Food Magazine May 2012

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Foodmagazine ingredients | processing | sAfetY | pAckAging | export

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INSIDE

WHaT's FresH

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Dairy

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Beverages

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TesTing

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A trip down memory lane with Sanitarium

How yoghurt is saving our dairy farmers

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Juicers keepin' it real with only the good stuff

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WELCOME

Foodmagazine

www.foodmag.com.au PUBLISHER – Michelle Graves E: michelle.graves@reedbusiness.com.au

The evolution of food Food used to be simple: you grew it, cooked it and ate it. But these days, things are a little more complicated.

EDITOR – Jessica Burke P: 02 9422 2862 F: 02 9422 2722 E: jessica.burke@reedbusiness.com.au ACCOUNT MANAGER – Mark Ryu P: 02 9422 2151 M: 0404 803 356 E: mark.ryu@reedbusiness.com.au QLD SALES MANAGER – Sharon Amos P: 07 3261 8857 F: 07 3261 8347 M: 0417 072 625 E: sharon.amos@reedbusiness.com.au SA, WA & NT SALES – Mark Ryu P: 02 9422 2151 M: 0404 803 356 E: mark.ryu@reedbusiness.com.au PRODUCTION COORDINATOR - Tracy Engle P: 02 9422 2707 F: 02 9422 2722 E: tracy.engle@reedbusiness.com.au DESIGNER - Rizwan Nawaz P: 02 9422 2322 F: 02 9422 2722 E: rizwan.nawaz@reedbusiness.com.au SUBSCRIPTIONS – CUSTOMER SERVICE Aus NZ O/S 1 year subscription 99 109 119 2 year subscription 189 199 209 P: 1300 360 126 F: 02 9422 2633 E: customerservice@reedbusiness.com.au RBI Manufacturing & Electronics Group Tower 2, Level 3, 475 Victoria Ave Locked Bag 2999 Chatswood DC NSW 2067 P: 02 9422 2999 F: 02 9422 2722

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ood and the path it takes to get to our plate is more topical than ever before.

It is no longer just about simply sustaining us through the day and having something to sit down to at night.

Nowadays, we are far more aware of the long-term impacts food has on our bodies and how we can work towards long healthy lives.

Organic and all-natural EDITOR: Jessica Burke ingredients, which took a food@reedbusiness.com.au backseat during the evolution of food preservation in the 1950's, is now very much back in vogue.

Companies are shouting their commitments to remove salt, sugar, fat and all artificial additives from the rooftops, in a sure sign that consumers have done a complete 180 on what they want from their food.

And if possible, we want it cheap and from Australia, which, if you speak to most people in the local food industry, may be a contradiction in terms.

Because while people would like to buy Australian food products, sometimes it is just too-hard-basket during the 1 2 . pdf P a g e 1 5 / 0weekly 4 / 1shop, 2 , and 3 the : 4increase 3 PM in cheap imports is making it

almost impossible for many producers to get a look-in.

Some local food execs are calling for an Australian-made aisle in supermarkets, which I personally think would be a great idea.

It would make the whole process simple and clear, and easy products for consumers to find.

With the focus on food nutrition increasing and awareness of the importance of exercise and detriments of smoking, many people alive today are expected to live well past 100 years old.

For me, the most pressing concern with this statistic is whether they change the age when you get a letter from the head of state congratulating you on, well, living.

from King William telling me what a stellar job I had done.

This month a man in Japan went well beyond just hitting the triple digits, when he turned 115, which incidentally, is more than double the life expectancy of Australians at birth 100 years ago.

Almost exactly that long ago, a man started baking and created one of the most well-known food companies in Australia today.

Sanitarium used to transport its products using horse and cart, boats and motorbikes and the company's first baker, Edward Hanlsey, even went door-to-door giving out samples of his products.

And 114 years later, the company is still going strong.

While we are continually hearing about the doom and gloom in our food manufacturing

We want it cheap and from Australia, which, if you speak to most people in the local food industry, may be a contradiction in terms Assuming we remain part of the monarch long enough for me to hit triple digits, I would be left very disappointed if, when that date ticked over, I was not greeted with a heartfelt letter

industry, and there is no doubt that the supermarket price wars are having a massive impact on local food production, there are still some companies managing to survive.

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Q&A

Food Magazine's Q&A I grew up in... Gunnedah in north western NSW. A small rural community which gave me a great background in the value of family, relationships and hard work. It was here that I completed high school.

In high school, I was passionate about... Radio announcing.

Apparently I have "the voice".

My current role involves...

Managing a great team of individuals who are focused on helping our clients develop new products and solve their food processing problems.

Greg Pyne, Sales Manager, Heat & Control Oceania

Before my current role, I worked...

As a management consultant for a large well known accounting firm.

Studies/training that has helped me in my current role includes...

Bachelors Degree in Business, majoring in Finance and Marketing along with over two decades working in a range of roles within the Heat and Control group.

My work is helping to better the food industry by...Bringing new technology to the industry. At Heat and Control

4 Foodmagazine | May 12 | www.foodmag.com.au

we have an active R&D program plus a lot of industry experience to draw from. This allows us to innovate for the industry and meet the needs of our clients and consumer demand. Recent examples of this include the Heatwave fryer which is the first fryer in the world to cook food products with curtains of hot oil rather then immersing the product in oil. Another example is the FastBackÂŽ horizontal motion conveyor which greatly reduces product breakage and seasoning build up.

The most challenging part of my role is... Ensuring my clients are up to date in relation to the changing technological environment and the processing advancements occurring worldwide within our industry. The pace of innovation has increased due partly to environmental and economic factors.

The best part of my role... Is most definitely, the sense of satisfaction that occurs when you help a client achieve their processing goals. You wouldn't be human if you didn't get a buzz out of helping someone else.

My favourite food is... Thai food along with some indulgevnt savoury snacks.

The thing that gets me out of bed in the morning is... I enjoy working with such a great team. I think my 20 something years at Heat and Control is a tribute to the people I work and have worked with.

The food industry needs to change... And be more adventurous in product development. There are many success stories out there of processors who have targeted niches markets with a unique and well positioned product.

The current food/brands that we will be eating in 50 years’ time are... Likely to have an emphasis on consumer convenience and health benefits. I also feel that Australian consumers have a much more adventurous palate then they did 50 years ago and this trend will definitely continue.

In 50 years, the food industry can look forward to... Greater advancements in processing equipment efficiency and versatility so that processors can adapt quickly to rapidly changing consumer taste and preferences.

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WHAT'S HOT ONLINE

WWW.FOODMAG.COM.AU

BY JESSICA BURKE

Cadbury officially Australia’s favourite chocolate The results are in, the favourites have been identified, and it's really no surprise that Cadbury is the most popular chocolate in Australia.

Roy Morgan Research conducted a study to find the leading chocolate brands in the Australian market, and in 2011, Cadbury came out on top in both the chocolate box and chocolate bar category.

It surveyed 18 641 Australians aged 14 and over between January and December

SABMiller's plans to make Foster's biggest brewer in Australia Following extensive speculation about whether CocaCola Amatil would buy a Fijian beer and spirits business previously owned by Foster's, it looks like the company will spend the $58 million to seal the deal.

As part of London-based company SABMiller's controversial takeover of Foster's last year, it also gained the rights to the Fijian company owned by Foster's.

Last year Coca-Cola Amatil sold its share in brewing business SABMiller, and at the time denied it had any interest in the alcohol market.

When SABMiller put Foster's Australian spirits and ready-to-drink (RTD) business up for sale in April, in a similar move to its Fijian sale, Coca-Cola decided not to buy it, but discussions are continuing.

And now the beverage giant has announced plans to buy an 89.6 per cent stake in Foster's Fijian business, which is held in Foster's Group Pacific Group.

The stake will cost Coca-Cola Amatil $58 million, and it has plans to then buy the remaining 10.4 per cent of the group.

And while Foster's is not Australian-owned, it could provide intense competition for Coopers, which became the largest remaining Australian brewer after the Foster's sale in 2011.

Foster's new chief executive Ari Mervis told investors of plans to make Foster's the biggest brewer in Australia.

Amid the takeover bid and other related issues, Foster's Australian beer sales fell 4.5 per cent in the six months prior to December 2011, and Mervis wants to change that.

SABMiller is aiming to increase its Australian sales by one to three percent each year over the next five

years, he said.

Profits are also expected to grow by 0.6 to 0.8 per cent each year.

His plan is dependant on improved sales confidence in Australia, which he said is improving.

Mervis, also confirmed to investors that, despite rumours to the contrary, Foster's will not be closing any of its plants, including the iconic Carlton and United Breweries plant in Abbotsfield, Victoria.

Behind both the Dairy Milk and Fruit last year, then projected the number to & Nut manufactured by Cadbury as third represent the national population. most popular was the Lindt Dark bar, It found that in 2011, more than 2 which was bought by approximately 648 million Australians over 14 would have 000 "in the past four weeks". purchased a Cadbury Dairy Milk bar "in lasta four and1 almost A D _ F D F O O S E P _ 1 1 . p d f the P g e weeks," 1 1 / 0 8900 / 1000 1 , 1 0 But : 2 fourth 8 Aand M fifth place were both achieved by Cadbury, with the Caramello would have bought the Fruit & Nut variety.

