenmorangie and Edrington, have invested in the

invest over £1billion in Scotch whisky production over the next five years to meet growing global demand for its brands. Scotland is one of Diageo’s largest spirit supply centres responsible for producing nearly 50 million cases of

TOP 100 Food and Drink Manufacturers in the UK and Ireland

Company Turnover 61 (56) Irish Distillers Group £360mE

Pre-tax Profits nd

62 (51) Young’s Seafood

£342.6m

£0.5m

63 (64) Weetabix 64 (65) Burton’s Foods

£325.9m £322.1m

£133.6m £13.1m

65 (67) Faccenda Group

£312.8m

£2.0m

66 (63) AarhusKarlshamn UK

£311.1m

£9.1m

67 (69) Meadow Foods 68 (73) The Cheese Company 69 (68) Icelandic Group UK

£300.6m £289.1m £268.1m

£0.1m £5.8m £3.8m

70 (75) Fuller Smith & Turner 71 (74) Cott Beverages

£253.0m £238.9m

£28.8m £10.0m

£237.0m £217.3m £213.9m

£35.4m £3.3m £7.1m

£205.1m

£4.2m

Coca-Cola HBC, Greece

£203.9m

£1.5m

£201.7m

£1.6m

Barry Callebaut, Switzerland Independent

£200.1m £191.6m

£1.9m £1.1m

£189.6m

£5.8m

72 (76) AG Barr 73 (72) Foyle Food Group 74 (82) JW Galloway 75 (79) Coca-Cola Hellenic Northern Ireland

76 (81) Barry Callebaut Manufacturing

77 (86) Yeo Valley Group 78 (80) The Real Good 79

Food Company (88) Dale Farm

80 (89) Finsbury Food Group Paul Moody, chief executive of Britvic.

Ownership/Status Pernod Ricard, France Part of Findus Group – Lion Capital, UK Lion Capital, UK Duke Street Capital Hillesden Investments AarhusKarlshamn, Sweden/Denmark Independent Milk Link Co-op Icelandic Group, Iceland plc Cott Corporation, Canada plc Independent Independent

plc United Dairy Farmers Group plc

Source: KEY NOTE, company accounts. * operating profits. Eur = £0.85.

FOOD & DRINK BUSINESS EUROPE, JUNE 2012

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Benet Slay, chief executive of Carlsberg UK.

Scotch whisky and white spirits annually. William Grant & Sons plans to invest Eur35 million in a new, state-of-the-art pot still whiskey and malt whiskey distillery in Tullamore in Ireland. William Grant & Sons, which is famous for the Glenfiddich Scotch malt whisky brand, first entered the Irish whiskey category in 2010 after acquiring the Tullamore Dew brand for about £150 million from Irish and UK cider maker C&C Group. Also in Ireland, Diageo is to make a capital investment of Eur153 million in a brewing centre of excellence at its famous St James’s Gate site in Dublin. Other Top 100 companies investing heavily include Nestle UK, Kraft Foods (now incorporating Cadbury), CocaCola Enterprises and Arla Foods UK. Nestle UK is investing £500 million over the next three years to modernise its manufacturing facilities, including £200 million to extend its Nescafe factory in Tutbury, Derbyshire. Kraft Foods is investing £50 million across its confectionery factories in the UK, while cutting the workforce by 200 people. Coca-Cola Enterprises, the UK’s largest soft drinks producer, is investing £50 million across three of its manufacturing sites in Great Britain. Arla Foods UK has commenced construction of a £150 million fresh milk

dairy at Aylesbury in England. Once completed, the dairy will process and package up to one billion litres of milk per year. UK grocery retailer Morrisons plans to complete a £200 million investment programme in the expansion of its manufacturing food arm by 2013. The investment is in line with the group’s aim to become the UK’s largest fresh food manufacturer by 2015. It will enable Morrisons to buy more fresh food directly from farmers than its supermarket rivals. Vion UK is currently Britain’s biggest manufacturer of fresh food, with Morrisons the second largest. J

Javed Ahmed, chief executive of Tate & Lyle.

TOP 100 Food and Drink Manufacturers in the UK and Ireland

Company 81 (70) Tata Global Beverages 82 (83) McCormick UK 83 (85) Dr Oetker UK

84 (84) Wrigley Company 85 (87) Lactalis McLelland 86 (78) Whyte & Mackay Group 87 (77) Wells & Young’s Brewing

88 (92) Ferrero UK 89 (93) William Jackson & Son 90 (94) Tangerine Confectionery Group 91 (-) Innocent Drinks 92 (97) Menderley Food Group (Tayto) 93 (98) Zetar 94 (96) Yoplait UK 95 (95) Daniel Thwaites 96 (100) Baxters Foods Group 97 (99) R&R Ice Cream UK 98 (-) Shepherd Neame 99 (-) McCambridge Group Holdings 100 (-) SA Brain & Co

Turnover £189.5m £188.6m £188.6m

Pre-tax Profits £28.5m -£0.7m -£5.1m

£183.7m £181.9m £169.5m

£44.8m £3.1m £12.4m

£169.2m £169.0m

£3.4m £0,6m

£168.4m

£7.7m

Charles Wells Ferrero International, Switzerland Independent

£153.8m £150.8m

£5.8m £4.4m

Independent Coca-Cola, US

£136.9m £135.0m £133.7m £126.7m £125.8m £121.4m £121.3m

£4.3m £5.6m £21.9m £7.0m £7.1m £19.1m 6.5m

Independent plc Yoplait, France plc Independent Oaktree Capital, US Plc

£115.5m £113.6m

-£4.2m £1.8m

Independent independent

Source: KEY NOTE, company accounts. * operating profits. Eur = £0.85. Paul Pulman, chief executive of Unilever.

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FOOD & DRINK BUSINESS EUROPE, JUNE 2012

Ownership/Status Tata Tea, India McCormick, US Dr Oetker, Germany Mars, US Lactalis, France UB Group, India


The fastest Palletiser on the Market ROBOT PALLETISER Ultra High Speed High Load Capacity Wide Operation Range Low Noise Level Energy Efficient Environmentally Friendly Adaptable Product Capability

LVP Conveyors Ireland LVP Conveyors UK Unit D7 North City Business Park, Dublin 11 Garston Road, Corby, Northants, NN18 8NH Phone: 00353-1-8643838 Phone: 0044-1536-747740 Email: info@conveyors.ie Email: sales@lvpconveyors.co.uk www.conveyors.ie www.lvpconveyors.co.uk


I FOCUS ON IRELAND

Ireland – The Food Island The food and drink industries in the Republic of Ireland and Northern Ireland are the largest indigenous manufacturing sectors in each country and play crucial roles in both economies. he food and drink industry throughout Ireland is characterised by a high level of overseas sales, particularly in the dairy, meat and beverage sectors. The food and drink industry in the Republic of Ireland has an annual gross output valued at over Eur24 billion and exports worth in excess of Eur8.8 billion. The Northern Ireland food industry generates more than £3.7 billion annually for the local economy, £2.7 billion of which is sold outside Northern Ireland. The food and drink industries in both countries are continuing to grow through a sharp focus on exports and innovative products.

T

Export Focus Due to the relatively small size of the domestic market, exports are a crucial source of revenue to Irish food and drink manufacturers. The Irish food industry has traditionally been strong in meat processing and dairying but has also developed a sophisticated convenience food sector as well as an international expertise in food ingredients. Brewing and distilling are key strengths on the drinks side. As the Republic of Ireland’s nearest

neighbour, the UK remains the main destination for Irish food and drink exports and purchased 41%, or Eur3.66 billion worth, of the total last year - up 6% on 2010. Great Britain remains Northern Ireland’s largest overseas market for food and drink products with annual sales there worth about £1.5 billion.

Food and Drink Manufacturers in Ireland Company 1 Kerry Group 2 Glanbia 3 Aryzta (Food) 4 Total Produce 5 Irish Dairy Board 6 Diageo Ireland 7 Moy Park 8 Dawn Meats Group 9 Greencore 10 ABP Food Group

Turnover (Euro) 5.30b 2.67b 2.58b 2.53b 1.98b 1.80bE 1.08b 1.0bE 946.1m 875mE

Pre-tax Profits (Euro) 435.2m 138.7m 322.3m* 34.4m 20.9m nd 32.7m nd 13.2m nd

11 Fyffes 12 Ballina Beverages 13 Dairygold Co-op 14 Dunbia 15 Kepak 16 Pepsi Cola International 17 C & C Group 18 Lakeland Dairies 19 United Dairy Farmers 20 Heineken Ireland

850.0m 800mE 757.8m 730mE 725.0m 700mE 480.0m 472.0m 470.8m 464.0m

12.5m nd 22.6m* nd nd nd 111.2m* 6.9m* 4.9m nd

The food and drink industries in the Republic of Ireland and Northern Ireland are the largest

Both the Government in the Republic of Ireland and the Northern Ireland Executive are committed to driving further export sales. In Northern Ireland the target is achieve a 15% growth in exports over the next four years. The agri-food sector in the Republic of Ireland is seeking to grow exports by 42% to Eur12 billion by 2020.

Ownership/Status co-op/plc co-op/pl plc plc co-op Diageo, UK Mafrig, Brazil independent plc formerly Irish Food Processors - independent plc Coca-Cola, US co-op independent independent PepsiCo, US plc co-op co-op Heineken, Netherlands

Source: Company accounts, Irish Times, Belfast Telegraph. * operating profits. £=Eur0.85

indigenous manufacturing sectors in each country.

FOOD & DRINK BUSINESS EUROPE, JUNE 2012

17


Top 50 Players The Top 50 food and drink manufacturers in Ireland, both North and South, are listed according to turnover in the Table. The top eight players have annual sales in excess of Eur1 billion. Global ingredients, flavours and consumer foods producer Kerry Group heads the league table, while Northern Ireland’s largest food company, Moy Park, with a turnover of £921.1 million (Eur1.08 billion) ranks seventh. Moy Park is the leading poultry processor in the UK and also one of the largest in Europe. Most of the major players within the Top 50 are active throughout the whole of Ireland and have also developed substantial businesses in Great Britain. Indeed, Irish food companies now hold UK market leading positions in areas such as convenience foods, ready meals, pizza, food ingredients, dairy products and beef.

The food and drink industry throughout Ireland is characterised by a high level of overseas sales, particularly in the dairy, meat and beverage sectors.

The top four Irish meat companies – Dawn Meats Group, ABP Food Group (formerly Irish Food Processors), Dunbia and Kepak - have built up a substantial processing base in the UK. The Irish Dairy Board is one of the leading players within the butter, cheese and dairy ingredients sectors in Britain. Greencore is the largest pre-packed sandwich maker in Britain and also holds leading positions in other convenience food sectors. Green Isle Foods, which is now part of Boparan Holdings following the latter’s acquisition of Northern Foods, is a leading player in frozen pizza with its Goodfella’s brand. Aryzta is a leader in the British speciality bakery products market. International Production Base Ireland is used as a production base by many leading international food and drink manufacturers. Both Coca-Cola and PepsiCo have built soft drinks concentrate factories in the country to serve their wider European operations, and Wyeth has a major baby food manufacturing operation in Ireland. Other major international food and drinks groups with a strong presence in Ireland include Nestle, Kraft Foods, Diageo, Pernod Ricard, Heineken, Mars, Coca-Cola Hellenic and HJ Heinz. J 18

Food and Drink Manufacturers in Ireland Company 21 Fane Valley Co-op 22 Irish Distillers Group

Turnover (Euro) Pre-tax Profits (Euro) Ownership/Status 436.6m 5.8m co-op 425mE nd Pernod Ricard, France 23 Arrow Group 351.0m 3.0m Queally Group 24 Linden Food Group 350mE nd Incorporates Linden Foods, Slaney Foods, Kettle Irish Foods & Irish Country Meats 25 Diageo NI 344.4m 4.1m Diageo, UK 26 Cadbury Ireland 325mE nd Kraft Foods, US 27 Green Isle Foods 325mE nd Boparan Holdings, UK 28 Keelings 300mE nd independent 29 Valeo Foods 300mE nd CapVest 30 Hilton Meats (Retail) 286.5m 9.3m Hilton Food Group – plc 31 Rosderra Meats 275mE nd independent 32 Gleeson Group 261.5m 5.31m independent 33 Carbery Group 256.5m 8.7m West Cork co-ops 34 Foyle Food Group 255.6m 3.9m independent 35 Coca-Cola HBC 241.3m 4.9m CCHBC, Greece 36 Wyeth Nutritionals Ireland 200mE nd Wyeth, US 37 Britvic Ireland 191.5m nd Britvic, UK 38 Arrabawn Co-op 180.1m 6.2m co-op 39 Carton Group 180mE nd independent 40 Town of Monaghan Co-op 174.0m 1.8m co-op 41 Manderley Food Group (Tayto) 161.1m 5.1m independent 42 Tipperary Co-op Creamery 146.0m 0.8m co-op 43 Monaghan Middlebrook Mushrooms 135mE nd independent 44 Pepsi Lipton International 130.0m 53.0m PepsiCo/Unilever 45 Kildare Chilling Company 130mE nd independent 46 Mars Foods Ireland 122.0m 4.0m Mars, US 47 Liffey Meats 120mE nd independent 48 Boyne Valley Foods 110mE nd independent 49 HJ Heinz Ireland 101.0m 14.0m HJ Heinz, US 50 Nestle Ireland 99.0m 1.0m Nestle, Switzerland Source: Company accounts, Irish Times, Belfast Telegraph. * operating profits. £=Eur0.85

