Food and drink business europe march 2015

March 2015

Glanbia Ingredients Ireland opens new â‚Ź180 million Nutritional Ingredients Plant

Food & Drink Business Website:

www.fdbusiness.com

C o n t e n t s

- 35 S TARCH

- 3 M ERGERS & A CQUISITIONS

€9 billion European starch industry faces stiffening challenges.

Coverage of British and international deals.

- 5-18 C OVER S TORY Glanbia Ingredients Ireland opens new €180 million nutritional ingredients plant.

PAGE 3

Brian Driscoll, CEO, Diamond Foods.

- 45 B RAND B UILDING Coca-Cola’s billion dollar brands portfolio expanded to 20.

P AGE 35

Jamie Fortescue, MD, Starch Europe.

R EGULARS - 18 & 19 D AIRY

Information Technology . . . . . . . . . . . . . . 14

€35 million innovation investment in Irish dairy processing.

Lakeland Dairies begins €36 million expansion of milk powder processing operations.

Processing & Manufacturing . . 15, 16, 22-28, . . . . . . . . . . . . . . . . . . . . . . 31-33, 38 & 44

PAGE 45

Muhtar Kent, CEO, The CocaCola Company.

Storage & Logistics . . . . . . . . . . . . . . . . . 17 PAGE 3

Roger White, CEO, AG Barr.

Energy & Environment . . . . . . . . . . . . . . . 17 Materials & Ingredients . . . . 18, 37, 47 & 48

- 21 P OTATO P RODUCTS

Bottling & Packaging . . . . . . . . . . . . . . . . 23

Lamb Weston/Meijer investing €120 million to expand production.

Quality & Hygiene . . . . . . . . . . . . . 25, 38-43

PAGE 47

Theo Spierings, CEO, Fonterra Cooperative Group.

Managing Director: Colin Murphy Editor: Mike Rohan Group Operations Manager: Sylvia McCarthy

- 22-28 A NUGA F OOD T EC 2015 International FoodTec Award winners announced.

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Jim Bergin, CEO, Glanbia Ingredients Ireland.

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- 29 G ROCERY M ARKET UK grocery market accelerates and Tesco returns to growth.

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M E E R R G G E E R R S S M Diamond Foods Acquires Majority Interest in Yellow Chips International snacks group Diamond Foods has acquired a 51% stake of Yellow Chips, a manufacturer of vegetable and organic potato chips based in the Netherlands. Yellow Chips markets its products under private labels and has its own premium brand, Go Pure, in Europe. Yellow Chips currently produces Kettle Brand Vegetable Chips for Diamond.

Following the acquisition, Yellow Chips' existing management team will continue to operate the company as an independent subsidiary.

Brian Driscoll, president and chief of Diamond Foods, says: "We are excited to acquire an interest in Yellow Chips, which enables us to better compete in the on-trend, high growth vegetable chip category in the UK and Europe. We are pleased to welcome the Yellow Chip team, which has done an outstanding job creating a high quality product for us."

Diamond is financing the acquisition through cash onhand.

Brian Driscoll, president and chief of Diamond Foods.

Mondelez International Expands in ‘Better-forYou’ Snacks Global snacking giant Mondelez International has acquired Enjoy Life Foods, a private US snacking company and the market leading brand in the fastgrowing ‘free from’ segment, for an undisclosed price. Enjoy Life offers more than 40 products, including cookies, chocolate, snack bars, and savoury snacks that are allergy-friendly and

& &

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

gluten-free.

“As we focus on continuing to drive growth in snacking, the acquisition of Enjoy Life Foods is a great strategic fit for us,” says Mark Clouse, chief growth officer at Mondelez International. “The Enjoy Life brand expands our portfolio into faster growing, on-trend, 'better-foryou' areas and provides an excellent platform to make these delicious offerings available to consumers with 'free-from' needs or simply looking for healthy-lifestyle options, both in the United States and beyond.”

AG Barr Moves into Cocktail Mixers UK soft drinks group AG Barr has acquired Funkin, a producer of cocktail mixers and syrups, for an initial cash consideration of £16.5 million plus up to a further £4.5 million subject to the achievement of certain financial performance targets.

The initial consideration represents an EV/EBITDA multiple of 10.6 times based on adjusted 2014 EBITDA. Funkin was founded in the late 1990s and offers a broad range of premium cocktail solutions including fruit purees, cocktail mixers and syrups.

Sales have been developed through close relationships across both the on-trade channel and increasingly in restaurants. The business is predominately in the UK but does have fledgling business units established in the USA and Europe.

The business has grown rapidly to achieve revenues of about £9 million in 2014.

The acquisition of Funkin will strengthen AG Barr’s portfolio, and takes the group into a new segment of cocktail mixers.

Andrew King, chief executive of Funkin, will remain with the business under AG Barr’s ownership and Funkin will operate

within the group as a supported, yet stand alone, business unit.

Roger White, chief executive of AG Barr, comments: “We believe that Funkin has created a unique niche in a growing market and together we can drive exciting growth in a new sub category. We have a proven track record of acquiring and developing high growth brands such as Rubicon.”

Roger White, chief executive of AG Barr.

Mid Europa Partners Acquires Danube Foods Group UK-based Mid Europa Partners, the largest private equity firm focused on Central Europe and Turkey, has agreed to acquire a controlling interest in Danube Foods Group, one of the leading branded consumer goods companies in Serbia. The transaction value has not been announced.

With revenues of more than Eur400 million in 2014, Danube Foods Group’s subsidiaries include Imlek and Mlekara Subotica, which on a combined basis represent the largest independent dairy business in the former region of Yugoslavia; Bambi, the leading Serbian confectionery producer; and Knjaz Milos, the leading Serbian producer of mineral water and other non-alcoholic beverages.

a group of companies that operate mainly in Mexico and are specialized in the production and distribution of cheese, with leadership positions in the categories in which they operate.

The $105 million (Eur93 million) deal will also see Parmalat acquiring a portfolio of brands, the most important of which include Esmeralda, El Ciervo, Mariposa and La Campesina Holandesa. In 2013, the acquired businesses reported net revenues of about $197 million (Eur174 million).

$5.8 Billion Pet Food Acquisition US food group, JM Smucker Company is acquiring pet food business Big Heart Pet Brands in a cash and share transaction valued at approximately $5.8 billion, which includes approximately $2.6 billion of net debt.

Big Heart Pet Brands is the largest stand-alone producer, distributor, and marketer of premium quality, branded pet food and pet snacks in the US. Big Heart Pet Brands' net sales are expected to be approximately $2.3 billion and EBITDA will be approximately $450 million for the fiscal year ending May 3, 2015.

Acquiring Big Heart Pet Brands will provide JM Smucker with an immediate and significant presence in the $21 billion pet food and snacks category in the US. The acquisition reflects JM Smucker’s strategy of owning leading food brands in attractive centre-ofthe-store categories, with a focus on North America.

Parmalat Expands in South America Italian dairy group Parmalat is expanding its interests in South America with the acquisition of

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

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COVER STORY

Glanbia Ingredients Ireland Opens New €180 million Nutritional Ingredients Plant Ireland’s leading dairy ingredients company, Glanbia Ingredients Ireland, has commenced production at its new, state-of-the-art nutritional ingredients plant at Belview in County Waterford, so completing a €200 million investment programme designed to increase processing capacity in readiness for the abolition of EU milk quotas.

G

lanbia Ingredients Ireland processes1.6 billion litres of milk annually or 30% of Ireland’s milk pool into a range of dairy ingredients for export to more than 50 countries. The company is performing strongly with profits of Eur39 million.

Glanbia Ingredients Ireland supplies a range of ingredients to the infant formula market and exports enriched milk powder to markets including West Africa, Middle East and Asia in consumer-ready formats. It also sells a range of dairy proteins into the clinical and sports nutrition sectors. The company is one of the key Irish dairy processors supplying cheese and butter to the Irish Dairy Board (which is sold under the Kerrygold brand). Glanbia Ingredients Ireland currently employs 668 people across its five sites in Ireland and in representative offices overseas. The company has market bases in Ireland, Germany, the US, Dubai and Senegal.

Glanbia Ingredients Ireland is a joint venture between Glanbia plc, the global nutritional solutions and cheese group, and Glanbia Co-operative Society, which is the main shareholder in Glanbia plc. Glanbia Ingredients Ireland is 60% owned by the Glanbia Co-operative Society and 40% owned by Glanbia plc.

Glanbia Co-operative Society has an option to buy Glanbia’s 40% Jim Bergin, chief executive of Glanbia Ingredients stake within six years.

Ireland.

In the process of forming the joint venture in 2012, Glanbia Co-operative Society reduced its shareholding in Glanbia plc from 51.4% to 41.4%. €180 Million Investment Glanbia Ingredients Ireland’s new greenfield facility at Belview has literally broken new ground in the Irish dairy industry and set new standards internationally. “Some Eur180 million has been invested in our new nutritional ingredients plant at Belview, with support from Enterprise Ireland. It is the largest single dairy investment in the history of the State and the largest infrastructure investment by an indige-

The nutritional ingredients plant at Belview has a weekly processing capacity of 19 million litres of milk.

nous company since 1929,” points out Jim Bergin, chief executive of Glanbia Ingredients Ireland.

The new facility will create 1,600 direct and indirect jobs, while contributing an estimated Eur400 million per annum to the economy - with particular benefit to farm families and rural communities The new plant has a weekly processing capacity of 19 million litres of milk. It has been designed to manufacture specialised milk powder products and nutritional ingredients to meet the demands of multinationals in infant formula and other industries operating in Asia, North Africa and around the world. Belview will produce concentrated skimmed milk, enriched milk powder, infant formula grade skimmed milk powder, infant formula grade whole milk powder and cream.

“Belview is a scalable facility that is also extendable. It is Ireland’s largest milk powder plant, and will produce high end ingredients produced to rigorous quality standards. A key feature for our customers is that we offer an owned and traceable milk supply from our farmer base of 4,800 suppliers,” Jim Bergin explains.

Fast Track Project The fast track project was delivered on time and on budget from

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

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ground-breaking in May 2013 to tional model whereby energy ineffifirst processing of milk in cient processing (short periods) are December 2014. At peak more avoided. Clean energy sources have than 750 people were employed also been utilised where possible. on the site. The safety record of “Thanks to cutting edge technolthe programme is commendable – ogy, the plant will produce a range approximately 1.5 million manof nutritional ingredients which are hours operated with only one HSA top quality and low micro, ensurrecordable incident. ing a suitable application across a The project brought together a range of infant and clinical nutribroad range of global expertise and tion industries,” he says. “Our low suppliers. In addition to Ireland, micro dry blend powders will be equipment was designed and supused in some of the world’s most plied from countries across Europe recognised infant formula brands including Denmark, France and from Stage One.” various Eastern European countries, and from further afield such Belview will produce concentrated skimmed milk, enriched milk powder, infant International Standing formula grade skimmed milk powder, infant formula grade whole milk powder Belview compares favourably with as New Zealand and China.

“The project also relied upon and cream. other dairies internationally in the support of a wide range of terms of scale, technology and agencies and groups, without whom the project would not have suc- environmental performance. With regard to the technologies utilised ceeded – Local Government, IDA, Enterprise Ireland, ESB, Bord and planned efficiencies, the facility is best-in-class.

Gais and local residents, to name a few,” stresses Jim Bergin.

Equipped with two 7.5 tonne/hr dryers, Belview is comparable in size with other European plants of this type, although smaller than the Advanced Design large scale processing plants in New Zealand. The facility will process The nutritional ingredients plant at Belview has been built to Infant approximately 19 million litres of milk per week at peak.

Formula Spec and European Design Hygiene guidelines. The new Jim Bergin comments: “International expertise on hi spec builds facility is highly automated with a focus on best in class efficiency for was brought in to work on this project. Specifically, 3D modelling water and energy usage and quality standards. There is also an empha- was utilised such that each and every component - floor, wall, pipe, sis on cleaning and re-cycling of water, as well as utilisation of some of valves, instruments etc - was modelled electronically and, thereafter, the most energy efficient process equipment available. Heat recovery installed exactly in accordance with the model. This modelling is a corner-stone of the plant’s design and operation, as is the opera- allowed for the design to be fully reviewed and validated before instal-

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

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lation, avoiding changes and providing assurances in relation to the safety, quality, operability and maintainability of the facility.”

plant at Belview, Glanbia Ingredients Ireland has also been modernising and expanding its existing facilities at Ballyragget in County Kilkenny and Virginia in Target Markets County Cavan under a total The plant at Belview has been investment package worth over developed specifically for the Eur200 million. export market with high growth At Ballyragget, Glanbia developing regions in particular Ingredients Ireland has significantbeing targeted. It will complement ly upgraded its butter plant. The the other sites within Glanbia A key feature for customers is that Glanbia Ingredients Ireland can offer an company has been processing butowned and traceable milk supply from its farmer base of 4,800 suppliers.

