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MARCH-APRIL 2013 www.asiafoodjournal.com MICA (P) 266/07/2012 PPS1595/07/2013 (022965)

Your Professional Guide To Ingredients and Processing

INGREDIENTS

Slimming Down Pastry Margarine INSIGHT

Growing in Asia PACKAGING

Integrating Sorting Systems PROCESSING

Sustainable Brewing

SPECIAL REPORT

The impact of new food safety regulations on production lines

S TH HO A W Fo IFE PR od X E A – W VIE si a orl W: 20 d 13 of

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Editor’s Note Re-looking at food security and testing The ongoing horse meat scandal has put meat production companies on the hot seat right now, and is causing a crisis of confidence for the meat industry. The news broke on January 15 – my birthday, of all dates – when the Food Safety Authority of Ireland advised five retailers in the country regarding the agency’s fi ndings of undeclared horse meat content in beef burgers. The keyword here is “undeclared”. In his report, Professor Alan Reilly, chief executive of FSAI, says the result was surprising in that the beef burgers they tested were not labeled as containing horse meat. This is too much to digest (no pun intended). During the testing period (November to December 2012), consumers have been buying and eating those products – because the labels say they are 100% beef. Little did they know. After further testing, other products – sausages, beef lasagnas, shepherd’s pies – were also found to have traces of horse meat, all of which were undeclared. Even mega furniture maker IKEA recalled its Swedish meatballs on suspicion that they contain horse meat. Apart from the horse meat, another thing I fi nd interesting here is the presence of undeclared pork meat in these beef burgers. It was considered “unintentional”, however, and was said to be because of the “cross-over due to the processing of different animal species in the same plant.” Come again? Shouldn’t there be strict regulatory guidelines regarding processing of such products, and that cross-overs like this shouldn’t happen? The thing is, even though we’re in Asia, we’re not shielded from this issue. In fact, these products have reached Asia already. Just recently, an imported brand of lasagna was pulled from shelves in Hong Kong because it came from one of the fi rms at the centre of the scandal. There are a lot of things to learn about this. As consumers now are demanding more information on the food they are putting on the dinner table, the burden lies with all the stakeholders in the food manufacturing supply chain – in that security, compliance to safety regulations, testing activities, as well as labeling, should be relooked at to fi nd the loopholes that cause such troubles, and enhanced to avoid such adulterations happening again in the future.

Stephen Las Marias Editor, Asia Food Journal

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GROUP PUBLISHER Wai-Chun Chen T: +65 6521 9770 E: waichun.chen@contineomedia.com

WEB OPERATIONS EXECUTIVE Franco Sevilleja T: +65 6521 9778 E: franco@contineomedia.com

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EDITOR Stephen Las Marias T: +65 6521 9765 E: stephen.marias@contineomedia.com CONTRIBUTORS Cai Christensen Henning Villadsen John Watts Moshy Cohen Neil Giles Nirvana Chapman Ron Duszanskyj TÜV SÜD SALES & ADMIN ACCOUNT MANAGER Jacqueline Chan T: +65 6521 9773 E: jacqueline.chan@contineomedia.com MARKETING EXECUTIVE Avery Li T: +65 6521 9758 E: avery.li@contineomedia.com ADMIN EXECUTIVE Lim Yann Ming T: +65 6521 9748 E: yannming.lim@contineomedia.com PUBLISHING SUPPORT PRODUCTION MANAGER Pauline Goh T: +65 6521 9772 E: pauline.goh@contineomedia.com DESIGN MANAGER Honess Ho T: +65 6521 9769 E: honess.ho@contineomedia.com GRAPHIC DESIGNER Olive Chan T: +65 6521 9785 E: olive.chan@contineomedia.com DATABASE & WEB MANAGER Lim Keng Boon T: +65 6521 9784 E: kengboon.lim@contineomedia.com

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IN THIS ISSUE

March-April 2013

Contents INGREDIENTS Reducing fat content in puff pastry margarines

SPECIAL REPORT

PG 14

Impact of new food safety regulations PG 8

SPECIAL REPORT 8

11

Increasing Awareness A TÜV SÜD study highlights the growing consumer attitude toward food safety, and how manufacturers could improve their processes to meet consumer demand.

PROCESSING Using sustainable ingredients in brewing

Make the Grade New European food safety regulations now include requirements for the type and location of product inspection equipment on food production lines.

PG 20

INGREDIENTS 14

Slimming Down Pastry Margarine Reducing the fat content in puff pastry margarines require the right type of emulsifier.

PACKAGING

INSIGHT 19

Improving the bottling line

Growing in Asia In an interview with Asia Food Journal, Palsgaard CEO Jakob Thoisen discusses the company’s expansion plans in Asia.

PG 24

PROCESSING 20

Sustainable Brewing More and more brewers are using barley as their brewing adjunct.

PACKAGING 24

Integrating Sorting Systems A flexible, integrated palletizer can improve a bottling line without sacrificing speed or handling quality.

MARKET TRENDS 26

28

Success Formula There are four key points to consider in developing strong beverage brands in emerging markets. Gaining Traction As companies look to future innovation, priorities will focus on unique ingredient offerings, textures, and clean ingredient statements.

2 Asia Food Journal March-April 2013

MARKETWATCH Find out about the latest product launches in the industry today. PG 31

IN EVERY ISSUE 01 EDITOR’S NOTE & SALES OFFICES 03 GRAB & GO 31 MARKETWATCH 34 CALENDAR OF EVENTS COVER: COURTESY OF PURAC ASIA PACIFIC.


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Asia Food Journal • DU: 18.03.13


INGREDIENTS

Industry Updates FORBES AND DEL MONTE TO BRING REDUCOL TO PHILIPPINES, INDIA Forbes Medi-Tech Corporation is partnering with Del Monte Pacific Ltd to manufacture and sell foods and beverages featuring Forbes’ Reducol throughout the Philippines, India and Myanmar. Reducol, is a cholesterol management ingredient made from coniferous trees. The ingredient some cholesterol into the body, has been included in yogurts, yogurt drinks, cheese and milk to support healthy cholesterol levels. In December last year, Forbes received a United State patent for an extraction technology for plant sterols and stanols.

MAREL APPOINTS NEW MD FOR FURTHER PROCESSING DIVISION Marel has appointed Gerrit den Bok to the position of Managing Director of the Further Processing Industry Center effective May 1, 2013. He will be reporting directly to Theo Hoen, CEO of Marel. den Bok will be replacing Bert Jan Hardenbol, who left at the end of February to pursue a career outside Marel. He has been with the company for 23 years, and has acquired extensive management experience as Manager of Service for Marel’s Poultry Industry Center.

EUROPE'S HORSE MEAT SCANDAL REACHES ASIA The horse meat scandal currently gripping Europe has reached Asia, where an imported lasagna brand was pulled from the shelves in Hong Kong, as Czech officials ordered similar action on frozen meals mislabelled “beef”. According to reports, Hong Kong authorities ordered ParknShop, one of the biggest supermarket chains in the city, to remove lasagna made by Findus, one of the firms at the centre of the scandal. The product was imported from Britain and made by French firm Comigel. 4 Asia Food Journal March-April 2013

Burcon nearing patent approval for CLARISOY Burcon NutraScience Corporation recently received a notice of allowance from the United States Patent and Trademark Office (USPTO) for a patent application covering a process for the company's production of CLARISOY soy protein. A notice of allowance from the USPTO is a written notification that a patent application has cleared internal review and is pending issuance. To date, Burcon’s patent portfolio consists of 218 issued patents in various countries, including 36 issued U.S. patents, and in excess of 400 additional pending patent applications, 81 of which are U.S. patent applications. The patent allowance which is the subject of this news release will be issued as a granted U.S. patent in the near future. CLARISOY, which is under license to ADM, a vegetable-based protein capable of offering both clarity and high-quality protein nutrition in low pH beverage systems. In March 2011, Burcon entered into a License and Production Agreement with ADM for the worldwide production, distribution and sale of CLARISOY soy protein. The agreement gives ADM exclusive rights across all geographic regions and all potential product applications to produce, market, and sell CLARISOY soy protein. ADM makes royalty payments to Burcon on the sales of CLARISOY under the license agreement. ADM's CLARISOY line includes a range of products for both low and neutral pH applications allowing food and beverage companies to easily include up to 10 grams of CLARISOY per serving.

Grab&Go INGREDIENTS

Givaudan expands flavour capabilities in India Fragrance and flavour company Givaudan has expanded its capabilities and resources in India by opening its new Innovation Centre in Mumbai, bringing innovative and creative flavour and taste solutions to its customers in the country. For the first time, Givaudan’s sensory science, flavour science and foodservice expertise will be available from within India. Food and beverage customers across the sub-continent will benefit from faster access to Givaudan’s tools and technical services, including Indian consumerpreferred flavour profiles such as mango, dairy and Indian spices and cooking cues. Representing an investment of over CHF3.7 million to meet rising customer demand for Givaudan’s technical services from across the Indian sub-continent, the new Mumbai Flavour Innovation Centre is also the latest demonstration of Givaudan’s on going commitment to expanding its creative and technical capabilities in India. Givaudan just completed the expansion of its flavours powder blend capacity at its Daman production facility and is planning a new flavours manufacturing site at Pune. India is one of over 40 countries in which Givaudan has a presence. In 2012, the company grew its business in developing markets by 13.2% in local currencies; it aims to increase its total sales in these markets to 50% by 2015 across all categories. This year, further investments will be completed in Asia Pacific, such as the expansion of new spray drying capabilities in Indonesia and the ground breaking of a new savoury facility in China.


INGREDIENTS

PureCircle getting ready to commercialize latest stevia innovation PureCircle is preparing to commercialize its latest stevia innovation, the high purity Reb D, which recently has received self-affirmed GRAS status following a detailed safety evaluation by an independent Expert Panel. In line with this, the company has elected to formally submit its GRAS notification to the FDA for the agency’s additional safety review. The high purity Reb D has been identified as having one of the best sweetness profiles of any steviol glycoside from the stevia leaf. This is said to further enable customers to develop naturally sweetened formulations with very low to no calories, particularly in food and beverages with higher sweetness levels, such as carbonated soft drinks. Its commercialization will play an integral role in extending the company’s breakthrough Stevia 3.0 innovation platform alongside other next generation innovations, such as PureCircle Alpha, SG95 and PureCircle flavor NSF-02. The PureCircle Reb D commercialization follows more than a decade of research and development that takes advantage of breakthroughs across the company’s entire vertically integrated supply chain. The development is made possible in result of discoveries through PureCircle’s Comprehensive Breeding Program involving in-house and partner (third-party) breeding centers, its agricultural investment across Paraguay, Kenya, China and the United States and industry leading extraction and purification capabilities. In addition to proprietary high Reb D content leaf varieties, PureCircle has now secured process, method and application patents to protect this new innovation, including a suite of more than 25 patents and patent applications for the ingredient.

CREATING TOMORROW’S SOLUTIONS

DO YOU WANT TO STABILIZE YOUR EMULSION WITHOUT AN EMULSIFIER?

DISCOVERY

Chr. Hansen innovation cuts sodium content in cheese by half Salt is an essential ingredient in cooking, food preservation as well as the manufacture of processed food. However, due to the link between excessive sodium consumption and high blood pressure, the World Health Organization (WHO) dietary guidelines recommend consuming less than 2g sodium, or 5g of salt, per day. Average sodium consumption in countries around the world ranges from 2.6g to 7.2g per person per day, requiring a 25- to 75-percent reduction to meet WHO recommendations. Most western countries and regions including the United States, Canada and the European Union have voluntary initiatives to reduce dietary sodium intake, including salt reduction in cheese. According to Timothy Wallace, Enzymes Marketing Manager, Chr. Hansen, reducing sodium in cheese is technically challenging as it has adverse impact on taste, texture and shelf life. Commercial attempts to reduce salt in cheese have been largely unsuccessful due to poor product quality. “Using SaltLite, cheese producers are able to reduce sodium levels up to 50% while ensuring exceptional product quality. Moreover, SaltLite contains only natural ingredients already used in the manufacture of cheese ,” says Wallace. SaltLite is the result of Kirsten Kastberg Moeller's PhD project carried out in collaboration between Chr. Hansen and the University of Copenhagen, Denmark. In her PhD work, Moeller, who is currently working as Development Scientist in Chr. Hansen's Cultures & Enzymes R&D department, explored the potential of adapting the existing cheese-making technology, by modifying process parameters and extending functionalities of added lactic acid bacteria and coagulant, to improve the flavor and texture of cheddar cheese with a 50% reduced sodium level.

