Food Magazine April 2014

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INGREDIENTS | PROCESSING | SAFETY | PACKAGING | EXPORT

APR/MAY 2014

Saving

SPC Print Post Approved 100007267

Has our last remaining fruit processor been brought back from the brink?

PLUS: NMW 2014 preview | How to change a winning recipe | Food safety innovations

Complete Food Packaging Solutions

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Filling and Packaging machines: • Pouches • Cheese Cutting • Cheese Wrapping • Cups • Bottles • Cans • Bag in Box • Cartons • Cases • PET Bottles

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WELCOME

Harnessing your chia Sometimes you just can’t predict how your target market will behave...

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EDITOR: Danielle Bowling danielle.bowling@cirrusmedia.com.au

ere at Food mag we very closely monitor the content we put on our website. Every day we keep an eye on which stories are performing the best, which ones haven’t worked, and which ones are generating the best, most relevant comments.

Sometimes - actually quite often - we’re left scratching our heads. The most news-worthy industry events are often steamrolled by light-hearted, even comical stories. Take a recent headline, ‘Flatulent cow treated for burns after dairy farm explosion’. It generated nearly twice as many pageviews as Nestle’s expansion plans in PNG. At the moment it’s all about the Chia Pod. About six months ago we published a short profile of the healthy on-the-go snack containing chia seeds, coconut milk and fruit. It wasn’t a star performer in terms of traffic, but it wasn’t bad either. That was until early February. The story had a massive, almost overnight, surge in pageviews – to the point that it was by far our number one performer for weeks on end, and it’s still performing well, almost two months later.

It wasn’t until I saw surfer Kelly Slater’s bronzed biceps

on TV, and heard him praising chia for helping to keep him fuller for longer, that I put two and two together. The power of advertising, ay?

Now before you start thinking that I’ve got an agenda here, let me say this - you don’t have to pay thousands for a celebrity endorsement in order to have your product recognised. Look at what happened to SPC. You can read all about their recent struggles and successes in our feature starting on page 8, but for them, all it took was a loyal consumer from Newcastle who came up with the clever hashtag #SPCSunday, and the huge outpouring of support that followed has gone a long way in demonstrating why our last remaining fruit processor needs to be kept afloat. SPC’s even considering using the hashtag in its marketing activity moving forward. And it’d be crazy not to.

What these two case studies tell us is that you don’t necessarily need a huge marketing budget to generate interest and support for your brand (although I’m sure it helps). You just have to find - or in SPC’s case, stumble across - that sweet spot that resonates with your audience, and like our Chia Pod traffic, it’ll just keep on keepin’ on. F

INSIDE 04 NEWS

12 RECIPE REFORMULATION

18 FOOD SAFETY

22 BYRON BAY COOKIES

Star labelling controversy; Taylors Wines’ big win; Warrnambool profits.

From administration to innovation - how this baked goods manufacturer got back in business with the help of its new owner, Rinoldi.

08 SAVING SPC

24 PLASTICS

Community support has gone a long way in keeping our last fruit processor on its feet.

ASSOCIATE PUBLISHER - Martin Sinclair P: 02 8484 0607 F: 02 8484 0915 E: martin.sinclair@cirrusmedia.com.au EDITOR - Danielle Bowling P: 02 8484 0667 F: 02 8484 0915 E: danielle.bowling@cirrusmedia.com.au JOURNALIST - Aoife Boothroyd P: 02 8484 0907 F: 02 8484 0907 E: aoife.boothroyd@cirrusmedia.com.au GRAPHIC DESIGNER - Rizwan Nawaz P: 02 8484 0322 F: 02 8484 0915 E: rizwan.nawaz@cirrusmedia.com.au

How to ensure recipe tweaks don’t become PR disasters.

New products to help you promote and manage food safety.

The Australian Institute of Packaging lists 10 things you might not have known about plastics.

16 GET IN LINE

20 NMW 2014 PREVIEW

26 ON THE SHELF

An efficient production line is a must in all manufacturing businesses.

National Manufacturing Week will this year also host plastics exhibition - Ausplas.

Our new look On the Shelf page profiles six new products on retailers’ shelves.

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www.foodmag.com.au | Apr/May 2014 | Foodmagazine 3

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NEWS

No need for stars, I make me fat, says MP

Reader comments Alan commented: "This is what happens when you combine ignorance and stupidity. It is embarrassing enough that this buffoon is the MP for Townsville, but absolutely terrifying that he is the chair of the federal LNP education committee. How does he think you educate people without providing them with information?"

Nella commented:

SELF-PROCLAIMED ‘fat’ Liberal MP, Ewen Jones has rejected the need for a Health Star Rating System, stating that he is to blame for his personal food choices, not the government.

“I carry weight, I am actually fat. It’s not the government that makes me fat, I make me fat,” Jones told the ABC. “I don’t need a government to come and tell me that what I’m eating is wrong.”

Jones’ comments came after Alastair Furnival, assistant minister for health and Fiona Nash’s chief of staff, resigned over his role in pulling down the Health Star Rating food labelling website. The website was

intended to provide consumers with information on the new labelling system before it’s due to officially roll out later this year.

A government official said the site went live ‘in error’, however health advocates fuelled speculation it was pulled down due to industry influence - sighting Furnival’s involvement in lobbying firms as a significant conflict of interest.

Jones believes that increased education is the answer to the nation’s obesity crisis, not a new labelling system.

“I think it’s through education and education in school, through healthy examples in schools, but not down to tuckshops,” he said.

"He's right. There's no end of websites advising us about healthy eating. If people aren't taking advice from the existing sites, they're not going to bother with another one."

John commented: "Appliances can have star rating systems because energy efficiency is easily measured. Food is far more complex and is dealt with biochemically in different ways in different people."

PRODUCTS manufactured by Mondelez, the parent company of Kraft, Cadbury and Oreo scored less than its competitors in three separate product comparisons undertaken by Choice.

Choice campaigns manager, Angela Cartwright, said that of the three comparisons, the Health Star Rating “shot down the Mondelez product each time.”

“Choice decided to take a closer look at Mondelez after the company attempted to discredit the Health Star Rating Scheme, claiming the scheme was

‘ill-founded, unscientific and confusing’, when in fact it was considerably informed by market research showing strong support for it,” Cartwright said.

“Our Health Star snapshot shows that it is possible to have considerably healthier versions of the same type of product. Choice thinks the Scheme will encourage companies to improve their product offerings and create a healthier food supply in the long term.”

A spokesperson for Mondelez International said that the Health Star

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Rating system is ‘confusing’ and that the algorithm is in need of ‘more work.’

“Given that the Health Star Rating shows that Philadelphia Cream Cheese is healthier than an apple, we believe more work needs to be done,” the spokesperson said.

“The algorithm has been changed numerous times and is expected to change again, so the results should be used with caution.”

Images: Photodisc (top) ; TimArbaev (bottom) - Thinkstock

Mondelez misses the mark in star rating comparison: Choice

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NEWS

Taylors Wines wins big in China CLARE VALLEY winery, Taylors Wines, has won the Australian Wine of the Year Trophy at the China Wine and Spirits Best Value Awards, for its 2010 Promised Land Shiraz Cabernet.

Following on from its 2013 Australian Wine Producer of the Year title at the same show, the winery this year took home 12 awards, including three Double Gold and six Gold medals across its Promised Land and Estate ranges.

