Food & Beverage Industry News - August/September 2017

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WELCOME

A big week for the food industry

A

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s I write this, Food & Beverage Industry News has just finished a huge week.

First off, on Sunday morning, we set up our stand at the ICC Exhibition Centre in Darling Harbour for foodpro 2017. Next, on Monday night, we polished our shoes and headed to Doltone House, Hyde Park for the annual Food & Beverage Industry Awards.

Then, on Wednesday morning we played host to Food Factories of the Future, a breakfast seminar held close by foodpro at the Novotel Darling Harbour.

This gave us just enough time to head back to foodpro to dismantle our stand, head back to the office and refocus on deadlines.

It was hard work, but the good news is we made it thorough – not only in one piece but actually energised. Why so? Because of all the news, products, ideas and people that the week brought us.

The were many highlights but I have to start with Harvey Beef, which was named ‘Best of the Best’ at the aforementioned awards for its Finest Quality Beef Range. The product’s marriage of quality produce with sustainability is hard to ignore. We profile all nine award winners in this issue.

At foodpro we were blown away by a range of things including Wiley, which backed up its augmented reality demonstration with a seminar on the same topic by Brett Wiskar; and an eye opening presentation on packaging and sustainability by Sealed Air’s Ron Cotterman.

Then there was Vaughan Constructions, who were not only on hand to discuss innovative plant design, but also featured a golf simulator on their stand.

Like all manufacturers, food makers always keep an eye out for the latest product, idea, technology or method to help grow their businesses. By necessity, they are always looking to the future.

In this context, Food Factories of the Future made perfect sense. The house full sign was out as our breakfast audience heard ifm efector’s Peter K. Wienzek talk about Industry 4.0 and food making; and listened to Vega Australia’s John Leadbetter as he looked to the future of level measurement.

Yes, it was quite a week – inspiring, energising and well worth the effort.

Matthew McDonald, Editor

INSIDE 12

38

28

Average Net Distribution Period ending Sept ’15

5,316

Printed by: Manark Printing 28 Dingley Ave Dandenong VIC 3175

Ph: (03) 9794 8337

6 MARKET WATCH

26 EFFICIENCY & DOWNTIME

10 FOOD INNOVATION

32 FOODPRO 2017

12 FOOD & BEVERAGE INDUSTRY AWARDS

36 FOOD WASTE

38 F OOD FACTORIES OF THE FUTURE 39 P ROMOTIONAL FEATURE PACKAGING 40 NEW PRODUCTS

www.foodmag.com.au | Aug/Sep 2017 | Food&Beverage Industry News 5

MARKET WATCH

Deal making ramps up F ollowing a drop in corporate activity in April and May, deal making ramped up in June and July with nine transactions announced in the food and beverage sector.

Acquisitions announced Date

Target Name

25 May 17

Australian Dairy Park

Ausnutria

Dairy

Undisclosed

29 May 17

Alpine Soft Drinks & Equipment

Buderim Ginger

Beverages

Undisclosed

30 May 17

New Zealand Dairy Company

Synlait Milk

Dairy

NZ$33 million

RangeMe

Efficient Collaborative Retail Marketing

Marketing & Distribution

7 Jun 17

Acquirer

Sector

Deal Value

Undisclosed

14 Jun 17

Camperdown Powder (90%)

Bellamy’s Organics

Dairy

$28.5 million

23 Jun 17

Delicious and Nutritious (25%)

Oliver’s Real Food

Natural and Organic

$0.4 million

5 Jul 17

Festival City Food & Liquor

Bidfood

Foodservice distribution

Undisclosed

6 Jul 17

Australian Vegie Gourmet (merger)

Yumi’s Quality Foods

Contract manufacturing

Undisclosed

21 Jul 17

The Cake Syndicate / Susan Day Cakes

Raphael Geminder / Green’s Foods

Baked Goods

Undisclosed

Hong Kong dairy company Ausnutria announced in May the acquisition of Victorian dairy manufacturer Australian Dairy Park (ADP). Upon completion of the transaction, Ausnutria will own the manufacturing, packaging and sale of dairy and milk powder products and related research and development activities.

Synlait Milk acquired New Zealand Dairy Company (NZDC) for NZ$33.2m ($31.2m). NZDC is based in Auckland and is constructing a blending and canning operation capable of making infant formula and milk powders. Synlait expects to invest an additional $23 million to develop the facility.

Raphael Geminder acquired The Cake Syndicate which includes Susan Day Cakes and Big Sister Foods. It is expected that The Cake Syndicate will be integrated with Green’s Foods. Geminder acquired CVC’s 43.5 per cent shareholding in Green’s Foods in December 2016, making him the largest shareholder of Green’s Foods. Expectations are that Geminder will use Green’s Foods as a vehicle for further acquisitions in the food and beverage industry in Australia, replicating the approach that proved to be successful in for the Pact Group.

Listings on the ASX Date

Entity name

Capital raised

Issue price

Sector

21 Jun 17

Oliver’s Real Foods Ltd (ASX)

$22.6 million

$0.20

Organic and natural

27 Jun 17

Allwellness Holdings (NSX)

n/a

n/a

Health and wellness

Oliver’s Real Foods, a fast food chain that serves certified organic product to customers, listed on the ASX in June 2017.

Allwellness Holdings, an Australian based pharmaceutical manufacturing group that exports product to China, listed on the National Stock Exchange.

Deal activity notably increased following the June 2017 financial year end and we expect this high level of activity to continue for the remainder of 2017.

Ben van der Westhuizen (left) and David Baveystock are directors of Comet Line Consulting, an advisory business that specialises in acquisitions and divestments within the Australian food & beverage industry.

For more information visit www.cometlineconsulting.com.au.

Commodity Outlook GRAINS & OILSEEDS – Local wheat prices increased by 10 per cent in June as a result of reduced local new season supply prospects, along with international wheat price rallies.

SUGAR – Rabobank has revised its 12-month price view down to US$0.145/lb by Q3 2018, which is the equivalent of $420/tonne at the current exchange rate.

SHEEPMEAT – The dry weather is also pushing sheepmeat prices down and supply is picking up.

HORTICULTURE – Consumers remain cautious despite improved food retail sales in May. DAIRY – According to Rabobank the sector has entered a season of transition.

WINE – Australian wine exports are being negatively affected by New World currency weakness.

FERTILISER - Below-average retail farmgate pricing will help growers through winter.

BEEF – Producer demand is expected to slow and prices should ease because of dry weather conditions.

Source: Rabobank’s Agribusiness Monthly, July 2017

6 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

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FOOD INNOVATION

Bread of the future Food & Beverage Industry News looks at how sequencing of the wheat genome is set to open new doors in the development of health conscious bread.

V

ivienne Stein, marketing services manager for Newly Weds Foods, has experienced some benefits from a side effect of the functional foods movement.

Working in the coatings and breadcrumb market, Stein says Newly Weds Foods was competing with major bakeries supplying into retail, as they collected returned bread from supermarkets to create cheap breadcrumb from their excess stock.

“However over time, developments of different types of bread with functional ingredients and additives made management of ingredient listings for crumb from returned bread very difficult. Ingredient listings became far too long for chicken and seafood processors using this crumb to include on their packaging. This

became an opportunity for us as we had the ability to custom bake with a shortened list of ingredients to produce crumb.”

Stein’s insight into the increasing popularity of functional food can be painted into a trajectory of what’s to come in the future of bread manufacturing. The latest report from IBISWorld confirms that demand for basic bread is going down while “one significant growth area has been functional breads that have been enriched or fortified with nutrients”.

But will this trend come at the cost of a laundry list of ingredients in every bag of bread, or could the future of bread be the best of both worlds?

A solution to boosting the nutritional value of bread without all the

additives might not be too far away.

Earlier this year, a comprehensive analysis of a wheat genome was published in the journal Genome Research. The United Kingdomled consortium provided the most complete map and assembly of the wheat genome to date. The project included input from University of Western Australia researchers from the ARC Centre of Excellence in Plant Energy Biology.

The ARC Centre’s Owen Duncan, a co-author of the study, explains that this mapping will have significant ramifications for the bread industry, with the potential to breed new wheat strands that can naturally offer the benefits of functional foods, in the very near future.

“When you know the sequence

of a gene, it’s a bit like knowing the instruction manual, on how you can get the traits you want,” he explained.

“Traditionally, to breed a new wheat gene from concept to commercial variety, it takes about 10 – 20 years, depending on the trait you are looking to exploit. With the sequencing we’ll see this speed up greatly. Now that we know exactly where those traits are in the genome, it could take as little as two to four years.”

This is especially good news for celiacs looking forward to better gluten-free bread products in the future. Through this study, Duncan and other researchers traced gluten proteins back to the wheat genes, and identified more than 100 gluten genes.

This analysis will be vital to changing gluten content in wheat.

Owen Duncan from the ARC Centre of Excellence in Plant Energy Biology.

10 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

"A solution to improving the healthiness of bread without all the additives may not be far away" “We’ll be able to see what gluten is immunogenic. These are the peptides that the immunity systems of people with celiac disease react to,” says Duncan.

“We might be able to modify the sequence and create glutens that are not immunogenic.”

The same theory of altering the wheat gene flows into functional foods, where extra nutrients may be able to be included in the wheat. With bread a staple of diets across the planet, this could improve the health of people the world over.

“As for the bread of the future, I see bread as being able to be a complete nutritional source, naturally filled with all the vitamins and minerals we need, rather than having to add these in, and depend on processing,” says Duncan “We can create a wheat that could be a complete dietary source.”

Advances in wheat genome research could also help the bread industry manage input prices, by stabilising production with a more resistant strain.

Duncan explains that other members of the ARC Centre of Excellence in Plant Energy Biology have been able to trace back the sodium transporter – the trait that allows wheat to grow in saline fields. As a result, they increased the yield of wheat by 25 per cent.

This is all welcomed news for an industry that is suffering from decreasing margins. The IBISWorld report puts bread production revenue at $2.7 billion in 2016-17, with annual growth for the past five years at just 2.8 per cent. The report estimates annual growth for the next five years will be just 1.8 per cent.

“Profitability in the market is currently low, competition is high, and major players are having to adapt to lower prices,” said Sam Johnson, a senior industry analyst with IBISWorld. A lower wheat price would be welcome, as the domestic price of wheat is a key external driver in determining profitability.

IBISWorld’s report Bread Production in Australia aptly pointed out that “Higher flour prices therefore do not always result in higher revenue”. Although flour costs have dropped since their peak of 2014, they remain a risk for bread manufacturers in an increasingly competitive market.