Would you like to replace your emulsifier with a soluble dietary fiber? Talk to us. We have the solution. We can offer you a naturally occurring carbohydrate derived from starch with excellent emulsifying properties: alpha-cyclodextrin. It interacts with triglycerides building up a surfactant like structure that stabilizes oil-in-water emulsions efficiently. Our alpha-cyclodextrin additionally provides viscosity modulations and increased mouth-feel. It is non hygroscopic and non-browning, colorless, neutral tasting and easy to handle. Wacker Chemicals (China) Pte. Ltd. Tel. +86 21 6100 3535, info.biosolutions@wacker.com www.wacker.com/emulsifier www.asiafoodjournal.com Asia Food Journal 5


BUSINESS

Industry Updates SPECIALTY PAPERS AND BOARDS SEEN GOING HEADTO-HEAD WITH PLASTICS According to a new, indepth market study from AWA Alexander Watson Associates, “Specialty Papers & Paperboards Global Sourcebook 2013”, the specialty papers and boards market has progressed through the years of the economic crisis, with an annual growth rate between 2000 and 2011 of 2.1%. The report projects that the market will continue growing in line with global GDP. The report, however, noted that growing “high technology” production capacity in Asia, particularly China, is negaatively affecting the traditional leading producer markets, Europe and North America, and international trade, globalization, and consolidation are now growing features, with their attendant upsides and downsides.

SAP BOOSTS OLAM'S OPERATIONAL EFFICIENCIES SAP has inked a long-term relationship with global agribusiness Olam International Limited on enterprise-wide UDD (Unlimited During Deployment) license agreement that allows Olam to deploy a wide range of SAP products. Olam has already implemented SAP solutions in three countries. Implementation is in progress in seven others. Eight of these operations are in emerging markets, which account for a significant portion of Olam’s business volumes.

PM Group lands $50M worth of contracts in India PM Group has been awarded a series of new project management and design contracts for the lifesciences and food and beverage sectors with combined capital values of almost $50 million in India. The company is currently working on projects in the growing Indian food, beverage and consumer health products sectors for clients including Danone, Unilever and McCain Foods. The company is also completing a range of complex life science projects for leading multinational clients in India including Lonza and Dr Reddy’s From left: Dave Murphy, CEO, PM Group greeting Laboratories. Krishna Kumar Gopala, Managing Director of PM This latest development, in addition to the Group in India and Allan Schouten, Managing Directorgrowth of PM Group’s China and Singapore Asia, PM Group. offices, represents PM Group’s commitment to growing its business across the Asia Pacific markets and allows them to better serve clients on a global basis.

BUSINESS

Waters sets up new solution centre in Singapore Waters Corporation has announced the opening of a new Solution Centre in Singapore. Located in Singapore Science Park II, Waters Solution Centre is equipped with advanced analytical application development and demonstration capabilities and training facilities dedicated to addressing the needs of laboratory scientists throughout Southeast Asia. “The scientific challenges our customers face in Southeast Asia are unique to this part of the world and Waters’ new Solution Centre is designed to address these challenges to ensure our customers are successful. Comprising a team of skilled analytical scientists, many at post doctoral levels, who will offer technical advice and develop applications to solve analytical issues, the Solution Centre will serve the increasing important markets of Southeast Asia along with Singapore and Australia,” says Mike Harrington, Vice President Europe and Asia Pacific for the Waters Division. Waters Solution Centre in Singapore further strengthens the footprint the global company already has in the region. In addition to establishing Waters R&D facility for Engineering in Singapore, the new Waters Solution Centre is an extension of Waters’ commitment to promote R&D in Singapore in support of the development of Singapore’s biomedical sciences sector. The Solution Centre will offer customers the Waters Omics Research Platform Solutions, the bestin-class instrumental systems for those in the pharmaceutical and life sciences, food, and clinical research areas. “Through development of applications to address the challenges faced by scientists in this part of the world, Waters hopes to leverage its momentum in food safety analysis and life sciences innovation and expand its capability in traditional medicine research and the development of new tools for the chemical industry,” says Mark Ritchie, Senior Manager of Waters Solution Centre. The new Centre will also be equipped with Water’s ACQUITY Ultra Performance Convergence Chromatography (UPC2), a new category of separations science that is proving to be a reliable complementary chromatography platform with unique workflow, application and environmental impact benefits compared to either liquid or gas chromatography platforms. This revolutionary technology replaces the use of organic solvents with safe, green CO2, while increasing analytical performance.

APPOINTMENTS

WHAT'S YOUR NEWS? Tell us and tell the world stephen.marias@ contineomedia.com 6 Asia Food Journal March-April 2013

Rockwell Automation names new regional director for Southeast Asia Robert Buttermore has joined Rockwell Automation Southeast Asia as its new Regional Director. Based in Singapore, Buttermore succeeds Scott Teerlinck and will be responsible for sales, marketing and business operations in Indonesia, Malaysia, Pakistan, Philippines, Singapore, Thailand, and Vietnam. Buttermore originally joined Rockwell Automation in 1997 in Cleveland, Ohio in the company’s Operations Leadership Development Program as an engineer. He advanced into roles of increasing responsibility in operations management, sales, sales management. Most recently, he was Global Business Manager for IEC Motor Control Centers, prior to relocating to Asia.


MARKET TREND

Natural food colours overtake artificial/ synthetic colours for the first time The value of natural colours have overtaken that of artificial/ synthetic colours globally for the first time, according to a new report into the food colours market from Mintel and Leatherhed Food Research. Global sales of natural colours amounted to an estimated $600 million in 2011, up by almost 29% from 2007 and demonstrating annual growth in excess of 7%. The share of the total food colours market taken by natural varieties has increased from just over a third (34%) in 2007 to nearly 39% during the period. In contrast, growth within the artificial/synthetic colours market has been more modest, with value sales increasing by less than 4% between 2007 and 2011. The segment is now worth an estimated $570 million, which is equivalent to 37% of the overall market (compared to 40% in 2007). “The results of the Southampton Six study has really accelerated the move toward natural colours in Europe, but other regions are also following suit as the consumer demand for more natural formulations builds and as key producers and retailers look to phase out artificial ingredients,” says Chris Brockman, Senior Global Food and Drink Analyst at Mintel. The food industry alone accounts for a 70% share of the natural food colours market compared to 27% for soft drinks and just 3% for alcoholic beverages according to the Mintel and Leatherhead Food Research report. Furthermore, according to the research, the use of natural colours in new launches of food and drinks outweighs the use of artificial/synthetic colours by 2:1 on a global basis. The report also highlights significant differences between regions in their migration to the use of natural colours. Europe has moved strongly towards the use of more natural colours, and leads the way globally, overall using them in 85% of new product launches between 2009 and 2011. Overall, the global market for food colours was worth an estimated $1.55 billion in 2011. This represents growth of 13% from 2007. However, while developing, average annual growth levels currently lie between 2% and 3%, down from the 4-5% experienced throughout most of the previous decade. “Much of this slowdown in growth can be attributed to the global economic recession, and its subsequent effect on consumer expenditure on many sectors of the global food and drinks industry, as well as the continued decline in demand for artificial/ synthetic food colourings,” Chris continues. The report predicts that the trend toward greater use of natural colours will continue, especially within premium food and drink segments and in products positioned for children.

BUSINESS

Manildra, MSM tap D&L to expand into the Philippines Australian food ingredients companies Manildra Group and MSM Milling have appointed D&L Industries Inc.’s wholly-owned subsidiary Oleofats Inc. as the exclusive agent for Manildra and MSM’s canola and its derivatives like high oleic canola and canola meal, as well as wheat and its derivatives such as wheat flour, in the Philippines. This deal with allow OFI to leverage its vast distribution network and deep customer relationships to extend Manildra and MSM’s reach into the Philippine canola and wheat market.

MARKET TREND

Steel food can industry reduces its carbon footprint

The iconic 425ml steel food can industry has reduced its carbon footprint, on average, by an impressive 30% between the period of 2000-2010, according to a new environmental performance study by Empac (European Metal Packaging) and its supply chain partners. This result proves that the metal packaging industry continues to achieve more with less, being thus aligned with the European Union’s resource efficiency roadmap and the need for effective resource conservation. This reduction in CO2 footprint has been achieved through a consistent decrease in the average can weight delivered to customers, combined with a substantial increase in steel recycling rates. Since 2000, the average can weight has dropped by some 6 percent while the average European recycling rate for steel has improved by 44 percent. Further double-digit savings can be achieved, in the medium term, with advances in both weight reduction and steel recycling rates. This study illustrates how European food can manufacturers have successfully decoupled economic growth from environmental impact. Today, food cans are lighter, safer, stronger and even more sustainable, and will continue to play a key and responsible role in the food chain. Data for this study was provided by the Association of European Producers of Steel for Packaging (APEAL), Soudronic, and TNO – the Netherlands Organization for Applied Scientific Research – using the Empac environmental scorecard.

APPOINTMENTS

Elfab appoints APAC general manager Pressure management specialist Elfab has appointed M.K. Kannan as general manager for Asia-Pacific. Kannan has 22 years’ experience in sales, business development and marketing roles, focusing on critical equipment and products in upstream, midstream and downstream markets across the AsiaPacific region. Elfab is one of Europe’s leading manufacturers of rupture discs, bursting panels and associated detection devices, predominantly catering to the chemical, pharmaceutical, and food processing industries. The company also delivers design, testing and consultancy services for pressure management. Outlining his vision for Elfab in the Asia-Pacific market, Kannan said in a statement: “We aim to be the preferred choice for high-quality rupture discs and detection systems, helping to maximise our customers’ operating efficiencies.” www.asiafoodjournal.com Asia Food Journal 7


SPECIAL REPORT

FOOD SAFETY/REGULATIONS

Increasing Awareness In a first-ever independent study, TÜV SÜD highlights the growing consumer attitude toward food safety and how manufacturers could improve their safety processes to meet consumer demand.

C

onsumer concern around product safety is mounting, according to the first-ever independent study TÜV SÜD Safety Gauge. About two thirds or 67 percent of the more than 5,000 consumer respondents stated that food safety is very important to them now, up from around 48 percent in 2007. An even higher percentage of consumers – 71 percent – expect food safety to be very important to them in the next five years. Consumer concerns were also shown to be particularly high when purchasing online. More than half or 55 percent of respondents, for example, stated they are more concerned about safety when buying food products online than in-store. The research, which also investigated the consumer electronics and children’s toy sectors, was undertaken by an independent research institute and conducted in top-tier cities in United States, the United Kingdom, China, India and Japan – five markets that represent almost half (48 percent) of worldwide gross domestic product (GDP). Apart from consumers, the study included surveys of more than 500 management-level employees in manufacturing, distribution and retail companies.

Safest segment Interestingly, the TÜV SÜD Safety Gauge found that consumers rate the food sector as the safest product segment, as compared to the consumer electronics and children’s toy sectors. However, within the segment, consumers were shown to consider “raw meat and fish” and “milk, dairy and eggs” to be the two food categories of highest concern. The study also suggested that consumer concerns may be linked with recent experiences. An average of 20 percent of respondents said they have experienced unsafe food in the last five years. Allergic reactions and food poisoning were the two biggest safety issues consumers reported experiencing over that time.

Purchasing criteria

Significant improvements have been made to product safety practices over the last fi ve years in major manufacturing markets across the world. 8 Asia Food Journal March-April 2013

Safety was listed as an important consideration for consumers when purchasing food products. When asked to rank a list of purchasing criteria according to importance, price, freshness and food safety (hygiene) were ranked as the top three factors, above brand. It is important to note that 75 percent of the consumer surveyed also indicated that they are willing to pay a premium averaging 15.5 percent over regular selling price for food products that achieve exemplary safety standards verified by a credible and independent third-party.