Ingredients Ireland’s operations. ter since 1968, when the “The Belview site will allow us Ballyragget plant was first opened. to develop a range of specialised infant formula grade nutritional “Remaining at the heart of the business ever since, we now have a ingredients which will enable a deeper penetration of the Nutrition wealth of experience to draw on across anhydrous milk fat (AMF), and Health and Wellness industries which we already supply with our butter oil/butter oil fractions, salted and unsalted sweet cream butter, portfolio of advanced milk proteins,” he remarks. “These are currently lactic butter and technical butter. Combined with our high quality, produced at both our Ballyragget and Virginia plants alongside our sustainable milk pool, this allows us to serve markets all over the enriched milk powders, butter, cheese, cream, and whey concentrates. world with exceptional butter ingredients and branded butter prodWe also recently acquired Wexford Creamery, which produces a ucts,” Jim Bergin explains. range of cheeses, and through a joint venture in Carrick on Suir we The Ballyragget facililty produces a range of butters, which are supmake technical butters for the baking industry.” plied to a range of global customers from branded retail butters such Jim Bergin adds: “We are seeing significant growth in many of the as Kerrygold through to top quality baked goods and biscuits. The industry sectors we supply into, particularly in the area of Health and new butter plant will facilitate a 45% increase in capacity from Wellness. The clinical nutrition and sports nutrition industries are 55,000 MTs to 80,000MTs by 2020. worth Eur16 billion and are currently growing at greater than 6% per Ballyragget is one of Europe’s largest integrated dairy processing annum.” facilities. In 2012, Glanbia Ingredients Ireland also invested Eur21 million in a new whey plant at Ballyragget to consolidate the site’s Additional Investment leadership position into the future. “We are still witnessing increasing In addition to the establishment of the new nutritional ingredients customer demand for whey protein isolate - which is a very pure form

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

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Warehousing Temperature Controlled HPRA Facilities Customs Warehousing Online WMS Supply Chain Management Vendor Managed Inventory KanBan Replenishment Lineside Replenishment Value Added Services Order Fulfilment Pick & Pack Distribution Systems Integration E-Commerce Transport 24hr Distribution Haulage Freight Forwarding Records Management Document Storage and Retrieval Household and Business Self-Storage Controlled access 24/7 Short-term and Long-term Contracts

of whey protein, suitable for various nutritional applications,” he says.

Our new nutritional ingredients plant at Belview is the final piece in place of that capital investment outlay. Phase 2 is the development and expediting of our innovation agenda to drive the development of high spec ingredients for the Health and Wellness and Nutrition industries.”

New Milk Protein Plant At its Virginia site, Glanbia Ingredients Ireland recently invested Eur7.8 million in a new milk protein plant enabling production of the next generation of advanced milk proteins SolmikoHD and Dairy Industry Outlook SolagoHD. Opened in December So how does he see the outlook 2014, the new plant processes milk for the Irish dairy industry in from counties on both sides of the light of the abolition of EU milk border between the Republic of quotas?

Ireland and Northern Ireland. The “Quotas have been in place milk proteins are used by the glob- The nutritional ingredients plant at Belview has been built to Infant Formula since 1984 and their removal at al clinical nutrition, sports and Spec and European Design Hygiene guidelines. the end of March has the potenconsumer food industries. The tial to radically transform investment at the plant will increase milk protein capacity from 4,000 Ireland’s rural economy. For the first time in 30 years, Irish dairy to 10,000 tonnes. farmers can increase their production without having to purchase In addition to producing enriched milk powders for export mar- additional milk quota rights. The current farming generation has kets, the Virginia site is the only supplier of cream for the Bailey’s never known farming without quotas so this really is a generational opportunity,” he replies. “It represents a momentous juncture, not liqueur brand, owned by global drinks giant Diageo. just for dairy farmers but for Ireland’s export economy.”

Jim Bergin draws a parallel with the situation in New Zealand, Development Strategy Glanbia Ingredients Ireland has now completed the first part of its which like Ireland has a large dairy industry and grass-based system 2020 growth strategy designed to ensure the company is well prepared naturally suited to sustainable dairy farming. When milk quotas for the processing of an increased milk supply following the abolition were introduced in 1984, Ireland and New Zealand both produced approximately 5 billion litres annually. However, in the absence of a of milk quotas.

Jim Bergin comments: “Phase 1 provided for a capital investment quota regime New Zealand now produces 20 billion litres of milk programme of Eur200 million in high spec processing infrastructure. annually.

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

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YOUR PROCESS HYGIENE & SANITATION SPECIALISTS

Glanbia Ingredients Ireland’s new Milk Protein Plant at Virginia was officially opened by representatives from the Governments of the Republic of Ireland and Northern Ireland - Heather Humphreys, Minister for Arts, Heritage and the Gaeltacht, and Arlene Foster, NI Minister for Enterprise, Trade and Investment.

Pictured (left to right) are: Liam Herlihy, chairman of Glanbia Ingredients Ireland; Heather Humphreys; Arlene Foster; and Jim Bergin, chief executive of Glanbia Ingredients Ireland.

a differentiated positioning in the global marketplace where our grass-fed, pastured and family farm method of dairying produces a highly sustainable range of quality ingredients, making Ireland highly cost competitive. Glanbia Ingredients Ireland has prioritised sustainability as a key focus for its business,” he remarks.

Indeed, Glanbia Ingredients Ireland’s Belview, Cavan and Kilkenny facilities represent a major statement of intent by the company and on behalf of the Irish dairy industry. “The Belview site will see production and manufacturing on a global scale brought to the South East of Ireland and demonstrates our confidence in, and commitment to, our suppliers and the Irish economy.”

The Glanbia Ingredients Ireland chief executive concludes: “The Government support, through Enterprise Ireland, is a further, significant endorsement of this vision and a vote of confidence in the Irish dairy industry and indeed in Glanbia Ingredients Ireland and our milk suppliers. Up until now the only disadvantage Ireland has had in the dairy field has been quota-imposed supply restriction.

The new era of dairy enabled by the removal of quotas at the end of March will allow us to break free of these shackles and significantly ramp up supply capability.” J

“The removal of milk quotas gives Ireland a unique opportunity to increase milk production and bring an additional Eur1 billion into the Irish economy.” He continues: “The strategic ambition of Glanbia Ingredients Ireland is to grow in international markets, particularly in high growth developing regions.”

Strong Market Fundamentals The market fundamentals are strong and the outlook is bright. Global consumption of dairy products is forecast to grow by 2% to 3% year-on-year until 2025. This is based on solid market demand that is built on sustainable global trends. He also points out that the earth’s population is expected to grow by almost 1 billion extra people during this period with the fastest growth rates in Africa and South East Asia.

Glanbia Ingredients Ireland will work through its global customer partnerships to target both developed and emerging markets. “For example, there are new and emerging middle classes with higher incomes in major markets such as China and the Middle East. There is increased awareness of the benefits of dairy products, westernisation of diets and a growing focus on health and wellness.”

Jim Bergin elaborates: “The new plant at Belview is also good news for other Irish dairy companies, as we have manufacturing contracts with eight other domestic processors which will be open to development or expansion from the Belview plant.

Belview is a scalable facility and so it will also provide platforms for further collaboration in the industry.”

Green Credentials The new plant at Belview along with Glanbia Ingredients Ireland’s other recent investments are expected to further enhance Ireland’s reputation as one of the best dairy producing countries in the world. “Ireland’s green credentials provide FOOD & DRINK BUSINESS EUROPE, MARCH 2015

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Orbis MES at Glanbia Ingredients Ireland Belview lanbia Ingredients Ireland’s Nutritional Ingredients plant at G Belview is the the largest Dairy Powder Facility in Ireland.

Work Commenced on the greenfield site in May 2013 and the facility will now be ready for full production in spring 2015.

Glanbia invested over Eur180 million in the new plant which will be capable of processing more than 700 million litres of milk and produce 100,000 tonnes of dairy powders a year. The new facility will manufacture a range of specialised milk powder products and nutritional ingredients to meet the demands of multi-nationals in infant formula and other industries operating in Asia, the Middle East, Africa and around the world

Belview features a state-of-the-art MES system which provides Production Workflow and Performance Management functionality as well as shop floor to SAP integration.

Orbis MES, a Dublin based company and a specialist provider of MES systems to the Food and Beverages, worked closely with Glanbia Ingredients Ireland to build a state-of-the-art system to match the demands of what was essentially a mixed batch and continuous process.

The system provides the following functionality around a data-

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base core: • Scheduling • Visual Factory • Paperless • Batch Records • Track & Trace • OEE • KPI • Mass Balance • Utilities • Reports • Analytics.

The system operates as follows: As product flows through the process from stage to stage all Production (Recipes and Transfers), Process, (Parameters and Trends) and Plant Data (Status and Usage) is recorded in real time and stored in an Operational Data Store (ODS). The ODS also integrates to external data sources like SAP and correlates Quality, Stocks and Raw Materials.

Within the ODS the multidimensional data sets are organised on an S 95 hierarchical model.

The result is a rich operational data source with over 50,000 real time process data feeds and a unique and detailed record for each unit of production and each segment of the process. This represents big data for the Dairy and the Orbis MES suite of Analytics mine this store and deliver the Manufacturing Intelligence required to enable best practice lean manufacturing. (Scheduling, Paperless Logs, Visual Factory, Batch Records, Track Trace, OEE, KPI, Yield, Reports and dashboards).

John Tobin, CEO of Orbis MES, states:“Belview is one of a new breed of Super Plant designed to operate at the outer edge of efficiency, quality and sustainability. It is a triumph of Engineering and Technology and testimony to the vision of and pioneering spirit of Glanbia. We are delighted that our MES system was chosen by Glanbia to provide the data, information and analytics to operate and manage Belview as a world class facility.”

Further information at John.Tobin@orbismes.com. J

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

I PROJECT MANAGEMENT

Glanbia Ingredients Ireland Belview – A Fast-track Project Delivered on Budget on Time n three years Glanbia Ingredients Ireland’s Igreen Belview facility has literally come from a field in County Kilkenny to a world class 24,000 sq m dairy plant built to infant formula standard. The largest single capital investment (?180 million) in Ireland by an indigenous Irish company, Belview was designed and project managed by PM Group to process up to three million litres of milk per day into a range of specialised milk powders and nutritional ingredients to meet the demands of multi-nationals in infant formula and other industries around the world.

PM Group began the project in 2011 initially working on the concept design and site selection and continuing through planning applications, IPPC licence application, full engineering design, procurement, construction management, commissioning and start up assistance to deliver first milk in December 2014 Projects of this size inevitably pose many challenges around design, safety co-ordination, scheduling, cost control and quality.

May 2013. Multiple other trade contractor appointments followed, culminating in the plant being ready to receive first milk in December 2014 on schedule. The construction management approach combined with strong cost management throughout the design and build ensured the facility was delivered on time and within budget.

Construction Safety

According to John Harte, PM Group’s Project Manager: “Construction safety was paramount at all times with a peak of 785 workers on site and over 1.5 million construction manhours executed in total. In excess of three thousand people received safety induction training on site during the course of the project.”

GMP is a particular focus for a facility of this size which featured 300,000 cu m of excavations, 40,000 tonnes of concrete, 35,000m of pipe, 536km of cable, 10,000 sq m of ducting and 1,180 instruments and all installed to the highest standards.

“The Glanbia Ingredients Ireland Belview project had quite an impact on our dedicated food engineering team. We have extensive experience in the design and build of major dairy and infant nutrition projects

in Europe and Asia. But to complete such a world class project close to our HQ was a fantastic experience,” says Tom Waters, Food Sector Director at PM Group.

For further information visit PM Group at www.pmgroup-global.com. J

Substantial Design Co-ordination

This type of complex process driven design project required substantial design co-ordination between the various engineering disciplines and the process (GEA) and utility contractors. The main feature of the site is a tower in excess of 40 metres, housing two large spray dryers. PM Group used the latest 3D modelling design tools to design a fully integrated facility.

A fast track Construction Management approach was implemented starting with an enabling works contractor appointed in FOOD & DRINK BUSINESS EUROPE, MARCH 2015

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Latest GEA Technology Creates One of Europe’s Largest and Most Efficient Dairy Plants For Glanbia Ingredients Ireland t was just 18 months ago that Iawarded Glanbia Ingredients Ireland GEA a contract to build one of Europe’s largest and most efficient milk processing plants in Belview, Ireland. The first production started in December, 2014: on time, on budget and exactly as planned.

Belview uses the latest dairy technology from GEA to process three million litres of milk a day into more than 100,000 tonnes of dairy powders a year. GEA supplied the complete plant drawing on the company’s full scope of dairy process technologies and components from milk reception through standardization, evaporation and drying to powder transport and packing.

Also the complete automation package was supplied by GEA. Glanbia’s new nutritional ingredients

plant builds on the latest in dairy technology, and it is a showcase for the most modern dairy plants in the world. It has been designed to ensure the most efficient operation in terms of overall equipment efficiency, energy and resource consump-

tion while producing products of the highest quality in a safe environment.

Building a plant this size on an 18 month schedule, delivering it on time and budget, requires solid expertise in managing large projects. GEA’s responsibility included the entire project from process design to project delivery. “Projects like this require careful planning and close coordination between our project management teams, headed by a project director, and the customer,” explains Jan Samsson, Project Director with GEA, and responsible for the Belview project. “We structure projects around that with a sponsor group representing the customer, the builder and GEA. It helps get ahead of challenges and thereby reduces risk for all.” J

Mechanical Engineering Services From MSL Engineering SL Engineering Ltd specialize in fabrication, installation, M commissioning and testing of process, utilities, and high purity pipework as well as process and heavy equipment installation.

MSL manage mutli-discipline sub contractors as part of many of their projects including HVAC, scaffold, craneage, insulation, painting, NDT etc. MSL’s business encompasses one-off construction contracts in addition to ongoing maintenance and term service contracts. Two recent examples of one-off construction contracts completed by MSL in the Food and Beverage sector are: Glanbia Project Purple 2014 Mechanical contractor for the New Dryer Building and New Powder Handling & Packaging Building at Glanbia Ingredients new facility, Belview, Waterford in 2014.

Irish Distillery Expansion 2012/13 - MSL were the main mechanical contractor for construction of the new brewhouse and new stillhouses at Irish Distillers, Midleton in 2012/2013. This included the fabrication, installation and test16

ing of 16,000 metres of pipework ranging in diameter from 15mm (0.5”) to 1050mm (42”). MSL installed 220 items of equipment including 6 distillation columns (36m high, 40tonne each) and 3 copper stills (20tonne each), see picture.

Both these projects were fabricated off-site in the controlled environment of MSL’s extensive, fully equipped workshop fabrication facility at Watergrasshill, Cork, Ireland. This is conveniently located just off the M8/M7 Cork-Dublin Motorway.