FOOD & DRINK BUSINESS EUROPE, JUNE 2012


Zetes Next Generation 3iV Crystal Multimodal Voice Solution Automates Stock Management Processes With Pallas Foods allas Foods, one of Ireland's leading P food service distributors, introduced an innovative warehouse automation system in several stages to help increase efficiency and productivity in its warehouse operations and ultimately to improve customer value. A First For Ireland - Multimodal Voice Zetes Ireland implemented the upgrade to the new generation Zetes 3iV Crystal multimodal voice technology system in the company's central warehouse in Newcastle West, County Limerick. As Zetes’ first multi modal voice implementation in Ireland it has achieved the automation of the stock management processes whereby more than 70 warehouse operators have been 'voice enabled' and can be guided through routine stock put away, inventory

management and order-picking procedures in real time. Voice Proves Reliable Choice For Non-bar-Coded Items Pallas Foods initially considered a system solely based on barcode scanning, but as products frequently arrive without barcodes, the voice system was deemed to be the better choice. Another benefit of Voice is that it increases productivity with a mini-

FOOD & DRINK BUSINESS EUROPE, JUNE 2012

mum of 15% and accuracy will go up to 99.9%. Zetes' system is designed to maintain service levels in the event of a systems failure, the software interface, known as a 3iV Connector, will continue working and capturing data even if one device should fail. According to Donald Riordan, Information Manager with Pallas Foods IT Department: “Zetes' system was technologically superior and not only offered us greater redundancy and resilience, but it was also hardware independent, giving us the freedom to use different devices in the future. Direct integration reduces the potential for data errors to occur because there is no database sitting between our ERP system and the voice terminals, data is exchanged in real time whenever an item of stock is moved.” J

19


I BUSINESS LAW

A&L Goodbody Provides Full Range of Legal Advice to Food and Beverage Sector &L Goodbody is internationally recognised as one of Ireland's leading law firms. With over 350 legal staff and a A total headcount of approximately 550, the firm advises the domestic and international corporate sector across every facet of business law. The firm has offices in Dublin, Belfast, London, New York and Palo Alto. A&L Goodbody has a wide ranging food and beverage practice which has been active in servicing the varied needs of the food, agri-food and beverage industries in Ireland for many years. The breadth of its practice is demonstrated by the diversity of its clients including some of Ireland’s most successful international and indigenous companies as well as multi -national companies who have a significant presence in Ireland. A&L Goodbody provides a full range of legal advice to companies and organisations in the food and beverage sector and specifically on: 1 Corporate transactions, such as: M&A, joint ventures and private equity investments 2 Competition law 3 EU law and trade regulations

4 Sales, marketing & brand issues, including: labelling & packaging, IP, advertising, sponsorship, promotional claims and product distribution 5 Product liability, food safety and health claims 6 Regulation of food and beverage products and contact materials 7 Product authorisations, including; pre-market approvals, application procedures and novel food authorizations 8 Licensing requirements, including, in particular, liquor licensing requirements 9 Specialist food-stuffs, such as: nutraceuticals, animal feeding stuffs, additives 10 Clinical trials 11 Crisis management. Visit www.algoodbody.com for further information. J

Specialist Instrumentation Services From PJ Boner & Co J Boner & Co is a specialist instrumenP tation company. It offers a number of services including Calibration Service, Instrumen-tation & Weighing Sales and Automation Control Systems. PJ Boner & Co provides a quality and efficient calibration service to all its customers in all aspects of Irish industry. The company can offer a scheduled calibration service or on-demand calibration service. Its calibration service covers all industries including pharmaceutical, healthcare, medical device, concrete, process, manufacturing and food & beverages. With 30+ years of experience as a business, PJ Boner & Co knows what its customers expect from their calibration provider and always delivers or exceeds customer expectations. PJ Boner & Co has a full range of certified Test Equipment that each fully qualified technician is familiar with to perform calibrations on-site or off-site traceable to National Standards. 20

Calibrations are performed using ProCal Calibration Management Software to complete calibrations in a timely, accurate and correct manner. In addition to its calibration service, PJ Boner & Co also supplies all types of instrumentation and weighing products and has existing agreements with international manufacturers to supply their high quality products to the Irish market. PJ Boner & Co’s automation offering includes Designing, Installing & Commissioning of Control systems using PLCs, HMI’s and PC’s and also using the full suite of SCADA and HMI software available to provide an excellent system to improve customers’ efficiency and quality within their own areas of expertise. PJ Boner & Co is an ISO9001:2008 company and works to keep its standards as high as possible through annual testing and internal improvement processes. J FOOD & DRINK BUSINESS EUROPE, JUNE 2012

PepsiCo Wins the 2012 Stockholm Industry Water Award lobal food and beverage company PepsiCo has been named the recipient G of the 2012 Stockholm Industry Water Award. PepsiCo has successfully reduced water consumption in its production, and extended its commitment beyond the company’s own operations to help solve water challenges on a broad scale. The company conserved nearly 16 billion litres of water in 2011, from a 2006 baseline, through the application of water saving equipment and technologies, creative recycling and re-use, and by deploying a water management system throughout its manufacturing facilities. J


I GREEN FACTORIES

Reducing Operating Costs and Improving C0 2 Footprint in Food-Processing he production, storage and filling of T beer in large quantities require extremely high amounts of energy, resulting in high operating costs for breweries presenting enormous potential for energy savings in the operation of refrigeration compressors, air compressors and gears by using state-ofthe-art speciality lubricants. “Reducing energy consumption is an important requirement of the installations’ manufacturers and operators, as energy costs make up a significant part of their total operating costs,” says Michael Stirnweiß, Head of Central Technical Sales at Kluber Lubrication. “However, energy does not only incur costs for the user; energy generation is also one of the main sources of climate-damaging C02 emissions. Reducing the energy consumption of a brewery is therefore also a marked contribution to environmental protection.”

formance products. Synthetic refrigeration compressor oils of the Kluber Summit R series, for example, enable refrigerators to operate with high efficiency due to reduced residues and oil carry-over. With these oils, refrigerators can be used for a wide range of applications with evaporator temperatures down to -50 C. Both Kluber Summit FG oils and Kluber Summit R oils are registered as NSF H1

ple from practice. A major brewery with three production lines shows high potential energy savings in the operation of compressors and gears. Their refrigeration compressor power in operation is 200 kW, air compressor power is 300 kW and gear power is 450 kW. Energy ffficiency increases between 0.5 and 15 percent were proven after the changeover to state-of-the-art speciality lubricants. The energy savings added up to 224,400 kWh, which is equivalent to more than Eur20,000 per year, taking as a basis 9.4 cents per kWh. Changeover to appropriate Kluber Lubrication speciality lubricants was easy and paid off after a short time.

Saving Costs With Synthetic Compressor Oils

The energy consumption especially of compressors constitutes a sizable proportion of operating costs. By reducing friction and offering better gap sealing, an appropriately formulated synthetic compressor oil contributes both to a higher volumetric efficiency and a reduction of energy consumption; less than one percent of the operating costs of a compressor are attributable to the compressor oil. Synthetic compressor oils turn out more cost-efficient when considering compressor operation as a whole. Further factors having a strong impact on the operational reliability of compressors are the lifetime of a compressor oil, its tendency to form residues, relubrication intervals and the oil vapour in the air. Compared with conventional mineral oils, high-quality synthetic compressor oils as offered by Klüber Lubrication are characterised by a high resistance to oxidation. Compressor oils of the Kluber Summit FG series are based on synthetic hydrocarbons. They are highly resistant to oxidation, leading to a clear reduction of residues. Besides longer oil change intervals, this enables longer filter and oil separator lifetimes, enabling in turn a reduction of maintenance and operating costs. The operation of refrigeration compressors also benefits from the use of high-per-

and certified according to ISO 21469, making the obvious choices for use in the food and pharmaceutical industries. Gear Oils For the Food Industry

Further contributors to high process reliability and reduced energy consumption are the synthetic gear oils made by Kluber Lubrication which are likewise registered as NSF H1 and certified according to ISO 21469. As their synthetic base oils are extremely resistant to ageing and oxidation, these lubricants offer a much longer service life and can increase gear efficiency considerably. Their good viscosity-temperature behaviour means that in many applications a single viscosity class can be used for both high and low temperatures. Kluberoil 4 UH1 N oils are gear oils for a normal temperature range and normal loads that even enable lifetime lubrication in certain applications. For high temperatures and high loads, the use of Klubersynth UH1 6 oils is recommendable as the optimised friction behaviour of the polyglycol base oil reduces power loss and clearly improves gear efficiency. An examFOOD & DRINK BUSINESS EUROPE, JUNE 2012

For a Lower C02 Footprint

The positive effects are not limited to savings in operating costs alone. If energy consumption is reduced, the carbon footprint of a brewery improves. Approximately 447 kg of carbon dioxide is emitted in Europe on average per megawatt hour, depending on the regional energy mix of fossil fuels, nuclear energy and renewable energies. The brewery saves 224,400 kWh, its carbon footprint improves by more than 100 tons of carbon dioxide per year. Kluber Lubrication is one of the world's leading manufacturers of speciality lubricants, offering high-end tribological solutions to virtually all industries and markets worldwide. Most products are developed and made to specific customer requirements. During its more than 80 years of existence, Kluber Lubrication has provided high-quality lubricants, thorough consultation and extensive services, which has earned it an excellent reputation in the market. The company holds all common industrial certifications and operates a test bay hardly rivalled in the lubricants industry. J 21


“Carbonostics is a truly innovative and pragmatic tool which will enable better decision making and help the food industry continue progress towards healthy, profitable and sustainable products.” Carmel McQuaid, Climate Change Manager, Marks & Spencer

Carbonostics The Sustainability Tool Built for Food • Carbon & Energy Accounting • Hot-Spot Screening • Product Lifecycle Assessment • Facility & Product Carbon Footprint • Product Portfolio Analysis

Carbonostics delivers the only seamlessly integrated suite of online, user-friendly carbon accounting and product lifecycle assessment applications designed specifically for the food sector. Carbonostics has democratized the field of metrics with its unique tools and robust database of over 3000 emission factors specific to food. Carbonostics puts a sustainability lens on your food products and business. Carbonostics is used by food, drink and ingredients manufacturers, retailers, foodservice suppliers, academics and food sector consultants.

Learn how Carbonostics can transform your business at www.carbonostics.com

Book a demo with a sustainability expert at contact@carbonostics.com


I GREEN FACTORIES

Carbonostics – Improving Sustainability and Efficiency, From Farm to Fork ith the growing emphasis on sustainW able business practices and energy efficiency, food and beverage processors are seeking user friendly, affordable and reliable environmental assessment tools, to help reduce their carbon footprints, and therefore their costs, right across their supply chains. To meet this requirement for more accessible sustainability metrics, Bluehorse Associates developed Carbonostics, an innovative online platform that delivers carbon and energy accounting, product-level lifecyle assessments (pLCA) and hotspot screenings. Carbonostics now delivers three levels of carbon footprinting - facility, product and organization - in one seamless system.

Carbonostics: Business + Brand organizational footprint analysis (facility plus product-level assessments) of a UK-based ready-meal manufacturer and a line of frozen lasagna products.