Consumer perception of food safety determinants Consumers reported a strong understanding of what makes a food product safe, and the majority of respondents indicated that product safety labels, country of origin and brand are the most important factors in determining safety. In addition, about two-thirds of consumers said they are aware of food safety labels such as FSSC (Food Safety System Certification), HACCP (Hazard Analysis and Critical Control Points) and IFS (International Food Standard). However, consumers also called for increased transparency in product safety labeling. Nearly one third or 27 percent said they are not aware of any food safety labels, suggesting companies that adhere to high standards could achieve a competitive advantage by more clearly communicating their products’ safety credentials on packaging. For known brands, the study showed safety labels and certifications reinforce consumers’ brand preference, particularly among consumers in China and India. The survey results note that many consumers favour food from developed countries over emerging markets from a safety standpoint. Consumers from the West said they perceive food products coming from within their own region as safest. Consumers had a less positive perception of food from Asia. Respondents from Asia, on the other hand, said they have a positive impression of food safety from their own markets, as well as developed markets.

Perceived product safety levels According to the study, significant improvements have been made to product safety practices over the last five years in major manufacturing markets across the world.

Across all three sectors, businesses were shown to believe that product safety levels in their industry have increased over the last five years. The food industry sector, in particular, shows a positive trend as twice as many companies reported significantly exceeding safety requirements in 2012 as compared to five years ago. In addition, a large portion of the business respondents indicated responsibility for product safety. Currently, 68 percent of food companies said they meet or exceed minimum safety requirements, with more companies (53 percent) predicting they will significantly exceed the minimum standards in the next five years.

The cost of safety Respondents from the food manufacturing industry indicated that they spend an average of 13.6 percent of total production costs on product safety measures. The most common safety practices undertaken by companies were revealed as being in-house product testing (69 percent) and staff training (65 percent). These were followed by practices such as exclusive sourcing from trusted suppliers, independent third-party product testing, product or process certification and ensuring the compliance of the entire supply chain to product safety requirements. The study also revealed that about half or 52 percent of the companies surveyed can ensure that their entire supply chain fulfils product safety requirements, and about 46 percent are able to trace every raw material of their food products throughout the supply chain. Companies from the food industry estimated they would need to increase production costs by 21 percent to achieve the highest safety standards available. This compared to an average of 19 percent across all sectors. At the same time, however, with current standards

Thanks to automation Dr John Maxfield now packs 15% more efficiently. The packaging line, which MULTIVAC supplied as a turnkey line, loads, packs, inspects and labels automatically.

Frankfurt, Germany 04. – 09. May 2013 Hall 11.0 / Hall 11.1

www.asiafoodjournal.com Asia Food Journal 9


SPECIAL REPORT Awareness of Food Safety Labels

Safety Practices Undertaken % of respondents, multiple mentions by Food Manufacturers In-house product testing

69%

Staff training

65%

Exclusive sourcing from trusted suppliers

62%

Independent third-party product testing

57%

Product certification

53%

Compliance of entire supply chain to product safety requirements

52%

Process certification

52%

Awareness of at least one food safety label Aware of food safety label but cannot recall its name Not aware of any food safety label

Safety focus during design and development stage of products Complete traceability in the supply chain

47%

46%

in place, food companies said they have had to conduct an average of 12 product recalls in the last five years at a cost of nearly 9 percent of revenue. Product recall costs coupled with escalating consumer demand and the intrinsic value that offering the highest safety standards has for your brand, suggest investing in enhanced standards can provide a commercial benefit.

good basic instrument for the food processor to identify, evaluate and control risks to food safety. Finally, testing, auditing/certification and training should also be undertaken at the distribution and retail stage. Checks, for example, should be conducted on the packaging, containers and storage facility, supplemented with hygiene and vendor assessment audits.

The state of safety

2. Leveraging the value of third-party testing There is a disconnect between the value consumers place on thirdparty product testing and certification and the amount conducted by businesses. Only half of the businesses surveyed or 55 percent, for example, said they use third-party testing and certification services, despite 90 percent of consumers saying they want to know products are independently tested before being launched in the market. Companies can work with independent third parties to ensure that their products are able to fulfill consumers' demand for safety and demonstrate their commitment to safety with certification marks.

The research findings present an opportunity for businesses to turn consumers’ increasing product safety demand into a business advantage. The TÜV SÜD Safety Gauge reveals that consumers are becoming more discerning and placing increasing value on the importance of product safety. Businesses, on the other hand, continue to place safety at the top of their agenda but expect increasing safety measures to come with costs. Contrary to businesses’ perception, escalating consumer demand coupled with substantial annual recall costs mean that investing in enhanced product safety can improve consumer well-being and drive commercial success at the same time. Specifically, the report suggested three main areas to improve safety levels to benefit businesses and consumers: 1. Farm-to-fork approach The modern day supply chain is extremely complicated. Unlike 15 years ago, corporations seek efficiencies not only through direct suppliers but suppliers’ suppliers, and often even further down the supply chain. This has made supply chain management from farm to fork even more challenging for the food industry. However, traceability is critical to speed up recall process and reduce scope of contamination for the food industry. A holistic approach to food safety begins at the farm level with seed testing, tests pertaining to animal feed, as well as soil condition. This should then be supplemented with auditing/certification, implementation of good agricultural practices and training of staff. It is also crucial to build food safety and quality into the production and manufacturing processes. For example, the HACCP concept is a 10 Asia Food Journal March-April 2013

3. Prevention, not damage control Reacting after the onset of a food scare is less effective than preventing it in the first place. Prevention is best achieved when food safety and quality are considered strategic objectives – ones that improve financial performance. This is evident from the high costs of recalls reported by respondents of the survey. Food recalls can lead to high indirect costs from loss in reputation. It is clear that companies are working hard to improve product safety. However, the results of this research indicate that the issues highlighted such as limited raw material traceability, independent testing and awareness of basic safety practices are common across major manufacturing hubs. Consumers will continue to demand higher safety standards from all companies. Are businesses prepared to give them what they want? They should be, as this survey indicates that high product safety levels not only enhance consumer well-being, but add genuine value to products and mitigate risk. These attributes are essential for remaining competitive and profitable in today’s turbulent economic times.


SPECIAL REPORT

FOOD SAFETY/REGULATIONS

Make the Grade Neil Giles discusses how new European food safety regulations will impact Asian food manufacturers’ production lines.

F

ood safety is a major concern for consumers and retailers alike. Rare, but high-profile food safety incidents due to foreign body contamination have served to keep the issue at the forefront of the public’s consciousness. To ensure consumer safety and protect manufacturer and retailer brands from costly product recalls, large European stores have for a number of years required their suppliers both locally and internationally comply with food safety standards. The principal standards accepted in Europe are the British Retail Consortium (BRC) Global Standards, which is the main standard in place in the UK and Scandinavia, and the International Featured Standards (IFS) in France and Germany and other European economies, both of which are recognised in other global markets. In most cases, to do business with retailers in these countries, the manufacturer must be BRC or IFS certified. In January 2012, the BRC Global Standards Version 6 came into force with regulations to enhance consumer safety, including requirements for the type and location of product inspection equipment on food production lines, maintenance procedures and documentation to demonstrate due diligence. In July of the same year, IFS Version 6 was also introduced with rigorous new demands for tighter controls over processing lines. Both standards are approved by the Global Food Safety Initiative (GFSI). Launched in 2000, following a number of food safety crises when consumer confidence was at an all-time low, GFSI is an initiative for the improvement of food safety management systems to ensure confidence in the delivery of safe food to consumers worldwide. Standards approved by GFSI are based on the Hazard Analysis and Critical Control Points (HACCP) programme, which requires manufacturers to audit their lines to identify potential risks to product quality and integrity. As well as demanding the adoption of the HACCP programme, Version 6 of the BRC

Simply installing a product inspection machine does not completely guarantee food safety. Manufacturers must look after the machines to ensure optimum detection sensitivity and performance. www.asiafoodjournal.com Asia Food Journal 11


SPECIAL REPORT

Maintaining an Effective Product Inspection System

Figure 1: The new BRC Global Standards stipulates that production lines include a means of identifying and removing foreign bodies, such as metal detection or x-ray inspection systems. Global Standards and IFS include a number of other amendments to protect consumers from safety threats, such as foreign body contamination and to safeguard against reputation-damaging product recalls.

Key BRC Standards Changes Prior to purchasing inspection equipment, food manufacturers must determine the contaminant threats to their production line and its potential source. The BRC Global Standards now states that manufacturers should undertake a HACCP audit on each food production line. Where a risk of contamination is identified, manufacturers must take steps to mitigate the threat. This is achieved by establishing a “Critical Control Point” (CCP) after the point where the contamination could occur. The HACCP audit process also identifies the principal forms of contamination on the production line, such as metal fragments or stone, by investigating the origin of raw ingredients, the steps in the manufacturing process and the packaging used. This can ensure food manufacturers locate their product inspection systems where they will be most effective, limiting the risk of foreign body contamination. The new BRC Global Standards stipulates that production lines include a means of identifying and removing foreign bodies, such as metal detection or x-ray inspection systems. The choice of technology depends on the nature of the contaminant threat. For example, if the only contaminant threat on the production line is shards of metal, then a metal detector will be the most appropriate technology. If the most likely contamination is from bone fragments, stone or glass, then it will be necessary to install an x-ray inspection system. Simple steps such as these can enable food manufacturers in Asia to “validate and justify” the location of the product inspection system on the production line. As well as requiring brand owners to install product inspection systems at each CCP, BRC Global Standards also stipulate that production lines should allow segregation of any rejected products from the manufacturing process. This includes the use of “an automatic rejection device for continuous inline systems”, such as an air jet removal device and lockable reject bin, or “a belt stop system with an alarm” to allow for manual removal. This ensures all contaminated products are fully removed from further processing, protecting the consumer. Installing foreign body detection and removal technology at every CCP can enable brand owners to locate the source of contamination and take preventative action to minimise the risk of future incidents. 12 Asia Food Journal March-April 2013

Simply installing a product inspection machine does not completely guarantee food safety. Manufacturers must look after the machines to ensure optimum detection sensitivity and performance. BRC Global Standards Version 6 requires food manufacturers to put in place a maintenance schedule or a condition monitoring system to continuously examine the performance of each foreign body detection machine. Such procedures can alert manufacturers and brand owners to any issues that could affect detection sensitivity, enabling them to rectify them before they become a problem. In addition, the new standards require food manufacturers to check their inspection systems regularly with test pieces containing sample contaminants, particularly ferrous and non-ferrous metal and stainless steel. X-ray inspection tests should also include soda lime glass, plastics and rubber where a risk of contamination from these materials has been identified. Testing should involve passing test packs repeatedly through the machine aperture to ensure the pre-determined sensitivity levels are being maintained. Ideally, the test samples should be of a variety of sizes and materials to guarantee the inspection system offers comprehensive foreign body detection.

Reporting Contamination Incidents Finally, for comprehensive compliance with BRC Global Standards Version 6 as well as protection for both brand and consumer, food manufacturers must implement procedures to rectify any problems identified after every contamination incident or test failure. A new clause now requires the isolation of all products manufactured since the last successful test for re-inspection. In addition, there should be adequate reporting mechanisms in place to alert operators to any product inspection problems. In the event of a product recall, manufacturers can demonstrate that they have undertaken all due diligence in minimising contamination risk to consumers. Though unstated in the updated standards, manufacturers should keep records for as long as possible to protect themselves against contamination claims that may occur years after the product has left the factory floor.

New IFS Requirements The key changes in the latest IFS regulations affect Asian food manufacturers most critically in the areas of senior management responsibility, production process, and measures, analysis and improvements. The updated requirements for Senior Management Responsibility relate to ensuring that personnel are sufficiently trained, understand their individual responsibilities in food safety and know that their performance is monitored. IFS Version 6 puts the onus for ensuring optimum food safety on every person involved in the production process, not just on the machine operatives. Product inspection systems that offer comprehensive monitoring and data collection software as well as options for remote access to contaminant detection records can enable manufacturers to demonstrate they have exercised due diligence in their processes and have adhered to food safety guidelines in the event of a contamination event. Inspection technology with enhanced security features, such as password-protected reject bin locks and touchscreen displays and recording of login attempts optimise manufacturers’ control over their production lines. IFS Version 6 contains new clauses designed to mitigate the risk of contamination of food products from metal, glass and other foreign bodies. These include comprehensive training on any product inspection equipment used on the processing line for all employees and regular changeover of machine operatives to prevent fatigue from affecting food quality.