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

Modular Fabrication

Recent modular fabrication carried out in the MSL’s Cork fabrication facility, aided by the overhead gantry crane, includes the Factory 1 HVAC Upgrade for MSD Clonmel and the Acetone Recovery Unit for GSK Irvine, Scotland. MSL then ship these modular units to the respective clients’ facility.

Please contact Dave Ronan at +353 85 7350816 or dave.ronan @mslengineering.ie for further information or enquiries. J

STORAGE

LOGISTICS

Complete Logistics Solutions From Store-All Logistics tore-All Logistics, headquartered at S Belview Port and adjacent to the new Glanbia manufacturing plant, offer a complete logistics solution to a wide and varied customer base. Store-All Logistics have a particular expertise in meeting the supply chain requirements of the pharmaceutical, food, and medical device industries. The company’s stock management services include warehousing (ambient and temperature controlled), order picking/packing and distribution throughout Ireland, the UK and Europe.

Store-All Logistics are licensed by the HPRA (Health Products Regulatory Authority) and operate to the strictest HACCP regulations. Store-All Logistics are AEO approved, ISO accredited and members of the Irish Road Haulage Association. These credentials are essential in order to demonstrate and sustain the standards expected by

View of Store-All Logistics’ Food Grade store Belview, Waterford.

the company’s manufacturing clients.

Quality is most important and it is therefore the lifeblood of everything Store-All Logistics do.

Store-All Logistics continuously develop programmes of self inspection, annual review, training, quality and performance management as the essential tools in the growth and development of their business. This ethos of continuous improvement and customer satisfaction monitorPadraig Keegan, Supply Chain Director, Glanbia ing helps Store-All Logistics to form Ingredients, congratulating Liam Dalton, Director, open, strong and long lasting relationStore-All Logistics, on the signing of the warehousing ships with all customers, both large and contract for the new Belview Manufacturing Facility. small.

Also included is Tom Minnock, Supply Chain Founded in 1993, Store-All Logistics Operations Manager, Glanbia Ingredients. have shown steady growth throughout the years to become one of the largest warehouse providers in the country. Store-All specialises in providing safe, secure and accesLogistics operate in excess of 600,000 sq ft of sible lock up units with 24/7 access for both high quality warehousing at five different home and business use. In addition, Store-All locations in Waterford / South Kilkenny. Logistics offer a document storage and manThe company’s workforce of almost 100 agement service, utilising the best industry includes a large base of loyal and experi- software to manage and secure their clients enced personnel, which ultimately bene- archive records. fits customers in consistency and quality For detailed information on all of Store-All of service.

Logistics’ services, please visit www.storeThe transport fleet is an integral part of all.ie.

Store-All Logistics’ logistics service, offerStore-All Logistics have achieved a lot in ing a range of transport units to provide their 22 years of trading, during which the clients with flexibility to meet their company’s philosophy has always been - to at demands.

Listen, to Solve, and above all, to Deliver on Store-All Logistics’ self-storage division their promise. J

EPS Delivers For Glanbia Belview PS were awarded the contract at the E new Glanbia Ingredients milk processing facility in Belview Port, Co.

risks, reduce disruption on site and reduce associated on site costs.

Kilkenny through their consultants, PMG (Project Management Group), to provide a Waste Water Treatment Plant & Water Softening Plant to service the resulting production operations associated with the new build.

The rigid programmes demanded by both these projects required EPS to take creative steps so as to maintain progress with the client’s target dates.

By opting to fabricate large sections of the plant offsite allowed EPS to improve delivery time, installation time, reduce associated health & safety FOOD & DRINK BUSINESS EUROPE, MARCH 2015

The standalone waste water treatment plant comprises the following principal steps: a stainless steel lined pumping station capable of a maximum peak demand duty of 680 cu m/hr, the provision of 4 No. glass lined steel balance tanks for pH buffering/correction, the removal of fats, oils & greases (FOG’s) through the use of a dissolved air floatation (DAF) tank, and the provision of analytical sampling & monitoring instrumentation. The water softening plant principally comprised 3 No. GRP ion exchange softening tanks which operate on a cyclical basis, a salt saturator tank & brine day tank. J 17

Ingredient Solutions Providing Innovative Cheese Ingredients For the Food Industry stablished in 2000 and based at E Boherbue in County Cork, the heart of the cheese producing region of Ireland, Ingredient Solutions is a leading producer of cheese and dairy products for the food industry.

Ian Galletly, Managing Director of Ingredient Solutions, states: “In what has been the most challenging grocery market in living memory we at Ingredient

Ingredients Solutions – ‘Big enough to cope, small enough to care, keen enough to compete’.

Solutions have been very in our facility in fortunate to have had a Boherbue, this investclose relationship with a ment will ensure we are company such as both capable of meeting Glanbia Ingredients our customers’ requireIreland over the past ments and to maintain decade and a half. Like our strong track record ourselves Glanbia are of developing new and prepared to invest in innovative products, an change and believe in essential advantage in a the long term advantage highly competitive interof ensuring they have national market”. state-of- the-art plant “Our Yellow Road and equipment. Their brand is a prime examYellow Road – the cheese range new €180 million dairy ple of how Ingredient that enhances customer loyalty and facility at Belview, shortSolutions and Glanbia increases profitability through ly to come on stream, is can work together to customer experience. a clear demonstration of deliver a cheese that their commitment to enhances customer loybeing able to respond to ever-evolving alty and increases profitability through consumer tastes”. customer experience”.

“In the past 12 months, Ingredient For more information visit Solutions has also invested €1.5 million www.ingredientssolutions.net. J

I DAIRY

€35 Million Innovation Investment in Irish Dairy Processing he Irish dairy processing sector is continT uing to ramp up its preparations for the end of milk quotas with the announcement

According to Gerry Boyle, Director of Teagasc: “The Eur10 million investment by its shareholders will future proof MTL and of an innovation investment of Eur35 milensure its relevance to all its customers, lion. The investment by Government and national and international in the years industry will position Ireland as a ahead but most importantly will world leader in dairy innovation, provide a platform to support the and help to maximise the long ambitions of the Irish dairy industry term growth opportunities created to produce value added foods and by anticipated increase of 50% in ingredients for international marthe Irish milk pool by 2020. kets.”

The investment is in the form of The DPTC is a collaborative two initiatives - a Eur25 million model in which the best research talDairy Processing Technology ent in Ireland relevant to industry Centre (DPTC) supported by needs is brought together with the Enterprise Ireland and the dairy dairy sector to solve strategic industry partners which will be research and innovation needs artichosted by University of Limerick; ulated by the sector. “The two key and a Eur10 million investment by outputs of the DPTC will be knowlTeagasc and the dairy industry edge and people - both will be shareholders in the expansion of absorbed by the industry and used the Moorepark Technology Ltd to deliver more efficient processes (MTL) pilot plant facility in Pictured at the announcement were (left to right): Richard Bruton TD, and better products and ingredients.

Minister for Jobs, Enterprise and Innovation; Simon Coveney TD, Minister The DPTC is like adding a new Fermoy, County Cork.

Of the ten major dairy compa- for Agriculture & Food; Gearóid Mooney, Head of Research & Innovation, software engine to the dairy sector,” nies involved, seven are investing Enterprise Ireland; and Professor Mary Shire, VP Research, University of says Padraig McPhillips, CEO of the in both initiatives - Arrabawn Co- Limerick.

DPTC. J 18

op, Aurivo, Carbery, Dairygold, Glanbia, Kerry, and Tipperary Co-op. Lakeland Dairies is part of the DPTC consortium only. The Irish Dairy Board and North Cork Co-op are investing in MTL.

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

I DAIRY

Lakeland Dairies Begins €36 Million Expansion of Milk Powder Processing Operations Irish dairy co-operative Lakeland Dairies is beginning a Eur36 million investment in an expansion of milk powder processing operations at its site at Bailieboro in County Cavan. The investment has been supported by the Irish Government through Enterprise Ireland. he overall development will lead T to the creation of 81 jobs across the Lakeland Dairies Group over a five year period. Up to 180 construction jobs will also be created by contractors during the building, installation and commissioning phases for the new processing facilities.

One of Ireland’s leading farmer owned dairy processing co-operatives, Lakeland Dairies processes over 800 million litres of farm produced milk annually into a wide range of value-added dairy food service products and food ingredients which it exports to over 70 countries worldwide.

Pictured (left to right): Michael Cantwell, Food Division manager of Enterprise Ireland; Michael Hanley, group chief executive of Lakeland Dairies; Richard Bruton, TD, Minister for Jobs, Enterprise and

Innovation; and Alo Duffy, chairman of Lakeland Dairies.

Well Positioned Following the abolition of milk quotas later this year, annual milk supply to growth in global demand for dairy prodLakeland Dairies is expected to increase by ucts,” points out Alo Duffy, chairman of some 40% to over 1 billion litres by 2020. Lakeland Dairies. “Lakeland Dairies is The development by Lakeland Dairies is focused on the creation of a bright and susdesigned to ensure that the co-operative is tainable future for our milk producers. This well positioned to take advantage of all includes investments in modern and future market opportunities for its milk streamlined plants which guarantee an producers. expanded milk processing capacity and proThe expansion will see the installation of vide the flexibility to meet global market a new 7 tonne per hour milk drying facility needs.” at Bailieboro where total milk powder proThe co-operative has over 2,200 milk duction capacity will increase to 19 tonnes suppliers and operates across 15 counties per hour. Lakeland currently produces on both sides of the border between the 80,000 tonnes of milk powders a year and Republic of Ireland and Northern Ireland. this will rise to 130,000 tonnes on comple- Operating major dairy processing facilities tion of the project in 2016. The co-opera- at Killeshandra and Bailieboro in County tive also produces 24,000 tonnes of butter Cavan, Lough Egish in County Monaghan, on the same site which provides for consid- and Newtonwards in County Down, erable flexibility in milk throughput and Lakeland Dairies had annual revenues of overall economies of scale for the food Eur545.5 million in 2013 and currently ingredients business. employs 700 people.

“When EU milk quotas are abolished this year, Lakeland Dairies’ milk producers Dairy Ingredients will have the freedom to increase milk out- Michael Hanley, group chief executive of put in line with continuing and future Lakeland Dairies, comments: “Growth in

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

our global dairy ingredients business is being fuelled by consumer trends and developments in food industry sectors where we have access to key markets and customers throughout the world. Over the past five years we have transformed our processing capabilities and have also underpinned our future export potential with new global logistics facilities.

The expansion of our operations at Bailieboro will create further advantages for our milk producers. In particular, we see continuing opportunity in the areas of infant formulae, dairy proteins and health related nutritional products, among other categories, where we are a globally recognised leading supplier of the highest quality milk powders.”

Maximum Return Michael Cantwell, Food Division manager at Enterprise Ireland, says: “Enterprise Ireland has worked closely with Lakeland Dairies in developing its expansion and investment plans for the post milk quota era. We are confident that this investment will result in the maximum return to the company and its farmer shareholders by focusing on high quality, value added milk powders for inclusion in top end applications such as nutritionally enhanced foods and infant formula. The investment will have very positive impacts for the region, not only in terms of the 81 new direct jobs it will create, but also in the indirect benefits to the local and wider economy.” J

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Visbeen: serving Europe daily Cool, Fresh & Frozen Lamb Weston / Meijer, producer of frozen potato products and logisticsservice provider Visbeen have entered into an innovative, multi-year cooperation for frozen-food distribution within Europe. This co-operation is based on partnership - sustainable solutions are created by taking a joint integrated look at transport opportunities throughout the chain and by using the latest technology. This forms the basis for strengthening the transport flows - other transhippers can link in in order to make the flows even more efficient.

Langeweg 20, 3244BH P.O Box 2, 3244 ZG, Nieuwe, Tonge, The Netherlands Tel No: 0031 187 607831

I POTATO PRODUCTS

Lamb Weston/Meijer Investing €120 Million to Expand Production Lamb Weston/Meijer, which specialises in the manufactures of deep-frozen potato products and dried potato flakes, is investing €120 million in installing a new, state-of-the-art production line for premium frozen products at its factory at Bergen op Zoom in the Netherlands. he facilities at Bergen op Zoom are being expanded to accommodate the new line, which is planned to be fully operational in mid-2016, resulting in the creation of approximately 50 new jobs. A second production line at the plant will significantly increase its capacity for producing French fries and other premium frozen potato products.

Lamb Weston/Meijer’s product range encompasses a wide range of fries, wedges and seasoned potato specialities in unique shapes and various flavours. Popular Lamb Weston potato products include Twisters, CrissCuts and Wedges, Private Reserve Fries and Stealth Fries. The company supplies both the retail and food service markets. Most products are sold under the Lamb Weston brand but the company also supplies private label products.

T

Popular Lamb Weston potato products include Twisters, CrissCuts and Wedges, Private Reserve Fries and Stealth Fries.

Setting High Standards The new line and the expansion of the facilities at Bergen op Zoom illustrate Lamb Weston/Meijer’s ambition to set high standards in the market in terms of both products and production facilities. The new line will enable the company to meet the growing international demand for high quality potato products and concepts.

As large quick-serve restaurant chains continue to expand rapidly across the globe, the new investment by Lamb Weston/Meijer is expected to accelerate its international growth with customers. International consumption of frozen potato products continues to grow with the worldwide frozen potato category project-

A recent innovation is Sweet ‘n Savour, a new

employs more than 1,300 people. Together with ConAgra Foods Lamb Weston, these products are sold under the Lamb Weston brand in more than 100 countries throughout the world.

The investment at Bergen op Zoom is being financed directly by Lamb Weston/Meijer with no additional capital investments from its joint venture partner.

sweet potato fries range.

ed to grow by 1.8 billion pounds between 2013 and 2018.