Demystifying LCA

The introduction of Carbonostics in 2009 has demystified and democratised LCA in the food and drink industry. “Bluehorse developed Carbonostics following discussions with Marks & Spencer concerning future needs for product carbon footprinting. There was a need to have a tool that was affordable and accessible to small and medium sized companies, as well as sophisticated enough for the larger suppliers. In addition, it had to have an accessible price point and easy enough to use by even those who are not LCA experts,” says Lori Gustavus, vice president, communications & marketing at Bluehorse Associates. She adds: “Five years ago the LCA market was swamped with complex LCA tools demanding expert handling. Consultants would come into companies and use those tools as black boxes and send back results that the company had no way to interpret and act upon. Carbonostics leveled the playing field and allows everyone access to the same decision support metrics.” Carbonostics offers a new approach to LCA that has proven to transform business and help executives make smart sustainability decisions. “It is our mission to bridge the gap between the science of sustainability with today’s strategic business needs. We stand behind the objective that sustainability can be a cost-savings and profit-generating activity,” she remarks. Wide Application

The Carbonostics tool is used by both large and small food and drink manufac-

turers in order to: • Identify areas to reduce carbon, cost, waste and water consumption; • Measure and report impacts in alignment with global standards; • Create Environmental Product Declarations (EPD); • Identify supply chain efficiencies; • Improve stakeholder and supplier relations; • Create product portfolio analyses to identify hotspots (ideal for large processors with 1000s of products to assess); • Guide new product design, innovation and R&D; • Enhance internal processes; • Controlled and confidential sharing of data and analyses with clients, suppliers and/or internal teams. An increasing number of food and drink processors are turning to Carbonostics to achieve their sustainability goals, whether by identifying supply chain efficiencies, reporting and compliance, stakeholder communication or new product development, innovation and R&D. Pin-pointing Hotspots

“A Carbonostics product analysis pin-points hotspots along the lifecycle which almost always debunks the assumptions processors have about their environmental impacts in their business and supply chains,” Lori Gustavus points out. Bluehorse Associates recently completed an analysis for a global ingredients manufacturer on one of its top ingredients. The FOOD & DRINK BUSINESS EUROPE, JUNE 2012

move to calculate the carbon footprint of the ingredient was prompted by pressure from one of the company’s main customers – a food processor, which in turn was being pressured by a retailer. The Carbonostics analysis highlighted carbon and cost hotspots in the processing and sourcing phases of the lifecycle of the ingredient. In the processing phase, the main source of carbon was found to be the natural gas used to fuel the production processes. The food ingredients manufacturer was working under the assumption that natural gas would have a lower carbon footprint than electricity, but this was not the case. “Now, they are in the process of exploring alternative energy sources which are being tested as scenarios within their Carbonostics analysis. In the analysis, an efficiency and cost-savings opportunity was identified as the company can use Carbonostics (and the scenarios function within the analysis) to make strategic business decision on what type of alternative energy source could be explored to ensure the carbon footprint and costs are lowered,” she explains. Further Enhancements

Bluehorse Associates recently launched a new Carbonostics Suite of carbon and energy accounting and product lifecycle assessment (pLCA) applications designed specifically for the food and drink industry. The new Carbonostics platform is the only application that allows seamless integration and calculation across three footprint levels - business or facility, brand or product, and organisation. It remains the only tool dedicated to food and drink businesses. The original Carbonostics (cost + carbon + nutrition) was a product level lifecycle assessment tool. The enhanced Carbonostics tool includes additional indicators such as waste and water and also allows users to calculate carbon emissions at the farm processing phase. The new platform has been also been expanded to deliver additional sustainability measurement options to food companies including the ability to process energy audits (carbon & energy accounting) which are often done annually for internal or external reporting, or to identify energy efficiency opportunities. J 23


I GREEN FACTORIES

Reducing the Dairy Industry’s Water Footprint Sustainability targets in dairy production facilities can be met through new advances in wastewater recycling and reuse. Alan Fairman from Veolia Water outlines the technologies which make increased water use possible. e have heard of the carbon footprint W and increasingly we hear of the water footprint. Veolia Water unveiled in 2010 an innovative initiative that assists in providing a more comprehensive assessment of the actual impact of human activity on existing water resources. Referred to as the “Water Impact Index”, the initiative is able to provide the first simultaneous analysis of a dual water and carbon footprint. The Index specifically incorporates both the volume and quality of the water extracted and then released back into the environment along with a Water Stress Index which addresses the actual level of stress on the existing water resources. The Water Impact Index will better enable industrial water managers to more effectively adopt best practices that make sense not only for capital and operations budgets but also for the environment and ultimately the customer and the community. One of the key considerations in assessing a company’s water impact index is the level of reuse within their systems. Recycle Treated Water

Large water consumption industries such as the dairy and beverage industries also fully understand that minimizing overall environmental impact has to involve water usage minimization and reuse where possible. According to the UK’s Envirowise, a dairy typically uses 1.3 litres of water for every litre of milk processed, mostly for steam raising and cleaning in place (CIP). Water reuse solutions however that allow water recycling on their facilities must also maintain compliance with existing water quality standards for the relevant proposed use, and not increase any potential risks to product or personnel as a result of reuse. One of the main technologies that can satisfy this requirement is Ultrafiltration. When Ultrafiltration (UF) membranes are used for wastewater separation the process is called a Membrane Bio-Reactor (eg 24

Western Corridor Recycled Water Project, Queensland Australia - Veolia Water’s largest advanced water cycling project in the southern hemisphere

3

plants

totalling

232

megalitres/day.

Veolia’s Biosep process). This process is a proven treatment technology with widespread use. By installing a Biosep process high quality effluent water can be created increasing the potential for recycling to other processes within a factory. These membranes provide a reliable barrier between the WWTP bioreactor in an activated sludge system and the industrial service uses for the recycled water. Reuse applications with Conventional activated sludge with clarification treatment plants normally necessitate additional treatment of the waste stream for TOC removal (eg Actiflo) and advanced filtration prior to sending the water for Tertiary Treatment. Tertiary treatments such as reverse osmosis, carbon filtering, ozone treatment and softening, are viewed as an essential requirement to give a robust guarantee to the quality of the recycled water. Recycling Example

By way of example, a recent project that Veolia was involved in was with one of the UK‘s most advanced dairies producing 400m3/day of process wastewater, which is treated and discharged to the local river. The dairy’s process wastewater plant had been upgraded to treat by Dissolved Air FOOD & DRINK BUSINESS EUROPE, JUNE 2012

Flotation (DAF) followed by a membrane bioreactor (MBR) to produce a crystal clear effluent that more than met the discharge consent to the river and provided substantial savings compared with sewer discharge. However, as the effluent was of such good quality it offered the opportunity of recycling. Pilot plant trials confirmed that the MBR effluent could be fed directly to a Water Reverse Osmosis membrane system so the initial system was installed to recover 200m3/day of the process wastewater to replace mains water in the CIP system. Veolia provided a MegaRO™ reverse osmosis technology which uses a membrane to remove 99% of residual COD, dissolved salts and bacteria from the treated process wastewater, producing water of equal or better quality than the mains supply. The MegaRO™’s low pressure membranes and high efficiency pumps make it one of the most energy efficient plants on the market. Low energy use means not only reduced carbon emissions but also low operating costs. The MegaROTM runs continuously and the permeate is chlorinated and stored for use in CIP. Incidentally the quality of the waste concentrate stream is still good enough for discharge direct to the river. Having seen the environmental and economic benefits of recycling process wastewater, the company are planning to install combined effluent treatment and recycling systems at some of their other dairies where process wastewater is currently discharged direct to sewer. Payback of 2 to 3 years is possible depending on local water and sewerage costs. Many of Ireland’s dairies and food industries are currently planning for plant expansions based on the improved outlook for the sector. Designing the associated effluent plant with upgrades to allow for water reuse should be seen as key to achieving a company’s environmental and economic goals. J


I LEAN MANUFACTURING

Lean Powder Processing Solutions atcon is a global leader in providing systems for handling dry M solids based around portable containers (Intermediate Bulk Containers or IBCs) for batch powder processes. Its main business philosophy is to help clients reap the benefits of Make to Order Production and Eliminating Waste. Matcon’s solutions are designed for production environments required to cope with varying order sizes, widening product portfolios, and more stringent regulations. Matcon’s main process and technical focuses are solids handling, dust containment and flexibility. Process Focuses Parallel Processing

The company promotes the use of a Matcon IBC System to separate (decouple) various process steps. This allows for processes to be reliably performed simultaneously instead of sequentially, which can increase production capabilities. Matcon calls this approach ‘Parallel Processing’ and its clients use this approach to reduce inventory; synchronize process cycle time; maximize capacity and flexibility; optimize utilization of equipment and labor; in essence, they revolutionize how they manufacture products.

Matcon typically looks at production in four areas: (1) Raw Material Handling/Recipe Formulation; (2) Material Processing (typically Mixing & Blending); (3) Packaging; (4) Cleaning. It is these areas (process modules) where Matcon focuses on implementing ‘Parallel Processing’. J

Solids Handling

All Matcon Solutions are designed to overcome traditional powder handling issues. Implementing a ‘Parallel Processing’ concept will not be successful if the chosen IBC System is incapable of effectively handling all products and recipes without causing segregation or production stops. Hygienic Solutions

Matcon also provides closed powder transfers utilizing easy-toclean equipment. These benefits further increase production by ensuring product integrity and reducing downtime for cleaning. A Matconbased solution does not just control dust but contains it. This is particularly important when there is a concern of allergens and cross-contamination. FOOD & DRINK BUSINESS EUROPE, JUNE 2012

25


I BAKERY

Sveba-Dahlen – Leading Innovation in Industrial Bakery The C-series is Sveba-Dahlen’s range of compact rack ovens, designed for installation in restricted spaces. It has a small footprint but is highly effective, simple and flexible.

aving invented the rotating rack oven H almost 50 years ago to revolutionise industrial baking, Swedish engineering company Sveba-Dahlen remains at the forefront of innovation in the sector. Rotating rack ovens introduced a new level of flexibility into industrial baking. Most bakery products can be produced in rack ovens and they are efficient and easy to operate. The products to be baked are loaded on racks and simply rolled into the oven before activating the baking process. Since the capacity range of rack ovens is so vast, they are used in most bakeries, especially where the baker is making a wide range of products. Indeed, rack ovens in different forms are found in almost every bakery today. Sveba-Dahlen offers rack ovens ranging in capacity from the S200 model that holds six trays in a fixed rack up to the I70 series that holds four 800X600 racks. Sveba-Dahlen has also patented an ingenious alternating rotation system (IBS), which makes the racks rotate in both directions. “By doing this the baking result is more even than in a traditional rotating rack oven and it also cuts the baking time on most products since the core temperature of the product is reached faster,” says Pierre Eliasson, marketing & communication man-

World Leader

ager of Sveba-Dahlen. “This has been confirmed by our customers who constantly refer to our ovens as energy efficient.” Energy Efficiency

Improving energy efficiency has been one of the key developments in rotating rack ovens in recent times, and Sveba-Dahlen has again been leading the way. “Sveba-Dahlen has worked towards making our ovens as energy efficient as possible by adding overlapping insulation to keep the heat inside the oven chamber so as not to lose energy through the walls and ceiling. The burner chambers work on the counter flow principle which optimizes the heat outtake from the heat exchanger, this together with our patented rotation system (IBS) makes the oven very energy efficient,” he explains. In addition to their high energy efficiency, Sveba-Dahlen’s extensive range of rotating rack ovens also offer bakers of all sizes a superior baking quality and, thanks to the IBS system, shorter bake times, resulting in higher capacity.

Established in 1948, Sveba-Dahlen has become a world leader in the development and manufacturing of equipment for the bakery industry, with over 300 tunnel oven installations delivered to customers around the world. Sveba-Dahlen is now an international business with a world-wide distribution network including sales offices in Spain, Hong Kong, Estonia and Russia. Operating from its base in Sweden, the company currently employs almost 300 people and has an annual turnover of Eur55 million. “Sveba-Dahlen stands for product development and we have always been one of the leading producers of bakery ovens in the world. We offer new and reliable technology and high quality components, and our ovens are very durable,” comments Pierre Eliasson. “Our customers get added value when doing business with us, they just don’t buy a product.” J

Continued Development

Sveba-Dahlen invented the rotary rack oven, which has now become an industry standard, in 1964. Since then, the company has continued to develop the concept, and currently offers rack, deck, and tunnel ovens, as well as prover rooms and prover lines to large and small industrial bakeries worldwide. Svena-Dahlen invests heavily in R&D in order to continually enhance its product range. For example, it has just re-launched the C-series single rack oven, introducing improvements on several features of the oven. FOOD & DRINK BUSINESS EUROPE, JUNE 2012

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I BREWING

Leadership Changes at SABMiller SABMiller, the world’s second largest brewer, is about to implement a number of key changes to its board and senior management team. eyer Kahn, who first joined the group in 1966, and who has been chairman of SABMiller since its primary listing on the London Stock Exchange in 1999, is retiring as chairman after 46 years of service with the group. Graham Mackay, who joined the group in 1978 and who has been group managing director since 1997 and chief executive since 1999, will become executive chairman, with the intention that he will continue in that role for one year, before becoming non-executive chairman in 2013. Alan Clark, currently managing director of SABMiller Europe, will become chief operating officer of the group and will succeed Graham Mackay as chief executive in 2013. John Manser, currently the senior independent non-executive director and chairman of the audit committee, will in addition become deputy chairman of the board. Sue Clark, currently the group's director of corporate affairs, will succeed Alan Clark as managing director of SABMiller Europe. The changes will become effective from the date of the group’s annual meeting on July 26th 2012.