Figure 2: Installing foreign body detection and removal technology at every CCP can enable brand owners to locate the source of contamination and take preventative action to minimise the risk of future incidents.

It is important, therefore, that product inspection systems are easy to use to simplify the training process and build operative confidence when using the machine. Product inspection technology with features such as touchscreen Human Machine Interfaces (HMIs), intuitive software and pre-set functions for product changeovers can reduce the amount of training necessary to ensure optimum detection sensitivity and minimise the risk of reputation-damaging product recalls. IFS Version 6 stipulates that food manufacturers introduce and document procedures describing the steps to be taken in the event of breakage of glass and other brittle material near the production line. These measures should include isolation of affected product batches, which can be achieved with the use of an x-ray machine or metal detector featuring an automatic rejecter and lockable reject bin to quarantine non-conforming food packs. This technology allows manufacturers to re-inspect isolated products, enabling them to be reworked to reduce product waste. Product labelling is another key focus of the new IFS Version 6. All information must be legible, indelible and meet customer-applicable product specifications. Importantly for Asian manufacturers, the updated standards stipulate that there should be a process in place to ensure that all product labelling complies with the current legislation of the destination country. This includes the display of ingredients, product weight and expiration date. All information should correspond to the product inside the packaging as well. Food manufacturers can fully automate this process using advanced vision inspection technology, minimising the risk of non-conforming packs reaching end consumers. These systems are capable of examining labelling information at high speeds and removing sub-standard packs from the line. It is important that any vision inspection equipment has easyto-use HMIs to facilitate the setup of the machine with new information both for product changeovers and for the guarantee of

compliance with new legislation in the future without the need to invest in new technology. IFS Version 6 for the first time contains guidelines regarding traceability of food products to identify the relationship between product batches and their labels. Manufacturers must now store samples of each product batch appropriately until its expiration date and, if required by retailers, for a determined period beyond. Advanced vision inspection and serialisation technology installed at key points on the production line can help manufacturers comply with these standards by enabling products to be tracked from the raw ingredient stage, through processing to packaging and palletisation until they are ready to be transported to the retailer, storing the information for later use. This ensures manufacturers can easily identify which sample belongs to which batch in the event of a product recall or request by the retailer. Such equipment is already in use in the pharmaceutical industry and optimises food manufacturers’ oversight of the entire production line, helping them demonstrate due diligence in the event of a product recall. Additionally, the guidelines in IFS Version 6 relating to maintenance and repair of product inspection equipment have been amended, as have those regarding the use of third-party service providers. Food manufacturers are now obliged to ensure that all product equipment processes are in good condition without any negative influence on food safety. Where manufacturers require maintenance from a third party, all the manufacturers’ specified material and equipment requirements should be respected by service providers. Food manufacturers can maintain the integrity of their food safety procedures by sourcing maintenance and other services from trusted suppliers. To ensure optimum performance of product inspection systems, they can take advantage of the dedicated service offering of their equipment providers. Service engineers can make necessary repairs, conduct audits or carry out product verification while the machine is in operation, enabling compliance with standards and boosting productivity as well. Finally, and most importantly for food manufacturers, IFS Version 6 stipulates that all measuring devices be tested regularly for accuracy, adjusted, and calibrated as necessary under a comprehensive monitoring system. Furthermore, the results of these checks, adjustments and calibrations must be documented and any necessary corrective action on weighing technology or production processes carried out. To comply with these standards, it is important that the product inspection system used be easily recalibrated or re-set in the event of a failed test. Systems with easy-to-use displays and dedicated test procedures built into the software can facilitate this process for properly adjusted equipment. Remote monitoring services can test many product inspection system performance parameters and undertake corrective action in real time without the need to disrupt production. In this way, manufacturers can ensure optimum production line security without compromising downtime.

Be Aware Across Europe, governments, retailers and consumers are highly aware of the issues of food safety, and updates to regulations, such as BRC Global Standards and IFS Version 6, are coming into effect all the time. Asian food manufacturers must understand any new guidelines that come into effect in Europe and other lucrative markets and take steps to ensure that their product inspection systems are compliant in every way. This is vital to safeguard consumer well-being, to protect their brand at home and abroad and to grow their business globally. NEIL GILES IS THE MARKETING COMMUNICATIONS MANAGER AT THE METTLERTOLEDO PRODUCT INSPECTION DIVISION OF METTLER-TOLEDO, BASED IN THE UK. www.asiafoodjournal.com Asia Food Journal 13


INGREDIENTS

THICKENERS/EMULSIFIERS

Slimming Down Pastry Margarine Cai Christensen talks about selecting the correct emulsifiers in reducing the fat content in puff pastry margarines.

P

uff pastry margarines have always been a challenge for the margarine industry to produce due to the many demands of the margarine, such as a non-greasy surface so that the margarine is easy to work with both by hand and by extrusion process; plasticity, so that it can be folded without breaking, because breaks will lead to insufficient lift and flaky structure in the puff pastries; and high functionality, so that the best expansion can be obtained. In recent years, new challenges such as no trans fatty acids in the margarines, no hydrogenated fats in the margarine and no lecithin in the margarine have been added. Furthermore, the fat content in puff pastry is significant because the amount of margarine rolled into the dough is about 35 percent. Consequently, because of declarations and also because of the costs of raw materials, calls are now made to reduce the fat content of the margarine. This article discusses the possibilities for fulfilling the above demands, and also by trial and evaluation demonstrates some important parameters.

Puff pastry and puff pastry margarines Puff pastry is characterised by its laminated structure of baked 14 Asia Food Journal March-April 2013

layers of dough separated by thin layers of margarine or fat. The ratio between the dough and the margarine is typically 2:1, as illustrated in Table 1. Ingredient

Weight

%

Flour

1000 g

39.1

Salt

10 g

0.4

Water

550 g

21.4

Puff pastry margarine

100 g

3.9

Roll in with puff pastry margarine

900 g

35.2

Table 1: Typical recipe for puff pastries.


During the lamination process each layer of dough will be separated by one layer of margarine. In puff pastry, the numbers of layers are typically 144 or 288. However, puff pastries with up to 1458 layers are also produced.

Dough

Margarine

Figure 1: Puff pastry dough with layers of dough and margarine. After preparation of the dough, the layers can be illustrated as in Figure 1. After baking, this lamination of the dough will result in a puff pastry with a nice lamination and volume (expressed as height and expansion).

H2O Dough

Steam

Margarine

H2O

Dough Margarine

Margarine

Dough

Steam

Dough H2O

Before baking Regular layers

During Baking Good Expansion

Figure 2: Puff pastry dough during baking process.

A puff pastry dough typically contains flour, salt, water and puff pastry margarine. In this article, we will focus upon the puff pastry margarine; both the traditionally type with minimum 80 percent fat content, and reduced fat types. Puff pastry margarines are characterized by the plasticity, which allows the margarines to be worked with and folded and extruded without breaking and becoming greasy. In order to obtain this margarine both the composition of the margarine, the processing and the tempering of the margarine are extremely important parameters.

Fat blends Typically used fat blends for puff pastry margarine contain palm fats and liquid oils as different combinations of these will form a good basis for creating margarines with very good plasticity. Palm fats are slow crystallizing fats and polymorph fats, which poses specific demands to the process of the puff pastry margarine: The margarine must be completely crystallized and most of the primary bondings removed and exchanged to secondary bondings in order to keep the plasticity of the margarine after production. Puff pastry margarine is subsequently tempered in typically three days to one week before distribution in order to obtain the best plasticity. If the puff pastry margarine is prepared for the dough by extruders, the final kneading of the margarine will take place during this process. If the margarine is used in traditionally manufactured puff pastry dough, the plasticity of the margarine after production and tempering is very important. www.asiafoodjournal.com Asia Food Journal 15


INGREDIENTS

Test system

Emulsifiers typically used In order to get the right performance of the pastry margarines, combinations of different emulsifiers are normally used: • Distilled mono- and diglycerides of fatty acids/ mono- and diglycerides of fatty acids (E471) will reduce the interfacial tension in the margarine emulsion, so that the final margarine, which is a water-in-oil emulsion, will contain a stable homogenous distribution of small water droplets which cannot agglomerate and create free water on the margarine. During the process of producing the puff pastry dough, it is necessary to work with the margarine by hand or by extrusion and unstable water-in-oil emulsions will create free water which will decrease the plasticity of the margarine and give breaks in the margarine and thereby make it difficult to produce the right quality of puff pastries afterwards. • Lecithin, (E322) is used in order to improve the plasticity of the puff pastry margarine because it also is an emulsifier and will additionally improve the solubility of the distilled mono- and diglycerides of fatty acids/ mono- and diglycerides of fatty acids (E471) in the fat blend for the puff pasty margarine. • Polyglycerol esters of fatty acids, (E475) are used in combination with distilled mono- and diglycerides of fatty acids/mono- and diglycerides of fatty acids (E471) in order to improve the crystal structure of the margarine. A high number of smaller crystals will have a larger surface area than a few large crystals in the margarine, and thereby the margarine with a high number of small crystals will absorb the liquid oil created during working with the margarine. Thus a non-greasy margarine is created. As illustrated in Figure 3 the addition of polyglycerol esters of fatty acids (E475) will also promote the crystallization of the margarine in the tube chiller, meaning that if polyglycerol esters of fatty acids (E475) are added to the recipe the process must be adjusted in order for the margarine not to be overworked, resulting in the margarine becoming more greasy and thereby less suitable for use in puff pastry production.

Emulsifier Type Added

Consistency

Surface

Plastic

Very dry

Palsgaard DMG 0093

Stiff

Dry

Palsgaard DMG 0291

Soft

Greasy

Palsgaard 1304

Table 2: Evaluation of margarine.

It can be observed from the above that the type of emulsifier has a significant impact on the consistency and the surface of the puff pastry margarines and thereby makes the margarines more or less suitable for producing the puff pastry dough and the baked puff pastry, as shown on Figure 4.

12 10 8 Expansion

It is very important to choose the right type of emulsifier in order to obtain the best puff pastry margarine and the best baked goods.

In order to illustrate these parameters, the following trials with puff pastry margarines with 80 percent fat content were performed: • Puff pastry margarine with distilled mono- and diglycerides of fatty acids/ mono- and diglycerides of fatty acids, fully saturated type, (E471)and lecithin, (E322) • Puff pastry margarine with distilled mono- and diglycerides of fatty acids/ mono- and diglycerides of fatty acids, (E471) partially unsaturated and lecithin, (E322) • Puff pastry margarine with a combination4 of distilled mono- and diglycerides of fatty acids/ mono- and diglycerides of fatty acids (E471) and polyglycerol esters of fatty acids, (E475)and lecithins, (E322) The puff pastry margarines were produced on a scrape surface heat exchanger and the margarines were tempered 1 week before evaluation. The evaluations of the margarines are shown in Table 2.

6 4 2 0 Palsgaard® 1304

Palsgaard® DMG 0291

Palsgaard® DMG 0093

C2

C3

PR M

PR M

P/ C

Figure 4: Test of different emulsifiers in puff pastry margarine. C1

C4 Ma rg ar in e

Figure 3: Effects of polyglycerol esters in puff pastry margarine. 16 Asia Food Journal March-April 2013

The trials show the differences in expansions if different types of emulsifiers are used and it is partly caused by the different qualities of the margarines and partly by the functionalities of the different emulsifiers during baking. Because of the lamination process the emulsion in the margarine will be stressed and a strong emulsion is necessary, so that no free water from the margarine will occur. Typically, a higher amount of emulsifier make the emulsion stronger, and the next trials were made in order to find an optimal dosage of emulsifier in this waterin-oil system, as shown in Figure 5. In this trial the dosage of lecithin3 was 0.50 percent and pH 3.8.


12 12 10

8 Expansio n

Expansion

10

6 4 2

8 6

pH 6 ,0

4

pH 3 ,8

2

0 0.50%0

.80%

1.00%

Dosage of Palsgaard 1304 ®

Figure 5: Test of different dosages of an emulsifier in puff pastry margarine.