Australian wineries dominated the 2014 competition, winning a total of 351 medals, ahead of Italy (139 medals) and Portugal (96 medals).

Taylors Wines managing director, Mitchell Taylor (pictured), said it was a significant coup for Australian wine

producers to be recognised in such an important market.

“With a burgeoning middle class, China is now the biggest consumer of red wine in the world and holds real potential for Australian winemakers,” he said.

“Building our reputation in the Chinese market has been an important part of our company strategy for many years. Achieving great success at prestigious competitions such as the China Wine and Spirits Best Value Awards goes a long way towards realising this.”

Proving China’s growing appetite for top quality drops, Taylors Wines’ Visionary Cabarnet Sauvignon 2009 is packaged in a commemorative six litre bottle and sells for $5,000. Four of the 10 bottles produced have been snapped up by wine connoisseurs in China.

FOOD MAG AWARDS UPDATE Dairy Technical Services Limited In 1954 Dairy Technical Services Limited was founded to provide microbiological and chemical test results for export products.

From the first laboratory to the extensive capabilities across multi-location facilities today, DTS has always provided accurate and prompt testing for the food and beverage industries.

In 2014 DTS celebrates 60 years. The driving force behind this successful Australian business is a dedication to quality, service, performance and customer service.

NATA accredited since 1961, DTS is the only Food Testing Laboratory in Australia that's owned by members of the food industry.

The business is passionate about understanding the needs of its clients, and aims to become an integral part of their clients' businesses through the provision of a comprehensive range of analytical and assurance services.

sales@dtsfoodlabs.com.au www.dtsfoodlabs.com.au

Image: denphumi - Thinkstock

2014 sponsor of the Health & Wellness category

Warrnambool posts $16m increase on half year profits WARRNAMBOOL Cheese and Butter Factory (WCB) has posted a 104.7 percent increase in half year net statutory operating profit after tax, equating to an additional $16 million on the same period last year, to $31.3 million.

The underlying profit after income tax attributable to shareholders increased by $21.2 million to $36.5 million, representing a 139.1 percent increase over the previous corresponding period.

“As indicated in our December guidance, the improved market conditions experienced in the last quarter of FY2013 have continued into FY2014,” said WCB CEO David Lord. “Despite the distraction associated with the takeover process, WCB has maintained its focus on maximising returns and the implementation of its strategic business initiatives.”

WCB was the subject of a three way bidding war between Bega Cheese, Murray Goulburn and Canadian dairy processor Saputo over the past six months.

Saputo came through with a successful bid on 12 February after achieving 87.92 percent of voting power in the company.

“Although the takeover process was lengthy and well publicised, the bids for WCB have realised an excellent premium for WCB shareholders,” said chairman Terry Richardson. “The WCB board believes Saputo’s final offer has been in the best interest of shareholders and other business stakeholders.”

Despite announcing record increases in profit, WCB has decided not to issue an interim dividend as the directors have decided to retain cash for investment and development.

For other stories and information please visit our website: www.foodmag.com.au 6 Foodmagazine | Apr/May 2014 | www.foodmag.com.au

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COVER STORY

Saving

SPC SPC Ardmona was on the verge of closure before community support (and a $100m rescue package) turned the processor’s luck around, writes Aoife Boothroyd.

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t was only a month or so ago that the future of Australia’s last remaining fruit and vegetable processor, SPC Ardmona (SPCA), was in doubt.

A steady influx of cheap imported tomatoes, a consistently strong Australian dollar and confusing regulations surrounding country of origin claims have all impacted on the processor, which warned it may have to cease trading in Australia if conditions didn’t improve.

SPCA reached out for government assistance, a request that was initially met with a $25 million pledge from Labor, but was later rejected by the Abbott government.

The processor also appealed to the Anti-Dumping Commission to have tariffs imposed on tomatoes imported from Italy on the basis that the cheap imports were causing material injury to local producers. The Anti-Dumping Commissioner ruled in favour of SPCA, and imposed a tariff of around nine percent on 14 Italian processed tomato brands.

The imposition of tariffs and increased consumer awareness of SPCA’s plight led to a steady increase in sales, but not enough to secure its future.

It wasn’t until late one Thursday night in early February that SPCA’s future would really take a turn for the better.

Newcastle resident and loyal SPCA customer, Linda Drummond pioneered a movement on Twitter that encouraged Australians to purchase SPC products over the weekend. She created the hashtag

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#SPCSunday which soon spread to various forms of social media including Instagram and Facebook.

In less than 24 hours, the hashtag had been used in over 1,000 tweets and reached the likes of Australian celebrities including Bob Katter, Magda Szubanski, Father Bob and Adam Spencer, who were all eager to support the cause.

By the time Sunday rolled around, the hashtag was tweeted over 7,000 times and sales of SPCA products had soared.

Food magazine recently spoke with Bronwyn Powell, the marketing and innovation director for SPCA about the #SPCSunday campaign and the impact that it’s had on the business.

Powell said that sales in the lead up to #SPCSunday were already increasing, but since the campaign, more consumers have been reached than they could have ever hoped for.

“In our key line and our key retailers we have increased sales by over 50 percent, which was actually happening before #SPCSunday.

We have had such great support from consumers, retailers and everyday Aussies, and now even more so,” she says.

“We are just overwhelmed with the everyday Australian supporter for our company. So it’s amazing, it’s really been fantastic.” »

Image: xubingruo (contents); Edsel Querini (cover) - Thinkstock

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Image: xubingruo (contents); Edsel Querini (cover) - Thinkstock

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Goulburn Valley growers and (left) Bronwyn Powell, marketing and innovation director at SPC. www.foodmag.com.au | Apr/May 2014 | Foodmagazine 9

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COVER STORY

APRIL 2013

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61 of SPCA’s peach & pear growers in the Goulburn Valley were delisted due to the high exchange rate and a decline in export markets (40 of these growers still supply SPC with other crops).

JUNE 2013 The company moved the fine print from the back of its packaging to the front, highlighting that ingredients are sourced locally.

12 months

for SPC

AUGUST 2013 Woolworths announced a $7m deal with SPCA, replacing imported fruit for its Woolworths Select range with produce from Goulburn Valley.

100% JULY 2013

APRIL 2013 SPC asked the government to help growers by imposing an emergency tax on imported tinned fruit.

When asked whether SPCA would consider integrating #SPCSunday into the company’s marketing activities, Powell says it is something that the company will be considering.

“We are definitely looking at how we can continue to support and grow this idea, whether it is in-store or online with consumers. It’s only early days but trust me, my team are crazily thinking about how we can help grow and support #SPCSunday and really connect with our consumers and the community.”

Since #SPCSunday, Coca-Cola Amatil (SPCA’s owner) and the Victorian state government announced a $100 million investment plan to assist the processor over a three year period. The cash injection will no doubt provide much needed assistance to the brand, however for the company to continue to prosper now and into the future, ongoing consumer support is vital.

The company announced it may be forced to close if the Abbott government refuses to come through with a $25m grant promised by the former Labor government.

$7m

big

OCTOBER 2013

SPCA had its anti-dumping case approved for formal investigation by the Australian Anti-Dumping Commission.

Becomes the first company to launch a 100% Australian grown baked beans product.