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Stable and Consistent The senior management team at SABMiller has been one of the most stable and consistent in the FTSE 100, with the chairman and chief executive being amongst the longest serving in their respective posts. Under Meyer Kahn’s leadership, both as group managing director and latterly as

SABMiller’s portfolio includes global brands such as Pilsner Urquell, Peroni Nastro Azzurro, Miller Genuine Draft and Grolsch, as well as leading local brands.

chairman, the group has grown from its South African roots to become one of the world’s largest brewers, with brewing interests and distribution agreements across six continents. The group's wide portfolio includes global brands such as Pilsner Urquell, Peroni Nastro Azzurro, Miller Genuine Draft and Grolsch, as well as leading local brands such as Aguila, Castle, Miller Lite, Snow and Tyskie. SABMiller is also one of the world’s largest bottlers of Coca-Cola products. Reflecting particularly strong growth in Latin America and Africa, SABMiller reported an 11% increase in revenue to $31.4 billion and a 12% rise in EBITA to $5.6 billion, with underlying lager volumes up 3% to 229 million hectolitres, in the 12 months to March 31st 2012. EBITA increased by 8% on an organic, constant currency basis, with all beverage divisions except for Europe contributing to growth. EBITA margin was 10 bps ahead of the prior year at 17.9%. SABMiller now generates about twothirds of its revenue in emerging markets, such as Latin America and Africa. However, growth in developed markets, like the US and Europe, has been hard to achieve. EBITA rose only slightly in the US and declined by 6% in Europe. The last financial year featured a number of significant merger and acquisition deals. In December 2011, SABMiller completed the $9.6 billion acquisition of Foster’s to become the leader in the Australian beer market. SABMiller has also entered a strategic alliance with Castel in Africa. In March 2012, SABMiller completed a strategic alliance with Anadolu Group and Anadolu Efes, exchanging its Russia and Ukraine beer businesses for a 24% equity stake in the enlarged Anadolu Efes group. The Russia and Ukraine operations have an enterprise value of about $1.9 billion. Anadolu Efes is now the vehicle for both groups’ investments in Turkey, Russia, the CIS, Central Asia and the Middle East. Outlook Looking ahead, Graham Mackay comments: “Trading conditions are expected to be broadly unchanged with further growth FOOD & DRINK BUSINESS EUROPE, JUNE 2012

Graham Mackay, chief executive of SABMiller.

in our developing markets but no more than modest improvements in consumer spending in some more developed economies. We will continue to develop and differentiate our brand portfolios, taking opportunities to improve sales mix and raise prices selectively. Unit input costs are expected to rise in mid-single digits in constant currency terms.” Tough Challenge in Europe Sue Clark will face a tough challenge when she takes over from Alan Clark as managing director of SABMiller Europe in July 2012. Alan Clark has headed SABMiller Europe since 2003, overseeing strong growth across its main markets but volume growth has been faltering in recent times due to the deteriorating economic environment. Indeed, beer markets continue to be affected by consumer down trading and the growing popularity of economy brands and packs, together with growth in modern trade and discounter channels, and declining on-premise consumption In the year ended 31 March 2012, SABMiller Europe reported a 6% drop (9%

Sue Clark, currently the group's director of corporate affairs, will succeed Alan Clark as managing director of SABMiller Europe in July.

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SABMiller’s Brands Drive Growth in the UK ‘World Beer’ Market SABMiller has announced that its UK subsidiary, Miller Brands, has delivered lager volume growth of 8% in the 12 months to 31 March 2012, despite a declining UK lager market. Much of this growth is the result of Miller Brands’ premium portfolio which has been a significant driver behind the popularity of ‘world beer’ in the UK. Peroni, Pilsner Urquell and Kozel all grew by double digits during the year. Recent research conducted by Miller Brands has found that World Beer is the only sector of the UK beer category experiencing significant growth. If the current trend continues, by the start of 2014 World Beer could be worth more than £2.1 billion in sales and make up 19% of total lager value. Gary Haigh, managing director of Miller Brands, says: “As austerity measures bite, consumers are more discerning about what they consider an everyday treat. When it comes to beer brands they are increasingly looking for brands with a story, heritage and interesting provenance. We see this trend continuing for the next few years resulting in a strong and vibrant world beer category.”

SABMiller Europe currently operates 18 breweries in eight countries.

on an organic, constant currency basis) in EBITA to Eur836 million on revenue up 2% to $5.48 billion as profit margins

slipped from 16.4% to 15.3%. Lager volumes fell by 1% on an organic basis to 43.1 million hl. EBITA was impacted by significant increases in raw material costs, although the group’s global procurement and regional manufacturing projects continued to deliver mitigating cost efficiencies. SABMiller Europe’s beer volumes in Poland and Romania fell by 4% and 8% respectively, although other markets generally saw improved volume trends. Going forward, SABMiller Europe will be significantly smaller in scale as the Russia and Ukraine businesses are now part of Anadolu Efes. The Russia and Ukraine operations have combined beer volumes of

about 7 million hl and net sales of roughly $680 million. Total annual brewing capacity is 10 million hl in Russia and 1.7 million hl in Ukraine. SABMiller Europe currently operates 18 breweries in eight countries - Czech Republic (3 breweries), Hungary (1), Italy (3), Poland (3), Romania (4), Slovakia (1), Spain (Canary Islands - 2) and The Netherlands (1). SABMiller Europe is the first of second ranked brewer by market share in the majority of these countries. It also exports significant volumes to other beer markets in Europe, of which the largest are the UK and Germany, and to other regions of the world. J

I DISTILLING

Diageo to Invest £1 Billion in Scotch Whisky Production iageo plans to invest over £1 billion major expansion at a number of D in Scotch whisky production over Diageo’s existing distilleries. the next five years to meet growing globDetailed plans will also be developed al demand for its brands. A major new malt distillery will be built as part of the investment, alongside a programme of

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for a second new distillery which will be built if global demand for Scotch is sustained at expected levels. The world’s leading premium drinks business also plans to invest in substantial new warehousing capacity to house the millions of additional litres of Scotch whisky which the distillation investment will produce. Paul Walsh, chief executive of Diageo, comments: “This is a pivotal moment in the development of the Scotch whisky category for Diageo. Over recent years our brands have achieved remarkable, sustained global growth. Scotch whisky is Scotland’s most celebrated manufactured export, led by brands like Johnnie Walker, resonating with consumers from Boston to Beijing.” He continues: “We expect that success to continue, particularly in the high growth markets around the world, which is why we are announcing this major investment in Scotch whisky production, committing over £1 billion in the next five years, to seize that opportunity for global growth. This builds on the founFOOD & DRINK BUSINESS EUROPE, JUNE 2012

dations we have already laid down over recent years through sustained investment in both production assets and in maturing Scotch inventories.” J


Pelliconi Focuses on Sustainability elliconi, the world's leading manufacP turer of crown corks, metal and plastic caps for the bottling industry, is committed to driving the business according to principles of sustainability, focusing on safety, innovation, respect for the environment, people care and creating value to stakeholders. Pelliconi is currently working with an external specialist consulting agency to formalize, systemise and improve company commitment toward sustainability. The sustainability project has already been launched and will involve the top management and CEO taking an active and formal role. Pellconi has currently assessed its positioning in terms of CSR in relation to national and international best practices with particular regard to: • ISO 2600 – international standard for Corporate Sustainability; • GRI-G3 Standard set of indicators for social, environmental, governance accountability; • Ethical Indexes (eg like Dow Jones Sustainability Index Requirements). The preliminary assessment has provided information for the further steps to be taken within the project. The CSR assessment has been made available to the Group management: • a detailed map describing the actual per-

formance in terms of CSR, strengths and weaknesses within the different areas of sustainability; • the draft of a detailed action plan to improve actual sustainability performance; • a formal identification of organizational roles and responsibilities to promote the diffusion of sustainability practices. Sustainability Plan Pelliconi will invest in human and economic resources to improve the performance and active work in the following areas: Accountability: • Sustainability Reporting • Sustainability policy Sustainability Governance: • Sustainability Director • Sustainability committee • Sustainability goals in the industrial plan. Continuous Improvement: • Specific project in the weakness areas of sustainability. CSR Project Targets Pelliconi’s objectives in the next few months will be: Sustainability culture: Point out the most critical areas to optimise internal processes ensuring that all company departments are involved with sustainability and social issues,

FOOD & DRINK BUSINESS EUROPE, JUNE 2012

Projects and targets: Define sustainability goals in the industrial plan, establish improved objectives and set specific projects to increase general accountability and stakeholder trust. Performance tracking: Implement a sustainability performance management system that satisfies social, economic and environmental expectations of stakeholders and society. In the next few years Pelliconi will continue to invest in projects related to environmental impact minimization, people care and safety, stakeholder management, community development, corporate governance and many other issues related to company sustainability. J Management Systems * Best available technologies and practices * Compliance with applicable regulation and GMP - EU/FDA Regulations for food contact materials - Product hygiene and food safety in all plants (HACCP and/or GFSI recognised schemes like BRC-IoP or FSSC) - Environmental regulations and standards (EU and CONEG) - Environmental management system in all plants (ISO1400 certified in Pelliconi Abruzzo plant) - Sector technical guidelines.

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I HEALTH & SAFETY

Accident Prevention in the Food and Drink Industry “Efforts to raise health and safety standards in smaller businesses, therefore, should be built around the specific challenges they face and should not be overly burdensome in terms of time or financial costs,” he adds.

ore than 5,000 injuries within the UK M food and drink manufacturing sector are reported to the Health and Safety Executive each year, representing about a quarter of all the reported injuries in manufacturing. Manual handling and slips and trips are the most common causes of these injuries. The Royal Society for the Prevention of Accidents (RoSPA) is a safety charity that has been at the heart of accident prevention in the UK and around the world for more than 90 years. “Accidents cause loss and suffering to the victims and their loved ones, employers and UK society as a whole,” points out Tom Mullarkey MBE, chief executive of RoSPA. “For this reason, our mission is to save lives and reduce injuries and we do this by promoting safety and the prevention of accidents at work, at leisure, on the road, in the home and through safety education.” Many of the services offered by RoSPA’s workplace safety department are relevant to firms in the food and drink industry, regardless of whether they are manufacturers, distributors or retailers. For example, RoSPA’s manual handling training courses, including its new BTEC Manual Handling Trainers (Level 3) course, and risk assessment services have been developed to address one of the major causes of injury in the food and drink sector. Also of particular interest on the training and consultancy front is RoSPA’s forklift truck training and consultancy services on issues such as on-site workplace transport and noise. Additionally, RoSPA offers a full suite of services to help firms manage occupational road risk, including management solutions like policy reviews, as well as risk assessment and driver training. RoSPA also offers a wide range of general health and safety training courses that are ideal for occupational safety professionals looking to improve their qualifications or any member of the workforce seeking to increase their knowledge and skills. Tailored Services

“We pride ourselves on being able to respond to the specific needs of our clients and, as such, we can tailor our services to the requirements of any organisation,

Health & Safety Achievements

Tom Mullarkey MBE, chief executive of RoSPA.

regardless of their size. In the food and drink sector, our work brings us into contact with multinationals right the way down to small and medium-sized enterprises (SMEs),” explains Tom Mullarkey. “When working with SMEs, it’s crucial to remember that they are not just smaller versions of large companies: they face distinct challenges when it comes to health and safety. As well as time constraints, tight budgets mean difficult decisions often have to be taken about how to invest appropriately in health and safety, and the recession has only served to increase these pressures. SMEs, for example, may find it difficult to access specialist help on health and safety, including training.” He elaborates: “We also know that SMEs tend to have higher accident rates and the effects of injuries and ill health on the business can be particularly acute. Accidents can interrupt business continuity, for example, where the prolonged absence of a key member of staff results in significant lost time. Accidents can affect future orders, limit output and damage workforce morale.” However, the financial cost of complying with health and safety regulations is different in small and large firms. One report has found that, on a per employee basis, SMEs may be spending nearly six times more than larger firms on risk assessment. FOOD & DRINK BUSINESS EUROPE, JUNE 2012

Another area of RoSPA’s work concerns the recognition of health and safety achievements. Each year, the RoSPA Occupational Health and Safety Awards - the largest and longest running awards programme of its type in the UK - provide recognition to firms that are committed to continuous improvement on accident and ill health prevention. More than 80 food and drink manufacturing firms were successful in the RoSPA Awards 2012. Sector award winners included Premier Foods of St Albans, which won the Food and Drink Manufacturing sector, and Chivas Brothers - Pernod Ricard of Paisley, winner of the International Dilmun Environmental Award (sponsored by GPIC). Organic yoghurt maker Yeo Valley provides a further illustration of RoSPA’s activity within the food and drink industry. In just seven years, Yeo Valley moved from Level 3 to Level 5 (Diamond - the highest level) in RoSPA’s flagship Quality Safety Audit scheme, which provides an in-depth analysis of the specific factors at the heart of an organisation's safety performance. “Working with RoSPA enables firms to gain access to our unrivalled suite of services across all areas of safety, enabling them to not only meet their legal and moral responsibilities when it comes to safety and health, but also to enjoy the very real business benefits of effectively managing this area of work,” Tom Mullarkey comments. He concludes: “For many SMEs, for example, the structure and formality of a risk assessment provides the only process and quality system they have, which they need to differentiate themselves from the ‘cowboys’. For larger companies, particularly in times of slow growth, effective health and safety management results in cultural cohesion, strong leadership and reduced costs from, for example, fewer vehicle fleet collisions or fewer employee absences through ill health.” J 33


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ISO 21469 Accreditation Gives Food Manufacturers Peace of Mind eading food-grade lubricants manufacturer ROCOL has made it L even easier for food and drink manufacturers using FOODLUBE® to pass retailer, EFSIS and BRC audits by becoming the UK’s first ISO 21469:2006 certified lubricants producer. The globally recognised ISO 21469:2006 certification ticks an important box for auditors as it provides credible, independent assurance that all ROCOL products are formulated, manufactured and supplied hygienically and safely. For any food and drink manufacturer using FOODLUBE lubricants, especially those reliant on leading retailers through long-term contracts, this provides a vital first step towards conforming with major supermarket, European Food Safety Inspection Service and British Retail Consortium audit requirements. Products in the FOODLUBE range are already NSF-H1 registered, which specifies the hygiene requirements for the formulation, use and handling of lubricants that may incidentally come into contact with products during manufacture. ISO 21469:2006 builds on the product-specific NSF-H1 standard to represent another important layer of safety approval. It means that products are manufactured to stringent recipe and hygiene standards using good manufacturing practices, dedicated equipment and strict handling procedures. Each product is hygiene assured as it has been independently verified by an NSF inspector and tested in their laboratories. It is then deemed safe for incidental food contact and certified as being manufactured only from FDA listed ingredients which are free from animal derived materials, nut oils, soya, dairy and genetically modified ingredients. Brendan Kendrick, UK sales director at ROCOL, says: “We are committed to helping UK food and drink manufacturers achieve excellence in safe, food-grade manufacturing which is why we have invested in securing ISO 21469:2006 certification. It means complete audit trail peace of mind for manufacturers who benefit by being able to prove that the lubrication products used throughout their processes have been subjected to stringent and rigorous hygiene and safety testing”. As part of its ISO 21469 certification, ROCOL provides risk assessments in the use of lubricants, conducts factory audits, helps customers develop and police effective quality assurance procedures and monitors product composition through ongoing sampling and retesting. J 34

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I FOOD SAFETY

ISO 21469 and its Implications For Users of Food Grade Lubricants, Fluids, Oils and Greases ll machinery requires lubrication in A order to keep it in good working condition. The manufacture of food, bever-

the desired standard and criteria for certification.

ages and pharmaceuticals adds an extra level of complexity due to the strict food safety regulations that govern the industry. Food Grade Lubricants must therefore be used in place of standard lubricants to facilitate the auditing requirements of the seller and to provide safety for the consumer. For many years, NSF H1 accreditation was accepted as the standard indication of food safe lubricants, this is an honour system and is unaudited. Developments in the field have now led to a more thorough process to ensure safety in the high risk sector of food and drink manufacturing. ISO 21469 is the highest accolade that a food grade lubricant manufacturer can achieve. It proves that a lubricant is manufactured in a hygienic environment, using both best practices and the safest ingredients.