The result of this trial confirms that a higher dosage of emulsifier will improve the baking result. Other dimensions are the effects of dosage of lecithin and the pH of the water phase of the margarines. The test used 1.00 percent of Palsgaard 13044 and a lecithin content from 0.00 to 1.00 percent. As shown in Figure 6, both the pH and the dosage of lecithin will have an important impact on the expansion of the baked puff pastries. These trials showed that a content of 0.50 percent lecithin and pH 3.8

0 0%

0.25%

0.50%

1.00%

Lecithin c on tent

Figure 6: Influence of lecithin and pH value.

is the best combination. By lowering the pH the oxidation of the fats and oils need to be monitored carefully. From the above mentioned trials, made with puff pastry margarine with 80 percent fat content, it can be concluded that: • The use of combinations of emulsifiers make the margarine more suitable for use in pastry production. • A dosage of emulsifiers of 0.80 - 1.00 percent, lecithin dosage 0.50 percent and pH 3.8 will provide the best baking results in puff pastries.

WHATEVER YOU MAKE, MAKE IT RIGHT, WITH COGNEX VISION

Contact: Cognex Singapore Inc Tel: 65 6325 5708 | Email: sales@cognex.com.sg

www.asiafoodjournal.com Asia Food Journal 17


INGREDIENTS

Reduced fat content As described above the content of puff pastry margarine is about 33 percent of the total puff pastry dough. Both in connection with declaration and costs there might be a wish to reduce the fat content of the margarine and thereby the baked puff pastry. The demands to the quality and performance of the puff pastry margarine are high, and these must of course be fulfilled in reduced fat puff pastry margarine, if possible. Another demand might be that the process must be similar to the process with puff pastry margarine with 80 percent fat content. Last but not least the quality of the baked puff pastries must be in line with the puff pastries baked with margarine with higher fat content. For this, article trials with puff pastry margarines with 60 percent fat content and 80 percent fat content were performed. The 33 percent puff pastry margarine in the dough (weight) this will reduce the fat content in the dough by about 6 – 7 percent. During recent years more consumer demands have appeared such as no content of trans fatty acids and hydrogenated fats and lecithin and if those can be included in the new products it provides new possibilities for the manufacturer of puff pastry margarine and puff pastry products, respectively. For the trials below the fat blend shown in Table 3 for the pastry margarine was used. This fat blend will be suitable for producing puff pastry margarine with a non-greasy surface and high plasticity.

Ingredient

After production both types of margarine were evaluated and they both showed a good and similar plasticity and with a non-greasy surface. The puff pastries were produced with 288 layers and after baking the height and expansion were measured. The results are shown in Table 5.

60% puff pastry margarine

80% puff pastry margarine

Height (average)

510

505

Expansion (average)

11.3

11.2

Table 5: Comparison of height and expansion.

From the results of the trials it can be observed, that the height of the baked puff pastries and the expansion are almost identical when using puff pastry margarines with high and low fat contents. The puff pastries produced with both types of margarines had a very good distribution of the layers and a crispy surface.

%

Palm stearin

46%

RBD palm oil

46%

Liquid oil

8%

Table 3: Recipe for the non-hydrogenated and non-trans fatty acid containing fat blend used in the trials.

60% puff pastry margarine

80% puff pastry margarine

Water phase Glucose

1.00%

1.00%

Salt

1.00%

1.00%

Water

38.00%

18.00%

Colour, flavourings, sorbate and/or benzoate might be added pH

3.8

3.8

2.00%

0%

Palsgaard DMG 00931

0%

0.80%

Lecithins3

0%

0.50%

Fat blend

58.00%

78.70%

Fat phase Palsgaard 13255

Table 4: Trials. 18 Asia Food Journal March-April 2013

It is possible to reduce the fat content from 80 percent to 60 percent in the puff pastry margarine and still obtain very satisfactory results.

Choosing the right emulsifier From the above trials, it has been shown, that a range of factors have an influence on the quality of margarines for puff pastry but also on the baked puff pastries. Furthermore, it has been shown that it is possible to reduce the fat content from 80 percent to 60 percent in the puff pastry margarine and still obtain very satisfactory results both with regards to the margarine but also in the baked goods. It is very important to choose the right type of emulsifier in order to obtain the best puff pastry margarine and the best baked goods. As shown, the dosage of the emulsifier also has a big impact on the baked goods. It is always important to consult the legislation and patent rights and test the performance in your own margarines and baked goods before introducing the solutions in the market. CAI CHRISTENSEN, M. SC. IN FOOD TECHNOLOGY, IS THE BUSINESS UNIT MANAGER, LIPID & FINE FOODS GROUP, AT PALSGAARD A/S.


INSIGHT

INTERVIEW

Growing in Asia Palsgaard CEO Jakob Thøisen talks to Stephen Las Marias about the company’s expansion plans in Asia.

E

mulsifier and stabiliser manufacturer Palsgaard A/S is expanding its presence in Asia by opening a new factory in Johor Bahru, Malaysia in the middle of this year. The new facility is expected to complement its Regional Application Centre in Singapore, where the company – on top of its product development for diary, ice cream, soya, and bakery and confectionery applications – is also adding a pilot plant for margarine. In an interview, Palsgaard CEO Jakob Thøisen highlights the reasons why the company is growing its base in Asia as well as some of the issues in the food industry that they are trying to address. Excerpts:

Asia Food Journal: Why is Asia important to Palsgaard? Thøisen: Asia is important because people here are getting wealthier and busier, creating a demand for prepared foods. Given Asia’s population – we would have a consumer base here of several billion people – that demand growth is significant. In fact, this is the largest growing region in the world. Europe is a mature market, so nothing much is happening there. Asia is the place to be if you want to succeed. That’s the main reason why we want to have a factory in Malaysia. Asia Food Journal: Tell us about your Regional Application Centre in Singapore. Thøisen: We’ve had this Technical Centre for a little more than 10 years now. If we go further back, we started 21 years ago with one person here. We have now invested more than S$10 million here. And the latest that we have (built) is the margarine factory that will be operational next year. We have a lot of activities here within the bakery, dairy, and ice cream industry. The whole idea is that we support the customers in an integrated manner as much as we can. We can go to the customers; we can take them here; suggest recipes and changes; or if the customers want to change something, we can make the products here. They won’t have to do it, there’s a downtime on that. We can do small scale here, and this is a huge advantage to the customer. We see ourselves as the service leader in this business. Asia Food Journal: You are currently constructing a new factory in Malaysia. What will be the activities there? Thøisen: Today, all our products are coming from our factories in the Netherlands or in Denmark. We will add to that production by having a factory in Malaysia. By having that, we will be able to bring down the lead time for the customers in Asia significantly. They have 28 days on average as of now; this will be reduced by about 5%. Asia Food Journal: How will this complement the Singapore facility? Thøisen: This will go perfectly hand on hand. They would really complement each other because we have, as far as I can see, what

Palsgaard CEO Jakob Thøisen. we need here. We have very skilled people here, very state-of-theart equipment, and we’ve been here for a long time, we have very good relations with customers throughout the region. So what is really needed now is to take the next leap and have a production here in order to make it complementary and complete. Asia Food Journal: What are your reasons for choosing Malaysia? Thøisen: Among the reasons are the proximity to the raw materials suppliers, particularly palm oil, which we use in most of our production. Then there’s ample space available there. On top of that, Malaysia’s got a very good infrastructure, that’s why we chose to be there. Asia Food Journal: Overall, what do food-related businesses want, and how can Palsgaard help them? Thøisen: Generally, food producers want safer and less costly formulations. And then of course, if we can help customers reduce fat, let’s say in a recipe, and make it a healthier product, then it serves two purposes: it reduces the cost and it also makes for a healthier product. Asia Food Journal: Palsgaard has a strong focus on CSR. How has that played out in Asia? Thøisen: More and more customers are saying they really value our doing as much work as we can in this area. In Europe, it is necessary to be in the forefront and be able to prove that you work diplomatically with this. From an overall perspective, we have a goal that is very ambitious I think for an industrial company: that is reducing our CO2 emission to zero by 2020. This is ambitious for a heavy consumer of electricity and high temperature steam, etc. But I can tell you, in 2007, we used 450g of CO2 per kilo finished products. We are now down to 180g. This will then be zero in 2020. We’ve come a fair bit of a way already within a short span of time. www.asiafoodjournal.com Asia Food Journal 19


PROCESSING

BREWING

Sustainable Brewing Henning Villadsen and Ron Duszanskyj highlight the advantages of using barley as a brewing adjunct.

B

rewing is a highly competitive and cost-sensitive business. Common to all players is a focus on leveraging innovation and technology to optimize operational efficiencies and drive down costs, as well as on building brand equity and consumer appeal. Due to continuous developments in equipment, brewing processes and enzyme technology, brewers are increasingly able to utilize different ingredients and raw materials for their products to be able to keep up with the competition and offer signature tastes and products.

Adjunct choices Although malt, along with water, hops and yeast, will remain the mainstream raw materials for brewing, there are many alternatives to malt that are commonly used as adjuncts. These include maize, rice, wheat and barley. For some brands, these adjuncts are very carefully selected and form part of the beer signature profile, whereas for others they are used simply because they are a lower cost starch source. However, the decision to use adjuncts is not usually based on financial criteria alone. A specific type and quantity of adjunct is subject to many restricting parameters including local availability and logistics. What’s more, for some beers, mainly in the premium market segment, brand identity and signature flavour and taste will dictate the composition, and therefore the cost of the raw materials required. Typically, therefore, brewers have less flexibility in the recipes of their global premium brands, but more flexibility to use lower cost adjuncts as alternatives to malt for new brand development, or for beers in the value segments. This allows them to reduce costs without compromising the organoleptic properties of the beer. In all cases, the raw materials selected need to have the right levels of extract and protein to provide the correct balance of carbon and nitrogen sources for fermentation. Also, there must be enough protein available to ensure the right level of foam, and a moderate to low level of non-starch polysaccharides to avoid lengthy processing with sub-optimal yields. In addition to these technical requirements, the security of supply and consistency in raw material specifications is high on the brewers’ agenda.

Continuous developments in equipment, brewing processes and enzyme technology are helping brewers to increasingly utilize different ingredients and raw materials for their products.

20 Asia Food Journal March-April 2013

The increasing use of barley When it was first introduced as a partial replacement for malt, the


use of barley was as low as 5 to 10 percent of total extract, but now a total extract of 30 to 40 percent is not uncommon. There are even 100 percent barley-based beers that have been on the market for over a decade. Today, the use of barley is widespread and has a significant impact on brewing in different regions throughout the world. In Japan, for example, tax on beers is imposed according to the amount of malt content. For second generation Happoshu beers, which normally contain less than 25 percent malt, barley has been an ideal choice as adjunct since it provides close flavor matching to traditional beer. In Central and Eastern Europe and Russia where brewers have focused on the use of barley in beers designed to compete in the nonpremium market segments, barley now account for up to 40 percent of total extract. Africa has seen the highest proportion of barley used. Designed for a very price sensitive market, beers have been produced using 100 percent barley. These beers have been highly successful in building volume and market share.