$25m JANUARY 2014 Federal government rejects SPCA’s call for assistance, with Abbott arguing the company’s owner, Coca-Cola Amatil, is profitable & well-resourced.

that they are buying Australian. When they are buying Aussie grown, and buying our products, I can assure [them] that they are clean, green and wholesome. We give consumers comfort that their food is premium quality and safe - that is critically important and something that we know and we can demonstrate.”

Powell says that differing standards in food safety is another concern that the Australian public will face should SPC close and shelf space be replaced with imported products.

The call for stronger country of origin labelling and more rigorous testing of imported fruits was heightened last year after high levels of lead were detected in Chinese canned peaches. Tests on the fruit showed alarmingly high levels of lead - up to twice the amount that is legally permissible under Australian and New Zealand food standards.

"There are a lot of things that we are going lose if we lose SPC." Food magazine asked Powell what she believed Australia would lose if SPC was to close. “There are a lot of things that we are going lose if we lose SPC. The first one that I have to say as the marketing director is great brands that have been around for nearly 100 years - many of them people have grown up with. Household names like Ardmona, IXL jam, Goulburn Valley and Taylors, which is a newer brand, those brands will be lost, and lost from a lot of our Australian childhood memories.

“And because we are an agricultural-based company with Australian grown fruit and vegetables – we are going to actually lose a lot of Australian growers. And the sad thing for me, the thing that probably brought me the most emotion in this job was that we would be losing 100 year old pear trees that have gone through three generations of families.

“The other thing is that consumers are going to lose the reassurance

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“One of the things I always say is actually look at where products come from… Have a look at the fine print and actually see where that product was really made and then ask yourself, do you really know what goes on in terms of the conditions that the product was made in?

Do we really know if they have the same strict laws that we have in Australia around food safety?”

Powell adds that innovation within the Australian fruit sector is also something that the nation stands to lose.

“We would lose all of the future innovation that myself and my team have been working on. Just one of those is Goulburn Valley Perfect Fruit [a soft serve fruit] which is currently in test market. We have loads of other ideas too that won’t be there if we go, as there is nobody else that really operates in fruit who can offer that innovation in Australia.

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Daniel Andrews, the leader of the Opposition in Vic, pledges $30m to SPC Ardmona if it’s successful in the November election.

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Coca-Cola Amatil and the Victorian government announced a $100m investment plan

Newcastle resident Linda Drummond, creates the hashtag #SPCSunday to boost support for the struggling brand.

$70m

$30m $100m $

#SPC

Sunday 668 Replies

24,000 tonnes

1,734 tweets

6%

MARCH 2014

16%

21.8m IMPRESSIONS

10,900 mentions 3,499 users

78%

8,498 Re-Tweets

Image: Michael Bevan

government SPCA’s call for ce, with Abbott the company’s oca-Cola s profitable esourced.

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FEBRUARY 2014

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RY 2014

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y t may be se if the rnment ome a $25m ed by the r

25m

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A $70m partnership between SPCA and Woolworths is announced and will see an extra 24,000t of navy beans, tomatoes and other fruit sourced locally.

Fruit is at the core of what we do.”

Although SPCA has been enjoying a spate of increased support from consumers and retailers in recent weeks, ongoing sales is what’s required to keep the company alive.

In mid-February, parent company Coca-Cola Amatil posted a $400 million slump in net profit, related to write-downs from SPCA. In order for the company to truly come back into prosperity, constant consumer support is paramount.

Spring Gully, a South Australian sauce and pickle manufacturer, provides a telling case study of how consumer support can make all the difference when a food brand is experiencing tough times.

The company was in a similar predicament to SPCA, albeit on a smaller scale, in mid-2013. It entered voluntary administration with debts of $4.9 million in July, but showed stronger signs of life months later as a result of community and retail support.

Fellow South Australian food brand, Robern Menz, launched the “Shop and Swap” campaign which encouraged consumers to swap one supermarket food item for its South Australian-produced counterpart.

Not long after Shop and Swap was launched, three weeks worth of Spring Gully sales were made over a three day period, with Foodland, IGA and Coles placing extra orders to make up for the increase in sales. In November, the company announced that it had cleared $1 million in debt.

The question is: can SPCA follow a similar path and pave a road to recovery with increased consumer support? Powell is hopeful.

“The support is certainly helping us; it is certainly saying to everyone that this is a company with brands and products that Australians want to keep alive.

“SPC is truly overwhelmed by the support, and we want to thank each and every Australian who has supported us – retailers and consumers.” F

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www.foodmag.com.au | Apr/May 2014 | Foodmagazine 11 AprMay14_Foodmag_100x297_H&C_InspectionOceania.indd 1

21/02/2014 17:08:55

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R CEREAL

w

specialisation

There is always a certain degree of risk involved when a company decides to tweak the recipe of a winning product.

By Aoife Boothroyd.

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onsumers are demanding folk; they’re always on the hunt for products that are healthier, cheaper, tastier and more convenient. And while food manufacturers are always looking to meet these demands, altering the recipe of an existing product can trigger a consumer backlash and, soon after, a PR disaster.

In the mid-1980s, the Coca-Cola Company was starting to lose market share to its main competitor Pepsi. In order to win back consumers, Coca-Cola reformulated the recipe for the first time in 99 years and renamed the beverage New Coke. The new recipe was met with a surge of consumer complaints and saw the return of the original recipe only a few months after New Coke’s launch.

Identifying the fine line between genuine product innovation and a potential marketing disaster is a complicated task that involves extensive market research, product testing and sometimes a bit of faith.

When the British subsidiary of Kellogg’s released a reformulated version of the veteran women’s cereal Special K in May 2013, it generated a host of complaints »

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ui

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ef r ulat o

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CEREAL

from previously loyal customers who called for the return of the original recipe. Consumers said the new recipe was too sugary despite holding the same sugar content as the original recipe, while others complained that the flakes were too hard.

These were all lessons that the Australian division of Kellogg’s no doubt kept in mind when they decided to increase the nutritional content of Special K Down Under by adding a higher wholegrain content to the cereal and decreasing its sodium levels.

Keeping special in Special K The Australian recipe for Special K had not been touched in over 50 years and as such, Kellogg’s made a conscious effort to tread very lightly and develop a new recipe that ticked additional nutritional boxes without compromising taste or texture.

Food magazine spoke to Special K’s senior brand manager, Kate Harris, about the process involved in changing Special K’s winning formula and what motivated Kellogg’s to take an educated risk on one of its most popular products.

“Special K as a brand has always been on a journey with Australian women and being around for 50 years meant that we needed to evolve with our consumers,” said Harris.

She explains that as the Special K consumer has evolved, the demand for healthy food options and better nutritional content in breakfast has also increased.

“We’ve listened to what they are looking for in a breakfast cereal and we’ve made positive changes to best meet those desires.”

According to Harris, the process of tweaking the recipe to meet the needs of the brand’s customers meant upping the nutritional content without changing the taste or consistency of the signature Special K flake.

“Making changes to our food and getting it right in the eyes of our consumers takes time. Replicating the

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taste and consistency was incredibly important. We used not only internal quality checks but also took the product to consumers to get their feedback through research.

“We know that consumers love the taste of Special K which is why we worked so hard to ensure that this did not change.”

Considering how the changes were executed in the UK last year, it was imperative that the Australian subsidiary adapted the recipe to suit the local market.