Testing

NSF International

The NSF was founded in 1944 to protect and improve human health on a global scale. It is an independent, non-profit making organisation providing product certification. It is dedicated to being a global leader in public health and safety-based risk management.

Thorough external product testing is conducted annually in order to ensure that conformance to the requirements of ISO 21469 remains up to date and consistent. Risk Assessment

Risk assessments must be carried out to ensure that all potential hazards within the manufacturing process are identified. areas. It certifies that the product has been formulated from FDA approved ingredients but does not regulate the manufacturing process and relies on the honesty of the manufacturer. H1 lubricants are suitable for use on food processing equipment in areas where there is potential for the exposure of the lubricant to food or its packaging. Typical applications of H1 lubricants are the lubrication of machine parts and corrosion inhibition. In order to receive the NSF H1 accreditation and be authorised for use where incidental food contact may occur, a lubricant must meet the category requirements that cover the formulation of the product, its labelling and a review of the proposed enduse.

FDA Listed Ingredients

How ISO 21469 Certification is Achieved?

The first step on the way to ensuring that a lubricant is suitable for ISO 21469 accreditation is to select ingredients that are food safe during initial development. The US Food and Drug Administration (FDA) provides a list of all approved ingredients. This ensures that only safe levels of any ingredient are contained within an NSF accredited lubricant. Once complete, the formulation is submitted to the NSF for assessment against the H1 standard.

In addition to the requirements for H1, ISO 21469 accredited lubricant manufacturers must go through an unannounced annual auditing process to ensure that all products are made to strict hygiene standards, using good manufacturing practices. Any manufacturer applying for certification will need to go through the four stage process detailed below. Certification will not be given until all criteria for each phase has been met.

NSF H1

Product Formulation Review

A lubricant with NSF H1 accreditation is acceptable for incidental food contact and can be used in and around food processing

The formulation review for ISO 21469 is used to make sure that all the component ingredients of a food grade lubricant meet FOOD & DRINK BUSINESS EUROPE, JUNE 2012

Production Facility Audit

Manufacturing site audits are carried out allowing the NSF to confirm that all the criteria for accreditation are met. Once the four stage process has been completed to the satisfaction of the NSF then the certification is awarded and the lubricant packaging is authorised to display the ISO 21469 NSF Certification Mark. The positive effects of ISO 21469 are felt by many stakeholders: • Lubricants manufacturers seek ISO 21469 accreditation as the highest accolade that can prove their suitability for food grade applications. • Auditors are reassured by the presence of accreditation as it allows full traceability of the lubricant manufacturing process. • Food manufacturers prevent contamination of their products and reduce waste whilst supplying safe products to major supermarkets and other distributors. • Major supermarkets audit the food manufacturers that they deal with in order to manage and reduce the risks to their customers. Supermarkets are also increasingly insisting that their suppliers use lubricants that do not contain mineral hydrocarbons. • Consumers are protected against the possibility of eating a product which is tainted with hazardous material. Once ISO 21469 certification is achieved it proves that a lubricant is manufactured in a hygienic environment, using both best practices and the safest ingredients. J 35


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BEST Innovations in Sorting Technology for Vegetables Processing he vegetable processing industry is beneT fiting from continual advances in sorting technology which have significantly enhanced food safety by improving the detection rates of unfit produce along with increasing speed and efficiency of production and yield. Sorting technology is used to detect foreign material and discolorations. As defects can have the same colour as the vegetables, not only is the colour inspected but also the structural differences or the quantity of water the products contain. BEST (Belgian Electronic Sorting Technology) Sorting, a Belgium-based subsidiary of the Norwegian TOMRA Sorting Solutions group, specialised in manufacturing sorting machinery for the food and non-food industry, has developed laser sorting systems, which guarantee high efficiency and minimal false reject. “Thanks to the flexible set-up and the combination of different technologies (laser, camera, biological features such as fluorescence and SWIR) it is possible to obtain the highest performance”, points out Bjorn Thumas, Sales Manager of BEST Sorting. Combination of Different Technologies

Fluo technology is based on detecting contaminants based on natural fluorescence, which is dependent on the amount of chlorophyll the products contain. Some vegetables contain a lot of chlorophyll for instance, whereas contaminants like stones or plastic do not. Short wave infrared or SWIR technology uses invisible infrared waves that are absorbed by water. Fruit and vegetables contain a lot of water, creating a major contrast against other non-water containing foreign materials. By combining several wavelengths with SWIR, contaminants, such as glass, cardboard and metal, are detected and rejected from the good product providing optimum sorting efficiency, with extremely low false reject. In the BEST sorting equipment, Fluo and SWIR technology can be combined within the same system amongst others. “This optical laser platform detects a number of defects that are not detected by traditional sorters today, allowing for a breakthrough in sorting efficiency”, he explains.

tomers and prospective customers to test the BEST sorting solutions in an environment that simulates their production process. BEST uses the customer’s products to demonstrate the efficiency of its sorters, allowing the client to evaluate the results before investing. Applications in Vegetable Processing

Lettuce processing line.

A further key advancement in sorting technology has been the development of the Flex & Smart sorting modules to sort for example frozen vegetables. “The flexible platform combines an easy set-up and programming for an optimal sorting performance. The digital Flex Sort module eliminates the need to select and change the optimal reference drum for each specific product. This revolutionary technology improves the contrast between good products and defects. The Smart Sort module helps the operator setting parameters by analyzing the incoming products. It automatically provides a program set up in a simple and timely manner”, says Bjorn Thumas. Simple Working Principle

Sorting machines have a relatively simple working principle. The food is fed through the machine via a free-fall system or conveyor belt. A control system (camera, laser, etc) scans and detects the unwanted objects (rotten vegetables, foreign material). After a few milliseconds the defects are hit by a precise, powerful burst of air sending them into the rejection zone while the good product continues on its way along the processing line. “100% accuracy in removal of all defects is never possible, but we always strive to reach this mark as closely as possible. That is also one of the reasons why we are constantly investing in new technology and the improvement of existing technology”, he remarks. The company recently opened its fifth BEST Sorting Solution Center (BSSC) worldwide at its headquarters in Leuven, Belgium. The Solution Center allows cusFOOD & DRINK BUSINESS EUROPE, JUNE 2012

For instance, BEST recently developed an adapted machine configuration to meet the specific requirements of the spinach processing industry. A special infeed system was successfully designed to obtain a single product layer with a perfect product speading, and the laser technology was further optimized. Thanks to the Fluo technology, structural defects and non-chlorophyll containing items can be detected. The unique solution guarantees a high throughput (up to 9 tons/hour), with a focus on the removal of foreign material. BEST technology is also able to sort different types of lettuce, ranging from iceberg, chopped and shredded, to romaine, spring mix, water cress, rocket salad and many more. The innovative company’s systems are also sorting different kinds of fresh and processed fruit and vegetables like bell peppers, jalapeno peppers, tomato dices next to your regular corn, peas and green beans etc. Latest Development

BEST’s most recent development for the vegetable processing industry is the Opus, a free-fall camera and laser sorter that detects foreign material using colour, shape and structure recognition technology. “The sorter is the most ideal and cost effective optical sorting solution for IQF fruit and vegetable processors. It provides continuous food inspection to ensure food safety and customer satisfaction at all times, by removing unwanted discolorations, foreign material, defects by shape, with maximum yield,” comments Bjorn Thumas. The sorter has a small footprint and the ideal inspection width to be integrated in an IQF fruit or vegetable packing line. The Opus features the new high resolution BEST camera that can be combined with FLUO and/or SWIR technology. The sorter has a capacity of 7 to 9 tons per hour. J 37


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Measuring the Effectiveness of Your HACCP Plan

QMS Solutions – The Specialists in Food Safety

s a front line food safety professional Raytech Consultancy Services business director, Ray Warrick, is asked to assess and verify HACCP plans for a wide range of food operation types and sizes. “Most businesses have a HACCP plan of some description in place. However, very few understand how to measure the actual effectiveness of their plan,” he explains. Control points can be easily verified through monitoring, tests and various procedures to show compliance with the HACCP plan. This is the work of an auditor. The key part that many operations miss is validation. This is the process of demonstrating that the HACCP system, as designed, adequately controls identified hazards to produce a safe product. This can be done using scientific or technical justification (will the HACCP work in theory?) or with initial practical demonstration proving the system can perform as expected (does the HACCP Ray Warrick, Business Director of Raytech Consultancy Services. work in practice?). “For example, we all know the theory and engineering behind a pasteuriser but does YOUR pasteuriser do the job effectively? The best time to do this validation is before you implement the plan and can be done by other experts within your company eg corporate level, or by external independent specialists and HACCP experts,” he adds. J

A

rish quality management consultancy Idesign, firm QMS Solutions specialise in the development and implementation of complete Food Safety Management Systems, including product traceability and recall, which are individually tailored to the specific needs of each client, such as large food processors, SMEs, laboratories, food packaging manufacturers etc. QMS Solutions assists clients with improving their food safety through the application of the principles of HACCP and all current food safety and quality standards. Through customised consultancy and training, QMS Solutions will design, develop and implement your Food Safety Management System. The main benefits of Food Safety

Quality Management Consultants

Specialists in Food Safety (HACCP) The main benefits of HACCP are; • Your processes become structured and organised around food safety & quality standards • Via systematic control HACCP prevents / reduces the likelihood of customer poisoning • You become compliant with the law • Systematic and repeatable processes to ensure greater efficiency and food safety • This structure promotes teamwork • Can prove due diligence in the event of court action • As a pre-requisite, such systems remove barriers to trade, allowing growth and expansion. • Saves your business money in the long run QMS Solutions. Quality Management Consultants 5,6 Glebe View House, Rivermall. Swords, County Dublin, Ireland Phone: 01-8957677, Mobile: 086-8799311, E-mail: info@qmssolutions.ie

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FOOD & DRINK BUSINESS EUROPE, JUNE 2012


QUALITY

Management Systems include: • Your processes become structured and organised around international food safety & quality standards; • Prevents/reduces the likelihood of incidences of food poisoning; • Full legal and regulatory compliance; • Systematic and repeatable processes ensure greater efficiency and food safety; • Proving due diligence in the event of legal

& HYGIENE

action; • As a pre-requisite, such systems remove barriers to trade, allowing growth and expansion • Saves your business money in the long run. In addition to guaranteeing food safety and legal compliance, QMS Solutions’ Food Safety Management Systems can also add value to a business by helping to identi-

fy where greater efficiencies can be achieved. All systems developed by QMS Solutions are based on international standards and facilitate existing and future systems integration thus resulting in greater efficiencies and more effective processes (eg ISO 50001 Energy Management, ISO 9001 Quality Management, ISO 14001 Environmental Management etc). J

Adam Equipment Presents ABK and AFK Bench and Floor Scales dam Equipment, a global provider of balances and scales, has announced the availA ability of its ABK and AFK industrial scales. Designed for heavy-duty industrial applications, Adam’s ABK and AFK scales are easy to use and deliver quick results for a wide variety of weighing tasks. Both the ABK and AFK are excellent for parts counting, percentage weighing, check weighing and dynamic weighing applications. They boast capacities ranging from 16lb/8000g to 1320lb/600kg and readabilities ranging from 0.0005lb/0.2g to 0.1lb/50g. The ABK and AFK provide six weighing units, including kilograms, grams, pounds, ounces, pounds:ounces and Newtons. With an RS-232 bi-directional data output, the ABK and AFK provide a computer and printer connection that enables seamless downloading of data. An adjustable indicator rotates a full 360 degrees and can be set to any angle; it can be mounted on the supplied pillar or attached to a wall for clear viewing. The sleek stainless steel indicator has superior sealing and is protected against heavy dust and wet environments. Built-in limit lights and colour LED indicators make the ABK and AFK ideal for check weighing, as the indicator shows when the weight is below, at or above the desired weight. Well-suited for warehouses or production environments, the display is vivid and easy to read, even in poorly lit areas, helping streamline activities and reduce data entry errors. For more information visit www.adamequipment.com. J