6 Foodmagazine | May 12 | www.foodmag.com.au

purchased by about 614 000 people and Cadbury Hazelnut bar by 588 000.

And if there was any proof needed that Australians have a sweet tooth, the research found that over 6.7 million Australians purchased a chocolate bar "in the last four weeks".

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NEWS

"Reduced salt" label reduced taste perception: study

A "reduced salt" label on a food product will make a consumer experience a reduced level of taste, even if it is not in fact lower in salt.

A Deakin University study recruited 50 participants to taste soups with the same salt content, but it labelled some as "reduced salt."

While those labelled as low sodium actually had the same salt content as the other soups, but participants reported that they found them less tasty.

After the initial tasting of each soup, participants could add salt to all the soups they thought needed it.

"We found that when a product was labelled as 'reduced salt', people believed the food was not as tasty as the unlabelled version, despite it having the same salt content," Deakin health expert Dr Gie Liem said.

"This negative taste experience resulted in more people adding more salt to the soup, than when such a label was not present.

"Interestingly, the Heart Foundation tick did not influence taste perception."

As cardiologists and nutritionists keep advising low-salt diets as the ideal way to curb the ever-increasing rates of high blood pressure, heart disease and diabetes, the findings from this study could impact the way salt reduced products are marketed, according to Liem.

"The reduction of salt in processed foods is needed and highly encouraged," he said.

"Often consumers can hardly taste the difference between salt reduced and non-salt reduced products.

"However, the results of our study indicate we need to be careful about how salt reduced products are marketed, so that consumers will not be turned off these products from a taste perspective."

Most people today consume eight to nine grams of salt each day, while the recommended dose is no more than four grams daily.

"This study highlights that promoting salt reduction as part of front-of-pack labeling can have a negative effect on how consumers perceive the taste of the product and on salt use.

"Therefore it's important for researchers, public health professionals, industry and governments to work together to carefully consider how best to communicate this message to consumers."

CHOICE targets major supermarkets over private labels

to speak publically, for fear that of the almost total control the major their company will be punished supermarkets have over the sector. for doing so.

"When two brands compete for The Senate Inquiry into the space on the shelf, and when one predatory pricing and bullying of those brands is owned by the Consumer watchdog Choice is behaviours of the major supermarket, it's not hard to figure taking on Coles and Woolworths, supermarkets is coming up against out who the winner is going to be," to expose the dirty tricks the major the same problem: Coles and she says. corporations are using to increase Woolworths have created a climate For over a year, food sales of their own private label of fear and nobody is willing to take manufacturers have been products and push other companies the risk and speak up. desperately trying to make out of the market.

Choice spoke with several governments and consumers see "The big two supermarkets use manufacturers and suppliers whose what Coles and Woolworths are tactics including poorer shelf product lines have been deleted by doing to their businesses. positioning and copycat packaging, the big two, who also wished to While food manufacturers to advantage supermarket generic remain anonymous. and growers will speak off the brands over established labels," the FlexiFruit, FOOD MAGAZINE, 150 x 192 CC-en24-AZ032_03_12 Kevin* is the managing director record aboutmm, the struggles they're Choice report stated.

Choice Ingrid A D spokeswoman _ F DKROM A Y Just _ 1 2 . facing p d f at the P ahands g e of1the major 3 0 / 0 3 / 1of2one , such 1 1company. : 1 3 "We A Mwere deleted to make room for their own supermarkets, very few are willing said the consumer watchdog is aware

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brands. They're reducing the third-, fourth- and fifth-most popular products in product areas," he told Choice.

"Woolworths and Coles argue that introducing and expanding private labels has stimulated innovation and competition in many areas of the market.

"Coles claims only under-performing products are cut.

"Coles told us it's because our sales weren't achieving targets," Kevin argued.

"But that's because they wouldn't put us in catalogues, we got no shelf space, we were hidden behind a column and they refused to let us have promotions, and that made it impossible for us to compete with the big boys.

"We suspect what they were really doing was targeting the products they wanted to delete so that it would be easier to justify in six to eight months' time."

John Durkan, Coles merchandise director defended the supermarket giant's decisions.

"Where we don't see innovation from branded manufacturers, we'll use the Coles brand to innovate," he said.

Local manufacturers call for exclusive Australianmade supermarket aisle Australian food manufacturers are calling for a dedicated "Australian made" aisle in supermarkets to make it easier for consumers to choose locally made products and keep local businesses afloat.

Glenn Cooper, chairman of Australia's largest beer brewer and entrepreneur Dick Smith are just two of the high profile names calling on the industry to take action.

Cooper believes laws which force supermarkets to set aside a minimum quota of floor space for locally-made food would be one way to slow the flood of cheap imports and prevent some manufacturers from tricking consumers into buying products they think are made in Australia, but are in fact made primarily from imported products.

"It's not realistic for busy shoppers to read every label to see its country of origin before you put it in your trolley," Cooper told Channel 7's Out Of The Blue program.

"So I think they [supermarkets] should be forced to have a certain amount of locally grown content and that it should appear in a clearly defined area designated for Australian-made products only.

"That may mean two milk areas, two butter areas but at least customers,

AFGC finalises draft legislation calling for Supermarket Ombudsman The Australian Food and Grocery Council (AFGC) has announced it is finalising the draft submission for a Supermarket Ombudsman to be a key part of the next Federal Budget.

The peak industry body has been urging the government to instate an Ombudsman and establish a Trading Code of Conduct, to stamp out the anticompetitive behaviours of the major supermarkets, which are pushing Australian food manufacturers and small businesses out.

The AFGC announced it would be starting on its draft legislation to present to the government back in January and AD_ F D L has I N enlisted M A R _ the 1 1help . pof d international f P a g e law1 2

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firm Baker and McKenzie in its bid.

The AFGC wants the Supermarket Ombudsman to ensure Coles and Woolworths are fair and transparent in their pricing and do not push more Australian companies and industries out of business, as they have done with the dairy and fresh produce industries, among others.

The AFGC also announced last month that it would be extending its representative reach to also include small to medium enterprises.

Following consultation with all stakeholders on the draft legislation the matter has been referred to the /government 0 2 / 1 1 ,for approval.

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when they choose something from that designated area, know they are buying Australian-made products," he said.

Along with being the chairman to one of Australia's most successful beverage companies, Cooper is also the deputy chairman of the Australian Made, Australian Grown campaign group, which aims to encourage more Aussies to buy local products and make the Australian Made definitions simpler.

He does not believe the Australian-made aisle would be a big cost or time implication for the supermarkets, which already have a number of local products, but are difficult to find amongst all the other imports.

"Say, for example, it was 30-odd per cent [of floor space set aside]," he said.

"Well, supermarkets may already have that level of Australian content of food as part of their normal stock but it's just not clearly defined as an area.

"Hopefully, enough people will get behind it to give some sort of leg up to our farmers who are, in many areas, being clobbered by imports."

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Sanitarium: The Bix and mortar story From humble beginnings to a world leader in food, with horse-drawn carriages and caf s in between, Sanitarium has seen it all in more than a century of existence. Food Magazine is taking a trip down memory lane to find out how this company got to where it is today.

T

his year Sanitarium celebrates 114 years of operating as Australia's wholly owned and operated food company with iconic brands and a trusted philosophy on health and wellbeing for our community.

Food Magazine takes a trip down memory lane from the company's humble beginnings in 1898 to the global mainstay it is today.

One baker's tale When the Company's first baker, Edward Halsey, began preparing the very first Sanitarium products in 1898, he was driven to improving health in Australia.

He rented a small bakery in Melbourne, and produced Australia's first batch of ready-to-eat breakfast cereal - Granola, made of wheats, oats, maize and rye and Granose, the unsweetened forerunner to Weet-Bix. With his team, Halsey went door-to-door delivering his products as a healthier alternative to the fat-laden, poor nutritional content foods that were popular at the time.

It wasn't long before the fledgling business relocated to larger premises, moving to Cooranbong, New South Wales, just south of Newcastle.

Ed installed bake house equipment in a large building, that had previously been a sawmill.

In 1900, he transferred to New Zealand - where he began making the first batches of Granola, caramel cereals and bread, in a small wooden shed in Papanui, Christchurch.

Original wheat biscuit

Transport back in time

Sanitarium's original wheat biscuit, Granose, was marketed in Australia and New Zealand during the early 1900s, not only as a breakfast cereal but as an alternative to bread.

During the 1920s, Sanitarium faced a challenge in the form of a new sweetened flake biscuit known as Weet-Bix, which was produced by a company called Grain Products.

In 1928, Sanitarium acquired Grain Products.

The first Company-owned vehicle was a decrepit horse and old dray that carried raw materials from Morisset to the factory and the manufactured goods to the train station for delivery to Sydney.

By 1902, both were so worn that Metclafe Hare built a 35 foot launch, 'Avondale,' for transporting finished product down Dora Creek to the station.

In the very early days in Sydney, one or two men pushed a hand cart up and down the streets with product which were later replaced by horses and drays.

In 1917 they were replaced with a large solid tyre Leyland truck and by 1928, the company purchased the first of many large vans in both New Zealand and Australia.

Most were Leylands, but some were Graham, Dodge and Reo trucks.

These are fondly remembered by the company for the beautiful artwork on the side and rear panels.