Harris explains that Special K is a global brand found in many countries, and decisions for the brand’s direction are made with each individual market in mind.

“The changes made in the UK are not the same as those made in Australia and New Zealand. As a global brand we always strive to take learnings from each market and adapt and reapply those where appropriate in another one.”

The new recipe was released on 3 February, and according to Harris, consumers have responded positively to the changes.

“When we were in the process of reformulating Special K, we wanted to be sure that our customers would be happy with the changes. The Special K consumer was kept front of mind throughout the process, which is why keeping the signature taste while also introducing the increased benefits of nutrition was equally important.

“The new Special K is now a better source of fibre than the previous recipe, a source of wholegrain, features about 15 percent less sodium and is still one of the highest protein cereals available.”

Slow and steady Early last year, fellow cereal manufacturer Uncle Toby’s reformulated its entire breakfast cereal range to comply with new nutrition guidelines set out by the federal government, making it one of the first manufacturers to do so.

Uncle Toby’s regional nutrition manager, Nilani Sritharan, said the transition to a more nutritious portfolio was no easy feat.

Sritharan told Food magazine that the key to making any change is ensuring that customers stay on-side. She said that making small, healthy improvements over time is by far preferable to introducing an immediate change, and that a slow transition period often results in consumers not even detecting a change at all.

In addition to keeping consumers happy, Sritharan said that keeping the cost structure

down is another factor that needs to be considered due to the time invested in R&D, as well as the use of more expensive ingredients.

However Sritharan said that healthy improvements don’t necessarily require new manufacturing processes, and that often changes can be achieved simply through a tweaking of manufacturing procedures.

“I don’t think it fundamentally changes the manufacturing process but you may find there are changes in texture or stickiness that we would have to work through and adjust for,” she said.

Sritharan sighted the popular children’s cereal Cheerios as a prime example. Since 2008, Cheerios has reduced its sodium content by 40 percent and boosted its fibre content by 25 percent, with wholegrain content rising by a similar margin.

“Increasing the wholegrain content can sometimes make the Cheerio a bit softer or affect the loop shape,” she said.

“So looking at some of the mixed grains we have in there, we have to try and balance that out.”

As was the case with Coca-Cola, Kellogg’s and Uncle Toby’s, any reformulation process is indeed a matter of trial and error but two key learnings will undoubtedly have you on the path to success.

Firstly, listen. Listening to your consumers is something that manufacturers need to keep top of mind during the reformulation process, no matter how fantastic the new health credentials may be. And secondly, whether a food manufacturer is tweaking a recipe to abide with new regulations or simply to improve the product’s nutritional content, slow, steady and subtle adjustments are the key to ensuring your new and improved product goes down a treat. F

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BETTER SERVICES BETTER RELIABILITY BETTER VALUE WE’VE STRENGTHENED THE SPINE OF THE EAST COAST FREIGHT NETWORK TO HELP GET YOUR BUSINESS ON TRACK.

Reliable trains East coast rail reliability is up 30 per cent thanks to projects such as the new Southern Sydney Freight Line, track improvements and the introduction of new locomotives by rail operators.

Better business story Every time your business chooses east coast rail instead of trucks, you can tell customers you’re producing three times less CO2, using three times less fuel, and helping keep 110 trucks off the road.

Better connections Better reliability and capacity means less wait time at terminals and better connections - helping rail be a key part of your logistics solution.

HOW WE DID IT: A $3 BILLION UPGRADE The Australian Rail Track Corporation (ARTC) has delivered a $3 billion upgrade to east coast freight rail lines over the last five years. To find out how to get your business on track, go to www.betterforbusiness.com.au

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Get in line There are a few key factors to consider when upgrading or investing in a new production line. Heat and Control has some pointers to help you get started.

C

hoosing the right kit is only half the story. It is not simply a question of buying the most suitable weighing equipment or distribution system. Yes, speed, accuracy and reliability are vital, but you also need to choose a supplier with a service and support team that understands your wants and needs, and provides the right solution if ever a problem occurs.

Every food and beverage retailer is looking for something a little bit different in their product range, be it a different type of snack, flavour or pack presentation, so manufacturers need to be able to customise their products and deliver exact requirements to their customers.

These days, weighing and packaging systems have become compact with a smaller footprint compared to previous single multihead weighers and bagmakers. As an example, they are able to deliver around 130 bags per minute for chips and as much as 220 bags per minute for extruded snacks, on small target weights. This is compared to the 80 or 90 bags delivered by equipment of the past, with modern day technologies helping to achieve accuracy within one percent of the target weight.

Factors that you should consider when looking to upgrade, or looking at investing in a new distribution line, include: • Consideration for system layouts with a view to future requirements • Provision for accumulation and feed modulation • Methods to divert product, sanitation, operator safety, cross-contamination, sustainability and product quality control.

While price, delivery and other commercial considerations are important, technical performance should certainly be the primary factor when evaluating which production line is best for your business.

Conveying Conveying (product delivery) has become an integral part of controlling the feed to the weighing and packing stations of any food product, and has become more sophisticated than simply moving product from point A to point B. When selecting a distribution system a processor needs to ask ‘do I need a vibratory conveyor or a horizontal motion conveyor for my line?’

16 Foodmagazine | Apr/May 2014 | www.foodmag.com.au

Vibratory conveyors come in two drive types, electromagnetic drives, which produce variable speed movements with short amplitude (lift) and high frequency (speed). Electromagnetic drives are best suited for lightweight, easy flowing products, and for conveying limited bed depths, spreading product, and fines removal. The other is a more aggressive, mechanical vibratory drive.

While vibratory conveying systems are very useful for breaking up product and keeping it separate, the constant bounce and impact of product on the pan is aggressive and can often reduce the quality of the finished product. Vibration can cause micro-cracks in some products, making them more susceptible to breakage later in the packaging or delivery process.

Additionally, there is often coating build-up on a vibratory conveyor pan but not on horizontal motion conveyor systems.

Rather than bouncing the product, horizontal motion conveyors slide the product along the pan. This has become the preferred means of conveying fragile and coated foods such as snacks, fresh produce and frozen prepared foods. The horizontal motion virtually eliminates product breakage and cracking and does not shake off coatings, breading or seasoning. At the same time as being gentle on the product, an added advantage is that seasoning, oil and other coatings do not build up in the pan, which in turn increases downtime for cleaning.

Horizontal motion conveyors are available with direct and inertia drives.

The horizontal motion allows gentle short term product accumulation, whilst uphill horizontal motion conveying reduces product damage in return loops.

While sliding product prevents breakage, coating loss and noise, it also has some limitations that become evident in horizontal motion conveyors: • Product spreading can only be achieved with specially shaped pans • Product travel rates are slower than aggressive mechanical drive vibratory conveyors, but may be faster than high frequency electromagnetic drive designs • Uphill conveying is usually limited to about 1.5 degrees, although in some special cases, it is possible to convey product up to eight degrees • Does not level piles of product without pan modifications • Difficulty conveying limp or sticky products.

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CONTROL & WEIGHING SYSTEMS

Direct drives use long strokes, producing travel rates up to (12.5 m/ min). In addition to greater throughput/ pan size, direct drives can also stop and start instantly, offer modular expandability, provide fast travel rates to reduce stale product complaints and improve the efficiency of seasoning applicators, weighers, bagmakers, and overall packaging room performance. (Inertia drives generally deliver slower product travel rates, have delayed stop and start operation, and do not work well in modular and packaging feed applications).