First pan-European Corporate Comms and Public Affairs Agency Team Focuses on Food urope’s first food industry-dedicated tation programmes and projects. E corporate communications and public Says Chris Woodcock, Managing affairs joint consultancy, operating across Partner at College Group: “Our clients Europe, has been launched, ahead of challenging times for the food and beverage market. FoodFirm is a highly experienced team of independent communications and public affairs consultancies, jointly dedicated to managing the reputation of the food and beverage market - from agriculture and raw materials to retail and consumer brands. FoodFirm has been set up by four toplevel agencies who specialise in both Public Relations and Public Affairs, operating as a single team. The four - College Group in the UK and Brussels, LJ Corporate in France, Schuttelaar & Partners in The Netherlands and Brussels

and Kohl PR in Germany - collaborate in different combinations to provide the ideal expertise and geographical presence to match each client brief. As well as their successful track record in joint working across borders, each member company has deep market expertise in food and drink sectors: they identify a growing call for integrated campaigns that truly predict legislative and policymaking trends and changes and use these to inform and strengthen corporate repuFOOD & DRINK BUSINESS EUROPE, JUNE 2012

benefit from our unique combination of a global and a pan-European perspective, as well as our indigenous understanding of the domestic markets in Germany, UK, France, Belgium and The Netherlands the countries where our founder consultancy partners are based. Integrated work already undertaken by the team has included campaigns to overturn taxation burdens on behalf of trade association members, sustainability stakeholder engagement briefs for large corporate brands and industry groups and educational platforms to promote diet and nutrition topics. FoodFirm’s website is live at www.foodfirm.eu. J 39


I MARKET FOCUS

UK Vegetarian Foods Market to Expand Further in the Future espite the recession, UK sales of vegD etarian foods increased over the past five years, rising by 7.7% from £730.4 million in the year ending January 2007 to £786.5 million in the year ending January 2011, although observing slow growth of 0.9% in 2010, according to Vegetarian Foods, a new Market Assessment from marketing intelligence provider Key Note. The market has been buoyed in recent years by the rising number of people that have opted for a vegetarian diet, as well as an increase in the number of people choosing to reduce their meat consumption for health reasons following recent studies that have suggested that red meat can cause heart disease, heightened cholesterol and obesity. Furthermore, the number of vegetarian restaurants in the UK has continued to grow, with 30 premium restaurants now in operation across the country, up 50% from 2007. Improvements to vegetarian meals

and recipe innovations have also made vegetarian meals much more appetising to consumers, as well as promising additional health benefits, such as a greater vegetable content, and containing ingredients which are lower in cholesterol and fats. Indeed, recent years have seen the Government grow increasingly concerned about the high level of calories in food,

which is thought to have propagated rising obesity levels in the UK. As a result, a number of Government campaigns, such as the 5-a-day fruit and vegetable dietary recommendations and Change4Life programme, have been introduced in order to help people maintain a more well-balanced diet and a healthier lifestyle. The Vegetarian Society has been quick to point out the health benefits of a vegetarian diet in response, with a number of figures suggesting that vegetarians are often less likely to suffer from obesity, coronary heart disease (CHD), high blood pressure and type II diabetes, among other conditions. These factors are likely to continue to drive sales of vegetarian foods in the future, with Key Note predicting a 10.3% increase in the market over the next 5 years, reaching £882.4 million in 2016. For further information visit www.keynote.co.uk. J

I MEAT PROCESSING

Linden Foods Named 2012 UK Manufacturer of the Year orthern Ireland-based meat processor Linden Foods has been named N UK Manufacturer of the Year in the 2012 Meat Management Awards. The win comes after the opening of Linden Food’s £10 million state-of-the art retail packing and product development facility in Dungannon in 2011. The Meat Management Awards, which are held annually, acknowledge the achievements and set the benchmark for excellence in the UK meat industry. Gerry Maguire, managing director of Linden Foods, comments: “We are committed to providing our customers with a range of exciting new products that are well ahead of current trends within the food retailing sector. The phenomenal growth we have experienced as a business in recent years is testament to this philosophy and gives as a platform for further growth.” 40

Meat processing company, Linden Foods, has been named UK Manufacturer of the Year in the 2012 Meat Management Awards. Pictured are Gerry Maguire, managing director, and Elaine Willis, innovation and business development manager at Linden Foods.

FOOD & DRINK BUSINESS EUROPE, JUNE 2012

Part of Linden Food Group, Linden Foods is one of the UK’s leading processors of beefs, lamb and rose veal products. It employs 500 people at its Dungannon plant, and has an annual turnover of £115 million. Linden’s customers include major retailers and companies within the catering trade throughout the UK and Ireland, such as Marks & Spencer; Booker, the UK’s largest wholesale cash and carry operator; and web-based gourmet butcher, Donald Russell. The Linden Food Group is a market leader in the fresh meat processing industry, sourcing and processing top quality beef and lamb for customers throughout Europe. The group has an annual turnover of £300 million and consists of four companies: Linden Foods, Slaney Foods, Kettle Irish Foods and Irish Country Meats. J


I RETAIL READY PACKAGING

Mastering the Art of Visual Disruption ‘

Visual disruption’ is a phrase used by DS Smith Packaging – the UK’s foremost supplier of corrugated packaging – to describe the power of Retail Ready Packaging (RRP). Competition on the shelf, says the company which services thousands of food and drink customers ranging from large international brands to small businesses, has never been so intense and RRP offers a huge advantage by complementing the primary and secondary pack to positively influence shoppers at the point of purchase. 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. Hub of Innovation 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 new 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 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. When it comes to the food and drink business in particular, RRP has another important benefit that has taken even some shopper marketers by surprise. Feedback from some of DS Smith’s customers suggests that when products are presented on the shelf in RRP, consumers are much less likely to reach to the back of the shelf to take the product with the longest best before date. This is because they understand that all the products within the RRP would have been packed at the same time. For popular products with shorter shelf life like cooked meat and cheese, this makes a significant difference to sales and waste. For DS Smith Packaging customers, store operation efficiency is also 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. FOOD & DRINK BUSINESS EUROPE, JUNE 2012

Waste reduction and time efficiency in store, says DS Smith Packaging, should not be underestimated. 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. DS Smith Packaging is the UK’s leading supplier of corrugated packaging. The company’s comprehensive range encompasses retail ready packaging, transit cases, consumer units, packs printed for gift and POS applications, and heavy duty industrial products. For further information visit www.dssmithpackaging.com. J

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Smurfit Kappa Ireland: The One Stop Solution to All Your Packaging Needs s the realities of an increasingA ly globalised marketplace continue to change and evolve, customers, both local and global, require increasingly higher standards of packaging and service to ensure their sustainable development into the future. With many organisations now focused on issues such as Carbon Footprint, FSC/FEPC, Food Contact, REACH and GMP Certification to name but a few, there is a need for packaging suppliers to help alleviate and indeed remove that burden.

Smurfit Kappa Ireland strives to meet that challenge and as part of the wider Smurfit Kappa Group, is ideally placed to service, source and manage the packaging needs of all companies, be it large multinationals or indigenous SME’s. With two integrated corrugating/conversion plants situated in Lurgan, County Armagh and Ballymount, County Dublin, from where its tightly managed logistics system supplies its local board conversion plants; based in Belfast, Cork, Galway, Dublin and Arklow, Smurfit Kappa Ireland provides an invaluable service to local, regional and national customers requiring paper-based packaging and ancillary products. As with all markets, it is important to

develop and refine a key competitive advantage that continues to meet and exceed customer expectations. To that end, Smurfit Kappa Ireland has developed a tightly integrated model both in Ireland

and further abroad with its sister operations across Europe. It is this relationship which allows the company to address the key requirements of all its customers. Innovation To maintain its position as market leader in paper-based packaging in Ireland, Smurfit Kappa Ireland continues to lead the industry in innovation through alignment with the Smurfit Kappa Group international centre for Corrugated Operational Excellence and the Paper Technical Support Department. This technical support allows Smurfit Kappa Ireland to provide customers with the ability to trace, verify and validate the technical aspects of the

FOOD & DRINK BUSINESS EUROPE, JUNE 2012

company’s packaging, a particular benefit to the pharmaceutical and export sectors. As a group Smurfit Kappa is fundamentally committed to sustainability and social responsibility in its interactions with its customers, suppliers, employees and within the communities in which it operates, and as part of its efforts on corporate sustainability, Smurfit Kappa Ireland has recently received FSC/PEFC Certification across all its sites. Security of Supply Allied to its sustainability focus is a guarantee of Security of Supply as part of the Smurfit Kappa Group. All manufacturing companies in Ireland are aware that raw material and commodity pricing continues to rise across the globe; the reality of this situation is that as an island, we are often exposed to the peaks of such cycles. One such exposure relates to a significant tightening and availability of paper supply in Europe. Smurfit Kappa Ireland is able to ensure security of supply to all its customers through its Paper Division, so that they are protected from last minute packaging shortages and changes to the composition and standard of the packaging they purchase. Smurfit Kappa Ireland, more than just a packaging supplier! 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 SHELF READY PACKAGING

Shelf Ready Packaging - ‘On Time Everytime’ ackaging is changing because the P way 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 ShelfReady 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 discount retailers in Ireland. 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.

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.

• Litho-Printed cartons and LithoLamiinated outer boxes and trays. • High quality Post-Printed corrugated boxes. • Polythene bags, sleeves, sheets and pallet hoods. • Pallet-Wrap, Edgeguards, Strapping and accessories, Pallets and Tapes • Protective Foams, Foam/Corrugated/ Wood composite packs • Labels, Loose-Fill and Bubble-Film. According to Mike Boland: “Ten years ago if a customer asked for a litho tray glued to a half slotted case, we would have had to say it can’t be done. Today, however, we will offer our customers a six colour plus varnish litho-printed tray with an automatic crash-lock base, and then spot glued to the tray we will have a three colour flexo printed half slotted case which 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

FOOD & DRINK BUSINESS EUROPE, JUNE 2012

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 w›th 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 w›th perforations right 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,” he remarks, “but it is the comfort of knowing we will consistently deliver quality products, ‘on time everytime’ that gets us customers for life.” J

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I SHRINK SLEEVE TECHNOLOGY

AKW Steams Ahead With Sleeving Investment KW has demonstrated its intention to A be recognised as one of the contract packing market’s leading players by investing £150,000 in the highest specification steam-sleeving machinery in the UK. The Manchester-based company, which is traditionally known for its transport and warehousing solutions, has been building up its contract packing business for the last five years and today boasts a technically driven service that works with a host of world renowned names, amongst them L’Oreal, P&G, Diageo, Unilever, Kelloggs and Heinz. Rebecca Davies, a director of AKW Group and head of its contract packing division, says: “Our aim is simple - we want AKW to be renowned for its contract packing capabilities and this latest investment shows just how seriously we are taking this challenge.” The new steam sleeving machine com-

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prises a RF150 sleeve applicator and Graham’s steam shrink tunnel, which is powered by a Certuss steam generator. It is capable of applying 150 sleeves per minute, which enables AKW to add high speed, cost effective and high quality sleeving to it product range. The machine also features: • a pitching device for automatic collation of twin packs; • motion sensors that count products in and out and trigger an auto stop function, which includes both visible and audible alarms, in case one does not complete the full cycle – this is a key safety aspect when sleeving aerosols; • a magnetic puck system for small and/or shallow products that ensures they enter and stay in the correct position throughout the cycle; • a large tunnel that ensures it can handle a

FOOD & DRINK BUSINESS EUROPE, JUNE 2012

variety of products. The machine’s full cycle includes a Secomak Turbo Air Knife Drying system, which ensures products are dry enough to be immediately packed into whatever end packaging format is required. For additional information on AKW Contract Packing call 0161 873 7355 or visit www.akwgroup.co.uk. J


Sleeves Play Crucial Role in Modern Look For Cornish Mead ong established mead and fruit wine proL ducer the Cornish Mead Company has become one of the first wine companies to use shrink sleeves as part of its packaging. The new eye-catching sleeves from CCL Decorative Sleeves are part of a radical repackaging for the 50 year old brand. The rationale behind the decision to seek new packaging for the Mead wines and liqueurs was twofold. Cornish Mead Company wanted to appeal to a new, younger audience of drinkers between 18 and 30 alongside its traditional older market; at the same time, the company could no longer use the very characteristic bottle that had made Mead unique for the last 50 years and was moving to a standard, lighter weight wine bottle. The all-over coverage of sleeves therefore provided the ideal medium for the new eye-catching designs created by Cornish design agency Glendall Design. CCL Decorative Sleeves worked

closely with Glendall, Cornish Mead Company and the sleeve application company, A&S Packaging, in the development of the project. The sleeves are UV Flexo printed in six to eight colours and feature a surface lacquer for a matt finish to further enhance on-shelf appeal. The sleeve material selected, 50 Micron high shrink PET, ensures a close fit around the bottle, in particular its narrow neck section. The 360 degrees full wrap design allowed by the sleeves retains the crest shape and deep, rich colours of the previous bottle along with new illustrative designs including a tattoo effect for the Mead products and fruit plants for the fruit wines. For further information contact CCL Decorative Sleeves on Tel +44 (0)1553 769319 or visit www.ccl-label.com/decorativesleeves and www.ccllabel.com. J