Johnson’s advice to bread manufacturers looking to the future is to continue along the path of functional foods and premiumisation, rather than trying to compete with in-house supermarket brands on price.

“Companies need to be looking at incorporating newer, healthier ingredients, or even just promoting natural ingredients that are already in their bread,” said Johnson. “Customers need to perceive that the products are healthy.”

www.foodmag.com.au | Aug/Sep 2017 | Food&Beverage Industry News 11

FOOD & BEVERAGE INDUSTRY AWARDS

Harvey Beef wins big at Food & Beverage Industry Awards Western Australia’s Harvey Beef took top honours at last month’s Food & Beverage Industry Awards in Sydney, winning the ‘Best of the Best’ award for its Finest Quality Beef Range.

Proudly sponsored by: Flavour Makers

I

t was a big night all round for the sixth generation family-owned company, which also took out the award in the ‘Meat, Poultry and Smallgoods’ category.

Accepting the award, Daniel Briggs operations manager for retail at Harvey Beef, said the win was “overwhelming”.

“This is a new factory for us. We have been around since 1919 and, in the last 12 months, we finally started our retail packaging division,” he said.

“We wanted to get our product out on a retail format, both in domestic and export. The opportunity was looking at a product that would extend shelf life and, with Sealed Air, we knew that was the best option for us. For the team back home, they are going to be so proud of this award.”

The company uses a chilling

process which is unique in Western Australia. Briggs explained that this allows them to get their product from slaughter to boning to processing, then into a retail package, all in the one facility. (For a full profile of the winning entry, see the ‘Meat, Poultry & Smallgoods’ category on p.22 – ed.)

“Standard packaging usually gives you around a 10-day shelf life whereas we have been able to exceed 35 days from fresh and also up to a year when frozen,” said Briggs.

“It means we have been able to get into a number of markets, including China, Hong Kong, Philippines and, of course, in the domestic market in Western Australia.”

Held at a sold-out Doltone House Hyde Park, the awards were again a great success. Host this year by Channel 7’s Natalie Barr, there were nine awards in all.

Food & Beverage Industry News would like to thank the award sponsors for their invaluable support – Flavour Makers (Platinum Sponsor), Creative Food Solutions, Nord Drivesystems, Miller Leith, Chr. Hansen, BeanScene Magazine, COG Advertising, Manark Printing and MEGATRANS2018.

Congratulations to the winners (their profiles appear in the following pages - ed.). Thanks to eveyone who helped make this a memorable event.

See you again next year!

JUDGES' COMMENT

Rowan Barnes (left), sales manager at Flavour Makers with Daniel Briggs, operations manager for retail at Harvey Beef.

12 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

"Harvey Beef has ticked a multitude of boxes with their Finest Quality Beef Range. Using the best quality Australian beef, they have increased shelf life in a sustainable way, ensuring that there is reduced packaging and food waste."

FOOD & BEVERAGE INDUSTRY AWARDS

Ingredient Innovation Apple Extract Flavour, Sweetener - Botanical Innovations Proudly sponsored by: Creative Food Solutions

B

otanical Innovations is an Australian biotechnology company which aims to add value to naturally occurring elements to create food and beverage solutions that combine taste and function.

The company’s Apple Extract Flavour and Sweetener is intended for use in functional foods, beverages and natural healthcare products. This sweetener is made from 100 per cent Australian apples.

With a Brix of 65-70 and containing only apple and concentrated apple fructose, this is a new fruit based

alternative to sweeteners and sugars for a variety of applications.

The company has concentrated phenolic-rich phytonutrients in the product, retaining natural antioxidants, as well as polyphenols including phenolic acids and flavonoids. In addition, it contains concentrated quercetin, triterpenoids, ursolic acid, vitamin A, vitamin C and minerals.

Applications of the product range include everything from savoury sauces and deserts to soft drinks and whole food supplements.

It has taken almost three years for Botanical Innovations to develop and commercialise its unique range of Australian nutraceutical flavours, fragrances and ingredients. Investing heavily in research and development, the company explored a number of

ways to value add apple pomace and seconds to create unique and novel functional ingredients, flavours and aromas which combine sustainability, nutritional benefits and taste.

The key challenges were how to process apples, breaking the fruit into its key components, skin, pulp and seed and then processing these components to create products with zero or minimal waste.

The company’s research is undertaken with a view to developing innovative new products and proprietary production methodologies.

Botanical Innovations contributes a unique range of Australian functional nutraceutical, flavours, and ingredients for functional foods and beverages.

The company’s product range includes, plant extracts, fermented

plant extracts, cold pressed seed oils, fermented fruit and vinegar, fruit powders and essential oils.

By unlocking nature’s secrets Botanical Innovations has created new classes of flavours, fragrances and ingredients that contain phenolic rich phyto nutrients, the natural chemical compounds produced by plants.

JUDGES' COMMENT "Botanical Innovations has lived up to its name, working out how to process the apple down into its separate components without any waste being produced to create this flavouring."

Kerry Ferguson (left), managing director of Botanical Innovations with Peter Cox, GM of Creative Food Solutions.

14 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

We’re very creative when it comes to delivering

Appetite Appeal Consumer demand for ready meals in Australia continues to grow. However, an even greater demand for premium quality ready meal solutions has resulted in the creation of Creative Food Solution’s “Appetite for Healthy” and “Meals for 2” ranges. With all ingredients sourced from Australia’s finest farm and produce suppliers, these ready meal ranges are chef-prepared and sous-vide cooked to seal in freshness, tenderness and authentic flavour. For further information or to order, call Creative food Solutions on (02) 8668 8250.

Creative Food Solutions is proudly partnered with Sydney-based Brand and Packaging Consultancy, Brand Marque P/L, to develop range naming, brand identity and bespoke packaging.

Visit brandmarque.com.au or phone: (02) 9409 0888

Appetite for Healthy Range

FOOD & BEVERAGE INDUSTRY AWARDS

Innovative Technology of the Year HMPS5000 Wraparound Case Packer - HMPS Proudly sponsored by: NORD DRIVESYSTEMS

A

wholly owned Australian company, HMPS specialises in the design, development and manufacturing of high quality machinery for packaging processes.

From its beginnings working with the South Australian wine industry, where it designed and developed the first Bag in Box machinery, the company has grown to offer case packers, RSC, palletisers, carton erectors and sealers, pick-and-place applications and specialised robotic solutions.

The company is able to offer innovative and specialised machinery which adapted to the clients’ unique requirements.

HMPS has developed a solution to automate food manufacturers’ end-of-line requirements. The solution automates the process with minimal operator involvement, while adhering to important industry health requirements.

The challenge in this particular project was the number of variables the machines had to deal with. One machine was needed to pack up to 12 products formats, weighing between 180g and 260g with an output speed of 10 to 30 cartons per minute. All of this had to be achieved seamlessly and with minimal changeover time.

The machine was required to place boxes of dry food into larger cartons, ready for palletising and shipping. It had to be easy to maintain, easy to clean and easy to operate.

It needed to be able to perform multiple functions and had to be easy to set up for various product lines. The HMPS5000 Wraparound Case Packer solution delivered an expected lifespan

Martin Broglia, managing director of NORD Drivesystems Australia (left) with Mark Emmett, managing director of HMPS. 16 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

of at least 10 years, and an ROI both in labour and material savings calculated that this machine would be offset within 1.5 years.

The machine is unique in terms of the amount of multiple variables it has to handle. It is robust, flexible and easy to operate and maintain.

The use of clever design meant that, with the push of an operator button, the changeover between product lines could be achieved within minutes.

How it works Products enter the system on an infeed conveyor system which allows product to either continue travelling narrow face leading into the case packer or, with the use of two differential speed belts, to rotate 90 degrees to wide face leading.

The inners then travel towards to a servo driven water wheel, standing them upright into a servo driven index system. Once the correct carton quantity is collated they are then

driven up to a servo side shift before being transferred into the carton by a Delta Robot.

Simultaneously, a flat wraparound blank is erected in Station 1 before being transferred and positioned in the loading station where the collation of products is loaded. The minor flaps opposite the loading station may be folded at this stage to ensure correct product alignment.

From here, the minor flaps are folded, fully locating the product and the hot melt adhesive is applied. The cartons are compressed to complete the sealing and then side transferred as firmly bonded cartons are discharged from the machine to await palletising.

JUDGES' COMMENT "This is a great solution to automate food processing lines, with the costs easily offsetting well before the lifespan of the machine."

NORD DRIVESYSTEMS offering Industry 4.0 ready drives with smooth surfaces for the food and beverage industry

to all the Congratulations ners of the in w d n a ts s li a n fi ge Awards. ra e v e B d n a d Foo be a part We are proud to iative. of this great init The

Gear Unit

n Strong bearings n Low noise n High power density

The

Motor

n High efficiency n Global Standards n All operating conditions

The

Drive Electronic

n Compact design n Easy commissioning n Scalable functionality

Wide power range – Versatile system solutions – High overall efficiency

NORD Drivesystems (AU) Pty Ltd 18 Stoney Way, Derrimut , Victoria 3030 Australia Phone: +61 3 9394 0500, Fax: +61 3 9394 1525 www.nord.com.au National Customer Service 1300 00 NORD (6673) au-sales@nord.com Member of the NORD DRIVESYSTEMS Group

FOOD & BEVERAGE INDUSTRY AWARDS

Paddock to Plate White Corn Tortillas, Totopos & Tostaditas - El Cielo Proudly sponsored by: Chr. Hansen

F

ounded by three Mexicans in 2012, El Cielo (‘The Heaven’), now employs over 20 people.

The company was established with the aim of promoting ‘The True Taste of Mexico’, offering the exciting flavours of traditional Mexican cuisine.

Following its successful production of a range of traditional Mexican products, including tostadas, salsa and tortillas, El Cielo set about realising the ‘Paddock to

Plate’ philosophy.

In 2016, motivated by a desire to use locally produced ingredients, the company scored an industry first when it grew and used its own 100 per cent Australian white corn in northern NSW. At about the same time, El Sabor, a restaurant that would use the corn, was established.

The corn project, over two years in planning and experimentation, not only helps local farmers but also meets the needs of consumers who demand locally grown products. The corn is used to produce White Corn Tortillas, White Corn Totopos (corn chips), and Tostaditas.

In conjunction with the farm,

extensive research and planning was undertaken in order to establish the best location for growing high quality white corn in Australia. This also required extensive planning with regards to logistics and ensuring the white corn would reach the production facility fresh.