In 1934, 'Big Bertha', a large Leyland truck that could fill a rail goods wagon with one load was used to make quicker trips by road and by 1935, the company was using 25 cars and 40 trucks and vans.

Some of the lesser known vehicles used in the company were three-wheel bikes.

As business improved in the early 1920s, sales representatives were supplied with motor bikes and sidecars.

The first Weet-Bix vehicles were ten Chevrolet vans similar to T-model Fords.

Similar small vans were used in Perth, Christchurch and Melbourne.

The first caf on Pitt Street In 1902, the first Sanitarium caf opened its doors, in Pitt Street, Sydney.

Throughout the 1900s Sanitarium continued to open vegetarian caf s and health food shops throughout capital cities in Australia and New Zealand.

The caf concept was designed to introduce people to a better way of living, and they received a good response from the community.

One customer was so impressed when he visited the Sydney store that he wrote asking for another meal to be prepared so that he could show his friends, and requested the meal be sent to him 300 miles away!

Over a six-month period in 1904, the caf served 8,000 customers, and by 1939 that had increased to 99,723 customers served in six months.

The stores flourished for decades in Australia and New Zealand until the 1960s, when they were eventually closed and Sanitarium shifted

Sanitarium's original wheat biscuit, Granose, was marketed in Australia and New Zealand during the early 1900s, not only as a breakfast cereal but as an alternative to bread.

Weet-Bix ads through the ages.

12 Foodmagazine | May 12 | www.foodmag.com.au

its focus to sharing health and wellbeing knowledge through the formation of the Nutrition Education Service, established in 1987 - which is now known as the Sanitarium Nutrition Service.

The Sanitarium caf story has not come completely to a close.

The journey began again in 2008, when Kitchen,

by Sanitarium, a whole foods caf was opened in Eagle St, Brisbane.

In the 1930s, most branch managers proudly drove grey Buick cars.

Global reach Sanitarium was an early pioneer in the export of foods to world-wide markets, and was making its mark on Southeast Asia as early as 1905.

The company opened a small warehouse in Clarence St, Sydney which was convenient to the wharves where ships left for the Pacific Islands and South-east Asia.

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Company records indicate initial shipments to Singapore in 1906, and within a few years sales were being recorded in South Africa, India, China, Malaysia, Burma and throughout the Pacific Islands.

Going global After World War I, Sanitarium moved its warehouse to Sussex St, and local wholesalers began buying the company's products and exporting them.

As the trade developed, Sanitarium appointed local merchants to act as agents in various markets and larger companies to act in broader regions.

In 1935, Sanitarium stationed a representative in Singapore with the title of Manager: Orient, to look after its interests in South-east Asia.

Sanitarium widened its product range and export trade after World War II, expanding into Africa, the Middle East, Mauritius, the Persian Gulf and North America.

Today, Sanitarium exports to 26 countries around the world.

Increasing health awareness While nowadays the message about health and the impacts of obesity and poor diet are starting to be recognised throughout Australia, Sanitarium has been forced to contend with the world's love affair with junk food and conveniences throughout the years, and managed to pull through into the successful business it is today.

"Greater consumer awareness of the obesity issue in

Weet-Bix bakers at Cooranbong Factory, circa early 1990's.

Early form of transport - Deliveries from the Pitt Street CafÂŽ Forklift loading truck- Elynn Lister- c1984 But it's still not all smooth sailing, as commercial general manager Dale Williams explained to Food Magazine.

"The manufacturing sector in Australia is doing it tough and as part of that sector it's no different for Sanitarium" he said.

"The rising cost of production through a range of

In the very early days in Sydney, one or two men pushed a hand cart up and down the streets with product which were later replaced by horses and drays.

Australia, the link between health and the food we eat, and an aging population are translating to consumer expectation for great tasting, healthy and convenient foods," Daniel Derrick, general manager of Innovation at Sanitarium told Food Magazine.

"In some sectors, the food industry is making gains in offering consumers healthy products."

Pa ge

contributing factors continues to put upward pressure on production while there is downward pressure from our customers.

"However, our key brands continue to grow with Up&Go enjoying phenomenal growth of more than 37 per cent and more recently our So Good range has experienced 11 per cent sales growth from last year through innovation.

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TOP LEFT: A shop window display of Sanitarium products TOP RIGHT: At the Sydney Easter Show in the old days BOTTOM LEFT: Sanitarium's Melbourne Retail and Cafe store circa 1920's www.foodmag.com.au | May 12 | Foodmagazine 13

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The Labelling Machine Company Where reliability comes as standard First Sanitarium delivery direct van, circa 1927

Rear of first Cooranbong truck - June 1934 Weet-Bix delivery truck

"Weet-Bix is iconic to Australian tables and with a penetration of 51 per cent, which means that over half of all Australian households have Weet-Bix in their pantry."

Nowadays, Sanitarium is continuing to innovate and deliver healthy products to customers throughout the world.

"Innovation and the health renovation of foods are vital to bringing consumers great tasting, healthy brands in new and exciting ways," Derrick said.

"As the food industry and suppliers of raw ingredients pursue healthier, convenient products we are constantly challenging ourselves and suppliers for innovative solutions to 'renovate' products.

"Over recent years we have achieved significant reductions in

salt in a range of products through the use of natural flavourings and new processing techniques.

In addition to the extensive range of food and beverages that meet the criteria for "low in salt" (less that 120milligrams of sodium per 100 grams), Sanitarium have developed several new products meet the "low in salt" criteria including Weet-Bix Kids with no added salt, Light n Tasty Macadamia, Honey with Oat Clusters and Up & Go yoghurts.

The company has also completed a number of projects to reduce the sodium levels in foods including cornflakes, where the sodium content has been reduced by a quarter and Weet-Bix Bites Golden Crumble which now have more than 15 per cent less salt.

Through forty years of changes

After more than four decades with Sanitarium, Lew Newman, Technical Officer at the company's Cooranbong Technical Department has seen a lot of changes.

Jessica Burke: What was Sanitarium like when you first started?

Lew Newman: I started working at Sanitarium's Cooranbong factory in 1970 - more than 40 years ago. It was a mix of permanent staff and student labour. Many families in the community had two, three on staff - often there could be somebody from the same family present over all three shifts. The management structure had fewer layers of administration - the office was run by one manager and the factory by a superintendent and a line foreman. The factory ran three production lines of Weet-Bix, one for cornflakes, and a cannery. Raw materials were stored in the same building as production and warehousing. Shift changes were heralded by a steam whistle from the Babcock & Wilcox boiler.

JB: How old were you when you started and what was your role?

LN: I was 20 when I joined Sanitarium to begin work as a laboratory technician. The first experiments I assisted with involved trialling new protein analogues, including one investigating the effects of a diet high in MSG, and another comparing the nutritional value vegetarian analogues.

JB: Why did you choose Sanitarium?

LN: I was taking some time off part-

way through a science degree to earn some money and reflect on my career direction. Sanitarium were investing in training people for new roles in quality control, as that discipline was new to most factory staff, and the opportunity represented for me an ideal mix of academia and practicality.

JB: What kind of changes have you seen over the years?

LN: I've worked at both Brisbane and Cooranbong factories in my time at Sanitarium, and seen changes at both sites. As understandings of quality control have grown, so has Sanitarium's technical department.

We have more specialist support staff for project work. One thing that hasn't changed is that I am still privileged to work as part of a great team.

JB: What is the single biggest difference you have seen over your time there?

LN: I've seen many changes over the past 40 years, including new products, improved manufacturing processes, and the expansion of our factory and production capacity. I've also noticed an increased integration with the broader food industry, and the use of specialist contractors, rather than a more selfsufficient approach.

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Ph 1300 553 378 www.aztro.com.au www.foodmag.com.au | May 12 | Foodmagazine 15

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Good culture all round

Little tubs of goodness that also help Aussie farmers are multiplying rapidly, and consumers are snapping them up even quicker than manufacturers can build their factories, as Jessica Burke reports.

Y

oghurt is one of the fastestgrowing food categories in Australia.

Whether its health consciousness on the part of consumers, or the range of flavours and types that manufacturers are producing, the rise in popularity cannot be ignored.

A mere few years ago, the Greek yoghurt category was almost non-existent in the Australian market, but the current demand is something that is not being ignored by manufacturers.

As dairy farmers struggle to survive the milk price wars and more dairy products become private-label domain, yoghurt and in particular, Greek yoghurt, is offering Aussie dairy farmers some hope.

"Greek yoghurt uses about triple the amount of milk compared to other yoghurts and we hope it will significantly impact the local milk consumption," Peter Meek, Managing Director for Bead Foods, which is launching Chobani Greek yoghurt in the Australian market, told Food Magazine.

Since launching Chobani in the US five years ago, the consumption of Greek yoghurt has risen dramatically, and Meek

anticipates a similar story in Australia.

"There really wasn't a Greek yoghurt category back in 2007, there were a couple of small niche players and then Chobani came along and almost created the mainstream category," he explained.

"It's gone from one per cent of the total yoghurt market to about a third of the market in five years.

"In Australia the greater yoghurt segment is not tracked by retailers, but based on our estimations, we think [Greek yoghurt] is about 15 per cent of the market, and it has seen strong growth in the last few years, mostly the plain variety because people like to add it to cooking and other things."