The benefits of using barley Barley is similar to malt – and approximately half the price The obvious difference between barley and malt originates in the malting process itself, where enzymes are produced and some initial degradation of mainly protein and non-starch polysaccharides occurs, but essentially the composition of barley and malt is very similar. Barley, therefore, is the adjunct most likely to achieve characteristics closest to those of 100 percent malt beer. What’s more, like malt, barley has a husk assisting good mash filtration, is a good source of starch, and has good protein and low lipid content. Additionally, there

Brewers can use barley as one of the key ingredients to make a base beer to which fl avour notes are added.

is no need to use a cereal cooker, as the gelatinization temperature of barley is similar to that of malt. Most importantly, barley is generally available at about 50 percent of the cost price of malt. Barley is a highly versatile raw material In the competitive market environment, brewers are increasingly trying to find ways to extend and further segment their range of

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www.asiafoodjournal.com Asia Food Journal 21


PROCESSING products. And all players want to achieve the highest quality product with the best organoleptic properties whilst at the same time being cost effective. Whether brewers choose to use barley as a partial replacement for malt, for a 100 percent barley-based beer, or for a new beer type; barley is a very versatile and economic raw material that helps brewers to retain and build their competitive advantage. Barley can be used for: • The development of local premium brands – where brewers have more flexibility in the choice of raw materials; • Private label beers and beers in the value segments. The similarity of barley to malt can be used to reduce costs by replacing part of the malt fraction with barley, while maintaining the quality of the beer to suit the brand positioning. • New beer styles designed to complement food – where brewers can use barley as one of the key ingredients to make a base beer to which flavour notes are added. • Cereal-based beverages, both alcoholic and non-alcoholic. It is possible to make a 100 percent barley-based beer and combine this with fruit juices. This is proving to be of increasing popularity with female consumers, who generally prefer less alcohol and a more fruity taste. Additionally, a barley-based wort can be used as the basis for non-alcoholic cereal beverages, to which vitamins, minerals and antioxidants can be added. What’s more, when brewers are using exogenous enzymes to enable the processing of a mash with a significant proportion of barley, variations in malt quality will have less impact on process efficiency, because most-enzyme activity required for processing provided from a standardized exogenous source. Examples of carbon footprint of the malting process Plant Type

Plant Features

kg CO2 per T malt produced

Old, inefficient

Fuel source coal

580

Saladin boxes No energy recovery on kiln Modern, efficient

Fuel source gas

250

Circular germination/ kilning vessel Control of air temperature Control of fan speed Air recirculation Glass tube energy recovery Examples of the increases in carbon footprint associated with 100% barley brewing Activity

Cause of increase

Transport

Higher moisture content of barley increases transport requirement

70

Brewhouse

Milling

120

Mashing

kg CO2 per T barley replacing malt

Barley is a sustainable option The replacement of malt with barley in the brewing process delivers a significant reduction in carbon footprint together with typical savings in raw material cost of approximately 50 percent, depending on market conditions. Although malt producers are making significant improvements in their overall energy consumption – a trend that will no doubt continue - when barley fully replaces malt, carbon footprint savings for the brewery are currently typically in excess of 60kg CO2 per ton of barley.

Requirements for using barley The economic and sustainability advantages of using barley are increasingly attractive as pressures grow on the market price of beer and raw materials. Additionally, advances in equipment, brewing processes and enzyme technology continue to facilitate the use of barley, allowing brewers to further exploit its potential. Compared to malt, barley kernels are harder and have a higher water content. This results in reduced milling rates, increased energy consumption and more mechanical wear. Longer mashing profiles are normally required starting with a proteolytic stand at 50°C, followed by a extended liquefaction and saccharification stand at 65°C. The mashing scheme impact is highly dependent on the amount of barley used, but also on the enzyme treatment employed. When using barley, brewers use the enzymatic activities present in the remaining fraction of malt, as well as the limited set of enzymatic activities present in barley (mainly ß-amylase and exo-peptidase). However, to ensure optimal process efficiency, the use of exogenous enzymes may be required. When 20 to 30 percent malt is replaced with barley, a relatively small additional treatment with exogenous alpha-amylase and protease could be required to ensure proper saccharification and fermentability. Above 40 percent barley, additional exogenous enzymatic activities are usually needed to break down non-starch polysaccharides, to ensure proper yields, fermentability, and brewhouse efficiency.

Brewers have a choice Brewers can use barley as a partial or full replacement for malt. In principle any level of barley can be used, although some changes in equipment or operation and the help of complementary exogenous enzymes may be required. The decision to use barley depends on the region, the brand, the beer style and specifications, the positioning of the beer, and last but not least, the market segment that brewers are targeting. Using barley has many advantages. These include: • Cost effectiveness: The reduction in costs of existing beer brands (for example, in the sub-premium range) without compromising brand identity and beer quality, by replacing a portion of the malt in the grist with barley. Other adjunct fractions such as maize, rice, and syrups can be maintained to retain the beer characteristics. • Versatility: more flexibility in further segmenting the portfolio. One example is the use of barley for the development of premium brands, where brewers may have more freedom in choosing their raw materials. A second is the use of barley in value and private label ranges of existing or future recipes. A third is the possibility to develop non-alcoholic barley-based beverages • Sustainability: in addition to typical savings in raw material cost of approximately 50 percent, the replacement of malt with barley in the brewing process delivers a significant reduction in carbon footprint. The options for brewing with barley are vast. Although there is little doubt that malt, along with water, hops and yeast, will continue to be the mainstream raw materials for the brewing industry, barley will play an increasingly important role in the production of many new beer brands and styles.

Wort boiling Enzyme use 22 Asia Food Journal March-April 2013

HENNING VILLADSEN IS THE GLOBAL MARKETING MANAGER FOR FOOD AND DAIRY, WHILE RON DUSZANSKYJ IS THE PRODUCT APPLICATION EXPERT FOR BREWING AT DSM.


PACKAGING

BOTTLING

Integrating Sorting Systems John Watts details how a flexible, integrated palletizer can improve a bottling line without sacrificing speed or handling quality.

T

hat 28-pack of bottled water or that case of beer are more than a modern convenience – they are engineering success stories. For one, the plastic bottles themselves are much thinner than the ones designed 40 years ago, and they get thinner every year. Technological advances continue to allow the beverage industry to trim the plastic or glass used in bottles, reducing material and production costs. Furthermore, beverage producers make a wide range of pack sizes to serve an equally wide range of retail outlets’ and consumers’ preferences. Meeting these market demands has posed challenges for the machine and equipment builders that create the packaging technology that assemble the bottles into cases and prepare them for shipment.

Woes of traditional palletisers In a bottling line, traditional palletisers use physical diverters to sort products into specific patterns for packaging. Since each new pack size or configuration requires a new pattern, diverters have to be added, removed or rearranged frequently. This conversion translates into up to three days of downtime, including testing on the plant floor. Additionally, the cost of new diverters, turning devices, or other components cost plant operators tens of thousands of dollars per configuration. Moreover, diverterbased palletisers often have trouble sorting and packing thinner bottles at high speeds without causing product damage by way of dents, popped tops and product spills – equating to financial losses for the bottler. Because of this, robotic-arm palletisers were developed as an alternative to diverters. However, such systems are often expensive to run and maintain. More importantly, robotic arms often require separate control platforms and even separate communication networks to carry out high-speed, precise motion.

An integrated bottling system To address this issue, Production Automation Inc. (PAI), a manufacturer of palletisers used in the beverage industry, and Kendall Electric Inc. engineered a palletiser to handle various pack configurations and sizes, as well as thinner bottles. The resulting machine – the Gantry Hybrid Palletizer (GHP) – was built using Rockwell Automation’s latest series of motion controllers, and utilises integrated motion on EtherNet/IP to connect the whole system from instrumentation level throughout the customer’s IT 24 Asia Food Journal March-April 2013

infrastructure and applications to provide the flexibility without sacrificing speed or handling quality in the bottling line. Designed for scalability, the machine can run in single or dual-head mode, complete with a gantry crane that stands above a conveyor belt carrying a steady stream of bottle packs. A robotic arm extends from each crane and moves laterally, reaching down to grab a case and position it into a predetermined pattern for palletising. Guards, meanwhile, are raised at various points along the conveyor to hold cases in place. At the end of the conveyor, the arranged cases are lowered onto a pallet in layers for shipment, based on order requests. Breaking away from outdated technology and embracing the latest innovation advances can help a bottling system be more efficient, ease plant maintenance, lower the total cost of operations, and be flexible enough to address the evolving needs in the industry. JOHN WATTS IS DIRECTOR, INTEGRATED ARCHITECTURE ASIA PACIFIC, FOR ROCKWELL AUTOMATION SOUTHEAST ASIA.


MARKET TREND

BOTTLING

Success Formula Moshy Cohen highlights some of the key points to consider in developing strong beverage brands in emerging markets.

E

conomic statistics and global demographics tell much of the story: for food and beverage entrepreneurs seeking to penetrate new markets, emerging economies outside of North America and Western Europe hold the greatest opportunities. As opposed to more established markets, areas of the world with a growing middle class and new wealth are less saturated with different brands, creating a need – and demand – for new products. As the numbers of middle class consumers in emerging economies rise, so too does the desire for new drink flavours and blends that reflect the varieties found in North America and Western Europe. To tap into this demand for new beverages, four factors are critical: industry knowledge and technical expertise, a commitment to quality, strong marketing support, and a focus on consumer tastes.

Learning from industry leaders Established and successful brands have amassed consumer loyalty through strong quality control and product consistency. Start-up companies with leaner resources and manpower can sometimes partner with them to get a head start in securing sales channels, quality may suffer as a result. Trusted international brands can also offer technical expertise, including a qualified research and development staff, to test and develop new beverage products, and conduct regular testing of concentrates and ingredients. In addition, global beverage companies that are well-established understand the complexities of test-marketing new flavors and introducing them into different regions. Furthermore, what works in one region can work somewhere else. A brand that has successfully marketed a new product in Brazil, for example, would be a good partner to have when introducing new products in, say, Ghana, or Vietnam.

A focus on quality The right partner can help start-ups manage supply chain logistics that are often encountered early as manufacturers get off the ground. One example is by providing guidance on water treatment. In many countries, securing safe and reliable water supplies is a primary challenge, and an absolute necessity for manufacturing beverages. Proper training and ongoing monitoring of water samples, as well as expertise on water conservation can help growing companies manufacture more with less. Besides logistics, the most important aspect of manufacturing is ensuring a qualified and quality-minded workforce. In emerging markets finding employees is generally not a problem; the 26 Asia Food Journal March-April 2013

challenges arise in keeping your workforce properly trained. Guidance on proper training programs is critical. Employees need to understand how to identify defects throughout the manufacturing process. Training should stress the need to remove sources of variability as a means for improving production. In this way proper training helps reduce overall operational costs and boosts productivity.

Leveraging marketing experience An experienced partner can also help franchises execute a well thought-out marketing strategy for a brand entering a new market. This includes help in defining target audiences, establishing goals, setting pricing that is competitive, and, finally, putting together an effective advertising strategy.

Putting the consumer first Rising wealth in emerging markets is creating great opportunities to develop diverse new soft drinks that reflect uniquely different tastes and styles. Ultimately, however, no matter how mature or new the market, launching a new beverage brand requires a dedicated focus on the consumer. It also requires a marketing strategy for the long-term. Building a solid brand with lasting appeal requires dedication and careful navigation, and an experienced partner can provide a bridge to the new frontier. Brand building depends on earning customer loyalty. An experienced partner can provide the experience and tools to help entrepreneurs embark successfully on the new marketing opportunities that lie before them. MOSHY COHEN IS THE VICE PRESIDENT OF MARKETING AT ROYAL CROWN COLA INTERNATIONAL.


MARKET TREND

BASIL/CHIA SEEDS

Gaining Traction Nirvana Chapman discusses how basil and chia seeds are helping more and more companies create innovations in their products. Basil seeds on the rise Basil is a ubiquitous herb, with varieties of the same plant Ocimum basilicum, found in a wide array of global cuisine from pizza to Pad Thai. Although its distinctive flavor and vibrant green color make basil leaves widely recognizable, the seeds of the plant are showing up in unique product offerings as of late. Fewer than 30 products have launched globally containing basil seeds since January 2008, but they feature boldly on the front label and are making overt health claims. Most new products containing basil seeds have been launched in Asia, where the seeds are part of traditional drinks such as faluda in India, but the UK is also starting to see some activity with this ingredient, showing the trend is spreading west (Figure 1).

China

India

Indonesia

Malaysia

Taiwan

Thailand

UK

Figure 2: Basil seeds’ physical property is mostly exploited in beverage offerings, which make up the majority of new product introductions.

Source: Mintel GNPD

Figure 1: Countries where products containing basil seeds have been launched from Jan 2008-Nov 2012.