The new production line for premium products reflects Lamb Weston/Meijer’s continuous investment in meeting the growing market and customer demands and the optimization of its operations. €20 Million Investment For example, last year Lamb Weston/Meijer commenced a Eur20 million investment programme at its site at Kruiningen in the Netherlands. The project entails the implementation of a fully automated potato sorting process in a new, state-of-the-art potato grading area.

The installation of a number of fully-automated potato sorting lines will make the complex potato sorting process considerably simpler and more efficient after delivery in mid2015. The system in Kruiningen will soon be reduced to a single flowing line, from arrival and sorting of the potatoes to processing in the plant.

Joint Venture Established in 1994 as a joint venture between ConAgra Foods Lamb Weston of the USA and Meijer Frozen Food of the Netherlands, Lamb Weston/Meijer operates five factories. Three of the productions sites are in the Netherlands at Kruiningen, where the head office is also based, at Oosterbierum and at Bergen op Zoomm. Lamb Weston/Meijer also has sites at Wisbech in the UK and at Hollabrunn in Austria.

With a current production capacity of 650,000 tonnes, Lamb Weston/Meijer FOOD & DRINK BUSINESS EUROPE, MARCH 2015

Product Innovation Constant new product innovation and successful extension to existing lines are central to the continued growth of Lamb Weston/Meijer.

From Wedges, Twisters and CrissCuts to coated and spiced fries, to sweet potato fries and potato-based appetizers, Lamb Weston has been at the forefront of the development of value-added potato products in Europe and further afield.

A recent innovation is Sweet ‘n Savour, a sweet potato fries range. The new range continues Lamb Weston’s approach of bringing food service operators innovative and profitable solutions that fulfill the growing consumer demand trend for sweet potato products across markets.

For restaurants, especially casual dining and quick service restaurants, differentiation from competitors and menu variation for diners is crucial. Market research conducted by Lamb Weston shows that consumers will order an additional side dish if Sweet ‘n Savour Fries are on the menu. J

Market research conducted by Lamb Weston shows that consumers will order an additional side dish if Sweet ‘n Savour Fries are on the menu.

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I ANUGA FOODTEC 2015

International FoodTec Award Winners 2015 Announced LG (Deutsche LandwirtschaftsD Gesellschaft/German Agricultural Society) has announced the winners of the International FoodTec Awards 2015. The prestigious accolades are being awarded to 18 innovations in the international food production and supplier industries – nine will receive the award in gold and nine in silver at a special ceremony at the Anuga FoodTec trade fair in Cologne on 24 March 2015.

Among the award-winners are companies from Denmark, Canada, the Netherlands, Austria and Germany. The International FoodTec Awards are organised every three years.

Gold Medals

The Gold Medal winners are:

Insort GmbH (Kirchberg/Austria) – Sherlock Food Analyser Production processes in the food industry are often extremely complex and pose significant technical challenges. Infrared spectroscopy is an ideal method for continuously capturing data about the chemical structure of food in a high-speed 'in-line' production process in a way that is contactless and does not damage the product. This invaluable information can be used to classify products and control product flows and processes.

Developed by Insort, the Sherlock food analyser uses infrared spectroscopy to continuously analyse product flows in real time in accordance with defined parameters and to make corrections to the process as necessary, thereby improving product quality. Food is a particularly challenging product to monitor because the factors that influence it are very complex The distribution of ingredients can be highly heterogeneous, for example, and there are different varieties to consider as well as changes that take place during the storage and production process. This meant that the Sherlock process diagnostics system had to be developed for use with a variety of foodstuffs in such a manner as to provide reliable, robust and high-precision analysis, within defined fluctuation ranges, even when faced with highly variable parameters.

• German Institute of Food Technologies (DIL, Deutsches Institut für Lebens-mitteltechnik) (Quakenbrück/Germany) – High Moisture Extrusion • Fritsch GmbH (Markt Einersheim/ Germany) - Multitwist twisting machine • GEA Food Solutions (Bakel/Nether lands) - GEA MultiDrum • Insort GmbH (Kirchberg/Austria) Sherlock food analyser • Krones AG (Neutraubling/Germany) Deaeration of fruit juices • Perfo Tec BV (Mijdrecht/Netherlands) -

Respiration control system • Sealpac GmbH (Oldenburg/Germany) Easy Lid • Stadtwerke Murau (Murau municipal utility company) (Murau/Austria) - Transformation of thermal energy systems • VEMAG Maschinenbau GmbH (Verden/Germany) - AML273 meatball loader.

Silver Medals

GEA Food Solutions (Bakel/Netherlands) – GEA MultiDrum 'Homestyle' or 'southern-style' breaded products, with their coarse, crispy coating, were once mainly enjoyed in fast-food restaurants, but are now gaining popularity as consumer products sold in supermarkets. Until recently, however, the appearance, bite and mouthfeel of these products have been below par.

This is because the industrial production process has always required a compromise between authenticity and efficiency.

To overcome these obstacles, GEA has developed an innovative home-style breader that splits the product stream and feeds the products evenly into multiple drums. The products leave the drums spread evenly across the belt, reducing labour costs by up to 80 per cent.

The GEA MultiDrum delivers consistent coating quality with the authentic home-style look, taste and bite. With a much shorter overall line, it has a far smaller footprint than single-drum breading lines with their accompanying spreading belts. The machine is easy to clean and thanks to the GEA OptiAir technology, the amount of dust in the work environment is greatly reduced.

22

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

The Silver Medal winners are: • ALPMA Alpenland Maschinenbau GmbH (Rott am Inn/Germany) - ALPMA RO HighTS membrane system • Bruker Optik GmbH (Ettlingen/ Germany) - MPA/LSM analysis system • Danish Meat Research Institute (Taastrup/Denmark) - 3D derinding of pork loin • Döinghaus cutting and more GmbH & Co. KG (Salzkotten/Germany) - Universal Ultrasonic Cutter • Intralox L.L.C. Europe (Amsterdam/ Netherlands) - DirectDrive System • K+G Wetter GmbH (BiedenkopfBreidenstein/Germany) - MW 200 mixergrinder • Kuchenmeister GmbH (Soest/Germany) Deodorisation and heat recovery

• Linde AG (Pullach/Germany) - CRYOLINE®SI – IQF immersion freezing • Smart Skin Technologies Europe GmbH (Gammelsdorf/Germany/Canada) - Smart Skin Quantifeel©.

The winners will all be on view at the DLG stand at Anuga FoodTec (hall 5.2, D 041).

The award winners were selected by a panel of expert international judges representing various disciplines, which included: Professor Emmerich Berghofer (University of Natural Resources and Life Sciences, Vienna/Austria), Professor Michael Gänzle (University of Alberta in Edmonton,

Krones AG (Neutraubling/Germany) – De-aeration of Fruit Juices Fruit juices need to be degasified prior to bottling for three main reasons: to avoid problems when bottling, to minimise oxidative reactions and to stop fruit particles from floating around in the bottle. In the de-aeration process, it is important to keep the surface area as large and turbulent as possible and to keep the thickness of layers as thin as possible.

This keeps the diffusion paths for the gas bubbles short. To limit the formation of foam, however, the juices should be subjected to a minimum of mechanical stress.

Krones has developed a 'swirl infeed' that avoids the drawbacks presented by the annular, spray and tangential nozzles that are most commonly used at the moment. This is designed to gently apply the product to the wall of the de-aeration tank, starting at the specially constructed container lid.

Because of the speed at which it is introduced and the adhesive force, a thin film of juice attaches itself to the walls.

Using the surface of the container, including the lid, enables the volume of the container to be reduced by more than a third. This saves not only space but energy too: the vacuum pumps can be smaller because there is less volume to evacuate. The turbulent product film allows a high rate of gas exchange that achieves low residual oxygen levels even at higher viscosities. Flavour loss can be minimised by adjusting the intensity of de-aeration to the particular product.

Canada), Dr Kees de Gooijer (Food & Nutrition Delta, Wageningen/ Nether lands), Professor Dietrich Knorr (Technical University of Berlin), Professor Alexander Kolesnov (Moscow State University of Food Production MGUPP/Russia), Professor Horst-Christian Langowski (Fraunhofer

Institute for Packaging and Packaging Technology, Freising-Weihenstephan), Professor Helmy T. Omran (Suez Canal University, Ismailia/Egypt), and Professor Achim Stiebing (Ostwestfalen-Lippe University of Applied Sciences, Lemgo/ Germany). J

I ANUGA FOODTEC 2015 PREVIEWS

HERMA at Anuga FoodTec 2015 – Labels For Guaranteed Freshness t this year’s Anuga FoodTec exhibition A in Cologne, Germany, HERMA (hall 7.1, booth D048) will present its innovative solution for the tamper-evident labelling of fresh food products. The HERMA 552 labeller seals the bottom and the sides of food packaging such as salad or sandwich boxes with a ‘watch strap’ label, thereby ensuring their freshness. The robust system is therefore ideally suited for the growing convenience food sector. Based on the highspeed labeller HERMA 400, it handles more than 100 products per minutes.

Manufactured from high-quality stainless steel, it is easy to clean and complies with the food industry’s strict hygiene requirements. In order to apply variable data to the packaging, printers can be easily integrated.

The new labelling system was developed by the British subsidiary HERMA UK which specializes in food industry applications.

HERMA’s laser-activatable labels which offer many advantages for food labelling are another key exhibit at the Anuga FoodTec.

Comprised of a laser unit, a label applicator, and special labels, HERMA laser systems do not require any other consumables or readjustments – unlike thermal transfer printing systems. Their wear-free operation prevents production standstills. The labels' special finish allows the laser to apply abrasionproof black inscriptions in the designated place. This process creates no smudgeable particles that would require removal by suction, and does not damage the label at all.

Both the labels’ adhesive and the labelling method feature an ISEGA certification, thereby qualifying for use in food applications.

Furthermore, HERMA will focus on a labelling solution for vertical form fill & seal machinery. This ultra-compact version of the HERMA 400 labelling system applies labels, e.g. with promotional information, to tubular bags for food. It requires no control cabinet, can be modified to suit any installation, and can be integrated in almost any position. A master encoder permanentFOOD & DRINK BUSINESS EUROPE, MARCH 2015

ly synchronises the speed of the label dispenser with the advance motion of the tubular bag packaging machine. The system processes up to 90 bags per minute. J

The innovative labeller developed by HERMA seals more than 100 food packaging boxes per minute with a ‘watch strap’ label indicating freshness.

23

QUALITY

& HYGIENE

I ANUGA FOODTEC 2015 PREVIEWS

Sentinel II – A Tailored Approach to Processing From TOMRA Sorting Food OMRA Sorting Food has T launched its state-of-theart Sentinel II sorter for the tomato and peach processing industry.

Sentinel II is a highly efficient, cost-effective, sorting solution that has been engineered with seasonal processors in mind. It offers a high degree of flexibility and can be configured to meet different specific requirements along the production line.

Sentinel II offers low, medium or high speed modes depending upon the specific application sort requirements.

Sentinel II Excels

When it comes to tomato sorting, Sentinel II outshines its competitors in terms of sorting efficiency, capacity, technical specification and durability. With three different sorter size offerings, it covers a capacity range of 40-200 tons/hour making it an ideal solution for the seasonal processor seeking off-colour, defect and foreign material control.

Sentinel II allows for a range of factory configurations so customers may choose, for example, to order a one or two camera inspection system in order to best meet individual process needs and to deliver a higher quality final product with less manual grading and downtime.

Sentinel II’s high resolution sensors and simple user interface allow the customer to set the sorter to reject a broad range of defects such as green, sunburn, mold, anthracnose rot or worm damage while also removing foreign materials such as cotton stalks, corn cobs, plastic, glass, metal, wood bone and animal matter.

An enhanced, patented, high-speed rejection system efficiently removes defects and foreign material, operating at higher speeds than previous models.

Jim Frost, TOMRA Sorting Food Market Unit Manager for whole product sorting, says: “Food processors will appreciate the flexibility and efficiency that TOMRA’s Sentinel II brings to their production lines.

Sentinel II can be tailored to customer requirements and sorting can be refined to such a degree that small mold spots and other discolorations can be removed to produce high quality fruit to be processed.”

Cost-effective Sorter

Jim Frost adds: “This element of adaptability means Sentinel II is a cost-effective option for processors of all sizes and generates an attractive return on investment. In addition, the positioning of the machine in the production line is not restricted; it can be placed in various locations prior to or post peeler meaning customers can operate their production lines in a way that is most efficient for them.”

Sentinel II has been designed with easeof-use in mind so that operators get the best value from their machine.

During trials, customers have given positive feedback on the ‘open plan’ design of the Sentinel II which, they say, makes it easier to operate and maintain, as well as aiding in the sanitation process.

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

An intelligent user interface allows operators to access data about the type of defects being identified permitting operators to adjust sorting quality quickly if required.

Furthermore, the user control system can offer diagnostics and maintenance information to highlight any potential problems with sorting before they occur.

Jim Frost says: “The launch of Sentinel II demonstrates our commitment to being at the forefront of developing innovative, cost-effective sorting machines which address the needs of the food industry. Its development is part of our long term vision to offer sorting solutions which include multiple capabilities to give our customers complete flexibility.”

He adds: “The more refined sorting process and robust reliability delivered by Sentinel II will give our customers peace of mind that they are meeting their obligations in terms of food safety and quality.

Meanwhile, the ability to process significantly higher volumes at high speed drives up productivity and efficiency on the production line.”

TOMRA Sorting Food, formerly BEST and ODENBERG, designs and manufactures sensor-based sorting machines for the food industry. Over 7,500 systems are installed at food growers, packers and processors worldwide. The company provides high-performance optical sorters, graders, peeling and process analytics systems for nuts and seeds, dried fruits, potato products, fruits, vegetables, meat and seafood. The systems ensure an optimal quality and yield, resulting in increased productivity, throughput and an effective use of resources. For more information on TOMRA Sorting Food visit www.tomra .com/food. J 25

I ANUGA FOODTEC 2015 PREVIEWS

Smarter, Faster Fluid Handling Solutions From Flowtrend lowtrend, Inc, an ISO 9001 certified F company, is the leading manufacturer of high-equipment and parts for the sani-

•All stainless construction: forged, precision-machined body and disc.