Selecting the proper type of direct drive will greatly reduce maintenance and energy usage, as well as improve safety and packaging feed efficiency.

Weighing and packing

maximum operating efficiency.

Technological advances have resulted in further increases for packer profit with higher production rates, reduced product giveaway, and lower cleaning and maintenance costs. We can summarise the developments in weighing technology as follows: • Speeds up to 15 percent faster than earlier models • Control unit with Windows XP operating system and e-mail capabilities • Capability for full integration and monitoring of other equipment on the line through single panel operator interface • USB camera for real-time monitoring of product conditions on the dispersion and radial feeders • Automatic timing settings that optimise productivity and reduce operator inputs • Reduced energy consumption • Quick and easy set-ups and product changeovers.

Heat and Control Packaging Platform. tions that can cause weighing errors, reducing productivity and efficiency. Structural members need to be located correctly to eliminate flat surfaces where debris can accumulate. Conveyors can also be elevated above the non-slip decking to facilitate cleaning. Another feature to consider is open frameworks that take minimal floorspace, and allow complete access to bagmakers, cartoners and other ground-level equipment.

Platforms are normally custom-

Tasks usually performed by manual labour, involving sorting, counting, weighing, bagging and case packing can be replaced with consistent, accurate and Finally, when designing/engineering high-speed systems, drastically reducing your plant layout, packaging platforms operational costs while increasing output also need to be taken into consideration. and productivity.

"Choosing the wrong partner can cost you much more Modern weighing technology brings with it higher speed and more accurate than you'd save by investing in a sub-standard supplier." weighments, increasing product yield, which in turn relates to less “giveaway” Modular packaging room platforms configured for each installation and can per bag. Computer combination weighreduce installation and cleaning costs include wash racks for weigher hoppers, ers deliver the performance processors in meat and poultry, plants and sanitary plumbing and pre-wiring for single point needed to meet high production requireproduction environments. connection to utilities, lighting, hose storments for their products.

Packaging platforms need to provide a age, catwalks, stairways, safety railing, Modern stainless steel weighers safe, stable support for product distribufloor drains and other features. provide more sanitary weighing systems, tion and inspection conveyors, weighers, Before you buy, consider testing your while new surface profiles and coatings control panels and other equipment. products. Some suppliers have equipment virtually eliminate product sticking. High- Lightweight structural members could set up and ready for customer testing to amplitude feeder drives provide powerful cause vibrations that are not easily help prove capabilities such as gentle control of product flow, while Pulse Width detectable but can translate into errors on handling, conveying uphill, or moving Modulation systems automatically tune the load cells of computer weighers. large quantities of product, as well as F D 0 4and 1 radial 4 _ 0feeder 1 7 _drives U N Ifor 1 2The 0 end 1 4result - 0 will 3 - be 2 weight 0 T 1 fluctua1 : 1 9 : 3 weighing 2 + 1 1 and : 0packaging 0 dispersion demo centres.

If this service is available, making use of it can be of value in the decision making process. During a product test or demo, you can also get firsthand experience with other features such as operator interface, ease of use, and possibly sanitation.

When choosing a supplier, as with any equipment purchase, the buyer is not just purchasing a piece of equipment but also entering into a long term relationship with the vendor. Choose a reliable supplier that understands your industry and offers up-front assistance with such things as system layout, sanitation procedures and avoidance of cross-contamination. Be sure that you are comfortable with the vendor’s ongoing assistance such as warranty, training, spare parts and technical support capabilities. Price should not be the only consideration; choosing the wrong partner can cost you much more than you’d save by investing in a sub-standard supplier. F Heat and Control manufactures food processing and packaging equipment systems. Contact them at info@heatandcontrol.com or visit www.heatandcontrol.com

www.foodmag.com.au | Apr/May 2014 | Foodmagazine 17

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in food manufacturing Effective food safety and product recall systems are imperative for manufacturers of all sizes, Aoife Boothroyd reports.

D

iscussing the mere possibility of a product recall is enough to send shivers down the spine of a food or beverage manufacturer.

Whether we’re talking about a small scale operation, or a highly reputable multinational company, neither is immune to the threat of contamination. Only last year, Fonterra embarked on a mass recall due to a botulism scare, while products from Jindi Cheese were linked to three deaths.

Even with exceptional food safety standards, there is always a chance that pathogens will slip through the cracks. So what are the best ways to ensure protection for your brand?

Advanced Oxidation Dow Microbial Control launched its Advanced Oxidation System (AOS) in July 2013. AOS is a whole room system used by food and beverage manufacturing/processing plants to sanitise all surfaces and the air. The system uses ambient air to generate Ozone and combines it with water to create a vapour that evenly fills the entire room.

According to Dow, AOS is a fully customisable solution that’s designed to complement conventional cleaning and sanitisation practices, enabling food manufacturers to effectively sanitise hard-to-reach problem areas including hidden areas in equipment, drains, vents and fabrics – and is even effective in dry environments such as bakeries.

“AOS Certified is particularly effective at reducing and controlling levels of the resilient listeria monocytogenes in highcare, ready-to-eat (RTE) and preparedfood environments, as well as in spiral freezers and chillers. The technology is also very effective against Escherichia coli, and Salmonella, and against other bacteria, viruses, yeasts and molds,” Dow said.

“The technology also runs automatically without relying on workers to do the sanitisation, so extra manpower isn’t required.

The sanitising agent is produced on demand using just air and water, so manufacturers also don’t have the burden of shipping and storing chemicals.”

Safety in ingredients Earlee Products has taken a slightly different approach to food safety by developing food ingredients that enhance the safety of processed meat products against pathogens.

“We saw an opportunity to develop some food ingredients that enhanced the food safety of processed meat products 18 Foodmagazine | Apr/May 2014 | www.foodmag.com.au

particularly against listeria monocytogenes, the scourge of ready to eat sliced modifiedatmosphere meats,” Bob Hamilton, managing director of Earlee Products, said.

Hamilton says Earlee’s products which consist of ready-to-use liquids, starches and edible oil lubricants, provide a natural alternative to pathogen control and can be integrated into existing processes.

“The ingredients are bactericidal to listeria, staphylococcus aureus and E. coli.

So whilst they are food ingredients, they promote food safety by eliminating potentially fatal pathogens. The dip can also be sprayed on processing equipment such as slicers and dicers.”

Take the guesswork out In addition to having the right processes in place to avoid a food safety scare, effective recall systems are also essential.

GS1 offers comprehensive traceability solutions for all sized manufacturers.

According to Richard Jones, general manager quality services, the GS1 Global Traceability Standard includes a: • Global Location Number (GLN) – a unique identifier of any player in the supply chain • Global Trade Item Number (GTIN) – a unique identifier of a traded unit • Serial Shipping Container Code, which uniquely identifies shipments of goods.

The GS1 Traceability Standard also utilises a range of GS1 Bar Codes to share master data between trading partners prior to conducting a transaction and in addition to Electronic Data Interchange (EDI) – for conducting electronic transactions.

Jones says that the implementation of an effective recall system such as the GS1 Traceability Standard offers significant

benefits to food manufacturers.