Basil seeds behave similarly to chia seeds in that they absorb water to create a gelatinous coating around each seed. This physical property is mostly exploited in beverage offerings, which make up the majority of new product introductions. Common claims on these types of beverages are that they are natural, suitable for vegetarians, halal, high in fiber, slimming, and promote digestive health. The thickened texture of these beverages may confer satiety benefits similarly to how chia is positioned in many products. 28 Asia Food Journal March-April 2013

Texture will be an important characteristic in satiety claims A recent study published in the journal Flavor by the University of Sussex and the University of Bristol highlights the role that texture plays in satiety in beverages. In the first part of the study, participants were asked to consume 16 fruit yogurt drinks with varying thickness, which was manipulated by changes in tara gum quantity. They were then asked to rate the overall thickness, creaminess, and stickiness of the beverages. In the second part of the study, participants were asked to evaluate how filling they expected the drinks to be, by comparing the drink to a comparable portion of pasta and sauce they felt would have the same effect on their hunger. Both higher thickness and creaminess were


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Todd Glance Executive Director, Global Supply Chain Strategy Dell, Singapore

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Bjorn Jensen Vice President, Global Logistics Electrolux, Singapore

Jaya Moorthi Director, APJ Logistics HP, Singapore

Teo Song Seng Senior Director – Logistics Management, Asia Pacific Avnet, Singapore

Joerg Bieseman Director of Logistics Automotive Asia Pacific Continental, China

Nihar Medh Director, Strategic Sourcing Dr Reddy’s, India

Jody Leslie Supply Chain Director, Malaysia & Singapore McDonald’s, Malaysia

Travis Wong Director Region Logistics Baker Hughes, Singapore

Rajeev Wasan Vice President of Manufacturing Honda, India

Dominic Chan Vice President, Order Fulfilment & Planning PCI Limited, Singapore

Kaven Koh Global Supply Chain Director FCI, Singapore

Roxane Desmicht Head of Corporate Supply Chain, Asia Pacific Infineon Technologies, Singapore

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20/3/13 11:59 AM


MARKET TREND Sub-category

Percentage of variants

Fruit/Flavored Still Drinks

42

RTD (Iced) Tea

15

Beverage Mixes

12

Shelf-stable Desserts

8

Nectars

4

Cooking Sauces

4

Seasonings

4

Soy Based Drinks

4

Sweet Biscuits/Cookies

4

Vitamins & Dietary Supplements

4

Source: Mintel GNPD

Figure 3: Top 10 sub-categories of products in which new introductions containing basil seeds have been launched, Jan 2008-Nov 2012. associated with higher expected satiety, with increased thickness showing the most filling effect. Creaminess enhanced the effect, but creaminess also enhanced the thin versions of the drinks showing that thickness was the most impactful lever to increase satiety. Satiety is becoming an increasingly alluring claim in an era of rising global obesity. Natural thickening agents such as basil and chia seeds could provide a unique texture profile with the added benefit of helping consumers feel full without having to add extra hydrocolloids or other thickening agents. As companies look to future innovation, unique ingredient offerings, textures, and clean ingredient statements will be high priorities and basil seeds can help deliver on all three by providing something new and different to several markets.

Chia’s potential Besides basil seeds, chia is also gaining traction across Asia. Chia continues to expand in popularity assisted in part by its use on celebrity chef television shows and trendy restaurant menus. Its increased popularity is reflected in the growth of food and drink containing chia, increasing 84 percent since 2009. Chia is an annual plant, known botanically as Salvia hispanica. It is a member of the mint family and native to Mexico, although now mostly grown in Latin America and Australia, regions which now account for a large portion of the launch activity containing chia. The United States accounts for the largest number of launches from one country, just over a third of launches between 2009 and 2012. Chia was made popular in the 1980s in the United States with the sprouted version adorning the heads and bodies of clay figurines called “Chia Pets.”

Source: Mintel GNPD

Figure 4: Food and drink launches containing chia by sub-category, global, 2009 - 2012. 30 Asia Food Journal March-April 2013

2009

2010

2011

2012

Source: Mintel GNPD

Figure 5: Food and drink launches containing chia, global, 2009Nov 2012. It has just recently come into popularity again and renowned for its health benefits. The seed has been around since the 14th century. It can be black or white in colour and has a bland taste. Chia can be used in various forms: oil, bran and the chia seed itself. Nutritional and gelling properties of Chia continue to be discovered. Chia’s unique health benefits set it apart from other ancient grains and seeds. It is a great source of omega-3 fatty acids, protein, B vitamins, minerals such as calcium, zinc, and iron, and high in dietary fibre (30 percent); comprising both soluble and insoluble fibre. Unlike flax, another seed known for its omega-3 content, chia contains no cyanogenic glycocides which are of concern to some for causing thyroid issues. The omega-3 found in chia is alpha-linolenic acids, ALA, which is found in some plant sources including flaxseed, walnuts and soybean. Additionally, chia boasts all eight essential amino acids, making it a complete protein which is advantageous over many other nuts and seeds. Lastly, chia contains natural antioxidants, glycosides Q and K, chlorogenic acid, caffeic acid, quercetin and karempferol. These benefits are becoming more widely recognized as chia is called out on front labels for its various health attributes. Other more recent functional benefits attributed to chia include its ability to absorb water. In foods, it has unique water-binding capability, able to bind up to 10 times its weight in water to make a gel which can be added to porridges and puddings. Gel-formation in the stomach increases the feeling of fullness, which could be used to bolster a satiety claim for a product containing chia. Satiety is a prominent claim in weight management products. There are currently weight management products formulated to form gels for this reason. A recent study published in the Journal of Food Engineering found that the outer layer of the chia seed, the mucilage, which makes up 5-6 percent of the seed, when extracted and hydrated, can absorb 27 times its own weight in water. These properties mean it could be used potentially as a hydrocolloid, to thicken food or form a gel. In 2009, chia gained novel food approval in Europe by the UK Food Standards Agency, and has been popping up worldwide in various food and drink categories. Nearly one quarter (23 percent) of launch activity is in the vitamin and dietary supplement area, which comprises chia seeds sold in individual packs. As regulatory approval of chia increases globally and consumers learn about its nutritional properties, chia will have a greater prevalence in food and drink introductions across both Asia and worldwide. NIRVANA CHAPMAN IS A GLOBAL FOOD SCIENCE ANALYST AT MINTEL INTERNATIONAL. SHE MAY BE REACHED AT NCHAPMAN@MINTEL.COM.


MARKETWATCH

Innovative formulation targeted at bone health LycoRed's Lyc-O-Fem is a slow-release formulation containing genistein in a new proprietary composition that supports bone health. Lyc-OFem, the first in LycoRed’s new line of products combining slow-release technology with genistein, tomato lycopene and an effective dose of vitamin D3, also provides a natural approach to alleviate menopause symptoms. The genistein in Lyc-O-Fem is a phytoestrogen derived from sophora japonica, the Japanese pagoda tree, and is standardized to 98% purity and specially formulated for slow release. The compound has been shown in research studies to support bone health and reduce vasomotor symptoms. Studies back the positive effect of genistein on bone metabolism in post-menopausal women, without the harmful estrogenic activity. Lyc-O-Fem contains lycopene from an all-natural extract of tomatoes. To develop a strain of non-genetically modified tomatoes rich in lycopene—up to four times the amount found in regular tomatoes—conventional cross-breeding methods were used and a proprietary method for extracting the tomato lycopene from these tomatoes was developed.

www.lycored.com

We're keen to feature products in Asia! If you’ve seen something interesting, tell us about it. stephen.marias@ contineomedia.com

MarketWatch

X-ray technology provides complete glass-inglass inspection

Carmit Candy expands functional confectionery line

Mettler Toledo Safeline’s InspireX R50G x-ray inspection system enhances glass foreign body detection in glass packaging at high throughput speeds. Ideal for inspecting small to large diameter glass jars containing a broad range of food products, the InspireX R50G offers manufacturers high detection levels across the entire container to meet increasingly stringent food safety standards. The InspireX R50G features an angled search head, enabling a single x-ray beam to inspect blind spots at the base, as well as in the body, maximising detection. The body, neck and cap are all fully imaged on the x-ray detector; ensuring comprehensive inspection of the container and enabling inspection of jar fill level as well. The machine can accurately inspect up to 1,200 containers per minute. Its high-speed automated reject device ensures only contaminated products are removed without the need to slow production.

Carmit Candy Industries’ R&D team is developing a new line of functional confectionery products designed to provide specific health benefits while maintaining excellent taste and texture. For each health indication, ingredients are carefully selected for their scientific support, regulatory approval and technical parameters. The ingredients are then incorporated into one of the confectionery carriers such as chocolate coins, toffee-chews, crèmefilled wafers and lollipops and undergo organoleptic and analytical testing, to ensure both ingredient stability and delicious taste. Some highlights of the new fortified confectionery product line are weight-management wafer-bar with glucomannan and potato extract; bone-health chocolate coin with calcium, vitamin D and vitamin K; and immune-health sugar-free toffee chew with echinacea, vitamin C and zinc.

www.mt.com

www.carmitcandy.com www.asiafoodjournal.com Asia Food Journal 31


MARKETWATCH

Laminating adhesives offer higher resistance to acidic contents Henkel’s solvent-based laminating adhesives Liofol LA 3963-21 and Liofol LA 3643-21, each used with hardener LA 6063-21, increase the resistance of food packages to acidic and other aggressive contents. The Liofol LA 3963-21 improves the sustainability of the packaging materials by allowing high solid content of up to 50 percent in the working mixture – compared to conventional 30 percent – so less solvent needs to be used, helping users save on material costs and reduce their energy consumption. Liofol LA 3963-21 also does not carry an R40 label. Another advantage of the two polyurethane-based adhesive systems is the innovative adhesion promoter they contain, which does not block the cells of the anilox roller. As a result, it is easier to keep the adhesive's application weight constant over the entire surface to be laminated. The new adhesive systems can withstand high atmospheric humidity, and have high temperature resistance after curing – making them also suitable for laminates intended for pasteurisable or retortable foods.

www.henkel.com

Enabling simple testing of rice quality Stable Micro Systems’ Rice Extrusion Rig conforms to the newly released ISO 11747 standard for rice testing. The new rig provides a simple, quick, accurate and economical method for measuring the eating qualities of rice, with additional design features specifically focused on making the testing cell more quickly removable and replaceable between tests. After cooking, a sample of the rice is placed in the rig’s testing cell. It is pushed down by a plunger of similar cross-section to the cell, compressing the rice and extruding it through holes in the base extrusion plate. Resistance to extrusion is measured as the ease of pushing the cooked rice through the perforated plate using compression and shear. It is calculated automatically and recorded as mean force, in kg/cm2. With the new tool, growers, processors and food manufacturers can objectively and accurately analyse their rice samples’ resistance to extrusion, enabling them to select the cultivars that satisfy both their own textural requirements and the demands of customers and consumers.

www.stablemicrosystems.com

Dicer features sanitary design Targeted at cheese and meat processing, Urschel’s AFFINITY Dicer delivers precision cuts, is simple to operate and maintain, and features a clean, sanitary design combined with rugged construction. Featuring stainless steel construction including Ra 32 stainless surface finish on all components within the product contact/cutting zone, the dicer’s design has been accepted by the U.S.D.A. Dairy Division. The machine's product contact/cutting zone is completely separate from the mechanical zone, thereby eliminating cross-contamination concerns. Its rounded tube frame deters bacterial growth, while the surfaces are slanted or curved to simplify wash down procedures. Great detail is also given down to the types of fasteners, threads, washers, and nuts used throughout the product contact/cutting zone to discourage bacterial growth and assist in cleaning practices.

www.urschel.com

Machine optimizes vertical bag sealing ROVEMA’s double-dragbar sealing jaws for vertical bag sealing are a cost-effective alternative to traditional sealing systems with vertical sealing belt. The retrofit is possible on almost all types of continuously running ROVEMA machines with a central fin seal, and offers compelling advantages in terms of maintenance and wear. Discarding the Teflon tape and the silicone rubber backing on the filling tube as well as the sealing belt and the brass sealing insert essentially reduces the maintenance required by the vertical sealing system. The resulting reduction in downtime leads to an increased machine availability and a high quality vertical bag seal, as well as lower operating costs. The retrofit option consists of a vertical sealing system with two sealing jaws, a bracket with pneumatically driven actuator, a cooling for the vertical seal with device for the fold down of the fin seal, adapter components for installation on the existing vertical sealing system mounts and the addition of a heating zone.

www.rovema.com 32 Asia Food Journal March-April 2013

Spectrometer paves way for state-of-the-art sorting systems Key Technology’s Product Definer is a state-of-the-art proprietary hyperspectral imaging spectrometer that helps Key analyze and evaluate new applications and technologies to develop new sorting systems that solve outstanding product quality problems. The Product Definer speeds Key’s ability to tailor the ideal intelligent sorting system for the specific characteristics of each product, to optimize sort performance and maximize every customer’s return on investment. It allows Key to develop a uniquely detailed understanding of the physical and physiological characteristics of customers’ products, defects, and foreign material. Unlike the single point spectrometers traditionally used, Key’s Product Definer gathers data from thousands of wavelengths simultaneously, capturing images from the visible range and far beyond. In addition to hyperspectral imaging data, this advanced Product Definer collects data about objects’ fluorescence. The images are saved, creating a spectral library of objects’ unique signatures and fingerprints.

www.key.net


CALENDAR OF EVENTS

SHOW PREVIEW

THAIFEX celebrates 10th anniversary THAIFEX – World of Food Asia returns for its 10th edition with three new conferences – World of Food Safety, Pack InnoTech and Cold Chain World – and the official launch of World of Seafood.