FT LKC- 2 Check Valve

tary industry. With offices in Houston, Texas, Denmark, and throughout the world, Flowtrend provides superior service, support and technical expertise at an exceptional value.

The FT LKC-2 is well-suited to prevent reverse flow of fluids. The FT LKC prevents pressure surges and is able to withstand high pressure. Features include: •Sizes 1”–3” •Quick disassembly for inspection and cleaning •Disposable air filter to remove impurities •Weld or clamp connection.

For further information visit www.flowtrend.com. J

FT ARC Seat Valve

The FT ARC valve is well suited for aseptic conditions and high sterilization temperatures. Options for the FT ARC include: • Air operated seat valve • Sanitary, flexible design: stop valve with

2-3 ports • Remotely controlled with compressed air • Reliable: few, simple moveable parts • All parts 100% interchangeable with OEM. FT LKB Butterfly Valve

The FT LKB Butterfly Valve is suited for fluid handling and process by automatic or manual control. Features of the LKB Butterfly Valve and LKLA Actuator include: • Manual or remotely controlled by air • Rising stem feature allows for addition of control tops for providing position feedback and housing of solenoids • Repairable actuator and valve • Valve and actuator laser etched for easy identification • Visual indication of open/ closed position • Valve, actuator, and components are 100% interchangeable with OEM.

The Future of Manufacturing – Siemens Supporting the Dair y Industr y Through Innovation eith Thornhill, Business Manager K Food & Beverage Sector, Siemens UK & Ireland, says that greater industrial technology awareness and deployment are required if the country is to reach the productivity levels necessary to maintain or expand its manufacturing footprint. Here, he outlines some industrial automation technology trends and touches on how Siemens is supporting the dairy industry going forward.

Today, manufacturing is changing faster than ever before and the drivers for this

include globalisation, individualisation, time to market and sustainability. Energy and resource efficiency are increasingly decisive factors in manufacturing competitiveness, even in developing economies adopting automation technology at rates that look set to further improve their traditional cost advantage.

Globalisation is driving the need for shorter innovation cycles, as time-to-market represents a competitive advantage for an increasing number of products. Localisation agendas are more apparent all over the FOOD & DRINK BUSINESS EUROPE, MARCH 2015

globe too, driven by interests in local manufacturing and jobs. Manufactured products themselves are becoming more complex and data generated from their production, distribution and use is growing exponentially.

Technology used in food and beverage manufacturing is also developing at a faster rate, largely due to the pace of change in microprocessor, communications and information technology. Much like consumer tech, industrial automation technology continues to offer users greater processing power, more memory, richer software fea27

tures, smaller footprints and lower relative costs.

The cost comparative is true for industrial robots too, which from just £15,000 also offer faster returns than ever before.

User expectations of automation technology are changing too, but ease of use, long

life-cycle and remote access to information are consistently highlighted amongst their needs with today’s plant manager expecting real-time data delivered to their smart device to aid decision making on the move.

The food and beverage industry across the UK and Ireland has recognised that innovation is the key to a competitive, safe and sustainable future that satisfies the local market and allows for the capacity increases required to realise the increasing export opportunities and growth.

Come and See

In particular, Siemens is supporting the needs of the dairy industry through the development of specific software library’s that can cover all aspects of dairy processing lines, in addition to a new predictive control capability for power data management on milk powder production lines. These are among many exciting Siemens technology solutions on display at Anuga FoodTec (see STAND C071, C079) aimed at solving

Keith Thornhill, Business Manager - Food & Beverage Sector, Siemens UK & Ireland.

some of the key issues facing the dairy industry today, including operational efficiency and energy management. J

I ANUGA FOODTEC 2015 PREVIEWS

GEA Shows the Latest Nu-Con Powder Handling Range EA will be exhibiting its latest GEA NuG Con powder handling technology at Anuga FoodTec in Cologne from 24-27 March, 2015. The exhibits on the stand will include: the GEA Nu-Con Vacuum Sampler; the GEA Nu-Con Generation 3 Rotary Detection System; the GEA Nu-Con Large Inlet Rotary Valve; and the GEA Nu-Con 12bar rotary magnet. All products are new from GEA since the last ANUGA Food-Tec and represent technology leadership in their fields.

tions to improve reliability and diagnose faults.

The Generation 3 RDS provides a contamination alarm giving an early warning of potential contamination; a seal controller, that continually monitors the condition of the valve’s seals using flow metering; maintenance warnings to alert users when critical components, such as bearings and drive chains, need to be checked or replaced; and data logging showing and recording the running resistance, speed, operating pressure and any contact or circuit faults in the rotary valve.

GEA Nu-Con Vacuum Samplers

GEA Nu-Con stand-alone vacuum sampler technology can be retro-fitted to large volume powder production lines widely used in the manufacture of infant formula and dairy powders. Vacuum sampling enables a plant to monitor product quality more effectively than traditional ‘bobbin’ or ‘screw’ sampling methods which can themselves introduce bacteria to the powder being processed. This improved method of sampling helps to ensure that a high quality of product output is maintained and provides track and trace data to the plant operator.

Large Inlet Rotary Valve

The new GEA Nu-Con Large Inlet Rotary Valve has been designed specifically for applications that require an uninterrupted powder flow through the valve, when handling products that do not flow well. Applications

Generation 3 Rotor Detection System (RDS)

GEA recently announced its Generation 3 Rotor Detection System (RDS) for rotary valves that is designed to help food processors protect themselves from the crippling costs of contamination during production and also provide a range of unique technical innova28

The 12-bar rotary magnet (shown with a round inlet but now replaced with a square inlet).

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

include: spray dryers, cyclones, and dust collection or recovery systems where throughput is not the deciding factor but fine product can bridge and restrict flow.

The new design is suitable for attaching directly to dryers and cyclones. It is formed from a single casting giving it high structural rigidity and smooth, easy-clean lines for use in high hygiene food plants. The high quality castings have been designed in accordance with ATEX 94/9/CE Class 2 Cat.1 Zone 20 to withstand dust explosions, making them ideal in high risk installations such as spray dryers, cyclones and dust collection systems.

12-bar Rotary Magnet

The new 12-bar demountable rotary magnet from GEA removes fragments of ferrous material from food and dairy powders to prevent contamination. The new 12-bar design has undergone a fundamental redesign (from the old 8-bar version) in close cooperation with one of the world’s leading manufacturers of powdered infant formula and in association with the Auckland University of Technology.

The new design, and rare earth Neodymium magnets, have given the new rotary magnet the ability to extract more ferrous material than has been possible in the past helping to ensure the quality of the final powder product.

GEA sales and technical staff will be on hand to answer visitors’ questions and discuss specific applications at ANUGA Food-Tec: Hall 09.1; Stand A080/E089. J

I GROCERY MARKET

UK Grocery Market Accelerates and Tesco Returns to Growth he latest grocery share figures from T Kantar Worldpanel, for the 12 weeks ending 1 February 2015, show the grocery market growing at 1.1%, the fastest rate since June 2014.

Fraser McKevitt, head of retail and consumer insight at Kantar Worldpanel, explains: “Shoppers are taking advantage of both lower fuel prices and the continuing price war among the supermarkets to slightly increase their grocery spending. This has pushed the market into 1.1% growth, low by historical standards but a considerable improvement compared to November 2014, when the market contracted.”

“All of the major grocers have continued to compete fiercely on price leading to likefor-like grocery prices falling by 1.2%. This is another record low, saving Britain’s shoppers £327 million over the past 12 weeks.”

Tesco returned to growth for the first time since January 2014, increasing sales by 0.3% compared to this time last year.

He adds: “Britain’s largest retailer is bouncing back from a tough year, with Dave Lewis’s efforts to overhaul the supermarket attracting an additional 236,000 shoppers into its stores in the last 12 weeks.

Despite the increase in sales, Tesco’s overall market share fell to 29.0%, down by 0.2 percentage points compared to last year.”

Asda reclaimed the title of second largest retailer this period with 16.9% of the market, overtaking Sainsbury’s, which traditionally performs more strongly at Christmas than the rest of the year. Both grocers saw sales fall compared with a year ago – Asda by 1.7% and Sainsbury’s by 1.0%. Morrisons’ sales fell by 0.4%, the best performance from the Bradford-based retailer since December 2013.

Fraser McKevitt continues: “Early results suggest that discounters Aldi and Lidl will

find their accelerated growth levels hard to match in 2015. Aldi’s growth of 21.2% is still impressive but a relative slowing from its 36% peak in May 2014. Likewise, Lidl’s maximum growth of 24% in the same period is now down to 14.2%. Despite this slowdown, both retailers are still taking share from the other retailers – rising 0.8 percentage points and 0.4 percentage points respectively to 4.9% and 3.5%.”

At the premium end of the market Waitrose has supported growth with a greater focus on price and promotion.

This has resulted in a sales rise of 7.2%, taking its overall share to 5.2%.

Grocery inflation has seen its 17th successive fall and now stands at -1.2% for the 12 week period ending 1 February 2015. This means shoppers are now paying less for a representative basket of groceries than they did in 2014. This is another record low since Kantar Worldpanel began recording GPI in October 2006 and reflects the impact of Aldi and Lidl and the market’s competitive response, as well as deflation in some major categories including vegetables, milk and bread. J

Groceries Code Adjudicator to Investigate Tesco hristine Tacon, the UK Groceries C Code Adjudicator, has launched an investigation into Tesco plc, having formed a reasonable suspicion that the retailer has breached the Groceries Supply Code of Practice. The investigation is expected to take place over the next 6-9 months and the Adjudicator has called for evidence to be submitted by 3 April 2015. It will cover the conduct of Tesco plc from 25 June 2013 (when the GCA was created) to 5 February 2015.

The investigation will consider the existence and extent of practices which Christine Tacon, the UK Groceries Code Adjudicator. have resulted in delay in payments to suppliers. It will also consider the exis- tioning) which are not related to a promotence and extent of practices where suppli- tion. ers have been required to make payments At this stage the investigation will focus for better positioning of goods (shelf-posi- on Tesco plc only and not extend to other FOOD & DRINK BUSINESS EUROPE, MARCH 2015

retailers. If, during the investigation evidence is presented to the GCA which indicates that the same practices have been carried out by other designated retailers, consideration will be given to extending the scope of the investigation to include them.

Christine Tacon says: “This is the first investigation I have launched and it is a significant step for the GCA. I have taken this decision after careful consideration of all the information submitted to me so far. I have applied the GCA published prioritisation principles to each of the practices under consideration and have evidence that they were not isolated incidents, each involving a number of suppliers and significant sums of money.” J 29

I AIR COMPRESSORS

Water-injected Screw Compressors – Now the Most Sensible Oil-free Option he technology of the water-injected screw compressor has been around for T some time as an option for genuine oil-free air. However, in the last few years, there have been a number of advancements which now make it the most economic option - both in capital outlay and in running costs.

When your air has to be 100% pure oilfree guaranteed, without the need for filters or catalytic convertors, then you should be looking at a compressor whose air is rated Class 0 ISO 8573-1, with absolutely no oil carry-over to contaminate your product.

The only solution is a machine where the output is totally pure at source.

efficiency to generate the correct volumes of air needed – meaning less air delivery per kW used.

a compressor is in the electricity used to power it – well over 70% of the lifetime costs. Any reduction which can be achieved in usage here can be significant and the Water-injected Screw shows that around 20% less power is needed to generate similar volumes of air.

Savings in wear and maintenance come from an aluminium bronze element housing which gives added strength and durability and the hydrodynamic bearings that ensure long life. Reverse osmosis ensures a constant supply of high quality water, avoiding corrosion and bacteria growth. Service is only required every 4000 running hours.

The heart of the WIS compressor.

Not Just Oil-free Just Add Water

There are two alternative technologies available – the dry-screw and the waterinjected screw. The former is more costly in capital outlay and in running costs. Heat generated in compression means loss of

Thanks to the superior cooling capability of water, the new Worthington Creyssensac WIS range removes the heat efficiently at source, meaning that more air per kW is generated.

The largest cost in owning and operating

Whatever solution you need for your business process, Worthington have the right compressor for you. For more details contact Worthington Creyssensac on Tel +44 (0)1925 817803, E-mail contact.uk@airwco.com or visit www.oilfreecompressors.eu. J

Compact Data Logger For Compressed Air Systems aving introduced the METPOINT H BDL data logger, BEKO Technologies has now released its little brother - the METPOINT BDL compact.

The METPOINT® BDL compact data logger allows for the connection of 2-4 transducers or sensors in a user-defined manner. With pressure transducers, for example, or with pressure dew point transmitters, volume-flow sensors, temperature sensors, clip-on ammeters, etc. Four limit values on the whole can be freely defined and assigned to two different alarm relays.

At the device, the measured values are indicated on a 3.5" colour display with a zoomable touch panel. It allows for tabular, graphic, and combined presentations.

Saving potentials become transparent via daily, weekly, and monthly reports. Any exceeded limits are highlighted in red. An

early detection of deviation from set parameters secures highest precision and process safety.

With a weight of only 3.5 kilos and a housing made of powder-coated aluminium, the METPOINT® BDL compact can be integrated easily into existing and new compressed-air systems. A connection to a server for networking with other systems is optionally possible. Due to the employment temperature of up to 50°C, installation points close to the production areas do not pose an obstacle to the BEKO data logger.