I POUCH FILLING & SEALING

Strong Growth For Stand-Up Pouches he positive advantages of the stand-up T pouch (SUP) will continue to drive strong growth in European demand for this packaging format, according to a report from PCI Films Consulting. Although developed nearly 40 years ago, the stand-up pouch has taken some time to be truly accepted in the European flexible packaging marketplace. In 2009, nearly 19 billion SUPs were estimated to have been supplied, accounting for 5% of the total value of converted flexible packaging used in Europe. Wet pet foods accounted for

almost a third of this volume and nonretortable food pouches were among the fastest growing. Report author Paul Gaster notes: “In recent years, attitudes towards the SUP have become much more positive as brand owners, retailers and consumers recognise the attractions of this format as a cost-effective, convenient and environmentally superior alternative to rigid packaging.” PCI’s study has found that, in the five years up to 2008, European demand for stand-up pouches grew by 10-15% pa. Demand

slowed during the economic downturn in 2009, but stronger interest from packers is expected to return in future years. The renewed interest in SUPs can be attributed to a variety of factors, including the development of new packaging machinery, which delivers much higher production and filling speeds, as well as improvements in sealing efficiencies. Other technological advances have helped improve functionality and better heat and puncture resistance of the laminate material. J

Riggs Autopack – Manufacturers of Depositors and Filling Machines iggs Autopack manufacture high quality R depositors, filling machines, transfer pumps and conveyor filling lines, for the food production industry. Established in the 1930’s, they supply food producers of varied type and size with clients typically ranging from start-up companies and cottage industries, through to multi-national and international factories. Over the years, Riggs Autopack's equipment has improved a large number of food manufacturers’ production processes, and helped companies meet growing demand for their goods. The Lancashire company take great pride in their machine range and excellent customer service. Providing a friendly and professional service, they employ an experienced and highly skilled team encompassing sales, design, production, research and develop-

ment, parts supply, service and maintenance. Riggs Autopack's Mod el 1000 range of depositors and filling machines is the main stay of the business. They are available as a semi-automatic stand-alone unit for small to medium scale food production, or as an automatic conveyor filling system for larger batch runs. Manufactured using high quality 316 stainless steel on product contact parts, these machines provide damage free and highly accurate volumetric depositing of hot or cold liquid, semi-liquid and suspended solid products, and fill most container types or size. With quick changeover times and easy setup, the Model 1000 depositing and filling machines are robust, reliable, hygienic and FOOD & DRINK BUSINESS EUROPE, JUNE 2012

quick to clean, easy to use and simple to maintain, with fully adjustable depositing volumes and speeds. They are supplied with an after sales support package and available for purchase, short or long term hire. A no-obligation on-site machine trial is also available upon request. If you're seeking to invest in a semi or fully automatic depositing system to accurately fill jars, bottles, pots, tubs, trays, foils, cake tins, cartons, buckets, jerry cans, pouches or bags, then Riggs Autopack could have the solution. For further information contact Riggs Autopack on Tel +44 (0)1282 440040, Email info@autopack.co.uk or visit www.autopack. co.uk. J 47


I INTERMEDIATE BULK CONTAINERS

Container Station For Aseptic Filling and Emptying roducers of foods, pharmaceuticals, P body and health care products or chemicals use mobile containers for the transport or intermediate storage of liquid products, ranging from ointments, creams, basic compounds for beverages through fruit preparations, yoghurts, flavours, pastes to paints and varnishes. The diversity of products being transported ranges from low-viscosity, diluted products to semi-solid ones. Such containers are used for transport to: the commissioned bottling company, to the customer, for further processing, or intermediate storage. This packaging is genuinely re-usable. It contributes to avoid waste and to conserve natural resources. For sensitive products, as in the food industry, the manual connection of the container to the production or filling unit is critical as the system is opened and microorganisms could penetrate. Based on the long-term experience with their customers, RULAND Engineering & Consulting developed a container station that offers some advantages in handling. Furthermore, this station eliminates the microbiological risk, the complete process is automated and documented. The Transport/storage Container Generally speaking, these containers have a volume capacity of 200 to 1.500 litres and can incorporate a huge range of extra features such as: • pressure-/vacuum container • double walls for heating or cooling • insulation • various angles of sloping bottom/outlet depending on the flow properties of the product • screwed down, hinged and screwed, or bayonet locking lids • integrated safety valves, ventilation valves, sterile filters and other fittings • stackability within a single system • material AISI 304/316L. What the containers have in common is the outlet valve. In the food industry the DN 50 butterfly valve with a DIN 11851 threaded connection has become standard. In pharmaceutical production

companies there is a larger variety in the fittings and connections. For them, special adapters are designed. Special Features of the RULAND Container Station The experience with the use of transport/storage containers in the production facilities of several customers was the incentive for the creation of a container station that would both improve working conditions and assure a safe work Filler head connected to transport container. process. Thus, RULAND added the relevant equipment to the basic design. tor is engineered to assure a safe connecFor an operator-friendly, time-saving tion even air is lost. The product and serhandling when connecting and discon- vice media valves are welded directly onto necting a pneumatic connector is used. It this pneumatic connector to keep dead enables the filling head to be pressed into space to a minimum and assure very low the butterfly valve of the container, creat- product losses. The filling head has haning a leakage proof connection. The actua- dles and is attached to a cantilever arm with balancer for easy, weight-free handling. The valves used for sterile filling meet aseptic process engineering specifications as diaphragm valves or butterfly valves, if sterility requirements are less stringent. The valves are arranged so as to avoid dead spaces that might not be fully cleaned during rinsing or CIP treatment. A sampling facility can be integrated if required. Temperature and pressure measurements are captured in both the feed line and the container for sterility control and monitoring. The key process parameters are set data in the control. A calibrated weighing module measures exactly the container content. An integrated electronic weighing machine allows automated filling. Bar code readers can read in directly the container number. Furthermore the control can be connected with other superior systems for dates exchange. The display is a standard version 5.7”. A 19” panel is available as a computerised alternative, offering more possibilities for data recording and archiving of the complete process Container station with electronic weighing unit and 19“ and for keeping records on compliance operator panel. of critical parameter. J FOOD & DRINK BUSINESS EUROPE, JUNE 2012

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I INTERMEDIATE BULK CONTAINERS

Realising the Benefits of Intermediate Bulk Containers ntermediate bulk containers (IBCs) offer Isavings food and drink companies significant cost and efficiency benefits when handling, storing and transporting large quantities of fluids and bulk materials. Lower costs due to reduced handling, storage and transportation charges are a key advantage of using IBCs. They are also hygienic, simple to use and transport and are recyclable. Indeed, IBCs have been devised specifically to save time and money on storage, handling and transport. Protection Throughout the Supply Chain IBCs are designed to offer complete protection for the goods being carried during the full supply chain, from filling and loading through transportation and unloading. IBCs are suitable for transportation by road, rail or sea. IBCs commonly have pallet type bases so that they can be easily moved by forklifts. Another feature is that they can be folded down to produce a more compact profile for transportation and storage when empty. Furthermore, IBCs can be stacked vertically. Available in a variety of shapes and sizes, IBCs are made from different materials

including plastic, steel and stainless steel, to suit the characteristics of the product being transported and the specific application required by the user. IBCs can be constructed from materials approved for use with food and drink products and to incorporate easy to clean surfaces to ensure hygiene standards are complied with. IBCs’ can be fitted with flexible liner bags, which are sterile and can be

filled without allowing air into the container. In addition to being a safe, hygienic and secure method for materials handling, IBCs offer increased productivity and lower packaging costs while maximising logistics and handling efficiency. Advantages The IBC storage and transport concept offers users several advantages over alterna-

tive methods: • IBCs are generally cubic in form and consequently are able to transport more material in the same area than cylindrically shaped containers and far more than might be shipped in the same space if packaged in consumer quantities. • IBCs usually incorporate plastic liners which can be filled and discharged using a variety of systems. • IBCs allow food and drink manufacturers to bulk package a product in one country and ship to many other countries or destinations, at a reasonably low cost, where the product is then packaged in final consumer form in accordance with local market and statutory requirements. Because IBCs are a reusable container system, they eliminate the need for large quantities of disposable packaging, associated with other methods of transporting goods, saving on packaging and waste disposal costs. IBCs are reusable, collapsible bulk containers which save space and costs on return journeys. Similarly, reusable plastic IBCs in closed loop supply chains have a significantly lower environmental impact than other rival systems of bulk handling. J

I AUTOMATED HANDLING

Dolav Precision Pallet Takes the Load 1200x1000mm, heavy-duty precision palA let, engineered to easily take heavy loads in highbay, narrow aisle, automated handling systems is now available in the UK and Ireland. Designed for integration in automated handling systems either after build or ideally during construction design, the Dolav MV 1000 polypropylene pallet meets rigorously demanding criteria. In an automated, high-tech warehouse, automatic pickers, conveyors and turntable need every single pallet to behave and perform exactly in the way for which the computerised equipment is programmed. This is exactly what the Dolav MV 1000 precision 50

pallet is designed for and delivers. Temperature performance parameters in use can be -15C to +60C and up to 80C during cleaning. Impact resistance of the new polypropylene compound is 30-50% better than HDPE compound at ambient temperature. This polypropylene Dolav pallet has three integrated skids and is reinforced with three steel bars. The new-design polypropylene Dolav MV 1000 precision pallet meets stringent specifications for maximum loads of 8000 Kg static, 2250 Kg dynamic and racking of 1750 Kg. At 1200X1000x150mm the pallet weighs just 25 FOOD & DRINK BUSINESS EUROPE, JUNE 2012

Kg and deflects less than 3mm in the 23 C ambient heat of the Israeli warehouse for 30 days at a load of 1000Kg on a 1000mm rack opening. Made from food-quality, easy-to clean polypropylene, the pallet is designed to eliminate cavities and all openings are capped. In addition to achieving compliance with FDA/GMP requirements for pharmaceutical environment, Dolav has added options including perforated platform, safety rim, two runners and nine-leg versions for other customers. For further information visit www.dolavuk.co.uk. J


I DAIRY PRODUCTS

Guerin Systems Guided Tour Within the International Symposium on Spray Dried Dairy Products – June 19-21, 2012 – St-Malo, France ollowing the previous highly sucF cessful symposia in this series — Rennes/FR (2001), Cork/IE (2004), San Francisco/US (2007) and Melbourne/AU (2009) — the forthcoming IDF/INRA International Symposium on Spray Dried Dairy Products is to be held in SaintMalo/France from 19 to 21 June 2012. For the very first time, the 2012 event is organized by INRA, the French National Institute for Agricultural Research — as research institution, in collaboration with IDF, the International Dairy Federation — as the international dairy industry platform. This event aims to bring together research and industry leaders to share ideas and information about new developments in two complementary fields of science and technology – the manufacture of dairy powders and the functionality of these products as food ingredients The translation of research findings into industrial practice will also facilitate the development of better modeling and control of spray drying processes and the application of new alternative technologies for the manufacture of dried dairy ingredients. The event organizers also wanted to offer participants industrial site visits. Our company Guerin Systems, specialist in powder handling, is one of those sites and offers a tour of his company June 18, 2012 (Powder Institute visit) The Process Development Centre – also known as the Powder Institute – offers you a unique way to simulate any kind of powder handling process, test many sensitive

products and validate your future production line. The Powder Institute, located in Le May, France, includes a pilot plant and laboratory, where we encourage you to submit your products and requirements to achieve a safe, optimized industrial solution. The Lab In our lab we can determine powder properties and characteristics, eg using laser granulometry measurements as well as ring shear testing. The results are then used as input data in our engineering calculations for all projects. Here we also analyse powder results from trials conducted in the pilot plant. To date, we’ve analysed some 4000 products, dairy to baby food and sugar, flour and mixed recipes.

small-scale validation testing has proven to be highly reliable when translating to the final plant design. To date, 100 participants from around the world have registered! (Nestle, Frontera, Arla Foods, Ingredia, Laita, Friesland Campina, Wyeth, Regilait, Eurial). This success reflects the reputation of our company in the field of powders processing and recognition by the greatest of our ability to become their partner. J

The Pilot Plant The pilot plant is mainly dedicated to validating process solutions and checking the feasibility of new settings, as well as developing new equipment and process solutions for R&D purposes. The pilot plant is organized around pneumatic conveying systems using different technologies, vacuum or pressure, dilute or dense phase. Then, individual flexible functions, eg mixing, sifting, dosing, big bag unloading etc, are added according to your process. Process functions are used as modules for reproducing real situations with machine combinations. This FOOD & DRINK BUSINESS EUROPE, JUNE 2012

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100% Recyclable Current BRC accredited Leakproof or draining Lightweight yet strong Preferred by French retailers Machine or hand erect

Packaging Systems Irl

For all your Packaging and Strapping needs Irish Rep.