Upgrades and development of processing machinery was required in order to facilitate the production of the products, while providing the fresh products to restaurants (including El Sabor) meant the Paddock to Plate dream was realised.

In order to maintain freshness, the grain is harvested in NSW, then immediately transported to a

production facility in Port Melbourne for processing. The products are then delivered directly to restaurants and independent retailers for sale.

JUDGES' COMMENT "El Cielo has taken the concept of paddock to plate one step further deciding to grow the corn themselves to ensure the best quality for the product. Their impressive supply chain sees them grow the corn, process it in their Port Melbourne facility and then deliver direct to restaurants as a fresh product."

Lisa Flower (left), marketing manager at Chr. Hansen, and Cesar Duran, managing director at El Cielo.

Lisa Flower, Marketing Manager at Chr. Hansen (left) with Cesar Duran, Managing Director of El Cielo.

18 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

Bioprotection is a natural way to inhibit spoilage and protect against harmful contamination in food.

Bioprotection is the art of using microbial food cultures to inhibit unwanted contaminants – preventing food spoilage enhancing food safety.

This not only helps you keep your products fresh and safe, it also helps you to build and protect your brand!

Keep it great !

Bioprotection using nature’s own resources to keep food fresh and safe

The natural way to keep it great!

Keep up with market trends

Keep waste down Food Waste is an economic and environmental burden.

Protect your effort and investment while reducing your carbon footprint. Use bioprotection to keep products naturally fresh and safe throughout shelf life.

Bioprotection can add to the appeal of your product and help you meet the growing demand for natural, healthier products without artificial preservatives.

Keep it safe

Keep your brand strong Use bioprotection to protect reputation, investment and growth. It will help you keep existing customers loyal and win over new ones.

Chr. Hansen Bioprotection can keep it great for fresh dairy, cheese, meat and wine.

Your product may be superior to competitors’, but the risk is just the same. Improve safety and product reputation with bioprotective food cultures.

FreshQ® helps prevent spoilage, extend shelf life and protect the goodness of your fresh dairy and cheese products.

SafePro®

BioSafe®

Viniflora®

helps to deliver a consistent cheese quality, while meeting a growing demand for natural products and ensuring maximum whey value.

helps prevent growth of undesirable flora and protects the authenticity of your wine.

Chr. Hansen Pty. Ltd. 49 Barry St. Bayswater, VIC, Australia 3153 Phone +61 3 9762 9600 www.chr-hansen.com

helps improve product quality and food safety of meat, salmon and salads.

FOOD & BEVERAGE INDUSTRY AWARDS

Health Foods Fermented Turmeric – Fermentanicals Proudly sponsored by: Miller Leith

MILLER LEITH

F

ermentanicals specialises in fermented, activated, sprouted and live foods, and aims to increase nutritional elements in ingredients and to help assist the absorption levels in our bodies by effectively creating “predigested” foods.

The company was born as the result of CEO Jayta Szpitalak’s kitchen experiments. From creating inspiring superfood health smoothies to fermenting spicy krauts and making her own vinegars at home, Szpitalak is always looking for ways to give nature a helping hand.

Fermentanicals’ Fermented Turmeric capsules are designed as much for taste as to support health. The company recommends customers open the capsules and sprinkle the contents into smoothies or onto food for added flavour. The product can be used in everything from savoury foods, to sweet foods (smoothies) and even as a tea.

The product is more than a simple culinary spice. Tumeric is as ancient as it is widely used and, because of its inflammatory and antimicrobial properties, it has been associated with numerous health benefits.

The company ferments turmeric using a lactic acid bacteria and molasses to increase the antioxidant and enzymatic activity, making it more effective to absorb. In other words, this makes it more bioavailable compared to standard (non-fermented) turmeric.

With all of its manufacturing practices centred around increasing bioavailability and absorption within the body, the company claims to have set itself apart from suppliers which don’t employ additional techniques for improved bioavailability.

After investing heavily in empirical research, Fermentanicals found that turmeric is an incredibly difficult spice for our bodies to digest. Studies indicate that fermenting turmeric goes further in

Stephen Borg, managing director of Miller Leith with Jayta Szpitalak, CEO of Fermentanicals. increasing absorption than simply adding it to healthy fats or piperine (as it is commonly found).

It proved to be difficult to find a manufacturer versed in the fermentation of turmeric powder, hence finding a few brands now experimenting with the fermentation of Turmeric as a vinegar or a liquid drink.

As a next step, they spoke to experts in Okinawa, Japan, where there is a long cultural practice of using fermented turmeric in tea, and were able to come up with best practices. In Okinawa, they use the Fermented Turmeric to

20 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

protect the liver from hangovers or excessive alcohol.

For the first iteration of the product to test the market, they sourced Fermented Turmeric from Okinawa, Japan and worked with a manufacturer here in Australia on encapsulation and bottling.

For the second iteration of the product, they are working with manufacturers on fermenting and implementing unique solutions to be able to dry back to a powder with great success. The result is a mild tasting version of turmeric that is far more soluble. With such unique innovation on all of their products, it

is their job to educate consumers on this research.

JUDGES' COMMENT "Fermentanicals has managed to achieve the difficult task of drying the fermented turmeric back into a powder form, providing a point of difference in the market for consumers, as well as showcasing a challenging manufacturing technique. The capsule design is also unique to the product, differing from other turmeric products."

FOOD & BEVERAGE INDUSTRY AWARDS

Beverage of the Year Utopia Sheep Whey Vodka - Hartshorn Distillery Proudly sponsored by: BeanScene Magazine

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artshorn Distillery was established 18 months ago by Ryan Hartshorn, a director and owner of Grandvewe Cheeses which produces sheep milk cheese.

Hartshorn has spent the last two years discovering how to turn the complex sugars held within

the whey (a cheese making waste product) and converting them into basic sugars to then ferment into alcohol and eventually distil. The resulting distillate has a delicately sweet bouquet and extremely smooth finish, thanks to the dairy influence and traditional aging methods.

The Tasmanian micro distillery is the first in the world to use whey in the production process. Apart from Utopia Sheep Whey Vodka, the operation also makes a gin. Making small 60 bottle batches using a glass

column ‘still’ designed by Hartshorn, the operation is the smallest distillery in Australia.

Each bottle and label is hand painted. All of the spirits produced are unfiltered, giving the products more character and complexity.

The sheep milk whey is fermented then put through a column still to extract the alcohol.

This alcohol is then refined in a seven times reflux still to create a smooth, creamy vodka.

Apart from its unique ingredient,

the other noteworthy thing about Utopia Sheep Whey Vodka is the fact that each bottle is unique. All are individually spray painted, then hand written and signed by Hartshorn.

JUDGES' COMMENT "Vodka using sheep milk whey? This is such a unique product, with Ryan being the only person in the world currently producing it."

Camilo Molina (left), BDM for BeanScene Magazine with Ryan Hartshorn, director of Hartshorn Distillery.

21 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

FOOD & BEVERAGE INDUSTRY AWARDS

Food Safety Equipment and Materials BladeStop Series II - Scott Automation & Robotics Proudly sponsored by: MEGATRANS2018

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cott Automation & Robotics is a leading global provider of automation and robotic solutions that improve productivity, reliability, yield, and safety for manufacturers and processors in industries including meat, food, mining and general manufacturing.

BladeStop Series II reduces the risk of serious injury by stopping the Bandsaw blade within a fraction of a second. The product is available worldwide and is uniquely designed

to reduce risks of serious injury by mechanically stopping the bandsaw blade when the unit senses that a person has come in contact with the blade.

BladeStop is available in two sensing methods. Upon sensing contact with the operator, the blade stops operating within 9 milliseconds. This can be a huge difference between having just a small skin cut of a few millimetres and an amputated finger or limb.

GloveCheck, the second sensing system detects operator gloves moving at high speed in a zone directly upstream from the saw blade and trigger the BladeStop mechanism to stop the saw blade within nine milliseconds. Major improvements to the new system include that it

stops bending of the blade after an emergency stop, and eliminates the risk of opening the saw to change the blade which is a dangerous task in itself.

In addition, it can be restarted quickly after an emergency stop, allowing the operator to continue working after a potentially hazardous occurence has been avoided.

The company is able to upgrade existing BladeStop Series I saws to BladeStop Series II by replacing internal components, which will dramatically improve existing saws in the market.

Scott Automation & Robotics are experts in providing total end-of-line automation and robotic solutions. They offer a complete service, from design, manufacture and project management

through to implementation and ongoing 24-hour support.

The company provides robotic and automation solutions and systems to a variety of industries including food production, foundry, mining technologies, meat and poultry, packaging and palletising, and metals industries.

JUDGES' COMMENT "BladeStop is a great invention, ensuring the safety of workers in processing facilities. The stop time of 9 milliseconds can make all the difference in an emergency situation."

Malcolm Macintosh, BladeStop business development manager at Scott Automation & Robotics (left) with Simon Coburn, show director for MEGATRANS2018.

22 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

FOOD & BEVERAGE INDUSTRY AWARDS

Meat, Poultry & Smallgoods Finest Quality Beef Range – Harvey Beef Proudly sponsored by: COG Advertising

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arvey Beef produces quality beef sustainably raised in the pristine environment of Western Australia. Owned by a sixth generation West Australian family of born and bred cattle breeders, for nearly 100 years the company has been raising a better class of cattle in a measured and sustainable way.

The company selects the finest West Australian cattle to produce premium quality graded beef. The Harvey beef range is graded to meet the standards enforced by Meat Standards Australia, which serve to guarantee a great eating experience. The hand selection process ensures uncompromised product quality reaches consumers each and every time.

Harvey Beef launched the premium beef range in Cryovac Darfresh vacuum skin packaging and a tray label depicting the pristine natural environment of Western Australia.

The product range was launched into Coles retail shelves in April 2017.

The range includes: The Porterhouse range - the Porterhouse cut is prepared from the Striploin, and is characterised by a lean but tender steak with a thin top strip of fat for extra taste.

The Scotchfillet range - Prepared from a Cube Roll, the Scotch Fillet is regarded by many as the most flavoursome steak cut. This is due to the middle seam of fat marbling which significantly enhances the flavour and texture of the meat during cooking.

The Eyefillet range - The Eye Fillet is prepared from the Tenderloin – and as the name suggests, is renowned for being the most tender cut of beef.

Retailers around the world

are challenged by food waste and subsequent economic loss. While mark downs and lost sales bear a financial impact to retailers and brand owners, the greater environmental impact of wasted product affects everyone.