For more than two decades, BEKO has developed, manufactured and sold highquality, reliable and efficient components and systems for compressed air processing and condensate technology. For further information visit www.beko-technologies .co.uk. J FOOD & DRINK BUSINESS EUROPE, MARCH 2015

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I AIR COMPRESSORS

Nitrogen, Vacuum and Compressed Air Solutions From Atlas Copco n Stand S2344 at Pro2Pac 2015, which O is being held between 22-27 March at Excel in London, Atlas Copco Compressors will be showcasing its efficient and sustainably productive on-site nitrogen generators, innovative new vacuum pumps and compressed air solutions for the food and beverage packaging industry.

A highlight of the stand will be the NGP Series nitrogen generators, which are designed to provide a cost-effective, reliable and secure supply of on-site nitrogen. The NGP generator’s working principle is based on Pressure Swing Adsorption (PSA) technology, which entails carbon molecular

sieves that separate oxygen from nitrogen.

The NGP series is therefore ideally suited to a wide range of applications including food and beverage storage and packaging.

Visitors will also get the chance to learn about Atlas Copco’s soon-to-be-launched GHS VSD+ vacuum pumps. The GHS VSD+ series is a new range of highly efficient, intelligent vacuum pumps featuring variable speed drive (VSD) and an innovative motor design that combine to produce a leap forward in efficiency that dramatically reduces lifecycle costs. Based on the proven plug-and-play design principles of Atlas Copco’s compressors, the new GHS VSD+ vacuum pumps have been designed to deliver peak performance at common operating pressures in industrial applications.

Atlas Copco also offers air compressors for the packaging industry, including the space-saving GA VSD+, an oil-injected screw compressor with variable speed drive, driven by a permanent magnet motor. This innovation is the most important one since the invention of Variable Speed Drive (VSD) technology by Atlas Copco 20 years ago. Thanks to the game-changing energysavings of average 50% that the GA VSD+ offers, this new compressor has helped

many customers reduce their energy costs ever since its introduction.

Visitors to Stand S2344 will also be able to hear about Atlas Copco’s oil-free compressed air solutions. With a wide variety of food and drink processing operations relying on the supply of clean, dry compressed air; Atlas Copco’s Class 0 certified compressors are guaranteed to ensure zero risk of oil contamination within the compressed air supply to sensitive process procedures and applications where air comes into contact with food.

For further information visit www.atlascopco.com. J

Training Days With BEKO Technologies EKO Technologies are offering training days to give people an B opportunity to increase their knowledge on a variety of topics including oil-free air, measurement technology, air treatment, condensate management and up and coming new products from BEKO Technologies. BEKO Technologies offer a basic compressed air training course and an advanced course for people who already have an extensive background working with compressed air.

BEKO Technologies have live demonstrations which provide an opportunity to test and see how the company’s products work.

Another option is BEKO Technologies’ e-learning interactive course – ‘The Basics of Compressed Air Technology’. This innovative course is available to all customers, giving you the chance to share and benefit from BEKO’s vast experience in compressed air.

The course ‘Basics of Compressed Air Technology’ gives an insight into compressed air from the end users point of view. It provides information about applications and their quality requirements as well as how compressed air is produced and distributed. It explains how the quality is influenced by the components and layout of a compressed air system. Throughout the whole course emphasis is placed upon the need to balance quality and energy efficiency. The course is aimed at people new to the industry or at sup32

port staff within distributors who need an overview. It is also the first step on a more detailed learning program for those who require it.

The training days can be tailored to specific areas for example ‘oil free’ or in-depth training on the large dryers EVERDRY. For more information, contact BEKO Technologies on +44 (0)1527 575778 or email ruth.goodison@beko-technologies.co.uk. J

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

I LEAN MANUFACTURING

Lean Maintenance Can Release the Full Potential of Your Maintenance Function year ago, the Operations Director was conA cerned. The company was making great strides in improving productivity, quality and cost performance yet to the director’s eyes, the Lean revolution had by-passed the maintenance function.

It was clear that effective maintenance is fundamental to meeting that challenge of increasing customer expectations. The traditional "maintenance as a necessary evil" was not going to be good enough to meet the future customer service expectations.

Lean Maintenance provided the answer. It incorporates the principles of lean thinking,

including a plan for every asset to assure flexibility and the systematic improvement of process capability. It helped the maintenance team to design maintenance standard work to reduce waste and non-value added activities.

Together with improved daily management and use of visual management, time was redirected towards focused improvement to systematically extend mean time between interventions and reduce quality defects. This proved to be particularly useful when introducing new products and equipment because the maintenance engineers had time to focus on designing out latent weaknesses before the new assets arrived.

There was still plenty to do but the maintenance improvement master plan at the core of the Lean Maintenance process has finally been aligned with the business strategy. In fact maintenance led lean projects are on track to deliver over 40% of the gains from the current lean programme.

To find out more about how Lean Maintenance can release the full potential of your maintenance function why not sign up to

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

DAK’s CPD Certified Lean Maintenance workshop, 21-23 April 2015, in Warwickshire, UK. During the workshop participants will review current practices against lean maintenance standards and use the insight gained to create a maintenance improvement master plan to deliver the full value adding potential of maintenance within a Lean, TPM or Six Sigma improvement programme.

Contact sue.catt@dakconsulting.co.uk or call +44 (0) 1491 845504 to book your place and for workshop brochure. Visit www.dakacdemy .com for full listing of DAK’s improvement workshops. J

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I STARCH

€9 Billion European Starch Industry Faces Stiffening Challenges With an annual turnover of about €9 billion and employing 16,000 people directly, the EU starch industry produces a diverse range of products, which are used as food ingredients and functional supplements in a vast array of food, non-food and feed applications. ncompassing 78 production facilities in 21 of the 28 EU Member States, the European starch industry processes in the region of 22 million tonnes of maize, wheat and starch potatoes into 10 million tonnes of starch and starch derivatives and 5 million tonnes of starch co-products each year. In addition to direct employment, the industry supports a further 100,000 people, chiefly farmers.

About 60% of the starch products are sold to food customers and 40% to non-food customers. The co-products are purchased chiefly by the animal feed sector, with the exception of wheat gluten which is sold mainly to the bakery sector. Of the 9 million tonnes of starch and starch derivatives consumed in the EU, 24% are native starches, 20% modified starches and 56% starch sweeteners.

E

Major Challenges and Opportunities EU Starch production has been steady for the past decade and is expected to remain so for the next two to three years. However, the industry faces a number of major challenges, including suffering from significant cost disadvantages compared with other starch producing regions of the world, as well as some significant opportuniJamie Fortescue, managing director of Starch ties.

Europe.

The European starch industry has had to contend with the ending of EU financial support to the potato starch sector in 2012 which is expected to precipitate a shift from potato starch to maize or wheat starch in some applications. It is also preparing for an end to quotas on EU isoglucose production in October 2017. Under the current EU sugar regime, the production of the starch-based sugar, isoglucose, is restricted to 700,000 tonnes a year.

This obviously presents an opportunity for EU starch producers and isoglucose output is expected to increase to between 2 million and 3 million tonnes over time, according to Starch Europe, the trade association which represents the interests of the EU starch industry both at European and international level. Starch Europe’s membership comprises 24 EU starch producing companies, togeth-

Starch is a fundamental link in the value chain between agriculture and thousands of end products in both food and non-food applications.

er representing more than 95% of the EU starch industry, and in associate membership, seven national starch industry associations.

Before October 2014 Starch Europe was called the AAF. Strengths and Weaknesses Although the European starch industry currently enjoys a strong position globally, its continued prosperity is far from assured and could be rapidly undermined.

Jamie Fortescue, managing director of Starch Europe, explains: “The EU is the world leader in potato and wheat starch (and also, by definition, wheat gluten) production. It is also the world leader in producing non GM starch. Partly because EU starch producers have been either restricted (in the case of isoglucose) or not supported to the extent that they are elsewhere in the world (in the case of biofuels and other bio-based products) in their production of starch commodity products, the EU is also a world leader in R&D and, linked to that, specialty higher added value starch applications.”

He continues: “However, other major starch producing countries, most notably the US and Thailand, have significant cost advantages over the EU in the production of commodity starches in particular.

In the case of US maize starch this results primarily from lower raw material costs (being based on GM maize), lower production costs (in particular energy prices but also regulatory compliance) and huge economies of scale. In the case of Thai and Vietnamese tapioca starch this is the result of lower raw material, regulatory compliance and labour costs.”

Market Trends While EU starch production overall has remained fairly constant, the non-food sector is expected to see decreasing demand from the paper and board industry. It is anticipated that this decline will be compensated for by increased demand from other non-food customers, for example in the chemical and pharmaceutical sectors, seeking to replace fossil-fuel ingredients with renewable ingredients like starch.

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

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A positive, progressive policy environment is essential, if the starch industry is to remain an important contributor to economic growth in Europe.

“But that development is not happening as fast as we would hope and is not helped by the current low price of oil and the relative lack of concrete policy support that the EU has so far given to the bio-economy compared to other countries,” says Jamie Fortescue “On the food side of the business, the end of isoglucose quotas should represent a clear opportunity for EU starch producers, but at the same time we are witnessing a significant increase in the level of negative media around the health impact of sugars, including starch-based sugars like isoglucose,” he adds.

Key Problems There is also a danger that the significant production cost advantages currently enjoyed over EU producers by other starch producing regions could increase further, as the energy price difference continues to widen. Furthermore, proposed EU regulation in areas such as Country of Origin Labelling could, if adopted, add further to EU starch production costs.

“At the moment the EU is protected from unfair competition from these regions by import duties on starch products. Today the EU is negotiating free trade agreements with, amongst others, the US, Thailand and Vietnam. If these negotiations result in a reduction/elimination of import duties on starch products from these countries, the lack of a level playing field with international competitors could have very serious consequences for EU starch companies,” Jamie Fortescue points out.

Industrial Renaissance Starch Europe has drawn up a manifesto for an industrial renaissance for the EU starch industry which details a number of priorities for the new European Commission. These include achieving a level playing field between EU sugar and isoglucose producers at the end of the EU sugar regime in 2017, and the implementation of the EU bio-economy strategy.

Starch Europe is also calling for fair competition between EU potato starch producers. The higher production costs, including those resulting from compliance with EU legislation, must be reduced or at least acknowledged, says Starch Europe.

In the absence of an international level playing field, import duties for starch products must be maintained, insists the representative organisation for the EU starch industry.

Another priority for Starch Europe is that EU and Member State health/nutrition policy must be based on robust science. J

Starch Europe represents a dynamic, growing and technology-driven industry.

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FOOD & DRINK BUSINESS, MARCH 2015

AGRANA’s Worldwide Focus on Sustainability GRANA, an internationally oriented A Austrian company, adds value to agricultural commodities to produce top quality foodstuffs and numerous industrial upstream products. With its close dependence on agricultural crops, AGRANA is passionately committed to the careful use and conservation of natural resources.

The company was founded in 1988 and is now the leading sugar company in Central and Eastern Europe as well as being a key producer, in the Starch segment, of special products and bioethanol in Europe. Starches are sold both to the food and beverage industry as well as into non-food industries (for example, the paper, textiles and building materials sectors). AGRANA is also the global leader in fruit preparations and one of the largest European producers of fruit juice concentrates. Around 8,800 people are employed at over 50 production facilities on all five continents.

AGRANA’s aim is to provide both its globally operating and its regional customers worldwide with high product quality, optimum service and innovative product development ideas and expertise. In line with the principle of sustainable, circular flows of resources, an important role is also played by valuable co-products of sugar and starch production at AGRANA, used for instance in the production of bioethanol, animal feed and fertilizer. AGRANA’s efficient use of raw materials is both an economic imperative and a way of practicing corporate responsibility. The high utilisation rate of raw materials of 98.6-99.9% reflects technological innovativeness and product development capabilities. The results of AGRANA’s Zero Waste Principle are eloquent proof that environmental and social responsibility are compatible with business logic, and show how AGRANA has internalised this funda-

mental principle of sustainability in its day-to-day operations.

The new AGRANA Research & Innovation Centre (ARIC), the central research and development facility of the AGRANA Group, focuses inter alia on food innovations for Clean Label, nutritional physiology, sweeteners and flavourings.

AGRANA Starch – 100% GMO-free Raw Materials AGRANA Starch and its subsidiaries process agricultural raw materials (corn, potatoes and wheat) into high-quality starches and specialty starch products custom-designed for a wide range of specific customer requirements. Customer loyalty is based on delivery reliability, support by application advice, customer-specific adaptions and continuous product development.

AGRANA sells only starches not derived from genetically modified organisms, which meets the growing demand of customers for non-GMO products. Producing Infant Formula for decades established AGRANA as one of the most experienced and important infant nutrition manufacturers. AGRANA Infant Formula is free from preservatives, artificial flavourings, colorants and cereal protein gluten.

Organic Products AGRANA is one of the largest organic food manufacturers in Europe and the largest producer of organic starch in the European Union. AGRANA was early to recognise the growing public awareness of sustainablity and health issues as well as the related increase in demand for organic products. The company now offers a range of independently certified organic products in all of its business segments.

AGRANA Starch has focused for twenty years on organic ingredients derived from organic potatoes, corn and waxy corn and has become worldwide market leader in the FOOD & DRINK BUSINESS EUROPE, MARCH 2015

production of organic corn starch, maltodextrin and dextrose. The AGRANA production facilities at Aschach (Upper Austria) and Gmünd (Lower Austria) are among the first processing plants in Europe to be certified as organic processors under EU Directive 834/2007 as amended (an ordinance governing organic farming methods and the labelling of agricultural produce and food).

AGRANA’s Latest Innovations – 70% Fat Reduction As combined on-pack claims like ‘natural, organic and fat-reduced’ now attract the consumer’s attention, AGRANA has developed a new organic pregelatinised maize starch - QuemLite® Bio - perfect to produce fat-reduced mayonnaises, sauces and dressings and notably an organic cook-up waxy corn starch - AgenaLite®Bio - for fatreduced sweet bread-spread like coconut or hazelnut cream - two perfect examples of AGRANA’s customer-driven innovations.