Back to basics The difference between Chobani and others on the market is the way it's made, which takes on an old-fashioned, traditional approach to making Greek yoghurt, which Meek believes is the main reason it has been so widely adopted in the US and will also be in Australia.

"I think firstly because almost all of it is natural and organic and properly strained. We call ours 'Greek yoghurt,'

not 'Greek-style" because we strain our yoghurt and it takes three litres of milk to make one litre of our Greek yoghurt," he told Food Magazine.

"The standard Greek yoghurt available in Australia is 10 per cent fat because it is just full cream milk with cream added and then it is fermented.

"But we start with lots of skim milk, we strain it and remove the fat, which makes it incredibly thick and creamy naturally because there are tons and tons of proteins in there.

"I think the health and wellness trend is growing and consumers are looking for products that are authentic.

"Our yoghurt is milk and cultures, what we don't use is the stuff consumers are saying they don't want: gelatines and thickeners and artificial additives.

Chobani has invested $20 million into building what Meek describes as "basically a whole new factory alongside our existing [Gippsland] one," to make the Greek yoghurt locally.

"We're putting in a whole processing plant to make the base yoghurt, as well as new filling lines, warehousing and storage capacity to store and ship," he explained www.foodmag.com.au | May 12 | Foodmagazine 17

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have all the information on it," he said.

"All I know is that for my business to be successful, I need a viable farming community behind me anything that will support that, I am definitely in favour of."

Dairy farming the second worst job

to Food Magazine.

Milking the dairy industry "In the process, we're also recruiting "The hope and expectation is that this people for the development and there will change the local milk consumption will be about 25 more peopled when drastically," Meek told Food Magazine. it's up and running, so we will have an "We currently source all Gippsland impact A D on _ FtheDwider WA Lcommunity M A Y _ 1with 2 . p d f dairy P afrom g eVictoria, 1 1so1 we're / 0 4already / 1 2 , employment&OOD -AG -!9 PDF 0too. buying that and once we start making

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Chobani locally, we will obviously increase the amount we're buying dramatically."

"Anything that uses local milk has got to be a great thing.

1 0 :"One 4 7reason A Mwe will make the milk here is that we will have access to a wonderful quality of milk."

When Food Magazine asked Meek for his take on the supermarket price wars and its impact on the dairy industry, he was hesitant to comment.

"It's a very complicated issue and I don't

This month, a US survey rated dairy farming as the second worst job you can have.

The findings of the American survey might not come as a surprise to most Australian dairy farmers, who are facing a slump in profits as the major supermarkets continue to sell milk for $1 per litre, despite a Senate Inquiry and an investigation by the Australian Competition and Consumer Commission into what the industry calls "unsustainable"prices.

Australian Dairy Association president Chris Griffin told Food Magazine earlier this year that farmers are leaving the industry in droves because they cannot manage to make a profit, or in many cases, break even.

"We know there's been at least 30 leave the industry in Queensland alone, and the majority are sighting the uncertainty of milk prices as the reason," he said.

Following the intense debate about the cost cutting by Coles and Woolworths and the ruling that $1 per litre was acceptable Food Magazine asked Griffin if the chances of the big two supermarkets increasing the price of milk to help with the increase in farmers' costs, including the carbon tax, would most likely be slim.

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"That's a question for Coles," he said.

"We believe the tactic all along by Coles was just to get people through its doors, and since dairy products are in 97 per cent of consumers homes, it's a draw card they've used.

"It's always at the back end of the

So much so, that from a big idea became an even bigger development for an entrepreneur and his yoghurt brand, which had a buyer before he even had a working factory.

David Prior has a unique take on the adage 'make the most out of your day'.

"Greek yoghurt uses about triple the amount of milk compared to other yoghurts and the hope and expectation is that this will change the local milk consumption drastically," supermarket, so you have to walk through all the other products and displays to get to it, so it is simply a marketing ploy they've implemented at the expense of the dairy industry."

When contacted by Food Magazine to find out if they would consider absorbing the cost increase, Jim Cooper from Coles said "we are not speculating about the potential impact the carbon tax will have on retail pricing."

The only profession deemed to be worse than dairy farming is being a lumberjack, according to the results collated by American HR group, CareerCast's.

The five key categories were used to determine the best and worst jobs were physical demands, work environment, income, stress and hiring outlook.

The importance of five With Greek yoghurt going from strength to strength, one may wonder whether there is any room left in the market for more mainstream varieties. And the answer is 'yes there is.'

Having started his day at five o'clock in the morning for over a decade, Prior treasures this moment each morning where he feels he can pause and create his day.

It was this philosophy that fuelled Prior to capture what he calls this 'five:am-ness,' and bottle it.

And so, the five:am organic yoghurt brand was born; but Prior also wanted to ensure his operation was environmentally sustainable.

At this stage of pipe dreams and grand ideas, the unimaginable happened: a major Australian supermarket decided to buy his product.

Only problem was, they wanted it by March 2011 - just eight months later and at this stage Prior didn't even have any equipment, let along a sustainable manufacturing operation.

"When the contract was signed to produce and distribute our yoghurt within an eight month timeframe, all we had was a 35,000 square foot site located just south of Melbourne, Victoria," explained Prior.

"Our site had no manufacturing system in place, inadequate air flow and water supply, and none of the technology needed to produce organic yoghurt."

Despite the short time frame, Prior did not want to sacrifice the environmentally sustainable factory he had dreamed of for his yoghurt brand.

In May 2010, five:am engaged Process Partners, a specialist dairy engineering and process improvement group, to help manage and execute the project, who conducted a detailed audit of five:am's requirements, taking into account its need to produce more variations of the product than was initially required to meet its March 2011 distribution deadline.

From this, they developed a manufacturing strategy for the plant based on budget and business objectives.

Process Partners joined forces with Schneider Electric to provide a full suite of automation and control technology in the small timeframe.

"Nobody can believe how quickly we got it up and going," Craig Roseman, Schneider Electric's food and beverage specialist, told Food Magazine.

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The machinery in the five:am plant had to be installed quickly

The trend towards good

sourced from a farm in Victoria.

"It is a certified organic farm, and it He agreed that the focus on health has went through rigorous process to get it opened up doors for more players in the that certification," he said. yoghurt category, including Prior.

Roseman told Food Magazine that "I guess why there has been such an while the supermarket duopoly is increase in the market in Australia versus impacting the market, the yoghurt sector the UK is that our consumption per capita is proving to be a hopeful case. is less than them so there was always "I guess we have, apart from the scope to increase it. independents, a strong duopoly between "There is definitely a trend towards Coles and Woolworths so they are always more wholesome food, and yoghurt is an going to have pretty strong market power example of that." and I think basically having market The milk used in five:am's yoghurt is anA important part it'sI organic D_ F OO D of MT M A Y _ 0 9 . p power d f means P a gthey e can 1 dictate 2 6 /a lot 3 / about 0 9 , what they want. processing, which Roseman said is

20 Foodmagazine | May 12 | www.foodmag.com.au

"There is that element of end users, some are more susceptible to that [supermarket power], while some can push back a little.

litre' farmers, a lot of our business is cut out or improved on too.

"Fortunately the yoghurt sector is one of the few dairy derivatives that is not home

"Fortunately the yoghurt sector is one of the few dairy derivatives that is not home branded to the extent that milk and cheese" "I certainly agree that it's not conducive to a healthy local sector in the long run, it is going to put strain on the businesses are already struggling.

1 : 2 0 that PM "We're not that different to 'a dollar a

branded to the extent that milk and cheese.

"The profit is driven out for manufacturers when a category becomes dominated by private label, but yoghurt has somehow managed to stay strong."

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BEVERAGES

Keep it simple, stupid Fruit drink, fruit concentrate, fruit flavouring, but where's all the real, proper juice?

Some companies are going back to basics with their juicing, and consumers can't get enough, as Jessica Burke reports.

F

ruit juice used to be simple. You got some fruit, squeezed it until liquid ran out and then drank it. But then, things got complicated.

Somewhere along the way, juice producers realised they could make those expensive fruits go further: put less of it in the bottle, but sell it for the same price. Genius!

Often additives like water, sugar and orange flavouring are mixed with the real stuff that looks like juice, and is stocked in supermarkets with all the other juices, but can only technically be called a "fruit drink."

Then there's "reconstituted" juice, which is a way of adding water to dry solids from which the water has been evaporated.

Taking the moisture out of the fruit, by using heat, is a way to make transportation easier and ensure availability all year round, but can result in many of the nutrients being extracted.

But as people become more aware of the impact of obesity and the part that food and drink consumption plays in that, there is more demand than ever for proper, traditional fruit juice.

Its juice like it used to be, only better.

When nudity is perfectly acceptable Ten years ago, Nudie Juice was launched by a man affectionately known as 'Tall Tim," and since its initial days, which came off the back of Tim Pethick's obsession with making fresh juices for his family, it has grown into a wellknown and trusted brand with state-ofthe-art juicing facilities, thousands of stockists and countless "Nudie addicts."

"Our proudest moments are often the unprompted bits of feedback that we receive from our consumers," Richard Glenn, Nudie's National Sales Manager told Food Magazine.

"We are continually amazed by the amount of people who take the time to contact us and tell us how much they love Nudies, their experience of their first nudie, or what they think of our new products.