Outside of the retail cabinet, a close examination of household waste shows that consumers contribute significantly to the total food waste.

The 35-day shelf life for the range in Darfresh vacuum skin packaging yields many benefits to retailers and consumers. For retailers it offers an extended merchandising period and less markdowns and better store inventory, while for consumers it enables extended freshness, a better eating experience and easy to open, knifeless entry. It also enables further distribution and greater food access for brand owners and processors.

The total vacuum skin seal prevents product purge, which works

to extend shelf life and enhance visual appeal. In doing so, this removes the need for a soaker pad found in MAP trays (food tray sealed with a flexible film containing meat product and combination of inert gases eg. nitrogen or carbon dioxide).

Low-profile trays allow trays to be designed efficiently and the customised skin film provides effective product protection.

This also facilitates palletisation efficiencies – enabling more product per pallet and reducing the need for less shipping cartons.

JUDGES' COMMENT "Harvey Beef has used an innovative packaging solution to increase shelf life, reduce overall packing and shipping materials and help to reduce food waste."

Daniel Briggs, operations manager for retail at Harvey Beef receiving the award for 'Meat, Poultry & Smallgoods'.

23 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

Ready Meals Appetite for Healthy Range - Andrews Meat Industries Proudly sponsored by: Manark Printing

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reative Food Solutions (CFS) is the commercial kitchen side of the business for Andrews Meat Industries and JBS Australia.

The company recently launched the Appetite for Healthy Range of meals, all of which are free from artificial colours, preservatives and additives. Available across the Metcash Group, the range is gluten free, and also low in sodium and saturated fats.

In addition, the products contain more good starches. For example, sweet potato replaces white potatoes and there are also added pulses, fruits, vegetables and spices wherever possible. There are four meals in the range • Spanish pork with chickpeas salsa and broccoli • Slow cooked steak, sweet potato mash, beef jus and broccoli • Roasted chicken thigh with a medley of seasonal vegetables and traditional • Handmade lamb Kofta, turmeric, sultana basmati rice and Pepponata sauce Given that all meals rate either 4 or 4.5 on the ‘Health Star Rating’, the range is taking a healthy lifestyle choice to the masses. Consumers can grab a pack in confidence that they are going to eat a well balance, nutritional meal every time.

Working with Sealed Air, the company designed a simple steps tray that does not need to be pricked before the microwave re-heat step.

Instead valves are built into the container, allowing the film to bulge and then release, as pressure builds.

In the microwave, this looks like the meal is breathing as it inflates and deflates during its short re- heat.

When the package is taken from the microwave the film will retract back 24 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

to a vacuum, which absorbs moisture back into the meal. This means that after one minute, when the easy peel film is removed, there is no dangerous steam release.

The second advantage of the container occurs in the actual re-heat process. The vacuum means that, when it is hit with microwaves, the meal re-heats uniformly with no crisping or drying out along the edges.

CFS specialises in sous vide cooking. During this process, the product is sealed under vacuum and then submerged in a water bath for six - 24 hours, depending on the size of protein. A computerised system is set up to cook to 0.1 of a degree of a pre-determined target temperature.

The product is also chilled in the same tank. This means it enters a tank raw and emerges fully cooked and chilled. During this process, the company conducts both a 6D Listeria and a 90/10 Botulinum kill step, while maintaining the finished product’s moistness and tenderness.

The beauty of this process is that, as the product is pasteurised, the shelf life will be between 28 - 56 days if it is stored between 0 - 4°C without the need to add preservatives.

This means that, unlike most five or six minute re-heat meals, these products take just three minutes to re-heat. Therefore, the meals are not over-heated, but are heated evenly throughout.

JUDGES' COMMENT "The re-heat container for the Appetite for Healthy range is a fantastic innovation - locking in moisture and allowing the packaging to 'breathe' in the microwave without pricking. Additionally, the cooking technique means that the product has an extended shelf life, without the need for any added preservatives."

FOOD & BEVERAGE INDUSTRY AWARDS

SMC Australia | New Zealand

Christine Clancy (left) representing Manark Printing, with Ian Hill, retail sales manager at Creative Food Solutions.

SMC – Understanding your dairy production process – all along the line At SMC we recognise that an ability to fully understand the challenges of any manufacturing process is the key to our future success. For this reason, we have developed specialist teams to work in key manufacturing industries throughout the world – our Industry Experts.

Our Dairy Industry Experts understand the important issues and regulations of your industry. Let us help you realize a positive impact on your bottom line as well as the environment.

25 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

EFFICIENCY & DOWNTIME

The true cost of homemade conveyor belt cleaners For food makers, keeping conveyor lines clean and free of product carryback is a particularly messy task. However, as conveyor specialist Flexco points out, trying to solve this problem with homemade solutions is tricky and comes at a cost.

Engineered conveyor belt cleaners are effective and affordable.

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arryback occurs when material transported along conveyor belts adheres to the underside of the belt instead of being cleaned off or released. If not managed appropriately, this can result in loss of product, excessive downtime and high cleanup costs.

Over the long term, it can lead to even more costly issues, such as product contamination, or fines resulting from regulatory noncompliance.

Assuming they’re in the best position to clean their conveyor systems, many food manufacturers try to mitigate carryback by making their own belt cleaners. This can be a mistake.

Sticky scenarios For one leading food manufacturer, the problem was that the sticky frosting drizzled over its breakfast pastries also stuck to its conveyor belts, gummed up its rollers and generally created a sanitation and cleaning nightmare. Additionally, the sticky buildup caused belts to mistrack, while the abrasive sugar in the frosting was causing them premature wear. The company tried

employing a homemade belt cleaner, but still found themselves replacing damaged belts every two weeks.

In another sticky situation, a snack food producer’s homemade cleaner was unsuccessful at cleaning up residue from the wet, sticky snack chip dough that was sprayed onto the belt during one stage of processing.

Not only was this a constant, stubborn mess, but also resulted in significant product loss.

As these examples illustrate, the failure to effectively control product carryback can gnaw away at profitability. Extended downtime— whether for belt repair, sanitation of the line, or excessive maintenance— means lost productivity. Similarly, manually scraping and scrubbing off product that has adhered to belts and rollers is time-consuming. Spillage that ends up on the plant floor is not only wasted product, but also a potential slipping hazard for workers.

Proper sanitation requires 100 per cent effort. The possibility of product contamination is real, and a single recall has the potential to bring down a manufacturer.

While homemade cleaning devices may be well-intentioned, it is

26 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

quite likely they are not designed to meet the requirements of the United States Department of Agriculture (USDA), which are highly regarded within the Australian food industry.

If the cleaner is created with material that has a rough surface finish, for example, or has small or hidden crevices, food can accumulate in these spaces and provide a place for bacteria to grow.

Problems with homemade cleaners In each of the scenarios above, an attempt was made to resolve the carryback issue with makeshift conveyor belt scrapers. These homemade devices can be seductively inexpensive at first glance, cobbled together in-house from spare pieces and parts, and with the intent of being custom-built to your belt system. But most operations find that their homemade cleaners actually cost more than they save in the long run, after factoring in performance and other key variables.

For a device to provide efficient and effective cleaning, it must exert just the right amount of pressure on the belt, so proper tensioning is

a critical factor. Many homemade scrapers apply too much pressure and cause damage to the belt or splice, clearly a counterproductive result.

Belt damage can also occur if the cleaner’s blade material is too rigid.

Other homemade cleaners do not apply enough pressure to the belt to remove all excess product, instead allowing it to accumulate on the belt and conveyor components. If a cleaner is present but not doing its job, it may be providing a false sense of security.

Additionally, some conveyor systems have variations in the belt or pulley that render a rigid tensioning system ineffective altogether.

For such systems, only a device engineered to provide consistent blade-to-belt contact will effectively prevent product carryback.

The ability to easily clean the cleaning device also may not have been considered in a homemade design. If a device is complicated to disassemble for cleaning, downtime will necessarily be increased, as will potential food safety risks. As cleaner blades experience edge degradation and need to be replaced, or when the cleaner needs to be removed as part of general plant maintenance, complicated cleaner construction will again impact downtime and productivity.

Engineered cleaners Engineered conveyor belt cleaners can provide an easy, effective and often surprisingly affordable alternative to homemade solutions. First and foremost, these engineered solutions do what they’re designed to do: eliminate conveyor belt carryback. By employing cleaners that thoroughly remove excess product from their belts, plants experience a reduced need to manually clean their belts, rollers, etc. to remove what homemade cleaners miss.

Eliminating carryback will result

EFFICIENCY & DOWNTIME

in far less product scrap. The snack food manufacturer in our earlier scenario decided to try an engineered solution for food manufacturers in place of their homemade cleaner: the FGP from Flexco. Designed for the toughest food applications, the cleaner’s spring tensioner was easily adjusted to ensure optimal blade-to-belt contact, maximising its cleaning capabilities. By significantly reducing carryback of the snack chip dough, the business was able to reduce scrap losses by 60 per cent compared to their homemade cleaner.

The cleaner is engineered with a simple-to-adjust spring tensioning unit that ensures optimal bladeto-belt contact. This made it an obvious solution for dealing with the sugary breakfast pastry frosting in our other real world scenario. The Flexco cleaner helped extend the manufacturer’s belt life by removing the abrasive sugar carryback, keeping it from accumulating on the rollers and other components, reducing excessive wear and belt mistracking.

Engineered solutions such as the FGP Primary Cleaner are designed for ease of use, including quick disassembly (under a minute in this case) for sanitisation. The FGP is actually the only engineered solution

The cleaner's quick disassembly/reassembly helps reduce the time and cost of overall maintenance.

that has USDA certification, with minimal crevices to harbour bacteria or other contaminants, a 32 Ra surface finish, only US Food and Drug Administration (FDA)approved materials and designed using only rounded interior angles to make sanitation easier.

The cleaner’s quick disassembly/ reassembly helps reduce the time

and cost of overall maintenance. In addition, the blade snaps off and back into place without removing any other parts, reducing the time it takes to clean or replace the blade.

The FGP is also designed with standoffs that allow cleaning without the need to remove the end plates.

By reducing or eliminating product carryback, cost savings

will begin to add up, more than offsetting the cost of purchasing an engineered cleaner.

This leads to reduced product waste and less belt damage due to mistracking or abrasion. In addition, the risk of employee injuries from slipping in spilled product is reduced and maintenance and sanitation costs are minimised.