Paul Addison Tel: +44(0)7845 549 478 paul.coolseal@yahoo.com

ITW Packaging Systems Ireland Unit W6 Tougher Industrial Estate Naas Co Kildare Tel +353 (0)45 440622 Fax +353 (0)45 440623 Email info@itwpackaging.ie

ITW Packaging Systems Ireland CIDO Innovation Centre 73 Charlestown New Road Portadown Co Armagh BT63 5PP Tel +44 (0)28 38333527 Fax +44 (0)28 38350309


I SEAFOOD

€15.5 Million Investment in Irish Seafood Processing Investment of €15.5 million is being made in the Irish seafood processing industry to boost its sales of value added products and exports. he new investment by a total of 21 Irish seafood processing companies, supported by grants of Eur3.2 million under the EU co-funded Seafood Processing Business Investment Scheme, is expected to generate over 142 additional jobs and increased sales of value added seafood products of nearly Eur44 million by 2015.

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Sofrimar - Leading Seafood Exporter Sofrimar, Ireland’s Seafood Exporter of the Year 2011, is making the second largest investment of Eur1.43 million, of which Eur357,502 is grant aided. Based at Kilmore Quay in County Wexford, Sofrimar employs about 100 people, having doubled its workforce since 2005. The company’s export markets include France, Spain, Italy, Portugal, United Kingdom, Belgium, Holland, Croatia, Switzerland, South Korea, Hong-Kong, Japan, China and Singapore with product being sold under the Sofrimar brand and retail private labels. Established in 1979, Sofrimar produces a diverse range of seafood with about 80% of its business generated by shellfish - whelk, scallops, crab, live lobster, langoustines, shrimp and winCoolSeal Seafood Packaging System The CoolSeal Seafood Packaging System is the latest fish box and packaging development from UK-based Tri-Pack Plastics. Coolseal Fresh fish boxes are designed specifically for delivering chilled fresh fish and seafood in perfect condition. The fish boxes are delivered flat, pre-folded and packed in bundles, minimising delivery and storage costs. The patented easy-erect design enables the box to be ready in one simple movement with no other assembly required. The patented technology is used to seal the edges to provide a strong hygienic box that is virtually unbreakable, a feature that eliminates the problem of polystyrene bead contamination and blocked drains. CoolSeal boxes have played a part in increasing Sofrimar’s export business of fresh seafood into the French retail market. Tri-Pack supplies scallop boxes to Sofrimar. Indeed, this is now a growing business sector for Tri-Pack throughout the UK.

kles - with the balance in whitefish, including monkfish and sole. The company offers its products in an impressive array of formats including fresh, frozen, live, cooked and pasteurised. It can also offer customers a wide range of products frozen at sea, including langoustine, monk and hake, a process which ensures the highest quality and flavour. Sofrimar’s partnership with the Kilmore Quay day boats, nearby the factory, guarantees optimum freshness and delivery of seafood to customers within hours of being caught. Pioneer of Scallop Processing Kilmore Quay is the home of scallop fishing in Ireland, and Sofrimar has been a pioneer of scallop processing. A management plan agreed between all the main stakeholders in the fishery guarantees the sustainability of scallops and ensures customers have a fresh, continuous supply. With over 70 fishing vessels landing their catches at Kilmore Quay, and at neighbouring ports along the east coast, Sofrimar is able to draw from a constant supply of pure, natural seafood. Due to the quality, consistency and timely delivery of its products, Sofrimar has developed strong relationships with its customers. Sofrimar is currently operating from a HACCP approved 4,000 sq m factory equipped with extensive cooking, chilling, freezing, cold storage and processing facilities for a broad range of shellfish and whitefish. Sofrimar is committed to continual investment in the latest plant and technology. It claims to have the most modern whelk-processing line in the world, and is one of the largest processors in Ireland and the UK, and a key exporter of whelk meat to the Far East. Its long-term holding system for live shell-

fish is the first of its type in Ireland. This sophisticated system holds lobsters and other shellfish in conditions that simulate their natural habitat, and allows Sofrimar to offer customers a continuous supply, particularly at times of peak demand. Investment Scheme The current funding under the Seafood Processing Business Investment Scheme, follows previous investment of Eur7 million by 21 companies in 2011 and Eur2.7 by eight companies in 2010. Simon Coveney TD, Minister for Agriculture, Food and the Marine, comments: “The SMEs undertaking this very welcome new investment represent the future of the seafood industry. The new investment involves companies significantly growing their businesses and also diversifying, which will lead to increased profitability and increased employment.” The Irish Government’s strategy for developing the food industry has set a target of revenue growth in the seafood sector as a whole of Eur300 million by 2020, with employment capable of increasing by 3,000 in that period. J Corrugated Containers Ireland Ltd, Beechmount Industrial Estate, Navan, Co. Meath • • • •

Corrugated Packaging Foam Packaging Timber Packaging KANBAN services Glued & erected food trays our speciality Food customers love the taste of our service! Contact David Lovett to arrange a Sales call – sales@corrugatedcontainers.ie.

FOOD & DRINK BUSINESS EUROPE, JUNE 2012

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I BAKERY

Sugars Reduction, Tailor-made Solutions – SweetPearl® and NUTRIOSE® ugars reduction is S another nutritional opportunity for

the benefits of SweetPearl® is the biscuit. Sugar reduction in a biscuit should take into account the following parameters: * Labelling * Organoleptic properties * Nutritional values.

ucts. Compare the organoleptic properties of sucrose, the traditional sweetener, with those of maltitol. Sensorial analysis of sucrose and SweetPearl® shows them to be very similar. Since SweetPearl® maltitol’s properties are bake-stable, this means the taste of a finished baked product or of its fillings that incorporate SweetPearl® must also be similar. But sucrose in a biscuit (or in baked goods more generally) is not only about taste. As a crystallisable bulking agent its impact on texture is also highly significant. Texture: Compare the physicochemical properties of SweetPearl® and sucrose: both are crystallisable di-saccharides and both have very similar properties. This means that their behaviour during the processing to finished product will also be very similar (recrystallization, viscosity, dissolution, etc). This in turn results in an almost identical texture. For the purposes of European labelling, SweetPearl® can be identified as either a sweetener or a bulking agent. At the same time its wheat or maize source can also be usefully identified. Calories: At 2.4 in the EU and 2.1 in the US, SweetPearl®’s calorie value is 40% less than that of sucrose. This substantially lower calorie count, combined with a lower glycaemic index (29 v 60 for sucrose), confirms the nutritional attraction of using SweetPearl® maltitol to reduce sugar content. For the consumer, the attraction of SweetPearl® is that it delivers the taste without the sugars.

SweetPearl® Labelling Benefits Label claims are an essential pre-requisite for successful products. Because SweetPearl® can achieve partial or total substitution of sugars while preserving or even increasing organoleptical properties, there are a large number of claim possibilities, from the dietetic mainly focused on the low glycaemic response of maltitol (SweetPearl® is a maltitol) and on the level of sugar reduction (“no sugars added” or “reduced in sugars”) to claims combining the attraction of sugar reduction with additional maltitol benefits (like taste) or other components (like fruits or cereals). Taste (sweetness): SweetPearl® makes it possible to associate attractive claims like those above with premium quality prod-

Application: SweetPearl ® Digestive Biscuits SweetPearl ®’s benefits become self-evident in a digestive biscuit created by Roquette’s application labs: this has all the taste and crispiness of the traditional digestive but none of its sugars, allowing an attractive “nosugar added” claim. The Roquette digestive biscuit concept is only one example of the many premium quality products without the

fine bakery goods in addition to fat optimisation. The challenge is to achieve a true reduction – even a total substitution – of simple sugars while preserving the right taste, especially of sweetness – at the same time as preserving the essential texture. That means emulating sugar, a bulking agent with an important and inherent texture-generating role. Roquette offers two approaches. 1. Total Or Partial Sugars Substitution With SweetPearl® Obtained from maize or wheat, Roquette’s SweetPearl® is a naturally sweet bulk sweetener with the properties to deliver a premium taste. The pre-eminent product to test

FOOD & DRINK BUSINESS EUROPE, JUNE 2012

sugars that are made possible with SweetPearl®.

2. Partial Sugars Substitution With NUTRIOSE® Soluble Fibre SweetPearl® offers total substitution of sugar in baked goods. However, if only partial substitution (up to 30% of sugar) is required, soluble fibre offers an effective alternative. Roquette’s NUTRIOSE® soluble fibre range Is obtained from wheat or maize. Its use in baked goods is ideal since it is 100% soluble and has low viscosity. It also offers a very efficient way to reduce sugar levels because of the richness of its fibre content and its own low levels of simple sugars. NUTRIOSE® is probably also the soluble fibre with the best digestive tolerance on the market. On top of that, both the taste and the colour (white) of NUTRIOSE® are completely neutral. Application: NUTRIOSE® Digestive Biscuits NUTRIOSE®’s neutral taste makes it possible to exploit a full reduction of up to 30% of sugars while still creating a biscuit with an attractive taste. This has been demonstrated conclusively in a NUTRIOSE® digestive biscuit created in Roquette’s application labs. The recipe benefits additionally from NUTRIOSE®’s properties as a bulking agent, which further increase its sugar-reducing effect. Under EU labelling rules this all adds up to an attractive “sugar reduction” claim combined with a no less attractive “cereal soluble fibre” claim. This appeal is reinforced by NUTRIOSE®’s low calorie value and low GI (25). Whether food producers want to be able to make a “sugar-reduced” claim or simply create an improved nutritional profile, NUTRIOSE® soluble fibre delivers the messages that can really make the difference. Contact: foodbusiness@roquette.com. www.roquette-food.com. J 55


Innovation For the Bakery Sector – YASO® itorex has developed an innovative raw F material - YASO® - for creating healthy bakery products with low carb, high dietary fibre, complete protein foods with gluten-free options. A growing number of people believe their health can be improved by eliminating certain foodstuffs from their diet and ten per cent of the European population identify themselves as intolerant to gluten. For these people YASO is a welcome development as it contains no gluten, lactose or cholesterol, no additives and no chemicals. YASO® is a 100% natural raw material for premium foods. Possibilities for serving the gluten-conscious consumer keep growing with YASO®, since it offers the opportunity for manufacturer to create a memorable food experience for customers in the gluten-free segment as well. YASO® is non-GM whole soya, sprouted under strictly controlled conditions, pasteurised and packed ready for use in the bakery. It brings a completely new, whole soya dimension to the use of soya in baking. Much of the food ingredient soya used in Europe is a by-product of the soya oil industry (soya meal, concentrates, isolates) and the nutritional value has been degraded in the process. In contrast, YASO® enhances the nutritional

value of soya through a patented special sprouting process. During the natural process of germination, enzyme stores in the soya bean activate and increase its nutritional value to provide for strong growth into a healthy plant. The nutrients that increase significantly include isoflavonoids, betacarotene, vitamin C, vitamin E and dietary fibre. Carbohydrates and proteins are also converted into less complex forms. Thanks to these natural processes, YASO® has better taste, can be easily digested and does not cause flatulence.

Searching to create something new and healthy for everyday use by health conscious customers, the inventors of YASO® were inspired to combine the unique nutritional composition of soya, the health advantages of sprouted foods and the complexity of processing on an industrial scale to produce a unique ingredient for food manufacture and catering that is a world first. Fitorex has created delicious recipes using YASO® in bakery, snack, pasta, functional food, meat-free and meat industry applications. To demonstrate the potential for YASO® in bakery, Fitorex developed YASO® cracker bread: a low carb, high dietary fibre cracker bread without yeast, with high protein and omega 3 and 6 content. It contains 29g protein and 15g fibre per 100g, with only 39g carbohydrate. Not only are the nutritional values good: it tastes delicious! Fitorex offers the cracker in varieties with spelt, with different spices and as gluten-free. For further information contacts: Lidia Szabo, sales and marketing manager, on Tel +36 1 453 0564, Email szabo. lidia@yaso.hu or Terry Young, UK Representative, on Tel +44 7761 752095, Email terry.young@yasofoods.com. J

Cargill Celebrates Opening of Orphanage in Cote d’Ivoire’s Soubre Region n orphanage, funded by Cargill, has A been officially opened by Pierre Douhou MBA, Cote d’Ivoire’s Director of Cabinet for the Ministry of Family, Women and Child. This much needed orphanage will accommodate up to 60 orphans from across the country providing them with a safe and secure home, as well as improved access to education and healthcare Speaking on behalf of Cargill’s cocoa and chocolate business, Yves Onghen, Training and Project Coordinator explains: “As part of Cargill’s Sustainable Cocoa Program, we strive to make a lasting difference in the rural communities where we live and work. For this project, we have worked with local non-governmental organisation ‘Compassion Esther’ to respond to the pressing need for safe hous56

ing for children in Soubre.” The project was commissioned by Cargill in 2010, following the discovery that local woman Mme Ouedraogo had taken twenty two orphans into her own home. As a direct result, Cargill built and furnished FOOD & DRINK BUSINESS EUROPE, JUNE 2012

this new orphanage. The Cargill Sustainable Cocoa Program is working to secure the long term sustainability of cocoa production and to improve the lives of cocoa farmers and their families. Cargill has been training Ivorian cocoa farmers for more than 10 years and today helps tens of thousands of farmers increase yields, improve quality and adopt more sustainable practices. Additionally through its partnerships with CARE and the IECD, Cargill is improving access to healthcare, drinking water and renovating schools in 10 communities in San Pedro and Daloa. It has also renovated over 40 schools to provide education and practical farming skills to help young people improve their employment prospects. J



F&D June 2012 issue