"We call these people 'Nudie addicts'.

"Last week we even received a picture from a lady who had embroidered a quilt with pictures of all of our nudie characters on it, impressive stuff!"

The ever-increasing number of 'Nudie addicts,' is clear evidence that consumers are looking for quality products, free

from preservatives but full of goodness.

Before Nudie entered the market, there weren't any mainstream juicers doing what Pethick was in his kitchen each morning, when he rose early to make up fruit juice and smoothie concoctions for his wife and daughters (and of course, himself), and so an opportunity was born.

After some deliberation, Pethick decided the best name for his company was one that summed up what his fruit was all about: nothing but the fruit, hence 'Nudie.'

From little things, big things grow In 2003, when the company launched, there were only three people, including Pethick, one stockist, one blender and one small office in Sydney's Balmain.

They went through 256 pieces of fruit in the first week, and sold 40 bottles, mostly to family and friends.

They even went doorknocking, gave out samples and delivered Nudies personally so people could taste the goodness for themselves.

Now, more than 70 people are employed by the company, and it has over 5000 stockists throughout the country, including supermarket, cafÂŽ and convenience store

chains, as well as independent retailers and food service operators.

Nudie goes through about 3 000 000 pieces of fruit per week these days and has a state-of-the-art juicing facility in South East Sydney.

And they're not stopping there.

"Within the last 18 months we've delivered some really strong innovation to the market," Glenn said.

"We spend a lot of time speaking to consumers and identifying trends to ensure that our product offering remains relevant.

"Our Nothing But range which was launched to address the growing consumer concerns around the use of concentrates and added ingredients in many of the other juice products on the market at the time.

"We launched with Nothing But 21 Oranges and Nothing But 20 Apples, taking nudie into the larger 'take home' segment of the market for the first time.

"In addition to the Nothing But message, we are also able to make the claim that we can get the product from farm to bottle in 72 hours, and that it is 100% Australian.

"For every 2L bottle, our farmers in regional NSW pick 21 oranges (give or take www.foodmag.com.au | May 12 | Foodmagazine 21

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a few) and squeeze them, they then deliver this juice to our factory in Sydney where we lightly pasteurise the juice and bottle it.

"We add nothing else to the juice and the whole process from beginning to end takes no more than 72 hours.

"We believe that the quality of the fruit we use and our strict discipline around this process allows us to have such a great tasting juice, which is currently the most popular chilled juice in the Australian grocery market.

"Based on the success of these lines we have since expanded the range into a 1L and 500ml offering and have also added 3 new variants to the range."

A more informed consumer Glenn told Food Magazine the company is always looking to innovate their products and ensure they are delivering what consumers want.

"We then became the first beverage company in Australia (and possibly the world) to add chia seeds to a beverage," he continued.

"As well as being the highest plant based source of Fibre and Omega 3, chia seeds also help to keep you feeling fuller for longer.

"We saw this as a great opportunity to create a nudie with chia seeds as a way of providing breakfast for people on the go, and have partnered with The Chia Co in Kimberley, WA to create the product."

media coverage surrounding some of the added ingredients which exist in the market, and consumers seem to be better educated when it comes to choosing beverage products.

"A lot of food brands do seem to be increasing their focus on communicating what their products do not contain, which tends to suggest that this message is resonating with consumers across many areas of their grocery shop."

Keeping the good stuff Another juice producer that is listening to the consumer demand for more fruity goodness and less additives is the Wild About Fruit Company, which produces two ranges of Low GI juices that are free from any nasties and full of flavour and health benefits.

The Wild Child "super-juices" and Wild About Juice ranges are based on apple juice sourced from orchards in the Yarra Valley and created with a "pure fruit" philosophy.

"There are no preservatives, no added sugar or water and no trendy boosts," the company told Food Magazine.

A few years ago a third generation orchardist in Victoria's Yarra valley, Ben Mould, wondered: "Could an apple juice be made that actually tasted like a crisp orchard fresh apple, and also contain as much of the nutrients from the apple as possible?"

Knowing that crushing the apple

Even many home juicers damage the cells of the fruit and remove a lot of the apple's antioxidants.

Then, Mould's patented juicing process, which uses the whole apple, maintains the antioxidants of the fruit and has a low glycemic index (GI) was born.

Well, an apple a day does keep the doctor away!

The company says its Wild about Juice contains twice the nutritional value of the fruit than any other fruit juice on the Australian market and an independent nutritional analysis on apple juices and apple-blended products in Australia confirmed that the unique processing method employed by Wild about Juice which processes the whole fruit retains the naturally occurring phytonutrients and flavonoids contained in apples.

Aussie! Aussie! Aussie!

The company's Wild about Juice range of healthy juices straight from the Yarra Valley are 100 per cent Australian, with absolutely no additives and is the first and only juice in Australia to be given a low GI rating.

The GI rating refers to the different ways certain carbohydrates behave in the human body and their effect on blood glucose levels.

Low GI foods and drinks produce only small fluctuations in blood glucose and insulin levels, which helps people lose and manage weight,increase the

As people become more aware of the impact of obesity and the part that food and drink consumption plays in that, there is more demand than ever for proper, traditional fruit juice.

Glenn believes the always-increasing demand for Nudie products is proof that consumers are becoming more educated about additives and their negative impacts, and turning towards healthier options.

"There has certainly been a lot of

22 Foodmagazine | May 12 | www.foodmag.com.au

caused oxidization, damaging the apple's delicate nutrients, which are found mainly in the skin, Mould had to develop something pretty clever.

Mould said that while most people have experienced the taste of commercially made apple juice - sickly sweet confectionary flavour that leaves a nasty after-taste, few had experienced good quality, sustainably juiced, delicious tasting real apple juice.

body's sensitivity to insulin, reduce the risk of heart disease and improve blood cholesterol levels.

They also leave you feeling fuller for longer, give added endurance for exercise and help re-fuel following exercise.

This 100% Australian, family-owned and operated business has been growing apples & cherries in the Yarra Valley since 1930.

Owner-operator Mould said the patented juicing process is healthier and

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and goji berries, in what the company more environmentally friendly than other describes as "the ultimate blend of the juicing techniques. world's finest super-fruits and a natural "This special process extracts and source of antioxidants to boost energy retains the goodness from the fruit by and fight free radicals." also juicing the skin which contains As these companies continue to grow, more fibre and antioxidants than the and the demand for proper, healthy juices flesh," Mould Explained. increases, the market will see more "Wild about Juice promotes natural innovation and creative combinations, nutrition, as it has no preservatives or and as Glenn told Food Magazine, the additives, and this juicing process also most important aspect for Nudie moving leaves minimal waste, making it highly forward is commitment to what they do sustainable." and why they do it.

The four powerful antioxidants "As a relatively young business just in that remain in the fruit through the our 10th year now, it's hard to say what revolutionary juicing process are catchins, the next 10 years hold in store. a potent form of antioxidant which are "We will just make sure that we stick good for coronary and cardiovascular to the values which have got us to where health, flavanols that help in the protection we are today and continue to do what's of cancer and supports cardiovascular been working for us so far." health, chalcones, known for their antiinflammatory attributes and Phenolic Acids (Chlorogenic), one of the most potent natural antioxidant groups known.

The Wild Child flavours consist of Green Cleanse; Antioxidant Energy; Mango Passion Veggie Detox, which are all made with using nature's own superfoods, and nothing else.

The Green Cleanse, for regeneration and rejuvenation contains apple, mango, banana, spinach, wheatgrass and spirulina to naturally detox and cleanse the body, whileAtheD Antioxidant _ F D B U Energy L M A Ycontains _ 1 2 . pdf Pa ge 1 2 0 / 4 / 1 2 , 2 : 3 7 apple, pomegranate, blackcurrant, acai,

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CAP & CLOSURES

Put a cap on it!

Making caps and closures convenient and practical.

T

"Customers want ease of access, he packaging that food and enjoyable consumption, and comfortable beverages come in are arguably reusability through the life of the just as important as the product purchased product." inside. And when it comes to accessing Numerous well-know packages have that product, consumers what simplicity, begun to change (think Nestle's Milo cleanliness and practicality, and the tin lid, for example), in recent years, change throughout packaging is evident. which is an indication of companies Less products requiring a can opener listening to consumers and staying fresh, in favour of ring-pull designs, screw according to Sing. tops instead of wine corks or traditional "Many iconic products have not had beer caps and the ability to reseal are all transit & handling, and delivering an easy and comments for their range of products. a 'facelift' for some time," he told Food commonplace nowadays. & enjoyable consumer experience."

"Consumer and trend research from other Magazine.