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6/07/2017 8:48:53 AM 27 www.foodmag.com.au | Aug/Sep 2017 | Food&Beverage Industry News

EFFICIENCY & DOWNTIME

Taking food safety to the floor It may seem innocuous, but the level of attention that you pay to your factory floor will inevitably improve food and human safety in the workplace. Steven Impey takes a closer inspection.

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inding a balance between product and human safety in the workplace is one of the food sector’s ongoing challenges.

Even on highly automated factory floors, the footfall still remains high wherever quality control requires a keener eye for contamination and operational assistance.

Especially in facilities such as abattoirs, dairy processors, and food factories – where human hand meets the production line – companies must maintain the highest standards for worker safety as well as product integrity.

“What food manufacturers are looking for is product safety – that is the number one issue,” said Ray

Schnitzerling, design director at Wiley, who design and build manufacturing facilities.

“You have to be able to clean your floors well and they need to have good drainage; but that doesn’t necessarily solve the human safety factor.

To stop people from slipping, you need to have good flooring systems – however, when you have really good slip assistance, it is going to be harder to clean.

“There is always this conflict between trying to provide something that is easily obtainable and drains well compared to an environment that is safe for workers and is suitable for pedestrian use,” Schnitzerling added.

Among some of the most

Roxset works directly with the industry to understand client demand.

28 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

common causes for injury within Australian industry, slips and trips are still prevalent.

The challenge is to have enough grit in the flooring that makes it easy to clean but remains safe to walk on.

Under section four of the British Retail Consortium (BRC) Global Standard for Food Safety, expectations are set out for the production environment. This will include the layout and maintenance of the facility and equipment, cleaning, pest control, waste management and foreign body controls.

“It is always a struggle to provide that slip resistance rating as opposed to the cleanability of your floor,” Schnitzerling said.

“However, another thing that is an issue is where you have people standing in the same position for long periods.”

At the top of the tree, stresses on the body are a major cause for long-term injuries, meaning a work environment must meet the needs on the people of the ground as well as the food and drink they produce.

One area that isn’t always taken into consideration is the type and standard of flooring a processing plant invests in.

For example, there are various floor materials that have rubber in them to combat body fatigue – although they are not always desirable in a food environment.

It therefore means knowing what

EFFICIENCY & DOWNTIME

sort of application you need to use in different work environments.

For example, in an abattoir, blood is very aggressive and requires a particular resin flooring that is not susceptible to blood corrosion.

In a milk factory, it is the same story. Whatever the food type you produce, you need to make sure that your flooring is resistant to corrosive food products.

At Flowcrete, the flooring design company based in New South Wales, its engineers work across a multitude of industries.

“Within food and beverage as well as other sectors, we try to work to educate people on what their specific requirements are,” said Ilona Osborne, Flowcrete’s marketing manager.

“Flooring is one of the most important things you can have in a food facility although, unfortunately, it really is an afterthought for a lot of businesses.

“That is why we try to work with businesses on the specification side of things and to look at how it benefits their facility.”

The non-slip issue can always be a safety problem, she explains – especially in wet-processing areas like abattoirs, which require flooring with quite a severe non-slip aggregate in it.

However, they can be quite difficult to clean so it is important to ensure that you have a good material that is easy to maintain and having the correct cleaning tools.

This may include an anti-microbial agent built into the resin which works to proactively kill bacteria on the surface of the floor and create a hygienic environment when accompanied by the correct cleaning procedures.

“We have been working with a lot of clients who have offered a lot of feedback. Traditional resin flooring systems can be difficult to clean which is why we have developed a gloss finish,” Osborne said.

“It’s all about continually looking at the facility and what the requirements are for an individual business and adjusting the flooring systems to suit.”

At Roxset, one of Australia’s leading flooring solutions providers, offering a one-to-one service is vital to getting the job done right first time and in a timely manner.

With profitability and production time now so tightly connected, knowing the ins and outs of the client’s targets is critical to making the right

Flooring is one of the most important features of food facilities. choice for any given floor surface.

Bruce Willan, Roxset’s managing director based in Sydney, explains why that is the company’s number one rule.

“It is a problem seen across the manufacturing industry, where people are becoming fascinated by the latest robotics and technology while the floor surface they work on is important to some but not necessarily to others,” he said.

“It is actually an integral part to any production business and, as an industry necessity, it is important that we provide a high quality food grade surface suitable for rapid installation while there is growing pressure in Australia to run your business 24 hours a day.”

Making sure that a client can easily maintain their floor and won’t need a recall after installation is a long-term investment and proves to be one of the biggest challenges across the industry.

“The time frame that we often work with is very limited – for the larger projects, it could take as few as five days to complete 1,000sqm – and requires, on our part, a good understanding of our clients and their needs,” Willan continued.

“At Roxset, we particularly like to interact with our clients directly so that they and their clients are best served rather than liaising with a thirdparty contractor.

“We therefore need to make sure to tailor each floor surface to each specific client and, on our part, requires a larger operation that can serve companies across the country, in any given sector, at any given time.”

Another area of importance is knowing a client’s internal traffic and the critical areas of the facility so that the architect can come up with a specific plan.

“Working with and learning from the client involved to achieve the best result means acting as one unit,” Willan said.

“More food processors are now dealing with clients on an international stage and want to look the part, so making sure your flooring is up to standards is the first step to making your factory look the part too.”

One of the misconceptions Osborne has recognised from events such as foodpro is the role resin plays in the maintenance of different industrial flooring.

At Flowcrete, they are offering cementitious polyurethane resin flooring that can be used as an alternative option in the food and beverage industry across a variety of sub-markets.

These flooring systems are designed to work within a punishing environment and provide wear, impact and chemical resistance, which is a benefit to areas where implements can drop on to and cause damage to the floor.

Cementitious polyurethane resins are also able to withstand thermal fluctuations from -40°C to 120°C, which are often found at different stages and zones of production.

Furthermore, they can also feature natural antimicrobial additives, which provide additional protection against bacteria and fungi.

“In one facility, you may have smoke rooms and you may have areas where you are pulling out hot trolleys or you may have cold rooms for process packaging,” Osborne explained “They all require different flooring technology – and you are not going to use the same flooring you use in a commercial kitchen as you would in a packaging area.”

The introduction of robotics into the workforce has also changed the way companies think about the surface they work on.

For example, processors may consider using their flooring to create zones where it is safe and not safe to work.

This could include painted patterns or lines in the floor’s material that show where people can walk and therefore requires a little bit more slip resistance.

“Factories will probably move to a lights out situation where there are no people within the factory during a period of time,” Schnitzerling said.

“Although there will be supervisors, who may only be allowed to enter the production area at a certain time, you are always going to have some manual processes in place.”

While most manufacturers are trying to replace manual work with automation, you still need floors that can be cleaned.

“That’s what food manufacturers are looking for most of all – a hygienic environment for the production of their food,” he added.

www.foodmag.com.au | Aug/Sep 2017 | Food&Beverage Industry News 29

EFFICIENCY & DOWNTIME

Ensuring standards are met for packaged foods Contamination accounts for a large portion of recalls in the food processing industry and can lead to high costs and even legal ramifications. Bestech has come up with a simple solution to put your mind to rest.

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ood processors are constantly looking to increase productivity – however, responsibility for product integrity doesn’t leave their remit when their packaged goods are shipped around the world for consumption.

On the contrary, businesses are fast adapting to strict standards for health, safety and quality right along the supply chain; from the farm where their ingredients are grown through to the factory floor where they are packaged.

Acting on issues of food waste, engineers at Bestech Australia – which specialises in sensors and instrumentation – have come up with a new device that ensures packaged Projekt2 25.07.17 09:39 increasing Seite 1 foods are sealed properly,

their shelf life and saving costs.

Sealtick offers a range of leak detectors to check the integrity of flexible packages like biscuits, chips, coffee and milk powder.

A small problem with package sealing on a production line can lead to extensive food wastage if the problem isn’t detected soon enough.

According to statistics released by the Department of Foreign Affairs and Trade, food products such as wheat and beef are among some of highest exports in the agriculture sector.

Amid a market tipped to pass $60 billion, a significant number of food products are manufactured and shipped every day.

In Australia, food contamination is one of the main causes for product

30 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

The system is suitable for a range of packaged foods and beverages.

EFFICIENCY & DOWNTIME

Bestech's Sealtick technology will detect a leak in packaged foods. recalls while microbial exposure is often the culprit for a spoiled product.

Down the line, recalls can affect businesses in many ways; the most worrisome include legal action, while grounds to halt production and a tarnished reputation can also give manufacturers sleepless nights.

Advances in food processing and food packaging play an important

role in ensuring manufactured goods are safe for consumption – meaning that both the food’s production and packaging go hand in hand.

“A small, hard-to-detect leakage can lead to a significantly reduced shelf life, and often spoilt product which could be soggy or moldy,” said Samson Sim, Bestech marketing engineer.

“This could bring a bad name to

Oxygen Analysers, Relative Humidity Sensors and Meters, Dewpoint Measurement

the brand. Leak testing the product ensures that it is fresh when it reaches the consumer.”

All food that is produced – after a sealing problem occurs right up until the time it is discovered – will have to be thrown away.

Traditional testing methods for leakage involve dunking the package in water. However this wet packet, even though good, has to be thrown out.

Sealtick uses a non-destructive dry test for package leak integrity.

Therefore, the tested good product can go back on the production line after the test.

The savings in cost that this solution can create could potentially pay for the machine in the space of a few weeks.

“A good brand is associated with good product quality and attractive packaging,” Sim said. “This packaging has to effectively seal and protect the contents inside to ensure a good customer experience.

“Sealtick offers very fast testing, taking only about 15 seconds for a test.

This allows regular integrity testing so the staff can push the boundaries of production speed while maintaining high seal quality and avoid costly wastage.”

Food packaging reduces the risk of product deterioration, maintaining

U.V Absorption Conductivity pH / ORP Colour

AMS Instrumentation & Calibration Pty Ltd Analytical Process Division

food quality while extending shelf life.

Deterioration to foods can happen three different ways, whether that is chemically, biologically or physically.

Chemical deterioration is caused by exposure to oxygen, moisture or light, which can cause compositional changes.

Biological deterioration includes exposure to micro-organisms, insects, rodents and other pests, which cause disease and can spoil the product.

Packaging also provides physical protection that shields food from direct contact. This can damage the product – which is why seal checks such as Bestech’s latest technology are worth the investment.

The companies that are using Sealtick for package leak testing have a consistently good product going out the factory, according to Bestech, who claim to have set a new benchmark in leak testing of food products.

The test is fast – around 10 to 15 seconds – and, while contaminant free, there is no water involved and is extremely sensitive; it can detect holes as small as 10 microns.