“The first benefit is that it is based on standards businesses are already using to meet trading partner requirements.

Therefore, no action is required to assign product identification or bar coding, as the foundational elements of the system are already in place with GS1 standards.

“Secondly, communication of this information between SMEs and their trading partners means that, in the event of a recall, products and raw material components can be easily identified ...

Studies have shown that a large part of the delay in product recalls is due to a lack of consistency in product identification between trading partners.

“Lastly, they meet all of their internal traceability needs using the same tools that interface with their customers.”

By not employing effective traceability systems, Jones says suppliers risk far more than a botched attempt at a recall.

“First is the legislative requirement to have traceability in the event of a recall and be able to meet regulatory demands to demonstrate capability. In Australia, there is a base level of regulatory oversight whereas in Europe and the US stringent legislation exists that is quite prescriptive in how a manufacturer must apply solutions to meet these requirements.

“In addition, there is a reputational risk.

Most customers acknowledge that mistakes will happen from time-to-time. But when a product recall event occurs, customers are looking for quick and decisive action. This is how manufacturers will be judged by consumers moving forward.

“If you do not have the information you need to effect a speedy and efficient recall, it can be more devastating to your reputation than allowing the original mistake to occur.”

Images: LeafenLin, BernardaSv - Thinkstock

Safety first

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Images: LeafenLin, BernardaSv - Thinkstock

FOOD SAFETY

SICK

Sean Carter, product manager identificanear field applications, usually <30cm.

“RFID is very affordable. The tranSensor system company SICK is also in tion and measurement, said.

They are not affected by the presence of sponders come in many different shapes the business of recall systems, specifi“Considering these sorts of numbers, water or metallic objects and there is a and sizes to suit almost every conceivable cally radio-frequency identification and that the onus is completely on the large range of transponders and tags for application. Additionally, the cost of the tags (RFID) solutions. supplier, the need for error-free tracking all sorts of applications. has reduced to the point where most are now According to SICK, effective traceabil- and code checking is pretty clear.”

• Ultra-high frequency 860-960 MHz considered to be disposable.” ity and code checking systems throughout Carter points out that in addition to capacitive coupling systems (UHF).

No matter the size of your business, the production process are essential. inventory issues, the potential for error also These are typically used in longer range Carter says food safety is not something “In terms of final inventory, the numbers in FMCG and food are stagger"This is how manufacturers will be judged by consumers moving forward." ing. One of the Australia’s major grocery players accepts 10,000 pallets of goods abounds in food processing. applications >30cm and the unique item that a manufacturer can compromise on. a day at distribution centres across the “Inaccurate labelling can easily lead to identifier of the tag is programmable.

“If the cost of a complete solunation - that’s over 3.6 million pallets a supply of the unsuitable product and make tion with multiple interrogators at first year, each stacked two metres high with tracing incredibly difficult. In the worst case, A number of high profile food and appears expensive, food and beverage multiple products, all needing to be india failure in process can result in contamibeverage manufacturers currently manufacturers should ask themselves vidually identified. A one percent inacnated product reaching the consumer.” employ SICK’s RFID solutions, includwhether they can afford not to have an curacy or no read rate using traditional bar SICK’s RFID technology systems fall ing Fonterra, however SICK says that effective track and trace system that code label technology would mean breakinto two distinct types: although the technology is highly sophis- minimises the chance of process errors ing down over 36,000 pallets per year for • High frequency 13.56 MHz inductive ticated, it is also appropriate for small to and maximises the chance of tracking F D0 4 1 4 and _ 0 double-checking,” 0 0 _ AI P 1 2coupling 0 1 4 systems - 0 3 -(HF) 1 4that T 0are9 used : 5 in 5 : 1 medium 5 + 1 1sized : 0 manufacturers.

0 manual handling them when they occur.” F

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With speakers already confirmed from Mondelēz International, Kimberly Clark, Campbell Arnotts, LION, Coca-Cola, Nestlē, Simplot, O-I Asia Pacific and Amcor Flexibles, to name just a few the 2014 AIP National Conference will be the only place to be on the 17th and 18th of June.

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NMW PREVIEW

What’s on at

National Manufacturing Week?

It’s that time of the year again - when manufacturing’s decision makers and suppliers unite to spread the word on the latest and greatest innovations in the industry.

A

n annual event, National Manufacturing Week (NMW) offers a unique opportunity for suppliers of manufacturing equipment and services to showcase their products to senior decision makers and specifiers from Australia’s manufacturing industry.

This year’s exhibitition will once again feature a range of dedicated Product Zones as well as an extensive program of education and networking events running parallel to the expo.

Held from 13 to 16 May, NMW will also play host to Australia’s premier plastics exhibition - Ausplas - making 2014 the first time in 24 years that Ausplas will be staged in Sydney.

A record 15 Product Zones will be on display at the event, including returning zones such as Automation and Robotics, Workplace Safety, Materials Handling and Welding Technology, as well as new zones including Digital Manufacturing, Additive Manufacturing, Engineering Services and Machine Tools.

Another new addition to the NMW program is the R&D Hub, an initiative which aims to foster innovation and the development of intellectual property and intangible assets. The R&D Hub will seek to enable innovation and commercialisation by facilitating partnerships and collaboration between the manufacturing sector and leading research providers, including government agencies, Cooperative Research Centres and universities.

The Hubs will include a Digital Technology Hub, a Health and Safety

Hub and an additional Plastics Hub (running within the Ausplas Exhibition) and will feature a broad range of presentations, demonstrations and innovations, including technical insights and peer reviews.

Presentations relevant to the food and beverage manufacturing industry include: • Sustainability: Materials Management and Recyclability - by Professor Veena Sahajwalla, director, Centre for Sustainable Material Research and Technology at UNSW (13 May, 12:30 - 1:15pm) • From Traditional Compliance to Cutting Edge Safety - Designing OH&S into the Workplace - by Peter Dunphy, director operations, work health & safety division at WorkCover Authority of NSW (13 May, 2:30 3:15pm) • Manufacturing Australia’s Future: Innovate or Perish - by Lachlan Mullane, partner at Hodgkinson McInnes (14 May, 11:15am - 12pm) • Technical Insights - Why Mobility in Manufacturing is a Must - by Kaido Schmidt, country manager, HansaWorld Australia (14 May, 1:15 - 2pm) • Lean Manufacturing for SMEs - by Tim McLean, managing director, TXM Lean Solutions (15 May, 1:30 - 2:15pm) • Innovation in the Food Manufacturing Sector: Capturing Growth Opportunities in Asia - by Geoffrey Annison, CEO Australian Food and Grocery Council (15 May, 3 - 3:45pm).

The details 13 - 16 May, 2014 Sydney Showground, Sydney Olympic Park National Manufacturing Week is free to the trade.

For more information, visit nationalmanufacturingweek.com.au

Opening times Tue 13 May - 10am - 4pm (Networking function - 4pm - 6pm) Wed 14 May - 10am - 6pm Thur 15 May - 10am - 8pm Fri 16 May - 10am - 4pm

20 Foodmagazine | Apr/May 2014 | www.foodmag.com.au

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NMW PREVIEW

4

LOOK OUT FOR Stand 1348 - Camfil Australia The Camfil Group develops and produces air filters and clean air solutions. The company provides air filtration products and services through four main business units: filters, power systems, air pollution control (APC) and airborne molecular contamination (AMC).