Shiv Singh, Marketing Manager Over the next 5-10 years, Singh sees countries is also valuable in identification "Innovation that increases at Cormack Packaging had a chat to the caps and closure market continuing to and testing of new product concepts." differentiation at point of sale, and Food Magazine about the demands grow and further establish its place in the The biggest misconception about caps addresses ease of consumption without of consumers and how the packaging packaging sphere. and closures is that they "are an 'add significantly changing the iconic image is industry is meeting these needs. challenging but if successful, rewarding The changes in the caps and closures to manufacturer and end user alike." arena address a lot of consumer Numerous well-known products have begun to change He explained that the processes of getting demands in regards to sustainability, "[There will be] closure manufacturers on, unimportant and of lesser branding customer feedback on a product are not convenience and quality. offering proactive approaches to product significance,'" Singh said. always the same, and have to be adapted to "There's a drive to lightweight caps manufacturers, new technologies from "In fact the closure and its marriage fit the audience, product and company. driving down cost and decreasing waste base resin development to end product to the bottle or container neck are both "Numerous manufacturers and brand factor of packaging and there is always innovation and early engagement in product in presenting the innovation A D _ FtoDimprove C A P 2end Muser A Y usage," _ 1 1 . p d owners f P use a goffline e 1& online 2 / 0focus 4 / groups, 1 2 , 1 critical : 3 3 and P essential M manufacturers' new product development." finished product, minimising leakage in and report groups to receive user feedback Singh explained.

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Food Magazine Awards deadline extended The biggest and most exciting night for the food manufacturing industry is almost here.

T

he 8th annual Food Magazine Awards are rapidly approaching!

With just three months to go, the entries are flowing in at a rapid pace and we are so pleased with the calibre of nominations we're receiving.

The gala event will be held on 1 August at Doltone House in Sydney and after the success of the display tables last year, we will again be offering finalists the chance to showcase their products on the night. "[The display tables] really gave guests and exhibitors a chance to touch, sample, try some of the finalists products and get some real time feedback," one 2011 attendee said.

"It was also a great way to break the ice and network."

Other guests on the night also had positive reviews of the tables, saying they were "very pleased to be able to showcase our range of products and receive feedback from attendees," and they were "a very worthwhile inclusion in the night" while others said they provided a good opportunity to discuss the innovation of the products.

With 14 categories including Snack

Foods, Health and Wellness, Ingredient Innovation, Ready Meals, Sustainable Manufacturing and Packaging Design, there is sure to be one for your company to enter this year.

With almost 400 guests last year, and over 100 entries, the awards were without a doubt something not to be missed.

In 2012, we've had a name change (we're now calling them the Food Magazine Awards, to save confusion) and added a bunch of new categories, so we're looking forward to this being the biggest and best we've ever put on.

And good news for those dragging the chain a bit and worrying that they won't meet the 25 April deadline for nominations, we have extended the last date you can enter to 15 May. This will be the absolute last date we can possibly receive nominations, to allow enough time to get them to the judges for them to decide on the winners to be announced 1 August at the event.

No company is too big or small to enter the annual awards, and we are happy to assist in any way we can, to further explain criteria, give advice or help people to understand the event.

"It was great to see small and medium companies win the majority of the awards," a 2011 attendee reported after the event.

"These types of awards are important for the smaller companies as it really helps to increase awareness of their brands and products.

"Ultimately small and medium business is the backbone off Australia."

So run, don't walk, to www.foodmag.com.au and get your nominations in now!

www.foodmag.com.au | May 12 | Foodmagazine 25

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PACKAGING

The 5 key trends in packaging There are a few key trends emerging in the packaging sector, and the industry needs to pay attention, as Pierre Pienaar, National President Australian Institute of Packaging (AIP) writes.

A

ny packaging consultant wishes they could predict the future, but unfortunately we can only look at some clear trends that have emerged in the packaging industry. If participants in this very important sector of the market are to keep up with change, they need to pay attention to these developments.

A D _ F O O D S Y M1 MA Y _ 0 9 . p d f

26 Foodmagazine | May 12 | www.foodmag.com.au

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Food Safety

Food safety remains the number one issue for the public and will continue to affect packaging materials.

Companies are under increasing pressure to develop new packaging which ensures healthy, safe, yet quick-toconsume products and they need to remain mindful that product recalls or liability cases and the resultant loss of customers can be an immeasurable cost compared with the expense of improving packaging which prevents mislabelling, spoilage, product-tampering or contamination.

Consumers' demand for smaller, 2 2 / 4 / 0 9 , healthy 5 : 2portions 5 P will M increase the demand for new packaging of existing products.

Sustainability Sustainability is a major trend affecting operations in packaging and considerations in this area are now a fact of life with bioplastics and renewable resources such as sugar cane.

But consumers still require greater clarity around what is really sustainable.

They are increasingly interested in their personal impact on the environment and are demanding more from manufacturers.

There is a need for ongoing discussions about codes and standards.

Australia's packaging industry needs to participate seriously in coordinated and cooperative efforts around global packaging sustainability and develop

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PACKAGING

honest measurement tools for the manufacturing industry to consider.

Private Labels The growing private label industry now represents a threat to the branded product.

Ever encroaching shelf space by private labels which do not carry the burden of the branded product's large advertisingmarketing budget is an indication that this sector of the packaging industry can no longer be ignored.

In 2009 private labels were responsible for 45% of products sold in Europe and 25% in the USA. The packaging industry needs to accept that consumers have matured in this area of purchase.

Whereas retailers and consumers were once loathe to experiment with nonbranded items, the private label market has been intent on improving the quality of its product.

In Australia, this has been most evident as private label sales have continued to grow.

Our challenge now is to capture and expand into the less saturated, emerging markets of Asia.

Manufacturers and marketers, however, would be wise to remember that a product with no brand history to depend on will heavily rely on its quality to do all the advertising promotion.

The growing private label industry now represents a threat to the branded product One cannot assume that a third world, emerging nation would be prepared to spend its hard earned, meagre income on A D _ F O O D S Y M M A Y _ 0 9 . p an d finferior P aproduct g e just 2 because 2 4 / 4the/ label 0 9 , offers the discount.

Economy and Education

Packaging Enhances Product Value Internationally and nationally branded consumer product companies and their partners subsequently need to respond by offering their customers enhanced value in the packaging.

Some companies have started redesigning packaging to more strongly differentiate their brands.

If the pack is all you have in a quality, price-competitive market, innovation becomes a priority.

Packaging uniqueness is forecast to be a major differentiator for successful products with colour coding on packaging within a product line being a preferred trend. Busy consumers have identified coded products help 9 : 2 3 that A colour M them distinguish between products.

As we recover from the worst economic slump in decades, trends from this recession include an increased demand for refurbished or upgraded packaging machinery and surges in the demand for copacking and contract packaging operations.

This has resulted in cutting costs throughout the industry in order to survive.

Reduced labour costs, automation and technology, rigorous evaluation of all expenditures in order to maintain productivity and the elimination of poorly performing business lines and products has meant only the best can stay.

Management consultants for retailers, wholesalers and manufacturers suggest that the packaging industry will suffer if it does not take itself seriously enough and ensure that its participants are continually being educated to improve packaging knowledge and skills.

I'd like to suggest that back-to-strongbasics, consolidation of business, a cooperative, consultative approach within the industry underpinned by ongoing education will ensure you reach the future in a vibrant industry.

Rheon Encrusting machines imagination your only limitation

Rheon products abound in meat & poultry, snack & health, bakery products such as cookies & bread dough’s, cheese, seafood, confectionary, pet food & even ice cream treats.

Continuous co-extrusioneg: sausage rolls, fruit bars and apple strudel.

Short or long log extrusioneg: croquettes & hot dogs.

Round deposits up to 300grams- eg: bread pockets, �lled meat & poultry meals, �lled doughnuts.

Ease of operation with a simple control panel from which machine operation is controlled at the press of a button. The panel also has 99 memories for calling up your products running speci�cations.

Low pressure feeding to handle materials gently & avoid fragile particulate breakdown in the casing and/or �lling - baked beans or vegetables into meat or potato casing, strawberries & cherries travel through the machine with minimal damage.

Options allow solid centres or a second �lling, open topped products, mosaic & shaped extrusions.

Stainless steel construction and fully hose-able for easy & sanitary cleaning.

Single, double and multi-head versions available. Test kitchen facilities available with development assistance.

FROM -

Phone: (61 2) 9939-4900 Fax: (61 2) 9939-4911 E-mail: ssyme@symetec.com PO Box 426, Brookvale NSW 2100 C22/148 Old Pittwater Rd, Brookvale NSW 2100

Visit our web site at

www.symetec.com www.foodmag.com.au | May 12 | Foodmagazine 27

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Submit your

Entry

Nomination Deadline Extended to 15 May 2012 for the 8th Annual Food Magazine Awards These prestigious awards recognise best practice and innovation in the Australian and New Zealand food and beverage manufacturing and packaging industries.

See your success and hard work rewarded at a glamorous gala event in Sydney 1 August 2012.

Why nominate?

• Exposure and publicity • Recognition for your hard-working team members • Valuable networking opportunities with key industry leaders

Download the Nomination Kit www.foodmag.com.au/awards FOR FURTHER INFO 02 9422 2759 awards@foodmag.com.au sponsorship opportunities Contact Mark Ryu T: +61 (0)2 9422 2151 E: mark.ryu@reedbusiness.com.au 2012 Categories • Alcoholic Beverages • Baked Goods • Confectionery • Dairy • Food Safety and Innovation in Non-Food PLATINUM SPONSOR

• Health & Wellness • Meat & Small Goods • Ingredient Innovation • Non-Alcoholic Beverages • Organic & All Natural

PROUDLY SPONSORED BY

• Packaging Design • Prepared Food • Ready Meals • Snack Foods • Sustainable Manufacturing

Nominations now extended to 15 May

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BAXX

The science of safe food manufacturing There is more to ensuring the safety of food than just wearing a hair net and following protocol, as Shaughan Syme explains.