AGRANA’s high level organic products stand for ‘quality made in Austria’ inspiring the consumer’s confidence: ‘We starch your organic innovations!’

For more information please contact AGRANA Starch Austria: info.staerke @agrana.com or visit www.agrana.com. J

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GEA Barr-Rosin Adds Value to Food, Feed and Ingredients EA Barr-Rosin has over 100 years of G experience in supplying industrial drying systems to the starch, sweetener and agrifood industries. From the proven Flash and Ring Dryers - developed by Dr Rosin and Barr respectively – to the more recent Superheated Steam Dryer (SSD™), the company has strived for excellence to develop benchmark technologies.

CERTEX™ ATEX Certified Explosion Vent Door.

As the world population grows and drives expansion of the middle class, so does the demand for carbohydrates, protein and functional ingredients. The recent shake-up of the EU’s Common Agricultural Policy has also

provided opportunities for the starch, sweetener and agrifood industries to develop new products. GEA Barr-Rosin is at the cutting edge of this revolution.

GEA Barr-Rosin works closely with its clients to add value to food, feed and ingredient products while optimising safety, efficiency and productivity. Confidentiality is ensured. Everything the company does is aimed at improving product quality and system reliability, achieving energy savings, controlling emissions, and therefore adding value to customers’ often heat-sensitive food, feed, pharmaceutical and technical grade starches, proteins and their co-products. Return on investment is optimised throughout the life of the plant.

The White Biotech industry, which is closely related to and indeed integrated with the starch industry, is also a key application area of GEA Barr-Rosin. In addition to adding value to various protein and recovered nutritional co-products with its Ring dryer, the company has recently achieved success in using its ROSINAIRE™ paddle dryer on starches and amino acids. Not only does this indirectly heated technology minimize the presence of oxygen, enabling thermally sensi-

QUALITY

Wheat starch and vital wheat gluten dryers at a plant in Germany.

tive products to dry without oxidation or the risk of thermal damage and loss of nutritional value, the low oxygen levels also minimize the risk of explosion. Industrial safety is imperative to GEA Barr-Rosin and its new CERTEX™ ATEX Certified Explosion Vent Doors are a testament to its focus. J

& HYGIENE

Aquadron Beverage Disinfection System Installed at Purity Soft Drinks ew Energy Management has installed an Aquadron beverage disinfection system at N Purity Soft Drinks’ site at Wednesbury in England. The system manufactures and doses a disinfectant agent and undertakes several tasks including treating process water, carrying out continuous disinfection within the bottling enclosure during a running bottling process and feeds the CIP system.

The system has allowed Purity, which specialises in juices and juice drinks packaged in modern and innovative packaging formats, PET and premium glass, to reduce chemical use at the site and will also reduce water use in the CIP cycle. Purity joins around 50 other Aquadron users who already benefit from constant disinfection within the bottling enclosure and reduced chemical and water use.

Roshan Gungabissoon of Purity comments: “Product quality and sustainability are key to Purity. The Aquadron allows us to maintain the highest levels of microbiological control whilst simultaneously reducing our chemical and water usage.”

New Energy Management is the sole UK supplier of the Aquadron system, which is manufactured in Germany by Innowatech. The Aquadron system is used for process disinfection in food and drink applications across Europe.

Further details are available at www.aquadron.co.uk or by contacting New Energy Management on 0333 772 0043. J 38

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

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& HYGIENE

FLOORS, WALLS & CEILINGS

Resin Flooring – A Long Term Relationship n food production it is vital that the correct flooring is chosen for Iflooring maximum safety and efficiency around the workplace. The main requirements in the food industry are a balance of durability, cleanability and an anti-slip profile, which all contribute to a safe and hygienic environment.

John Lord has a longstanding and successful relationship with the leading and innovative British supplier of premium, fresh and added-value food products.

Previously, John Lord has been involved in a number of resin flooring projects for this forward-thinking company, such as their sausage, bacon and other meat factories in the UK. Taking into consideration the fresh meat products, possible greasy spillages and also the cleaning regime, John Lord turned to their non-tainting, URAGARD HT resin flooring range to cover all applications within the factory environment. In the processing areas the URAGARD HT62W polyurethane resin floor was installed and back-rolled to create a sufficient compromise between a high grade, anti-slip profile for safety under foot and the cleanability of the floor. A vibrant Buff yellow colour was the chosen resin colour range to help highlight dark waste food on the floor. In the packaging and storage areas of the factory, the URAGARD MT resin floor was installed due to its smooth surface, excellent cleanability and long-term durability against packaging machinery and factory traffic.

John Lord takes ‘Total Responsibility’ on every project involving their exclusive resin flooring range. From floor design and manufacture through to installation, John Lord is committed to meeting your flooring requirements. Specify your own floor online or contact the Technical Sales Team for advice on the best flooring system for your business; +44 (0)161 764 4617, enquiries@johnlord.co.uk, www.john-lord.com. J

“We have been working with John Lord for well over 10 years now within the food industry. John Lord provide a one-stop resin flooring solution for the factories utilising their URAGARD flooring. From site purchase to first production, the involvement of John Lord was an integral part of the project’’s success.” – Project Architect.

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

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& HYGIENE

HYGIENIC STEEL

Protection For Food Processing n demanding food processing environIvehicular ments where constant pedestrian and traffic is present along with an extensive cleaning regime, a hardworking and efficient factory is very important.

One of the main elements in processing areas is the drainage system, which takes care of all the waste water produced throughout the factory. Having inappropriate or non-existent drainage in the factory can be very costly in the long term and unhygienic for operatives.

Recently, ASPEN Stainless has been working with a leading pie manufacturer renovating their factory with a brand new stainless steel drainage system. With heavy factory traffic passing through ASPEN chose their heavy duty drain channel and 2 bar support channel covers to withstand the weight passing over. The drainage channel was designed to stretch throughout the processing area and

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underneath the machinery for maximum coverage and increased water flow rates.

In addition, outlets with removable trash baskets were installed to manage trapped waste in the drainage system preventing

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

any blockages and increasing cleaning efficiency.

Stainless steel 304/316 is the ideal material choice hygienic conditions. The stainless steel surface has excellent cleanability and provides a maintenance-free, non-tainting solution to any food and drink industry looking to improve their facilities. Aspen Stainless manufactures their full range of stainless steel products at their manufacturing site in Nottingham, UK and has their own installation teams working throughout the UK and internationally.

ASPEN Stainless has their full product range available online at aspen.gb.com with full product technical data available to download. To discuss your stainless steel requirements for your food and drink environment, contact the technical sales team today; +44 (0)115 986 6321, aspen@canalengineering.co.uk. J

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X-RAYS & INSPECTION SYSTEMS

Higher Detection Rates With New MettlerToledo X37 Series xtending its range of next generation xE ray inspection systems, Mettler-Toledo Safeline X-ray has designed the X37 Series for optimum product inspection of tall, rigid containers, including cartons, doypacks, plastic and glass containers and metal cans. Available in a number of flexible technology alternatives, the X37 Series can be configured with different detector sensitivity options supported by a range of power generators, to detect and reject contaminants, such as metal, glass, calcified bone or high-density plastics. This customisation enables food and pharmaceutical manufacturers to reduce Total Cost of Ownership (TCO) and comply with safety regulations and guidelines by consistently guaranteeing contaminant-free products.

In order to suit a variety of tall, rigid packaging applications, manufacturers can choose between a 0.4mm and a 0.8mm detector diode. The 0.8mm detector technology is five times more sensitive to x-ray than traditional systems, ensuring unparalleled precision in the contaminant inspection of food and pharmaceutical products.

For the inspection of composite cans, cartons, tubes, doypacks and plastic containers, for instance, producers can select a 20W generator which can result in a significant reduction of power consumption and cooling requirements, as it offers the same preci-

sion as a conventional 100W device.

“Traditionally, food processors have needed to implement high power x-ray systems to inspect cans or glass containers at high speeds, sometimes in excess of 1,000 products per minute,” explains Daniela Verhaeg, Marketing Manager SBU X-ray Inspection, Mettler-Toledo Safeline X-ray.

“The X37 Series, with its new detector technology and class-leading inspection software, is able to offer equal or, in some cases, improved detection levels whilst typically only needing one fifth of the standard x-ray energy power consumption.

Consequently, this allows food and pharmaceutical manufacturers to substantially reduce operational costs while also maintaining the utmost level of safety and quality for their products.”

The new x-ray range can be fully configured to the particular needs of a specific production facility. Manufacturers can, for example, select different high-speed reject systems to match their production needs and guarantee easy and effective product rejection. Suitable for a wide range of product types, the system is available with fully adjustable pusher and air blast options with a large vision window on the tunnel and chute.

As the X37 Series range can easily be integrated onto existing customer lines, manufacturers can maintain high volume production targets and do not have to reduce line speeds. Optimum product inspection is achieved at high throughput levels of up to 1,800 containers per minute, depending upon product configurations. Furthermore, the x-ray systems are capable of simultaneously performing additional quality control checks, such as assessing the fill level of products, measuring the head space, detecting missing caps on plastic bottles, identifying agglomerates, such as flavour and powder lumps, and inspecting for packaging defects.

All models of the X37 Series are hygienically designed, providing a robust system fit for all applications. The X37 Series is IP65 rated as a standard and can also be upgraded to IP69. J

The Pies the Limit For Loma’s New X5 SpaceSaver X-ray Systems has recently completed one Loma of the first installations of an X5

SpaceSaver X-ray inspection unit.

Manufacturer of savoury pastry products, The Welsh Pantry, chose the new model for its groundbreaking detection performance, super compact design and ease of use.

The Welsh Pantry is using the advanced X5 SpaceSaver X-ray system to inspect its pie products for glass, ceramic and stainless steel contaminants. Adhering to Loma’s ‘Designed to Survive’ ethos, the X5 SpaceSaver measures only one metre in length enabling customers to reclaim valuable floor space.

Alan Shaw, Technical Manager at The Welsh Pantry, comments: “I have a longstanding relationship with Loma having FOOD & DRINK BUSINESS EUROPE, MARCH 2015

used its equipment at a previous company, as well as in my current role at The Welsh Pantry. The need to inspect pies for a range of foreign body contaminants, not just metal, down to the smallest size meant Xray technology was the best choice for this particular application.

“However, like many food production facilities, space is at a premium so the launch of the Loma’s super compact X5 SpaceSaver X-ray with significantly smaller footprint was great timing. The system’s market leading detection performance is also helping to further strengthen our strict quality control and food safety procedures.” J 41

QUALITY

I

& HYGIENE

X-RAYS & INSPECTION SYSTEMS

A 360 Degree Look at Investing in a Combination X-ray Inspection and Check-weighing System onsidering an investment in a highly accurate, fully integrated, C combination X-ray inspection and check-weighing system specifically designed for food production environments? If so how do you satisfy the needs of your Operations, Technical, Quality and Maintenance groups, all different functions and with seemingly different goals and requirements? However, if you cut through the white noise its obvious that there is no reason why you cannot have the best of all worlds.

Sourcing a Solution

•

• •

•

So, what should you look for when sourcing a solution?

From an END USER perspective the following six attributes are what are commonly thought to make a quality product, starting with the most important: • The machine must fulfill its purpose: Clearly the most important; if the product does not help you do your work, it doesn’t fulfill its purpose and it doesn’t matter how polished, slick or fast it is. Start by comparing the specifications - but remember just because the spec is the same it does not mean that the performance is. Test and compare machines from different manufacturers. Let the results speak for themselves.

The machine must be easy and intuitive to use: It should be obvious where components go or what will happen when you click a button or follow a link. Think about your operations, your people and your working environment, will the machine you are considering be too complex?

The machine must work as expected: Bugs, defects, crashes, hangs are clearly bad.

It must be responsive: If the machine control doesn’t react fast or give constant feedback, your operators will get frustrated with it.

It must be easy to get unstuck: Good, accessible and searchable documentation, and training are key to a quality product.

• It must be consistent: The machine must have a consistent “look and feel”, with consistent and predicable user interfaces, functions and processes.

Supporting the Equipment

If conversely you are responsible for supporting the equipment, some very different criteria apply: • Quick to deploy: A fast and reliable installation is important.

• Must be enterprise ready: It’s no good if the product doesn’t fit with your existing structure, doesn’t eliminate or at least integrate with standard systems and protocols, or doesn’t support your distributed enterprise setup.

• Simple to support: The machine must be easy to troubleshoot. If something goes wrong, it needs to be easy to find out what it is and get it fixed. If you have to look at log files, they should be easy to sift through – but looking at log files really should be an exception rather than the rule.

• Simple and easy to set-up and configure: Setting up the product so it meets your users’ particular needs should not require a degree in troubleshooting. It should not give you unnecessary choices either it should just make the product work really well with well-chosen defaults.

• No security issues: You really don’t want to know what the guys over in IT think of people that introduce products that put the business at risk.

• Easy on resources: Products that need more than their fair share of scarce engineering or technical resources are expensive to run and deploy.

What “good looks like” is different depending upon your perspective but Sparc Systems will provide a 360 degree look.

For further information contact Sparc Systems Ltd at Sales@sparc-systems.co.uk or Tel +44 (0)1684 310000. J

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

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I BEST PRACTICE

Want Continuity Across Shifts? Want Real Behaviour Change? – You Need a ‘SeaChange’ us sustainability is all “howFor about communication and well people feel connected to the message. Yet a strange thing happens within organisations: tonnes of money & resource investment is given to the ‘WHAT’ piece of the message- the system itself, while much less resource is invested in the ‘HOW’ piece- the way we do the communication across crews & Shifts,” says Ger Cummins, CEO of SeaChange Ltd. Many Organisations realise the need to have the very best systems – striving for competitive advantage in everything they do – but still find themselves pushing against a glass ceiling when it comes to achieving sustainable results. This is a big risk for Organisations. SeaChange accurately measures this risk and implements innovative solutions to achieve consistent communications between departments, crews and across shifts – SeaChange delivers more of the ‘HOW’ to partner clients.