“We are always looking for a longer shelf life for our food products and the market is growing fast,” Sim added.

Head Office: Unit 20, 51 Kalman Drv Boronia VIC 3155 Ph: 03 9017 8225 Fax: 03 9729 9604 NSW Ph: 02 8197 2825 WA Ph: 08 6364 0205 QLD Ph: 07 3333 2825 SA Ph: 03 9017 8225 www.ams-ic.com.au sales@ams-ic.com.au

Oxygen Analysers, Thermal Conductivity Analysers, NDIR Analysers, Multigas Analysers, OEM Analysers

Industrial Water Analysers and Liquid Analytical Products (pH, Conductivity, ORP, Dissolved Oxygen, etc) www.foodmag.com.au | Aug/Sep 2017 | Food&Beverage Industry News 31

FOODPRO 2017

A dream factory – highlights from foodpro Food & Beverage Industry News goes on a fantasy shopping spree at the latest foodpro, setting up our dream food factory.

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tepping out onto the floor of foodpro – Australia’s largest food manufacturing expo that took place from 16 – 19 July – is a bit like stepping into the future. From Omron robots delivering chocolate, through to the holograms spinning messages of food waste on the Sealed Air stand, it’s the country’s most comprehensive overview of what products and services are – or will be – available on the market.

For many food manufacturers, much of this technology will be out of reach. Food & Beverage Industry News is throwing caution to the wind with a wish list of what we would have picked up from foodpro if money was no option for our dream food factory. Here are our top picks.

Vaughan Constructions When considering the merits and opportunities of constructing a new

building, we would bring on the expertise of Vaughan Constructions.

Vaughan has provided innovative solutions for over six decades, more recently for the likes of Coles, Woolworths, Torino Foods, Hilton Food Group, Coca Cola and PepsiCo. Craig Jones, Vaughan Constructions’ development manager, told Food & Beverage Industry News that central to their advice is guidance through compliance hurdles of local

councils, building codes, standards and most importantly through the various supplier options available.

“There are over 3,000 different elements to a building, which means over 3,000 decisions and product material options within each element,” he said. “Vaughan explores these options and provides guidance on each decision and adopt solutions which represent or exceed industry best practise.”

Beyond construction of the building, Vaughan Constructions would also be providing us with guidance on the selection and management of process equipment.

BASF

Craig Jones, Vaughan Constructions development manager.

32 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

Next we would bring on BASF, who would be helping us out on two fronts.

First up, BASF would be installing a new Ucrete floor. Ben Rix, marketing manager construction for BASF, said that it’s “the world’s toughest floor” and could last us more than 20 years.

“You’ve got some harsh processes in your factory, think about emptying vats out, hot water and sanitising and cleaning the floors,” said Rix. He explained that our new Ucrete floor will resist the effects of extreme temperatures and harsh chemicals will be non-slip and impact resistant.

“You can have pallets scraping along the floor and they will still look terrific,” he said. He noted our floor will also help us keep our hygienic certification.

BASF would be helping us out on a second front with some functional ingredients for our foods. Although floors and ingredients don’t usually go together, as the largest chemical company in the world, Harry Haikalis, business and sales manager nutrition & health, explained that BASF is such a diverse company that most Australians will encounter BASF products multiple times throughout

FOODPRO 2017

their daily lives. The starting point for the company is that they ask themselves: “How do we improve people’s lives with chemistry?”

This leads to the company’s work in functional ingredients, which we’ll be investing in to improve our products. We’ll be including the company’s Vegapure Plant Sterol into our food, which has been clinically proven to reduce cholesterol by 10 – 15 per cent if our consumers eat just 2 – 3 grams a day of it. We’ll also be using BASF’s natural beta-carotene as our natural food colouring, harvested from an algae cultivated in Australia’s own pink salt lakes.

“It’s nature’s pigment,” Haikalis told us.

We’ll probably also include some fun ingredients from BASF’s partner Connell Brothers Co. (CBC). Carol Toft, business manager for Connell Brothers, will provide us with BASF’s Lamequick, that can be used to make a consistent and delicious mousse, ice cream, or cupcake filling. We might also include some edible glitter, to really make our product stand out.

Nord Drivesystems When it comes to fitting out our factory, we’ll be taking on the expertise

the aluminium. As a result it provides corrosion protection against a wide spectrum of PH, clearly outlasting any epoxy paints.

“It’s the Nord alternative to stainless steel, but so much better because stainless steel weighs a tonne, it costs a lot, and is sensitive to heat,” said Pillai.

“So you really can’t use it for most motors in food manufacturing facilities.

You can run our motors 24/7.”

ifm efector

BASF marketing manager construction Ben Rix (left) and business and sales manager nutrition & health Harry Haikalis. of Nord Drivesystems. Offering everything from geared motors to frequency inverters, Nord is one of the world’s leading manufacturers of drive technology.

In our plant, we’ll be including the NSD TupH surface and corrosion protection on our motors. Vinod Pillai, sales and applications engineer

for Nord Drivesystems, explained that the sealer functions a bit like an epoxy paint, in that it is applied to an aluminium alloy to protect the metal against corrosion. The difference, however, is that the NSD TupH is electrically catalysed onto the surface, with an anticorrosion layer that forms a permanent bond with the surface of

To keep an eye on our factory, and improve our processes, we would be installing IO Link sensors from ifm.

Paul Shackelford, sales representative for IFM, explained that the sensors would not only allow us tight control over individual parts, but we could collect data from our factory at the top level to improve our overall processes.

“It’s the latest and greatest technology. It allows you to see digital signals from sensors without any analog to digital converter loss,” he explained. “This is going to give you a very accurate picture of what’s happening.”

Using IO Link’s smart observer software, we will measure and monitor all aspects of the factory, looking at long-term trends, comparing month on month, and seeing how we can improve.

Don’t mess around, ensure maximum protection with NHP! To ensure high cleanliness and quality is achieved, NHP brings to market a range particularly suitable for food and beverage applications where ease of cleaning is paramount.

Our robust range of stainless steel enclosures are designed to comply with specific hygiene requirements, as well as optimum flexibility for varying project needs.

For your next food and beverage project, visit nhp.com.au/more/fbenclosures

NHP ELECTRICAL ENGINEERING PRODUCTS 1300 NHP NHP | nhp.com.au |

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19/07/2017 www.foodmag.com.au | Aug/Sep 2017 | Food&Beverage Industry 4:24 NewsPM33

FOODPRO 2017 Matthews Australasia Automation is key to reducing labour costs and increasing productivity within the factory, but requires a way to stay updated with the latest tracking technology.

Matt Nichol, national key account manager at Matthews Australasia, explained how integrated software could deliver us a clearer picture across our business.

“The great thing about foodpro is that it is of course a lot more foodfocused compared to other similar expos,” he said.

“We have learnt a lot from people visiting our stand and, speaking about automation and Industry 4.0, people are keen to know more about the simplicity of technology.

“Businesses want to use fewer operators on their equipment and we have proven that integration software is beneficial across primary, secondary and tertiary applications throughout the food industry.

“The factory of the future is all about automation. By reducing the number of operators in the packaging process, automation can give you full traceability for your product.”

DTS Food Assurance Traceability has become a must-have within the food industry – enabling

operators across the supply chain to track their product.

Jasmine Lacis-Lee, DTS Food Assurance’s technical manager for microbiology, spoke about the benefit of having a broad analytics system that would allow us to stay up to speed with our supply chain.

“Within the manufacturing industry, everyone is looking for something faster. From our perspective, we have to make sure we keep up with that,” she said.

Lacis-Lee pointed out that there has been a push in the past 10 years for laboratories to provide results as fast as possible and there are certainly specific methods available for us to now to do that.

“What we can also now offer is a programme called SafeOps, which provides traceability throughout the supply chain and allows manufacturers to record data,” she said. “From our perspective and speaking with clients every day, that is what they want – the ability to record analytical data and trend this data along all stages of the production process.”

Wiley Rising energy costs are now an ongoing concern for manufacturers and it is no different for food and

Vinod Pillai sales and applications engineer for Nord Drivesystems.

beverage businesses trying to keep the lights on.

Brett Wiskar, R&D and innovation director at Wiley, explained why monitoring power use in any given area of production will help our new business keep bills down.

“From my experience, there are a

few areas manufacturers talk about when it comes to looking to the future. Operation analytics is the heartbeat of their operation,” he said.

“The other is the cost of energy and the need for a visible representation of this throughout the business.

“We will see factories that have dashboards for all different operations, which offer contextual awareness of how the business is evolving.

He said that by doing this, it will us make real-time decisions of how we can run our business better.

Vega Australia

Paul Shackelford, sales representative for ifm efector.

34 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

Level Control will be important for our factory. Like all food and beverage makers, we will need to be able to accurately measure our vessels, tanks and so forth. Vega Australia’s managing director John Leadbetter explained that the first thing to do is determine exactly what we want to get from our level measurement.

“Do you just want to stop your silo over-filling?” he explained. “Do you want to know when it gets to a certain point or do you or do you continuously need to know how much is in there so you can do your planning?”

Next Vega would work out exactly what we are measuring in our vessels.

“Certain products have certain approvals required,” he said. “The next thing well ask you is can we physically have a look at your silo, your tank or

FOODPRO 2017

whatever. We need to have a look at the fitting were going to be adapting to.”

Following that, the company would examine the electrical set up involved.

“We need to know power is run there correctly,” said Leadbetter. From there, once we know what we need, Vega Australia would ascertain our delivery expectations then work out what type of after sales support we need and make sure we receive both.

AKA Cleaning Machines Hygiene and cleanliness is of critical importance in the food industry. Our new factory will use quality cleaning equipment to help ensure we meet and exceed food safety standards.

Richard Hilton from AKA Cleaning Machines will supply us with dry ice blasters.

“Dry ice blasting is similar to sand blasting but there’s no secondary waste; no sand,” said Hilton. “You get a thermal shot and the dry ice pallet simply turns to gas and then the debris falls away to the surface.”

“The main benefit of this is that it’s completely dry and sanitary. In addition, its fast and you can use it on hot ovens.”

And since dry ice blasting is not adding any material that needs to be collected, it allows the cleaning operator the ability to reach and clean areas and parts of machinery that normally only can be done by hand.

Lafert Electric Motors Australia It is important that all machinery in our dream factory prioritises hygiene. This includes the motors

Richard Hilton from AKA Cleaning Machines. and drives we will use to drive some our machinery. As Peter Harrington from Lafert Electric Motors Australia explained: “An important thing in food processing these days is washdown. It’s imperative you keep everything clean.