Understanding the science that goes into making the food industry safe is complicated business.

Last month, we asked why food manufacturers are not being proactive about safety and spoke to Shaughan Syme about his company's machine, which can remove the chance of certain bacteria.

Here, Syme further explains how the BAXX machine works and what the impact can be on companies who use it.

F

ollowing on from last month's article which included the benefits of the BAXX machine, I'd like to expand a little on the information provided for the benefit of any food manufacturers wishing to follow up about Baxx and its ability to clean the air of dangerous pathogens for them. The article cites our competition with ozone in our market, which can admittedly be an equal deterrent to pathogens as Hydroxyls, but only at concentrations that are dangerous to anything living including humans. At the low concentrations deemed safe to humans it is ineffective and leaves an odour many find unpleasant to work with.

Ozone extremely A D _ must F D be TR O M A Ycarefully _ 1 2 . pd controlled, and the final requirement is

produce Hydroxyls is virtually cost free. to flush the areas with fresh air which There are no filters to clean/replace or defeats the purpose anyway by allowing servicing required. new contamination to enter.

Hydroxyls were discovered approx UV can be effective but only at close 100 years ago by Louis Pasteur while quarters. Its ideal up against Hepa investigating the health differences filters for example, but is effectiveness between living at high altitudes and low is drastically reduced in high humidity altitudes as the article states. conditions and UV lamps must be His research was much later picked up replaced every 6 months. by the British Army in the late 1960's as a In contrast, Hydroxyls are safe for the possible means to combat germ warfare. living in any concentration and in fact clear They confirmed that natures own the air of many odours and compounds that Hydroxyl was a water molecule seeking to would otherwise be unpleasant. Hydroxyls replace its missing hydrogen atom. It does are effective in all conditions down to this by being drawn to and attaching to the freezing, including steamy kitchens, dry wall of a single celled organism (bacteria powder rooms, wet environments and just f about P aallgambient e 1 conditions.

2 0 / 4 / 1 2 , 1 1& : virus 5 1 cells) A Mand ripping the walls hydrogen atoms out to replace their own.

Most importantly, using Baxx to

Thus hydroxyls return to being a water molecule and the cell dies of a ruptured wall - much like a popped balloon.

This makes it a very effective mechanical action rather than a chemical reaction which safeguards against immunity.

All this accomplished simply by an invention that draws only 120 watts approx $50 per year, and is maintenance

UV is also drastically reduced in effectiveness in high humidity conditions. free. Install it and forget it. Its always safeguarding your production and packaging environment.

Tronics Shrink PS Labeller

Patent Pending

Ea single or continuous Easy label application lab Ph: 1300 661 300 sales@tronics.com.au www.tronics.com.au www.foodmag.com.au | May 12 | Foodmagazine 29

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TESTING

Leaner Quality Getting quality products into good packaging is only half the battle for food manufacturers, who need to know their item can be properly scanned at the end of the line, as head of the IDS Group within Matthews Intelligent Identification, Mark Dingley writes.

B

uzz words like lean manufacturing, six sigma, kaizen, Overall Equipment Effectiveness (OEE) are the hot topics for discussion these days when Australian manufacturing is facing tough economic times, and these issues are all -dependent concepts with 'quality' as the lowest common denominator,

Quality: One of the biggest issues in food manufacturing Food and beverage manufacturing needs inbuilt checks and balances to ensure the product is shelf ready before it reaches the end customer.

This includes the smooth flow of product through the supply chain to the end customer.

Any defects, rework, waiting times, motion times are all examples of waste or non-value adding activity that ultimately add cost to the product which the end consumer has to pay for.

A simple example is the barcode quality on the shipper cartons and pallets.

Coles and Woolworths scan receive products at their Distribution Centres (DC).

This means that suppliers are required to be compliant for the DC to operate at optimum efficiency.

If the barcode quality is poor and cannot be scanned then the shipment has to be manually processed at the retailer's end.

A severe case can be an incorrect barcode which can cause a shipment to be rejected at a DC resulting in delay in supply and loss of goodwill with the retailer."

"Quality is about more than a product simply 'working properly. Quality is about meeting the needs and expectations of customers" Another example we came across was when a manufacturer shipped incorrect packaging to the retailer and it reached the consumer.

This error was only discovered when the end customer opened the product and found the "wrong" product inside.

Quality is about more than a product simply "working properly".

Quality is about meeting the needs and expectations of customers.

These may include performance, appearance, availability, delivery, reliability, maintainability, cost effectiveness and price explained Mr Dingley.

Meeting the 'Quality' expectations of retailers and end consumers "Use of quality control solutions can not only reduce wastage and errors, they can also increase automation and improve efficiencies.

These include simple measures like barcode scanners on production lines to ensure every barcode that is printed on a product or applied via a barcode label can be scanned before it leaves the manufacturer's facility to sophisticated systems like machine vision inspection solutions that can check the physical product, dimensions, packaging, appearance and more."

Quality control, the traditional approach to quality, is mainly about "detecting" defective output as opposed to preventing it. Quality assurance, a more proactive approach, is about designing production and packaging processes that minimise chances that the output will be sub-standard.

The iDSnet software solution locally developed and supported by Matthews Intelligent Identification that integrates all the coding, labelling solutions as well as peripheral devices like weighers is all about quality assurance.

The software accesses a central database for all product information, has pre-set formats and templates to ensure the right information (such as use-by date, barcode, batch number) goes on the right product at the right time (the location of the pallet label on the pallet) as well as communicates with peripheral devices like machine vision systems and barcode scanners for quality control.

The software can also be integrated with Enterprise Resource Planning

(ERP) solutions like SAP and Warehouse Management Systems (WMS) as well as Manufacturing Execution Systems (MES) in the organisation to improve real-time track & trace.

Establishing robust quality assurance and quality control processes have far reaching implications for manufacturers.

In one instance, a manufacturer shipped cans of tomato sauce with the wrong labels and had to recall the entire shipment at their own expense from the retailer. In addition they had to pay fines, have been given a warning and put on a 'watch' list.

Any future errors could cost them their supply agreement with the retailer.

These situations can be avoided if robust quality processes are established to start with.

Beyond Quality Control One of our customers is using the reporting tool to capture not only the downtime and availability of the production line but also the quality metrics including number of rejects, reason for rejects via reject codes and number of rejects in a set time period so that they can immediately get an alert if the rejects go over the normal tolerance level.

At that time they can assess the situation and stop the line to fix the issue up-stream rather than have a lot of defective product.

Quality Control is often seen as the 'necessary evil', a non-value adding process that is required however, the underlying value lies in establishing an integrated lean manufacturing process that incorporates quality assurance and quality control and is measured for continuous improvement. www.foodmag.com.au | May 12 | Foodmagazine 31

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TESTING

The trouble with gluten is...

The availability of gluten-free food choices is increasing as consumers demand more alternatives. How can food manufacturers eliminate the room for error with gluten and is there such a thing as gluten intolerance that is separate to Coeliac Disease? Jessica Burke found out.

32 Foodmagazine | May 12 | www.foodmag.com.au

O

ne in every hundred Australians are affected by coeliac disease, but 75 per cent are undiagnosed, meaning that about 160,000 Australians have coeliac disease but don't yet know it.

Gluten is a protein found in wheat, rye, barley and oats, which causes small bowel damage in people with coeliac disease when consumed.

They experience what is referred to as villous atrophy, where the tiny, fingerlike projections which line the bowel become inflamed and flattened and the surface area of the bowel available for nutrient absorption is markedly reduced, causing various gastrointestinal and malabsorptive symptoms, according to Coelic Australia.

A number of serious health consequences can result if the condition is not diagnosed and treated properly.

People are born with the genetic predisposition to develop coeliac disease but environmental factors play an important role in triggering coeliac disease in infancy, childhood or later in life.

"We know one per cent of the population has coeliac disease, but the issue is that only 25 per cent of them are diagnosed at the moment," Penny Dellsperger, Accredited practicing Dietician told Food Magazine.

"I think there are better ways to diagnose, and it's being picked up on because of the increased awareness, so it's difficult to know if the rates are actually rising, or if we're just better at

picking up on it now.

"In terms of how quickly it is rising, we believe one in 100 Australians has coeliac disease at the moment, but it could be more than that, "In terms of gluten intolerance, there is not enough evidence out there to know how many people have that.

"I did hear a figure quoted recently that about 10 per cent of the population is on some sort of gluten restriction, but I don't know if that is right or necessary.

"It might just be a bit of a fad, and it is a bit of a double-edged sword, because for those who do suffer from coeliac disease it's good because there is more gluten free food available and having that awareness is good, but on the other end of the sword they may be down-playing the real implications of having coeliac disease."

Part of the reason for the number of

are specific medical tests to diagnose and manage coeliac disease and we know exactly how to manage it, whereas with gluten intolerance it hasn't even been officially decided if there is a separate gluten intolerance to ceoliac disease," she explained.

"If it does turn out that there is a separate condition, that will have implications on how it is dealt with, because at the moment there is no valid test and there is not any damage long term as there is for is no long term damage like there is with coeliac disease.

"Because of that, the actual management could be quite different, with coeliac disease we know people must follow a strict gluten-free diet for their entire lives, whereas with gluten intolerance, as long as the person is feeling fine, then they are fine.