Since 2005 SeaChange has delivered programmes into blue-chip organisations such as Dell, C&C, Diageo, Viridian, and Danone.

Both of the Danone Early Life Nutrition (ELN) factories in Ireland, and their sister

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sites in France & Holland, are actively progressing ‘continuous communications improvement’ using SeaChange within the following areas: • Health & Safety / Quality? risk visualisation & prioritisation brings risk to life • Front Line Leadership? individual ‘manager impact’ improves across Shifts • Senior Team Coaching? positive impact of senior mgmt. on staff behaviour is maximised • Selection & Assessment? minimise risk at the beginning by hiring the right fit for the organisation.

SeaChange solutions include interactive tools and systems to improve communication; 13 Danone sites across Europe have invested in the innovative SeaChange JSA SAFE-TTM software to calculate risk, communicate local risk, and train on best practice behaviours.

The cloud-hosted software enables EHS managers, Facility Managers and Oper-ations Managers to easily and quickly capture, input and store critical information into a personalised smart-library. It then remembers and recalls critical information for efficient JSA (JobSafety Awareness) poster creation.

“Our innovative approach leads to sustainable results. We identify and measure the psyFOOD & DRINK BUSINESS EUROPE, MARCH 2015

chological factors impairing progress, we implement practical and interactive solutions that engage hearts and minds at each critical layer (senior mgmt.; front-line mgmt.; operations), and we measure continuous improvement so that best practice grows from the ground up,” explains Dr Paul Cummins, MD of SeaChange Ltd. International safety audit scores clearly reflect the cultural evolution and the significant progress made. Both Irish Danone plants have received record-breaking results, have won International safety awards and lead the way within the wider Danone group.

These results are clear indications that Danone ELN have found the missing piece – The SeaChange Way®.

“SeaChange enabled us to break through the ceiling and make a real behavioural breakthrough onsite, giving us outstanding results and notoriety within the global group,” says Liam Carmody, Site Director, Danone Nutricia Wexford.

SeaChange programmes are proven to increase staff awareness and ownership on the factory floor. Performance-related results include reducing waste, accidents and absenteeism while increasing consistency across shifts, near-miss reporting, staff morale and productivity. J

Ger Cummins, CEO SeaChange.

I BRAND BUILDING

Coca-Cola’s Billion Dollar Brands Portfolio Expanded to 20 he Coca-Cola Company’s roster of billion-dollar brands has been expanded.

T Two tea brands the company developed and launched from scratch – Gold Peak and FUZE TEA – both passed $1 billion in

Two tea brands developed and launched from

to us in the global nonalcoholic ready-todrink beverage industry,” says Muhtar Kent, chairman and chief executive of The CocaCola Company. “Through a strong global focus on building locally relevant and innovative brands, our company, together with a network of strong local bottling partners, has worked to successfully double the size of our billion-dollar brand portfolio in less than a decade.”

Gold Peak made its US debut in 2006 and has posted double-digit growth every year since. The premium tea brand, which targets drinkers who prefer a home-brewed taste, is one of America’s fastest-growing iced tea brands. In fact, Gold Peak drove nearly 30% of all dollar growth in the US ready-to-drink tea category in 2014. Gold Peak fans can choose from several varieties, including Sweet Tea, Lemonade Tea, Unsweetened Tea, Diet Tea, Raspberry Flavored Tea and Green Tea.

Muhtar Kent, chairman and chief executive of The Coca-Cola Company.

The addition of FUZE TEA, Gold Peak and I LOHAS brings The Coca-Cola Company's billion-dollar portfolio to 20 brands: J

scratch – Gold Peak and FUZE TEA – both passed $1 billion in annual retail sales in 2014.

annual retail sales in 2014. I LOHAS mineral water, sold in Japan, also crossed the milestone mark last year, bumping up Coke’s current billion-dollar portfolio to 20 brands.

Since 2007, the company has added 10 brands to its billion-dollar portfolio across a range of beverage categories. Not far behind, a pipeline of 16 additional brands currently generate annual retail sales between $500 million and $1 billion.

“We are taking definitive steps to capture the enormous growth opportunities available

The Coca-Cola Company's 20 Billion-dollar Brands: 1. Aquarius 2. Ayataka 3. BonAqua 4. Coca-Cola 5. Coca-Cola Zero 6. Dasani 7. Del Valle 8. Diet Coke/Coca-Cola light 9. Fanta 10. FUZE TEA

11. Georgia 12. Gold Peak 13. I LOHAS 14. Minute Maid 15. Minute Maid Pulpy 16. Powerade 17. Schweppes * 18. Simply 19. Sprite 20. vitaminwater

* Schweppes is owned by The Coca-Cola Company in certain countries other than the US.

KitKat "Celebrate the Breaker's Breaks" Campaign Launches in Europe he first ever global advertising campaign from KitKat, “Celebrate T the Breaker’s breaks”, is now launching in Europe, starting with the UK. The campaign, which will reach more than 20 key KitKat markets globally in coming months, provides a fresh take on the iconic Nestlé chocolate brand’s sign-off line, ‘Have a break, have a KitKat’, by celebrating the many different types of breaks that ‘breakers’ take.

These include those who break together, or on their own, those who share their breaks with the world, and those whose breaks are out of this world.

The new campaign connects with many social platforms, including Twitter, Tumblr, and Facebook with the hashtag #mybreak, and has already been rolled out in Brazil and Japan, two of the biggest KitKat markets globally. J FOOD & DRINK BUSINESS EUROPE, MARCH 2015

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Fonterra Commissions New Ingredients Plant in Europe ew Zealand-based Fonterra Co-operaN tive Group has commissioned its new dairy ingredients plant in Heerenveen, in the north of the Netherlands. The plant produces whey and lactose specialty ingredients that will be used in high-value paediatric, maternal, and sports nutrition products by Fonterra and its global customers.

Built on a 25 hectare site that has been developed in partnership with Dutch cheese manufacturer A-ware Food Group, the plant is Fonterra’s first wholly owned and operated ingredients plant in Europe.

The plant forms part of Fonterra’s fully integrated global supply chain from the farm gate direct to global consumers, using Fonterra’s milk pools and manufacturing sites in New Zealand, Australia, and Europe.

“The commissioning of our new plant in Heerenveen further strengthens our ability to deliver high quality, advanced dairy nutrition that meets the needs of our priority markets and global customers,” says Theo Spierings, chief executive of Fonterra.

“Fonterra has substantial intellectual prop-

European and global customer base, delivering a secure, reliable source of high quality ingredient products.

The new plant will produce 5,000 metric tonnes of whey protein and 25,000 metric tonnes of lactose annually. It will operate around the clock - 24 hours a day, 365 days a year. Approximately 50 new employees currently work for Fonterra at the site.

A-ware Food Group’s adjacent cheese plant was also recently commissioned on schedule. J Theo Spierings, chief executive of Fonterra.

erty in the manufacture of functional whey protein ingredients and had been looking for some time for a source of high quality whey to enable us to commercialise these innovations. Our partnership with A-ware Food Group fits well with our strategic priorities aimed at increasing the volume and value of our ingredients and branded products.”

The new plant’s location and capacity will enable Fonterra to better serve its

Tate & Lyle Launches DOLCIA PRIMA™ Low-Calorie Sugar ate & Lyle has launched DOLCIA T PRIMA™ Low-Calorie Sugar, its newest ingredient set to transform the way the food and beverage industry develops low- or reduced-calorie products. DOLCIA PRIMA™ is Tate & Lyle’s brand name for allulose, a low-calorie sugar that exists in nature and can be found in small quantities in some fruits and foods people eat every day. It was first identified in wheat in the 1930s. Tate & Lyle’s DOLCIA PRIMA™ delivers the satisfying mouthfeel and sweetness of table sugar, but contains 90% fewer calories, so food and beverage manufacturers are expected to be able to significantly reduce the calories in products while maintaining the same taste and enjoyment of sugar that consumers demand.

“One of the biggest challenges our industry faces is reducing calories while maintaining the taste experience consumers expect from their favourite foods and beverages,” says Abigail Storms, Vice President, Platform Management, Sweeteners, at Tate & Lyle. “Now food

and beverage manufacturers can contribute to this public health challenge by using DOLCIA PRIMA™ Low-Calorie Sugar.

Working with DOLCIA PRIMA™, our culinary teams have learned that it is possible to provide consumers with products with all the taste, all the mouthfeel and all the texture they expect, but without all the calories. In taste trials, consumers ranked low-calorie versions of foods made with DOLCIA PRIMA™ equally with the fullcalorie versions.”

DOLCIA PRIMA™ Low-Calorie Sugar can be used in a range of applications

FOOD & DRINK BUSINESS EUROPE, MARCH 2015

including beverages, yoghurt, ice cream and baked products to reduce calories or to make lower-calorie options taste even better. Unlike high-potency sweeteners, DOLCIA PRIMA™ is 70% as sweet as sucrose (sugar) and has the same temporal taste profile, which means it provides a clean, sweet taste as well as the functionality of sugar. In fact, products made with DOLCIA PRIMA™ ranked at parity with fullcalorie full-sugar versions in preference taste tests across a variety of foods.

DOLCIA PRIMA™ can be formulated successfully into many different food products that usually contain sugar because it delivers many of the benefits that sugar offers, such as adequate browning when baking, bulk and texture. It can also depress the freezing point when making frozen products. It is a highlysoluble, liquid ingredient, which means it is easy to use in liquid products and adds bulk and texture in formulations.

Learn more about DOLCIA PRIMA™ by visiting www.dolciaprima.com. J 47

New, Low-sodium, MSG-free Salt Ingredient srael-based Salt of the Earth has launched Iespecially its Umami-Essence Sea Salt ingredient designed for a comprehensive range of sauces. Using Umami-Essence Sea Salt in a new or existing product formulation can help dramatically decrease sodium levels—in some formulations by up to 50%—while boosting flavour. The all-natural Umami-Essence Sea Salt is low in sodium and, most importantly, contains no MSG or artificial ingredients.

“This innovative ingredient can help food manufacturers keep the consumercraved salty flavour while maintaining a low amount of sodium in the final application,” explains Aliza Ravizki, R&D manager of Salt of the Earth. “It’s a ready-to-use liquid formulation that can naturally intensify umami, the so-called 5th taste of the finished dish.”

“The characteristics of Umami-Essence Sea Salt help food scientists innovate healthier reduced-salt recipes that contain only natural ingredients and don’t compro-

mise flavour,” explains Giorit Carmi, marketing manager for Salt of the Earth. “It provides food manufacturers a much simpler way to include a clean label claim on products and to comply with the global salt-reduction agenda of cutting sodium in processed foods.”

Umami-Essence Sea Salt is a proprietary blend of sea salts and a natural vegetable extract that provides distinctive umami flavour. Umami Essence can be easily incorporated into sauces, pizza toppings, salad dressings, Bolognese-style meat

sauces, lasagna and other products.

Umami-Essence Sea Salt is highly soluble, vegan and holds kosher certification.

“This is the first specifically umamienhancing ingredient developed by Salt of The Earth,” adds Aliza Ravizki. “We tested the formulation in a range of sauces, pizza toppings and more and achieved outstanding results in terms of saltiness and savoury flavour. This superior ingredient enables clean labeling while avoiding MSG and enhancing the final product flavour.”

Salt of the Earth produces and markets advanced sodium-reduction solutions made from natural salts harvested from the Red Sea to food manufacturers and retailers worldwide. Salt of the Earth is a deeply rooted, renewal-focused company. It has engaged a sustainable strategy to implement the management commitment for the environment, community and its employees.

For further information contact Salt of the Earth on Tel +972-4-9549531 or visit www.saltoftheearthltd.com. J

Frutarom Strengthens its Global Position in Flavours and Colours rutarom Industries, one of the world's F ten largest companies in the field of flavours and specialty fine ingredients, is continuing with its strategy for rapid and profitable growth with two more acquisitions.

The company has acquired Ingredientes Naturales Seleccionados (Ingrenat) of Spain for up to $9.1 million (Eur8 million).

Ingrenat specializes in the research and development, production, and sales and marketing of natural extracts from plants which include, among others, paprika, rosemary, bixin, alfalfa and more which deliver taste, colour, and antioxidant activi-

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ty solutions for the food industry.

Ingrenat's sales grew 10% in 2014 to about $9.8 million.

Ingrenat's operations will be integrated into the activities of Frutarom's Specialty Fine Ingredients division with which it shares similar profitability margins.

The acquisition of Ingrenat is a continuation of the implementation of Frutarom's strategy of deepening and expanding in the plant-based segment of natural food colours and antioxidants. The natural food colours activity joins the natural colours activity of Montana Food, which was acquired in September 2014, and of Vitiva for which the purchase agreement was signed in December 2014.

Meanwhile, Frutarom has acquired UKbased FoodBlenders for up to $ 3 million (£2 million) Established in 1998, FoodBlenders develops, manufactures, and markets savoury solutions which mainly include spice and seasoning mixes, functional ingredients, marinades and sauces for the food industry, with particular emphasis on the convenience foods segment. In 2014 FoodBlenders posted sales of approximately $3 million (£2 million) with profit margins FOOD & DRINK BUSINESS EUROPE, MARCH 2015

similar to those of Frutarom in the same area of activity. FoodBlenders has a site in England where it develops, manufactures and markets its products which is located within close proximity of Frutarom's Wellingborough site, and it has a wide customer base which includes British food and private label manufacturers.

FoodBlenders' product line and technologies complement the product portfolios and activities of UK-based Savoury Flavours and EAFI which were acquired by Frutarom in 2012 and 2011 respectively and which also specialize in savoury flavour solutions. The proximity to the Frutarom site at Wellingborough and the complementary line of products promise to generate synergies between FoodBlenders' activity and Frutarom's expanding savory activity in the UK and throughout the world. J