Stand 2622 - Hurl Nu-Way Hurl Nu-Way has been importing quality products to Australian manufacturers for over 100 years. At its stand you'll see Hurl Nu-Way's air compression product range, including Hitachi screw air compressors, GE Roots blower packages and Secomak air knives.

Stand 2335 - Hodgkinson McInnes Patents

Stand 1429 - DGS 3D DGS 3D will be exhibiting the eco-friendly 3D printer, the Mcor Iris.

This printer builds low cost, durable, stable models in more than one million colours from regular A4 copy paper.

Stand 1544 - ECI ECI M1 is an Enterprise Resource Planning (ERP) software solution designed for growing manufacturers. M1 automates and integrates every business process from quoting through to invoicing and point of sale.

Stand 2519 - HW Technologies

Hodgkinson McInnes introduces cost effective HW Technologies provides technical processes to help you maximise wealth from solutions for production, acoustics and your innovations and R&D while also mitigatergonomic workplaces. HW Technoloing risk. Hodgkinson McInnes will showcase gies provides an extended service that some of its services including commercial includes customisation, consultancy, innovation strategy, business asset creation troubleshooting as well as extensive after andF risk management strategies. sales support and service.

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reasons to attend

1. A revised floorplan giving more space to sectors and technologies that are driving industry growth. NMW 2014 will incorporate a record 15 Product Zones, as well as the Ausplas exhibition and the R&D Hub, where industry members can connect with research providers.

2. The food industry will have access to a range of zones relevant to its sector, including the Automation & Robotics zone and the Materials Handling zone, the Workplace Safety zone, while also learning about new solutions for sustainable production in the CleanTech zone.

3. On the afternoon of Day 1, the NMW/Ausplas exhibition will close its doors at 4pm and all visitors, exhibitors and delegates will be invited to join hundreds of manufacturing professionals for drinks at a networking session.

4. For the first time in 2014, NMW will facilitate ‘One-toOne Meetings’ which will provide prescheduled meetings between qualified buyers and vendors. This is a great opportunity for visitors and exhibitors to meet, network and discuss their unique business requirements and offerings in a private environment.

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www.flexco.com www.foodmag.com.au | Apr/May 2014 | Foodmagazine 21

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BAKED GOODS

From administration

to innovation This time last year, the Byron Bay Cookie Company was in serious trouble. But with new owners and a renewed commitment to innovation, things are looking up for this much loved Australian brand. Danielle Bowling reports.

I

n March 2013, the Byron Bay Cookie Company announced - much to the surprise of consumers and fellow manufacturers - that it had entered voluntary administration. “The Board has exhausted all avenues prior to making the decision to appoint voluntary administrators. The Board has the support of employees, customers and suppliers and is confident that the business has a future and sees this as an opportunity to restructure its manufacturing division,” Jacqueline Schurig, director of the company said at the time.

And she wasn’t wrong. The popular biscuit brand was snapped up by Rinoldi just a few months later in July. Since then, it’s been all systems go in an effort to get the brand not just back on its feet, but as a frontrunner in Australia’s food manufacturing industry.

Emilie Emond, marketing manager for the Byron Bay Cookie Company, says the acquisition by Rinoldi has completely transformed the company.

“At first, people were asking why a

pasta company would purchase a cookie company, but to me it didn’t sound odd at all, it just made sense because Rinoldi is a manufacturer with a lot of experience.

It’s one of Australia’s oldest manufacturers, having been around since 1878 and they have the expertise that we obviously needed. And then for them, they acquired a very strong brand, so it did make sense.

“The mood at Byron Bay Cookie Company has completed lifted,” Emond told Food magazine. “And from a cultural point of view, Rinoldi is a family-owned business.

They’ve got a very strong, positive, friendly culture and that’s transferred over into the Byron side as well. So you can see that people are happy to go to work every day.

It’s made a tremendous difference.”

While there were staff casualties when the company first entered voluntary administration, 15 new employees have been hired since Rinoldi stepped in, and the new owners are making some serious investments to ensure the longevity of Byron Bay’s future.

22 Foodmagazine | Apr/May 2014 | www.foodmag.com.au

“From a practical point of view, the bakehouse in Byron Bay has seen a lot of improvements, because from the get-go Rinoldi has been investing in the site. For example, it’s introduced new processing equipment, and a new ERP [enterprise resource planning] system which we desperately needed … So now we’re in a better position to supply our customers in full and on time,” Emond says.

a lot to us, and obviously we’re still supplying to them – both domestically and internationally.

“That’s such a core part of our brand.

A lot of people know about us because of Qantas,” Emond says.

In other good news for the brand, Jetstar has announced its agreement to stock Byron Bay’s gluten-free Dotty cookie on its flights, both domestically

"Yes, for the first couple of months there was a bit of damage control..."

The Byron Bay Cookie Company credits the loyalty of its customers, including David Jones and Qantas, for its ability to get back to satisfying orders so quickly.

“We were very fortunate because all of our customers stuck by us. The best example is Qantas. We’ve been onboard Qantas for 10 years now and as soon as we were in trouble they reassured us that they were going to continue ordering from us, and that’s something that meant

and into Asia as well.

“That’s another big win for us,” says Emond, who believes the company’s customers were so loyal during Byron Bay’s troubles because they know how hard manufacturing is in Australia at the moment and were keen to stand by a local brand.

Instead of making a song and dance of its acquisition, Emond says Byron Bay Cookie Company’s strategy throughout the past 12 months has simply been to

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ADVANCING Food MANUFACTURING

put its head down, work hard and keep its customers happy.

“Our first focus was [to ensure we were able] to fulfill our orders … Because we’ve got such a strong presence in the café world, it was important for us to be able to supply our cafes, because at the end of the day when people grab a cup of coffee and they see the jars on the counter, that’s the biggest brand exposure you can get. So it was important that we could continue supplying, and keep those jars full.”

Once that was guaranteed, the marketing team was able to work on a very subtle marketing campaign, including attending industry events, conducting product sampling and promoting the brand through social media.

But the end of the day, it all comes down to the product. 2014 will be a year of innovation and product development for the Byron Bay Cookie Company, Emond says, because there’s no better indication that a company is thriving than if it continues to release products that are

in demand and sell well.

“Product development has always been a strong area for us, but I guess in the last 12 months we had to kind of put it on hold. I know we released an Anzac biscuit in 2012, which worked really well for us, but we want to kind of push the boundaries when it comes to new flavours.

“We’re investing a lot in new product development. There are other new flavours in the pipeline as well for 2014; it’s important for us to stay fresh and relevant. We know that our customers love our classic flavours, but there’s always a need to keep innovating and keep the offering current,” she says.

“To be honest I’m quite impressed with how the company’s been turned around in such a short period of time.

Yes, for the first couple of months there was a bit of damage control, but we’ve already managed to get back to where we were. And getting Jetstar onboard was a big win for us. It was like ‘OK we’re back. We’re strong.’” F

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www.foodmag.com.au | Apr/May 2014 | Foodmagazine 23

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PACKAGING

10 things Image: Thinkstock - Deklofenak

you didn’t know

about plastics

F Did you know that the word ‘nylon’ is derived from ‘New York’ and ‘London’?