T

HAIFEX – World of Food Asia is celebrating its 10th anniversary with a host of new and interesting conferences and events. This year will see the launching of World of Seafood, an official collaboration to crown the best coffee bean from Asia in the new Roasters’ Choice Award, a Thailand Ultimate Chef Challenge event, and three new conferences tackling the key issues in food and beverage manufacturing industry and supply chain: World of Food Safety, Pack InnoTech and Cold Chain World. Organised by Koelnmesse, the Department of International Trade Promotions, and The Thai Chamber of Commerce, THAIFEX – World of Food Asia 2013, to be held at the IMPACT Exhibition and Convention Centre in Bangkok, Thailand, from May 22 – 26, is expected to best its performance last year, where more than 25,000 visitors turned out to see the extensive showcase from more than 1,100 exhibitors. This year, the event targets to fi ll all three halls from Challenger 1 to 3 as it offers 1,200 exhibitors from 30 countries. The fest is also expected to attract 27,000 trade visitors this year, up 10% from last year. “The success of THAIFEX – World of Food Asia is driven by the confidence of our exhibitors, 80% of whom are repeat exhibitors. With 95% of the space sold three months before the event in May, it demonstrates the importance of THAIFEX – World of Food Asia as the preferred gateway for exchange and networking in Asia,” says Michael Dreyer, Vice President Asia Pacific, Koelnmesse. “Each year, we innovate new segments to ensure that buyers and exhibitors alike are able to extend their reach and enrich their experience. Last year, we introduced the Thailand Ultimate Chef Challenge. In our 10th year, we are looking forward to the launch of the World of Seafood platform as well as the Roasters’ Choice Award.” New country groups include the Italy Pavilion, a successful pilot project between Koelnmesse and Federalimentare (the Italian Food & Drink Industry Federation), alongside Fiere di Parma, which sees 50 Italian companies occupying over 600sqm. Visitors will also discover new country groups organised by the Brazilian Embassy, Korea Fishery Trade Association, Taiwan Frozen Food Processors’ Association, Turkish Confectionary & Sweet Promotion Group and Turkish Flour, Yeast and Ingredients Promotion Group. Returning country pavilions including China, Cambodia, Japan, Korea and Singapore registered strong growth at the show in 2012. These pavilions are coming back in greater strength this year. Korea, for instance, will bring together 80 companies - 60% of which are new to Asian markets. “THAIFEX – World of Food Asia is a very important entry point for our Korea companies to Asia. We are investing additional resources this year into THAIFEX to build a stronger presence of Korea food and beverage products at the show,” says See-chan Sung, Deputy Director, Export Strategy Department, Overseas Marketing Team from aT Center, Korea.

34 Asia Food Journal March-April 2013


Recognizing product and service excellence in the manufacturing industry!

Gala Dinner & Awards Ceremony • August 29, 2013 • Pan Pacific, Singapore

AWARDS OVERVIEW Following the successful inaugural Asian Manufacturing Awards 2012, which took place last September, nomination is now open for the Asian Manufacturing Awards 2013. Organised by the Manufacturing Group of publications at Contineo Media, the annual Awards provides timely and valuable recognition for those companies providing industrial technology solutions and value-added services that are enabling regional manufacturers to reach and sustain the required levels of world-class performance. For more information, please visit http://awards.manufacturingasia.co MARCH-APRIL 2013 www.asiafoodjournal.com MICA (P) 266/07/2012 PPS1595/07/2013 (022965)

MICA (P) 265/07/2012 PPS 1627/11/2012 (022884)

www.PharmaAsia.com March-April 2013

March 2013

MICA(P) 264/07/2012 PPS 1628/01/2013(022899)

January-February 2013 www.LogAsiamag.com

Your Professional Guide To Ingredients and Processing

MICA (P) 262/07/2012 PPS1672/01/2013 (022917)

AWARD AWARDCATEGORIES CATEGORIES

The voice of pharmaceutical manufacturing

Face To Face Interview with Bosch Packaging Technology

INGREDIENTS

Logistics & Supply Chain Best Bar Code Technology Provider Best Cold Chain Logistics Provider Best Express Logistics Provider Best Lift Truck Provider Best RFID Technology Provider Best Storage Systems Provider Best Supply Chain Software Provider Best Third Party Logistics (3PL) Provider Best Warehouse Automation Provider Best Warehouse Management Systems Provider

Organiser

Industrial Software Best CAD Systems Provider Best CAM Systems Provider Best ERP Systems Provider Best Plant Design Software Provider Best PLM Systems Provider

Food & Beverage Industry

Batch Automation

INSIGHT

Growing in Asia

Water Analysis Wireless Wars

PACKAGING

Integrating Sorting Systems

DEBUNKING INDIA’S TRUCKING MYTHS

Drug Testing Ensuring quality in pharma manufacturing

FUNDAMENTALS OF RFID HONG KONG GROWING

PROCESSING

Sustainable Brewing

Operations Excellence Designing out contamination

SPECIAL REPORT

Make the Grade The impact of new food safety regulations on production lines

S TH HO A W Fo IFE PR od X E A – W VIE si a orl W: 20 d 13 of

Automation & Control Best Automation Systems Integrator Best Embedded Systems Provider Best Fieldbus Infrastructure Provider Best Industrial Network Provider Best Industrial Wireless Provider Best Machine Vision Provider Best Process Control Systems Provider Best Process Instrumentation Provider Best Process Safety Systems Provider Best Programmable Control Systems Provider Best Robotics Provider Best Servo Drive/Motor Provider Best Variable Speed Drive Provider

Slimming Down Pastry Margarine

INTO THE RIGHT LIGHT

www.CEAsiamag.com

2013 Forecasts By Industry Heavyweights

The key to continuous manufacturing

For more information, please contact your Asian Manufacturing Awards rep at:

Best Food/Beverage Processing Equipment Provider Best in Food/Beverage Safety & Testing Innovative Food/Beverage Ingredient Innovative Food/Beverage Packaging Design Innovative Food/Beverage Packaging Machinery

Caroline Yee I Account Manager Tel: +65 6521 9751 Email: caroline.yee@contineomedia.com

Pharmaceutical Industry

Jacqueline Chan I Account Manager Tel: +65 6521 9773 Email: jacqueline.chan@contineomedia.com

Best Pharma Clinical Trials Service Provider Best Pharma Packaging Solutions Provider Best Pharma Production Technology Provider Best Pharma Testing Technology Provider

Yullie Tan I Account Manager Tel: +65 6521 9749 Email: yullie.tan@contineomedia.com

Corporate Social Responsibility Best Energy Management Technology Best Solution for Sustainability

Avery Li I Marketing Executive Tel: +65 6521 9758 Email: avery.li@contineomedia.com

Editor’s Choice Award Best Technology Innovation

Official Media Your Professional Guide To Ingredients and Processing

The voice of pharmaceutical manufacturing Covering control, instrumentation, and automation systems

Outlook Manufacturing trends and opportunities in 2013


CALENDAR OF EVENTS

SHOW PREVIEW

Calendar The inaugural World of Seafood will highlight Asia’s most innovative processed, value-added and frozen seafood products. With three new groups from China, Korea and Taiwan, World of Seafood, which is shaping up to become the “must-attend” seafood sourcing platform, will feature brands such as Bonito Seafood, Hyacinthe Parmentier, Johnwest, Mareblu, Navire and Petit Ventuna Seafood.

Roasters’ Choice Award Asia, which has some of the most important coffee growing regions in the world due to its tropical and subtropical climates, is seeing rapid growth in the coffee industry. The inaugural Roasters’ Choice Award, a collaboration with the Barista Association of Thailand, will see top international and local judges grading and crowning the Best Coffee Bean from Asia.

Conferences The World of Safety conference will feature distinguished international speakers including Neil Marshall (The Coca-Cola Company, USA), Robert Baker (MARS Inc., Thailand), Idwin W. Bouman (Friesland Campina, Netherlands), Anil Nair (Kraft Foods, UAE), Yves Rey (Danone Group, France) and Tipvon Parinyasiri (Food and Drug Administration, Thailand) discussing and exploring methodologies and strategies to achieve total food safety and drive customer confidence. The Pack InnoTech conference, meanwhile, will have case studies from eminent speakers including Arun Prabhu (Arla Foods, Denmark), Leonardo Bianchi (Burton's Biscuit Co., UK), Arno Melchior (Reckitt Benckiser, UK), Bimal Kumar Lakhotia (Hindustan Coca- Cola, India), Thomas Schneider (World Packaging Organisation, USA), Kitti Wangwiwatsilp (CPF Thailand), and Ralph Moyle (Australian Institute of Packaging), examining the latest developments in innovative global packaging, including strategies to reduce food waste and drive sustainability and business profits. Finally, Cold Chain World will discuss optimising methodologies for preserving and ensuring shelf-life of perishables and frozen foods. Prominent industry experts including Michael D'A llura (Phillips Seafoods, Thailand), Dr. Rodney Wee (Asia Cold Chain Centre, Singapore), Pawanexh Kohli (National Centre for Cold-Chain, Development Department of Agriculture & Cooperation Agriculture Ministry, Government of India), Chris Catto-Smith (Freshport Asia, Thailand) will be sharing their experiences on the food cold chain.

www.worldoffoodasia.com, www.worldofseafood.com 36 Asia Food Journal March-April 2013

JULY 2013

10 – 13 Food and Hotel Indonesia 2013 Jakarta, Indonesia

5–8 PackPlus South 2013 Hyderabad, India

www.pamerindo.com

www.packplussouth.in

24 – 26 Food & Hotel Vietnam 2013 Ho Chi Minh City, Vietnam

18 – 20 China Bevtek 2012 Shanghai, China

www.foodnhotelvietnam.com

www.chinabevtek.com

MAY 2013

SEPTEMBER 2013

7–8 Asian Packaging Summit 2013 Singapore

11 – 13 Fi Asia 2013 Bangkok, Thailand

www.asiapackagingsummit.com

http://fiasia-thailand. ingredientsnetwork.com

7–9 SIAL China 2013 Shanghai, China www.sialchina.com

7 – 10 HOFEX 2013 Hong Kong www.hofex.com

15 – 16 7th Annual Foodnews Juice Asia Bangkok, Thailand

16 – 20 drinktec 2013 Munich, Germany www.drinktec.com

17 – 20 Food & Hotel Malaysia Kuala Lumpur, Malaysia www.foodandhotel.com

MARCH-APRIL 2013 www.asiafoodjournal.com MICA (P) 266/07/2012 PPS1595/07/2013 (022965)

www.juiceasia.agraevents.com

Your Professional Guide To Ingredients and Processing

14 – 17 Seoul Food & Hotel 2013 South Korea www.seoulfood.or.kr

22 – 26 THAIFEX – World of Food Asia IMPACT Exhibition Center Bangkok, Thailand www.worldoffoodasia.com

INGREDIENTS

Slimming Down Pastry Margarine INSIGHT

Growing in Asia PACKAGING

Integrating Sorting Systems PROCESSING

Sustainable Brewing

SPECIAL REPORT

Make the Grade 26 – 28 FI Philippines Philippines http://fiphilippines. ingredientsnetwork.com/home

JUNE 2013 ProPak Asia 2013 Bangkok, Thailand www.propakasia.com

The impact of new food safety regulations on production lines

Know of an industry event? Tell us about it. stephen.marias@ contineomedia.com

S TH HO A W Fo IFE PR od X E A – W VIE si a orl W: 20 d 13 of

World of Seafood

APRIL 2013


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