“However, when you start washing down standard gearboxes and electric motors you have

problems. For example, there is the possibility of corrosion, paint can come off, and they can rust badly,” said Harrington.

Harrington pointed out that in the US it’s now compulsory to have stainless-steel motors and gearboxes in any food processing plant. He added that, while this is not yet law in Australia, food makers are

starting to see the sense in using stainless steel motors and drives.

“And that’s why we’re doing so well,” said Harrington.

For 50 years the Lafert Group has developed the ability to adapt the highest quality standards to any specific market demand. The company also provides solutions for application and OEM requests.

www.foodmag.com.au | Aug/Sep 2017 | Food&Beverage Industry News 35

FOOD WASTE

Waste not, want not While there are clear humanitarian, environmental and economic reasons to reduce food waste, the solutions to the problem are not as clear. Food & Beverage Industry News spoke to Karl Deily, President of Sealed Air Food Care to hear his views on how to best address this problem.

T

he Food and Agriculture Organization of the United Nations estimates that one third of all food produced globally each year is wasted.

Food waste also has major environmental implications.

According to the World Resources Institute, if global food wastage were a country, it would rank only behind China and the US as the world’s third largest greenhouse gas emitter.

In Australia, according to the Federal Government, consumers waste 20 per cent of food they buy, while the commercial and industrial sectors waste around three million tonnes of food annually. All this is estimated to cost the Australian economy $20 billion a year.

The Federal Government has committed to reducing Australia’s food waste by 50 per cent by 2030.

It will hold a National Food Waste summit involving government, industry, academia and the not-for-

profit sector in November this year.

The government has flagged the possibility of introducing incentives to reduce the amount of food ending up as landfill.

In other words, there has never been a better time than now for industry to address the problem.

With this in mind, Food & Beverage Industry News caught up with Karl Deily, President of Sealed Air Food Care to hear his views.

Where and why?

First off, Deily explained that food loss and food waste are two distinct things. The former includes food that is lost during harvesting, while the latter covers waste by the processor, retailer or consumer.

While food loss is still a significant problem in the developing world, Deily explained that it is not as significant in developed economies. “In modern economies around the world most of the food

is lost at the retailer and consumer level,” he said. “At the retailer it can be as high as 12 – 15 per cent, with some produce items as high as 30 per cent on a weight basis. When you look at calories wasted, dairy and meat products are significant contributors.”

There are a number of causes for the food waste problem. At the consumer level, much of it comes down to a lack of awareness.

According to Deily, while Australia ranks relatively highly in this regard, globally “most consumers don’t feel that they’re responsible for food waste, or its not high on their agenda but they feel they contribute to it.”

In actual fact, throwing out food has a significant impact.

“If a consumer throws away 2kg of meat they’re not just throwing away the meat. They’re also throwing away over 2,000 litres of water, 1kg of grain, 23kg of CO2

There has never been a better time for industry to address the problem of food waste.

36 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

emission that it took to produce the product, process it distribute it and get it to the consumer,” said Deily.

At the retail level, the causes of food waste are more complex. The issue of “ugly produce” or food that does not meet the cosmetic standards of retailers (or consumers) is one important factor. According to Deily, shelf life is another. Too often, supermarkets find themselves having to either mark down prices as products approach their “best by” dates or, worse still, throw away food that has passed this date.

“Everyone is grappling with the difference between best before date, use buy date, sell by date, etc. These can all be very confusing,” said Deily. “They’re based on a statistical model, [whereby] if you have a sell by date and the food is thrown away, 50 per cent of the food you are throwing away is perfectly good because you have to determine an average life for the product.”

FOOD WASTE

He pointed to a proposal to simplify the system by introducing a clear “Expires On” date which would only be used for foods such as meat where food safety can’t be compromised.

Other foods, like yoghurt, would carry only a “Best if used by” date.

Consumers would be encouraged to use their discretion (and senses) to work out if such foods are still okay.

Solutions According to Deily, reducing food waste requires an end-to-end approach.

“We have to have logistics that protect the product through transportation. We have to have technologies that enable the retailer to merchandise the product in a way that minimises waste. Then we have to come up with labelling and information that resonates with the consumer,” he said.

According to Deily, packaging can be part of the solution.

“If you show consumers a cucumer unwrapped then show them one wrapped, they’ll say they want the unpackaged product because plastic has got to be bad for the environment,” he said.

However, what they don’t factor in is the fact that the packaged item lasts two to three times longer than the unpackaged item. Therefore it is more likely to make it to the consumer and less likely to end up as landfill where it will rot and produce methane (a more potent greenhouse gas than CO2).

Deily added that in the case of meat, when the whole supply chain is considered, the carbon foot print of the product may be up to 300-400 times larger than that of its packaging. “So we look at what technologies can we use to extend

the life of the product as long as possible,” he said.

Emerging technologies, such as the Internet of Things (IoT) will play an important role in reducing food waste.

According to Deily, IoT can help with tracking product, monitoring product temperature, and even with inventory and management control.

“IoT through connectivity and Quick Response (QR) or bar coding can ensure the oldest product is shipped and consumed first. And that there is better coordination between what is sold at retail and what is needed to be produced for replenishment of stock,” he said.

This technology can even help the consumer.

“We’re working on some QSR code technologies through the IoT which will drive an improved engagement with the consumer and the products they buy. This will enable the consumer to better understand how to use it, how to cook it and whether it’s okay to freeze at the end of its shelflife,” said Deily.

Benefits for businesses Apart from its humanitarian and environmental costs, food waste makes bad business sense.

“Globally, it’s estimated that 1.2 billion kg of meat is thrown out at retail every year... Businesses are throwing away over US$9b of product that they don’t sell,” said Deily.

The good news is that cost and waste reduction go hand-in-hand.

To illustrate the pointed Deily pointed to a study Sealed Air did for a UK retailer. By changing the package format in just one food category the retailer was able to reduce the amount of food they were throwing away by 350,000kg

"If global food wastage were a country, it would rank only behind China and the US as the world's third largest greenhouse gas emitter." and provide a new package format that appealed to the consumer. This equated to an increase of value of US$19m from reduced food waste and increased product sales.

“We have data to show that every dollar you invest to minimise food waste there is about a $14 return on investment,” said Deily. “This is why prevention is preferred over strategies that either recycle or recover food that is about to become waste.”

Sealed Air Deily pointed out that Sealed Air, predominantly a plastic packaging supplier, is judged by some as part of the problem. But he maintains the company is part of the solution.

For example, the company’s award winning Cryovac Darfresh on Tray more than doubles the shelf life of red meat when compared to the standard Modified Atmosphere Packaging (MAP) process. In addition, it produces no film scrap and up to 40 per cent less material waste.

Another product, the Cryovac Freshness Plus film includes components which absorb oxygen before it reaches the product thereby enabling significant shelf life extension of products such as avocado and bakery goods.

Food waste at the manufacturing level can be effectively managed through improved process technology. Deily explained that this is because the sector operates in a closed environment and can therefore ensure that all processes

are monitored and controlled.

Pork producers, for example, make it their business to market and merchandise almost every part of the animal. Apart from food for human consumption, they produce animal food and can even make fertiliser through blood recovery techniques.

“A lot of the loss for processors is just losing some of the economic value, so we work a lot with customers on making sure they maintain the highest value of their product by improving the yields and operational efficiency,” said Deily.

For example, Sealed Air has implemented technologies for deboning a turkey breast as thoroughly and efficiently as possible. The company works in processing plants to help in ways that (directly or indirectly) help reduce waste.

Finally, Deily mentioned Sealed Air’s efforts to reduce food waste by smarter portioning. “We look to deliver product that can be portioned in smaller portions, in a manner that is good for the whole value chain.”

Around the world Sealed Air’s new packaging solutions and technologies are being recognised.

Closer to home in Australia and New Zealand, Cryovac Darfresh for fresh pork and Cryovac Freshness Plus for fresh avocado won the votes of the judging panel at the 2016 and 2017 ANZ Save Food Packaging Awards. Each solution was able to significantly extend the shelf life, enable wider food distribution and access, all while reducing food waste.

www.foodmag.com.au | Aug/Sep 2017 | Food&Beverage Industry News 37

FOOD FACTORIES OF THE FUTURE

Food makers look to the future In these times of fast moving technological breakthroughs and innovation, ‘Factories of the Future’ has become an often-heard expression. Food and beverage makers recently gathered in Sydney to discuss what the term means for their sector.

A

gathering of food and beverage in July heard that, as we move further into the new century, new technologies and Industry 4.0 will become increasingly crucial to the success of their businesses.

Food Factories of the Future was held before a full room at the Novotel Darling Harbour in Sydney last Wednesday morning. The event complimented foodpro which was taking place at the same time at the nearby ICC Exhibition Centre.

The two keynote speakers on hand for the seminar were Peter K. Wienzek, business development manager systems, ifm efector and John Leadbetter managing director, VEGA Australia.

Presenting first, Wienzek pointed out that food makers in 2017 have access to data that simply was not available in the past. Today, he said, everything is online and globally accessible. While this represents a challenge for the industry, it also offers huge opportunities.

He said that, provided it is used correctly, data can help the food factories of the future cut costs while maintaining quality. It can deliver benefits in terms of energy

Peter K. Wienzek, business development manager systems, ifm efector. savings, production efficiency, process optimisation, condition based maintenance, and more.

Leadbetter devoted his presentation to the important topic of level control. He said that, whether

they are dealing with beer, grain, sugar or milk, food manufacturers require level control technology to monitor their tanks, silos, and vessels. Depending on the application, they can choose between Level John Leadbetter managing director, VEGA Australia.

38 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

Transmitters, Level Switches and Pressure Transmitters to perform this task.

Leadbetter outlined latest developments in this area, including radar level transmitters, pressure transmitters and the use of Bluetooth communications. He said that these new technologies, coupled with a continued emphasis on hygiene, will help the factories of the future run efficiently and profitably.

Following the presentations, the speakers took part in a Q&A session.

A sample of audience questions included: how big a challenge do Industry 4.0 changes represent for individual businesses?; who within management structures needs to take ownership of these challenges?; and the ins-and-outs of level control and compliance for food makers?

Food Factories of the Future was organised by Prime Creative Media, publisher of Food & Beverage Industry News. We would like to thank our two speakers, as well as all those present.

PROMOTIONAL FEATURE - Packaging

Dairy packaging made easy HMPS, an Australian machine builder that provides customised end of line packaging solutions, has continued its growth in the dairy industry by working closely with customers on specialised designs.