"We know one per cent of the population has coeliac disease, but the issue is that only 25 per cent of them are diagnosed at the moment," undiagnosed cases of coeliac disease is the varied symptoms that come with the condition.

Some people suffer severe symptoms, while others are symptom free and there is also a lot of confusion about coeliac disease and gluten intolerances, as Dellsperger told Food Magazine.

"Obviously ceoliac disease is quite different to being gluten intolerant, there

"There certainly is research going into gluten intolerance or sensitivities and hopefully there will be developments on that.

Coeliac Australia says if a person is suffering more than one of the high risk factors, they should not be ignored.

The high risk conditions include Iron Deficiency, Anaemia and other Vitamin and Mineral Deficiencies, Autoimmune Disease, Weight Loss,

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Infertility and Gastrointestinal Symptoms.

Those with a family history of the disease should also get tested, as it is a genetic condition.

Other less common symptoms, which are often thought to be unrelated, but could point towards a gluten intolerance include altered mental alertness and irritability, bone and joint pains, fatigue, weakness and lethargy, easy bruising of the skin, recurrent mouth ulcers and/ or swelling of mouth or tongue and skin rashes such as dermatitis herpetiformis.

In children, failure to thrive or grow normally can be indications they may have coeliac disease.

There is no cure for the condition, and those who suffer from ceoliac disease are sensitive to gluten throughout their lives.

But as the rates of coeliacs rises, so too is the number of gluten-free options available.

As long as the gluten free diet is strictly adhered to, problems arising from coeliac disease should not return.

If a person with celiac disease consumes gluten, they may not suffer any symptoms, but they will do damage to the small bowel.

This is why the testing capabilities for gluten are continually undergoing improvements, as the impacts of coeliacs consuming gluten become more apparent.

Andrew Odd from Australasian Medical and Scientific Ltd told Food Magazine the improved testing capabilities for gluten "has been a long while coming but finally getting there."

He said the two new gluten testing kits launched by Romer Labs make it simpler and more accurate for manufacturers to ensure there are no traces of gluten in its products.

The AgraStrip Gluten G12 is a lateral flow device for onsite factory testing and the AgraQuant Gluten G12 is an ELISA for quantitative testing in the laboratory.

The brand-new test kits use Romer Labs proprietary gluten detection technology, which employs a next generation antibody, called G12.

"Essentially, it is a colour-change device which can be used on surfaces for environmental monitoring purposes, areas or materials with cross-

contamination issues with batches of products, it and can also be used in testing raw materials and finished products," Odd explained.

"There are some very basic tests involved, but at the end you've got a strip which has come colour lines appear which give a visual indication of whether a sample was positive of negative for a particular allergen, in this case gluten."

He said the new technology affords food manufacturers peace of mind and quality assurance.

"For starters it gives them good confidence in the products they're manufacturing and they don't have to run the risk of undeclared allergens being present in products and having to possibly recall a batch," he told Food Magazine.

"It gives greater control over qualitycontrol programs and allows action to be taken immediately, in real time, because they don't have to wait for it to be sent to laboratories.

"The sensitivity levels are very high.

"It detects down as low as five parts per million and currently, there is a lot of international consensus that 20 parts per million and above is considered a problem, so it can beat that level.

"But the levels can also be customised so it isn't too sensitive.

"Previously the tests to do this sort of analysis were really only available to laboratories, but these strips are making it a lot easier for manufacturers to do the testing on-site, and they don't need any equipment to run them."

Children with undiagnosed coeliac disease can suffer lack of proper development and behavioural problems.

Coeliac Australia works to raise money and find better treatment for children with the condition, by studying the immune responses to gluten in children and working towards new treatments, including a coeliac vaccine and treatments to prevent or control the acute "food poisoning" that can be experienced in coeliac disease, developing a diagnostic test for coeliac disease that is effective in people already gluten free without requiring a prolonged gluten challenge and potentially avoid the need for an intestinal biopsy altogether.

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www.foodmag.com.au | May 12 | Foodmagazine 33

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ON THE

SHELF For the love of caramel Product: Caramelicious-Cocoa flavour Manufacturer: Caramelicious Ingredients: Sugar, glucose, water, butter, salt, cream, cocoa Shelf life: 12 months Packaging: GĂŠraldine Terrin, Labomine design (France) www.labominedesign.fr

Product Manager: RĂŠmi Tremsal 0435 096 398 Website: www.caramelicious.com.au

EVENTS DIAA Ice-Cream Science and Technology Course May 1-3 Melbourne, VIC Hosted by the Dairy Industry Association, the course would cover topics such as ice-cream mix composition and formulations, mix processing, the freezing process, sugars and stabilisers, emulsifiers, flavours, defects and food safety. www.diaa.asn

Nothing but good Product: Chobani Greek Yogurt - Plain Manufacturer: Chobani Pty Ltd. Ingredients: Cultured pasteurized nonfat milk, live and active cultures: S. Thermophilus, L. Bulgaricus, L. Acidophilus, Bifidus and L. Casei. Contains milk.

Shelf life: 50 days with refrigeration Packaging: Chobani Pty Ltd. Product Manager: Peter Meek (03) 9706 4707 Website: www.chobani.com.au

You lucky duck!

Product: Lucky Duck Apple Cider Manufacturer: Lucky Duck Cider Company Ingredients: Braeburn Apples, Yeast, Water, Sugar, Sulphites Shelf life: 12 months Packaging: Steve Benn Product Manager: Shane Capron 0401 211 782 Website: www.luckyduckcider.com

AIP National Conference 2012 June 14-15 Marriot Resort and Spa, Surfers Paradise, QLD The AIP National Conference is a two-day event that will cover a broad range of topics relating to packaging, incorporating current trends and future developments, case studies and real-life applications, along with a revisiting of some packaging fundamentals.

Issues like sustainability, openability, ease of use and recyclability are just some of the new developments that will be canvassed. www.aipack.com.au

45th annual Australian Institute of Food Science & Technology (AIFST) convention July 15-18 Adelaide Convention Centre, SA The 45th AIFST convention offers the latest information important to food technologists and scientists, sales and marketing, food educationalists, nutritionists, retailers, management and those in other food-related positions. www.aifst.asn.au

34 Foodmagazine | May 12 | www.foodmag.com.au

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PRODUCT SHOWCASE

A breath of fresh air Compressed Air and Power Solutions Australia (CAPS) has announced that Ingersoll Rand's compressors have been upgraded to comply with the ISO 8573-1 Class 0 2010 standard.

The certifications were granted to the entire range of Ingersoll Rand air-cooled and water-cooled oil-free rotary screw compressors (37 to 350 kW) and watercooled, oil-free centrifugal compressors (160 to 5,000 kW) by TĂœV RheinlandÂŽ,

a global leader in independent testing and assessment services.

Air purity is essential to many critical processes in industries such as pharmaceutical, food and beverage, electronics, and textile. Class 0 - created in 2001 in response to industry demands - is the most stringent air quality class and certifies that a compressor discharges air free of added oil aerosols, liquids and particulates. Oil-contaminated air can spoil and ruin products, creating significant loss of revenue and customer trust. Ingersoll Rand oil-free technology can help reduce these risks.

Oil-free compressors provide purer air, save users time and money while improving their productivity, and reduce maintenance costs.

Compressed Air Australia 1300 787 688 www.capsaust.com.au

Minimising contamination Cassida, Fuchs' range of industry leading food grade lubricants, have received a complete visual overhaul to ensure that the risk of contamination due to human error is minimised.

The updated product range will feature a clean, white appearance to differentiate it from other non-food grade products, and Cassida's range of grease cartridges and aerosols will now be colour coded based on application.

While the benefits of using synthetic fluids and greases in food production machinery has been extensively proven and documented, contamination from the incorrect use of application specific lubricants can cost the food and beverage industries millions of dollars in expensive product recalls and irrevocable damage to brand reputations.

Misuse of lubricants in a food or beverage manufacturing environment due to human error can be common, even with good engineering and operational practices. The use of non-food grade lubricants in these environments causes additional unnecessary risk.

The new labelling and colour coding will allow manufactures to integrate Cassida's colour system into their HACCP policy program.

Fuchs Australia 1800 1800 13 www.fuchs.com.au

Get the results Herma have designed the smallest and most compact label applicator to be easily integrated into a form fill & seal / flow wrap.

There is a comprehensive range of modules and accessories for mounting in any application or machine - vertical or horizontal.

Full motion control allows for precise speed matching of label onto film application speeds of up to 185 metres per minute with exact register of +/- 0.5mm, making the accuracy a stand out for

corrective overlabelling.

The Herma 400 applicator runs in continuous or intermittent modes with a clearly laid out operating panel and a special unwind unit giving consistent web tension.

On valve applications such as coffee, steam release or two-way air release valves, it has automated synchronisation of labelling and punching to specified production speeds.

Various shapes and patterns can be placed into webs at speeds of up to 2,400 per minute

which is all controlled by the Herma.

The built in servo control system eliminates interconnecting cables so the applicator looks like an integral part of the whole system and not a ‘bolt on extra'.

Result Packaging (03) 9706 4474 www.resultpackaging.com.au

www.foodmag.com.au | May 12 | Foodmagazine 35

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