Pierre Pienaar from the Australian Institute of Packaging shares some interesting insights on plastics and packaging.

ew of us stop to think twice about the pack we are about to open. All that our minds are focused on at the time is to get to the contents, so when we experience difficulty in opening the pack we have lots to say about packaging in general.

Packaging plays such an important role these days in everybody’s life that consumers don’t for one minute stop to think about how they manage to apply deodorant in the morning, eat a bowl of cereal or buy a litre of milk. With this in mind, here are some tips to keep in mind when you’re considering what your next product’s packaging will look and feel like: 1. When designing packaging, always design with the end in mind. Think of the full supply chain, from cradle to grave, and what the package will endure along the way. Thought should be given to shape and size at unit level so that containerisation can be maximised and overall costs reduced.

2. Conditioning is essential before making tests on many materials and containers. Properties of certain materials are a function of the environmental conditions in which they find themselves. For example, the thickness, or caliper, of a piece of chipboard varies with the humidity of its environment.

3. The word ‘nylon’ is derived from ‘New York’ and ‘London’, where DuPont’s research facilities were located in 1935.

24 Foodmagazine | Apr/May 2014 | www.foodmag.com.au

4. Karl Ziegler, a German chemist, developed polyethylene in 1953, and the following year Giulio Natta, an Italian chemist, developed polypropylene. These are two of today’s most commonly used plastics.

5. ‘Plastic’ is used interchangeably with ‘polymer’. Usually ‘plastic’ refers to the finished formulated product, whereas the more correct word ‘polymer’ is used to describe the pure basic material.

6. The word ‘polymer’ is derived from the Greek word ‘poly’ meaning ‘many’, and the Greek word ‘mer’ meaning ‘unit’, i.e. a polymer is a ‘many-unit’ material.

7. Bakelite or polyoxybenzylmethylenglycolanhydride, is an early plastic. It is a thermosetting phenol formaldehyde resin, formed from an elimination reaction of phenol with formaldehyde.

It was developed by Belgian-born chemist Leo Baekeland in New York in 1907. It is one of the first plastics made from synthetic components. It was great for electrical components like plugs.

8. Cellophane looks and feels like a plastic but is not a plastic. It is a thin, transparent sheet made of regenerated cellulose. It was invented by a Swiss chemist, Jacques Brandenberger, who in 1900 was inspired by seeing a wine spill on a restaurant’s tablecloth, and decided to create a cloth that could repel liquids rather than absorb them.

9. We incorporate additives into plastics in order to enhance or improve their performance both during processing and in use of the resulting mouldings or films. Examples are: Plasticisers: these are often necessary to reduce the rigidity of some plastics so that processing is easier at a lower temperature and so that permanent flexibility can be achieved.

Stabilisers: these protect the polymers against physical or chemical deterioration when subjected to atmosphere effects or to high temperatures during processing.

Slip additives: these are added to films in order to reduce the corffecient of friction between two film surfaces.

10. If each Australian family used one less plastic bag each week, that would equate to 253 million fewer bags being used in a year.

If more of us, both as industry members and consumers, thought about packaging a little more, and genuinely appreciated and understood its advantages and real purpose in the supply chain, as a population we’d greatly reduce wastage and packaging pollution, and go a long way towards achieving the three Rs: reuse, recycle and reduce. F Pierre Pienaar is education coordinator at the Australian Institute of Packaging.

Contact him at educate@aipack.com.au

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The easiest way to find the right products and suppliers

MANUFACTURING | MINING | INDUSTRIAL

8

ferret.com.au

(

1300 156 836

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ON THE SHELF

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1 - Wattie's Squeeze & Stir soup

2 - Trumpeters Alcoholic Ice Tea

Wattie’s Squeeze & Stir soup delivers the goodness and flavour of real soup with a rich soup paste in a convenient sachet. The two new flavours - Creamy Chicken and Sweetcorn and Chicken are both available in 70g single-serve portions.

The ice tea in Trumpeters Alcoholic Ice Tea is extracted by use of a cold infusion method, and super premium vodka is added. It’s a twist on a New Orleans recipe from the prohibition era in the 1920s.

Manufacturer: Heinz Watties Shelf life: 12 months Packaging: Plastic Sachets Website: www.watties.co.nz

4 - Skinny Cow Choc Cherry ice cream cookies Creamy low fat cherry flavoured ice cream sandwiched in chocolate biscuits and containing no artificial sweeteners. They’re 97 percent fat free and each serve contains only 127 calories.

Manufacturer: Peters Ice Cream Shelf life: 18 months Packaging: Multipack of four (170ml x 4) Website: www.peters.com.au/brands/skinny-cow

26 Foodmagazine | Apr/May 2014 | www.foodmag.com.au

3 - Organic Apple & Raspberry Fruity Water This fruity water is a mix of 70% organic apples, raspberries and a splash of spring water (30%). It has no concentrates, preservatives, artificial flavours, colours or added sugar.

Manufacturer: N & C Beverages Shelf life: 12 months Packaging: Singles, four packs and 24 bottle cartons Website: www.trumpetersicetea.com

Manufacturer: Whole Kids Shelf life: 12 months Packaging: 200ml carton Website: www.wholekids.com.au

5 - Chai Latte Cookies

6 - It's The Duck's Nuts

These cookies blend a traditional selection of chai spices with large chunks of white chocolate.

They’re available now as a cafe cookie, single wrap or a gluten-free option.

Grown in the Byron Bay hinterland, It’s The Duck’s Nuts are available in eight flavours including Milk Chocolate, Dark Chocolate, Honey Roasted and Wasabi.

Manufacturer: Byron Bay Cookie Company Shelf life: Nine months Packaging: Available as individually wrapped cookies and bulk packs for cafe jars Website: www.cookie.com.au

Manufacturer: Duck Creek Macadamias Shelf life: 12 months Packaging: Vacuum sealed packs, card outer satchel Website: http://duck-creek.com

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2014 Food Magazine Awards

10 YEARS

HURRY, entries are closing soon for the 10th 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.

Submit your entry and you can see your success and hard work rewarded at a glamorous gala event.

The categories for 2014 are: ● Baked Goods ● Confectionery ● Dairy ● Health and Wellness ● Meat and Smallgoods ● Ingredient Innovation ● Organics ● Food Safety and Innovation in Non-Food ● Prepared Foods ● Ready Meals ● Snack Foods ● Beverages

nominations Extension

29 April, 2014

All �inalists will be pro�iled in Food Magazine and on the website.

They will also be given two free tickets to the gala dinner where the winners will be announced.

For more information on the awards or to download the nomination kit please visit: www.foodmag.com.au/awards

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MOVING FOOD FORWARD foodpro is Australasiaâ&#x20AC;&#x2122;s largest gathering of the food and drink processing industry.

This triennial event is a showcase of the latest manufacturing technology, packaging solutions, ingredients and more.

Meet face-to-face with the best in your industry, and find efficiencies to position your operation for the future.

Find better ways to do what you do best at foodpro 2014.

Size 297 (D) x 235 (W) %

Date March 12, 2014 2:53 PM

FD0414_000_DIV

Co-located with the 47th Australian Institute of Food Science and Technology Convention

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COMING TO MELBOURNE THIS YEAR!

REGISTER FREE AT foodproexh.com/FOOD2 using priority code

FOOD2

22-25 June 2014 Melbourne Convention & Exhibition Centre

12/03/14 2:51 PM