A

ccording to HMPS dairy industry specialist and applications engineer Glen Foreman, there are many factors to consider when packaging dairy.

With consumer trends changing and packaging becoming more and more innovative to appeal to customers, the innovation around packaging these products has had to be stepped up.

Dairy pouches, for example, have made an appearance in the past few years. According to Foreman, these present different handling challenges because of their various spouts’ shapes and sizes. The changing shape of the pouch during transport can lead to handling difficulty.

One of the ways in which HMPS handles this product is to start the packaging by moving the product from a flat position on the conveyor into a paddle index that stands them on their bases. The spouts are then positioned using grippers and clamps to

individually place these into position, all at high speed.

Regardless of whether you are packaging UHT, plastic bottles or tubs, the fact remains that customers are looking for faster automation with more flexibility.

According to Foreman, although plastic bottles are easier to handle, they raise the issue of bounce on the conveyor when bottles hit each other at high speed, popping lids and seals due to force. Excess line accumulation applies pressure to the bottles causing the bottles to compress or change shape and position. Managing the speeds of the bottles on the infeed requires special consideration and handling.

“One of the techniques we use is product diversion. By diverting bottles into multiple lanes using servo diverting arms, it slows down the speeds and makes the product more manageable on the conveyor belt,” said Foreman.

Packaging of dairy pouches using an indexing system.

In the dairy industry, there is always the hygiene factor to consider. “Generally, foam and warm water are used during the cleaning processes. The foam is hosed on and left to dry. It might then be wiped down or rinsed off with a mild to warm water wash at medium pressure. The machine needs to be easy to clean and products must be waterproof. Electronics, motors and gearboxes need to be IP rated for

wash down. Corrosive resistant, full stainless-steel or coated aluminium products are used throughout,” said Foreman.

During construction, care is taken to minimise areas where liquids can collect and to avoid flat surfaces so that water can run off the machine.

Internally, customers have their own quality hygiene standards and HMPS build according to these quality requirements.

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www.foodmag.com.au | Aug/Sep 2017 | Food&Beverage Industry News 39

NEW PRODUCTS

High-speed BOPP film INNOVIA Films has introduced its latest high speed Biaxially Oriented Polypropylene (BOPP) film - Propafilm REF. This new coextruded material compliments their already wellestablished range of high speed materials and increases the options for its customers.

The film was designed with speed in mind. The product presents a wide sealing range, when compared to standard coextruded films. At typical laboratory conditions, scientists have been able to confirm over 30¡ C lower heat seal threshold (the minimum temperature required to achieve acceptable seal strength of 200g/25mm) compared to basic films. In addition to the wide seal range, this film also provides an enhanced hot tack performance over standard films. This means that the seals, when pulled still hot, resist opening on a larger range of temperatures.

Combined, these two properties enable the film to be ideally

suited to horizontal-form-fill wrapping applications.

Besides offering excellent machinability, the film also provides excellent clarity for visual impact and good moisture barrier for product protection.

It is suited to a variety of applications and markets such as biscuits and bakery, confectionery, dried foods, tea and cosmetics.

Innovia Films 03 9303 0600 www.innoviafilms.com

Mobile label and receipt printers BROTHER International (Aust), provider of mobile printing solutions, has launched its RJ-2 Series of two-inch mobile label and receipt printers.

According to the company, these two-inch format printers are the fastest, most compact, lightweight, and notably versatile printers in their class, incorporating the rugged durability and rock-solid reliability that have made the existing RJ lineup popular.

Designed to wirelessly print both labels and receipts, the series was engineered to meet the varied and rigorous demands of today's mobile environments. Available in four models, the printers support Bluetooth and Wi-Fi technology, in addition to iOS, Android, Windows mobile and Windows operating systems capability. Of special significance is the IP54 certification and drop protection, and advancements in speed and power further differentiate the new series.

The RJ-2050 and RJ-2150 models are the first in the two-inch category market to feature both Apple MFi certification and Apple AirPrint compatibility allowing easy wireless printing from iPhone, iPad and iPod touch.

Smaller size, rugged construction and broad flexibility, make the series well suited for applications in industries such as retail, public safety, parking, pharmacy, lab, hospital, field services, manufacturing, warehouse, route accounting, and more.

An experienced Brother Corporate Division is available in Australia to deliver the right solution for nearly any field application, including development support to utilise the Software Development Kit (SDK) available for iOS, Android and Windows Mobile.

Brother www.brother.com.au

SPECIALIST MAGNETS FOR THE FOOD & DAIRY INDUSTRY

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Call Us NZ 0800 55 77 33 / AU 1800 318 019 | sales@aurora-nz.com | www.aurora-nz.com www.foodmag.com.au | Aug/Sep 2017 | Food&Beverage Industry News 40

LET’S PROVIDE THE CLEANEST WATER POSSIBLE.

The Food & Beverage industry faces many challenges to move, treat, analyze and monitor water in their manufacturing processes and a responsibility to also safely return water to the environment. Xylem is your trusted partner to deliver the technology and experience in these areas with a global network of experts and the local presence of 16 locations across Australia & New Zealand with sales, service and rental capabilities.

For more information, please visit us at www.xylem.com/en-au

NEW PRODUCTS

High pressure processing WITH consumers wanting fresher and healthier foods, companies are looking to new technologies to help minimise processing, while preserving quality and safety. Hiperbaric is a leader in one such technology, High Pressure Processing.

High Pressure Processing (HPP), a new non-thermal cold pasteurisation technique, extends shelf life while respecting the sensorial and nutritional properties of food.

Because it doesn't involve heat treatment, products

Automatic spray nozzles PULSAJET automatic spray nozzles can be used in a variety of different applications within the food industry.

The high-precision spray nozzles are excellent for use in applications that require spraying viscous coatings such as peanut butter, glaze, caramel, chocolate, butter, gels and slurries. In addition, they can be used to spray antimicrobial and mould inhibiting agents and can be used for lubricating, conveyor spraying, moisturising and scoring applications.

The spray nozzles utilise Precision Spray Control (PSC) to apply an even and consistent amount of coating to the target. PSC works by turning the electrically-actuated spray nozzles on and off at high speeds without changing the pressure of the nozzles which allows for the spray angle, coverage and drop size to remain unchanged.

Production is increased due to the fast cycling of the spray nozzles (up to 15,000 cycles per minute) allowing them to keep up with high line speeds.

An issue commonly reported is misting, which affects both the application at hand and worker safety. Excess misting becomes airborne instead of coating the product or target which leads to inaccurate coverage and workplace hazards such as slipping due to the mist on the floors and equipment. Using a PulsaJet spray nozzle in conjunction with an AutoJet Spray System will lead to a reduction or complete elimination of misting.

Added benefits of using PulsaJet spray nozzles and PSC technology are a reduction in product scrap due to the over or under application of coatings, lower production costs and reduced clean-up time.

Spraying Systems Co 1300 212 878 www.spray.com.au

42 Food&Beverage Industry News | Aug/Sep 2017 | www.foodmag.com.au

undergoing with this technique maintain their original freshness throughout their shelf-life.

HPP destroys pathogens without heat. Because this reduces the need for preservatives, the process opens up the possibility of clean label products.

Using this technique, products which are already sealed in their final package, are introduced into a vessel and subjected to a high level of isostatic pressure (300'600MPa/43,50087,000psi) transmitted by water. Pressures above 400 MPa / 58,000 psi at cold (4 10ยก C) or ambient temperature inactivate the vegetative flora (bacteria, virus, yeasts, molds and parasites) present in food, extending shelf life and ensuring food safety.

According to Hiperbaric, HPP can be used with a wide range of food products. Since the company's equipment was

developed first to treat meat products, there is a significant amount of machines that are used for meat applications.

The recent growth of juices and drink products, has seen many machines installed for this application. Juices and drinks, dips and meats are dominating the HPP market.

Products like guacamole, benefit from HPP in various ways including respecting the freshness of the original fruit ingredient, extending the microbial shelf life and extending the commercial shelf life thanks to the inactivation effect of HPP on the PPO enzyme of avocado.

HPP is considered eco-friendly as 85 per cent of the process water is recycled, filtered, and then re-used for the next cycle.

Hiperbaric 03 9768 2722 www.hiperbaric.com

Wireless switches and sensors THE growing wireless capability of field equipment is creating a raft of new design possibilities. The inherent positioning flexibility of wireless and convenient placement of the central receiver provides a simple way to save on long, awkward cable runs.

NHP offers a comprehensive wireless solution, to suit the demands of evolving applications.

This extensive range of wireless switches and sensors includes pushbuttons, footswitches, limit switches, miniature remotes and inductive sensors. All products are suitable for industrial automation and the building services industry. In addition, there are IECEx certified versions available which are suitable for Hazardous Area Applications.

These industrial-strength wireless switches and sensors communicate with higher level control systems via reliable wireless transmission and further open up new possibilities in terms of machine interfaces and increased design flexibility and mobility.

With the option of either battery-powered or battery-less operation, battery-less versions are able to generate their own power through the energy generated by clicking the switch to "Electrodynamic Energy Generation".

Specialised devices, "Universal Transmitters" can be connected to any standard industrial device with relay output, creating a solution where the outputs can be switched wirelessly.

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NHP Electrical Engineering Products 1300 NHP NHP nhp.com.au

Get Locked The safety gate system PSENmlock offers a safe interlock and safe guard locking in the one slimline device.

Utilising a dual-channel control for the safe guard locking function makes the switch particularly suitable for machines that have a hazardous rundown time that requires Cat 4 or PL e protection, such as rotating equipment, robots or moving process lines.

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Melbourne • Sydney • Brisbane • Auckland

Ph: 1300 723 334 Ph: 03 9560 0621 Fax: 03 9574 9035 www.pilz.com.au www.machinesafe.com.au www.foodmag.com.au | Aug/Sep 2017 | Food&Beverage Industry News 43

CONNECT

RELIABILITY AND OPERATIONAL CERTAINTY Proudly supported by

Emerson and Prime Creative Media have partnered to host workshops and seminars targeting production optimisation, reliability improvements, plant safety and emissions reduction. International speakers and local experts will present Reliability & Operational Certainty case studies across multiple industries.

Monday 28 August 2017 - Brisbane Wednesday 30 August 2017 - Melbourne Friday 1 September 2017 - Perth To see the full program and to register please visit

bit.ly/EmersonConnect

For enquiries, please contact Simon Coburn 03 9690 8766 or simon.coburn@primecreative.com.au