Food Review – June 2018

SOUTH AFRICAN

www.foodreview.co.za

Journal for food and beverage manufacturers JUNE 2018 Vol. 45 • No. 6

INSIDE:

Beverage Review & Packaging Review

Convenience processing without compromise

Understand and manage

food safety risk

Robotics and automation:

showcase manufacturing ingenuity

beverages

dairy farming

dairy processing

utilities

transport

food

core technologies

Milking & Cooling

Seperators

Decanters

Homogenisers

Valves

Spray Drying

Aseptic Filling

Brewery & Dairy

Compressors

Packages & Skids

Ice Machines

Freezers

GEA Southern & Eastern Africa 48 Reedbuck Crescent, Corporate Park South, Midrand 1682, RSA Tel. + 27(0)11 392 7114, Fax. +27(0)11 392 7000 info-sea@gea.com

www.gea.com

engineering for a better world

CONTENTS JUNE 2018 | Vol. 45 • No. 6

A case for product recall and contamination insurance

PAGE

12

Add value to RTEs

PAGE

23

06 NEWS

ID Logistics expands its level of control

Global industry loves SA nuts

A new era for Sunspray

Bureau Veritas focuses on transformation

08

NEW TO THE SHELF

The hottest products to hit the streets

10

COMPANY FOCUS

Siemens - your digital partner

27 Beverage Review BeverageREV IE SOUTH AFR ICAN

June 2018 | Volume

www.foodre view.co.za

“The Cape Vintner Classification currently has 22 members and an additional eight are in the process of accreditation.”

June

| Volu 2018

me 43

| Number

New cultivars to beat the drought Cape Vintner Classification laun ched Local label nab export award s

6

REVIEW g n i g a k 33 Packaging Review Pac

CAN H AFRI SOUT

.za iew.co oodrev ww w.f

12 CONVENIENCE FOOD PROCESSING

Meal options for time poor consumers

Ishida puts an end to water ingress

Tna launches new data management tool

Innovative solutions for portion cutting

Infrared inspections and the maintenance mix

Embrace local technology

20

ROBOTICS & AUTOMATION

ABB puts an end to voltage sags

Machine solutions impact the food industry

23

RISK MANAGEMENT

Why you need comprehensive risk insurance

The economic costs of pests

Effective approaches in pathogen control

etal M proves its mettle

s can achine auger m om line Bosch’son your bott save

Labelstal Paarlto digi moves

“The metal packaging industry is aware of challenges and is in the process of finding solutions to address issues and improve recovery and recyclability” June 2018 | Food Review

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8 | Number 6

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EDITOR’S COMMENT

EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmediapub.co.za

The

convenience T

factor

he global convenience food market is expected to grow at a healthy CAGR to the year 2020. Emerging markets may even experience double-digit growth rates in significant categories. We all know that busy lifestyles, ageing populations, convenience, innovation, longer shelf life and ease of use are the cornerstones of modern convenience food. Conversely, technology and packaging innovations are widening food choices available to market in various frozen, chilled and packaged forms.

As a busy working mom with two young children, I often find myself stocking up on convenience items to tide us over when there just isn’t time to cook dinner. With more women in the workforce, the demand for convenience food is rising, primarily in emerging economies.

The biggest threat to this sector in developing countries is the lack of proper storage and logistics. One of the major drivers for industry growth is widened distribution channels and the tendency to buy off-the-shelf.

Large multinational corporations follow multiple strategies to develop and penetrate the market for convenience products in different regions. Providing items that match local consumer taste is of utmost importance. A case in point is South African consumers’ insatiable appetite for all things crumbed and coated. In our convenience food processing feature, which starts on page 12, we unpack some of the latest value adding technology for this specialised sector. We also look at the growing market for robotics and automation and how innovative solutions in manufacturing efficiency depend on data, lots of data. More on page 22.

If you haven’t yet safeguarded your processing or manufacturing facility with product recall and contamination insurance, our interest piece from Tony Webster of AON South Africa is an article not to be missed. Turn to page 23 for the real facts behind the insurance hype.

There has been a lot of concern about our wine industry in the face of the drought in the Western Cape. Beverage Review looks at how Distell is tackling this challenge with a focus on water saving strategies, advances in vine planting programmes and drought resistant grape varietals (page 30).

We end this edition with an article on Novus Holdings’ increased capacity as well as an update on the metal packaging industry with new Metpac-SA CEO Kishan Singh in PACKAGING REVIEW.

Assistant Editor: Aarifah Nosarka +27 (0)11 877 6209 aarifah.nosarka@newmediapub.co.za

Layout & Design: Kirsty Thomas +27 (0)11 877 6168 kirsty.thomas@newmediapub.co.za ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmediapub.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmediapub.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmediapub.co.za INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmediapub.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmediapub.co.za Production Controller: Rae Morrison Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park 2092 Tel: +27 (0)11 877 6111 Fax: +27 (0)11 877 6198 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published on behalf of Media24 by New Media Publishing (PTY) Ltd. MANAGING DIRECTOR Aileen Lamb

I hope you enjoy the read, until next time!

CHIEF EXECUTIVE OFFICER Bridget McCarney EXECUTIVE DIRECTOR John Psillos NON EXECUTIVE DIRECTOR Irna van Zyl

EDITORIAL ADVISORY BOARD Two doctorates in chemistry; leader in the field of palm oil; SAAFoST president 1993-2001 and honorary life member; past president, Society of Cosmetic Chemists SA.

Dr Aubrey Parsons With a PhD in biochemistry, an MBA and a Institute of Brewing and Distilling diploma Heidi also serves on the Innovation Hubs BioPark and UNISA’s Life Science advisory board.

HEAD OFFICE

Managing director of Symrise South Africa; chairman of SAAFFI.

Rudy McLean

Head of communications, Tetra Pak Sub-saharan Africa.

Penny Ntuli

Dr Heidi Grimmer Founder, creative director and entrepreneur of Strategic Communications Company (Stratcom).

Gail Angela Macleod

Food Review | June 2018

Postal address PO Box 440, Green Point, Cape Town 8051

Food Review is published by New Media Publishing (Pty) Ltd 11 times a year and circulates to executives in the food and beverage industries. Views expressed in this journal, other than where specifically stated, are not necessarily those of the publisher.

The editor welcomes for publishing consideration news items, press releases, articles and photographs relating to developments in the food and beverage industries. No responsibility is accepted should contributions be lost.

She is a qualified food technologist with an honours in Bachelor of Commerce in Business Management and a PMD at the Gordon Institute of Business Science.

Kerusha Pillay

4

New Media House, 19 Bree Street, Cape Town 8001 Tel: +27 (0)21 417 1111, Fax: +27 (0)21 417 1112 Email: newmedia@newmediapub.co.za

Food Review is printed and bound by CTP Printers - Cape Town Copyright: all rights reserved. ISSN 0257-8867 Readers are prohibited from using the contact details displayed in any advertisement or editorial within the pages of this publication to generate and/or distribute unsolicited bulk emails or other forms of mass marketing correspondence.

Our Promise is inside Vivit Foods manufactures to the dairy, bakery and catering industry. We supply customised and creative products and packaging solutions

Dairy Industry

Yoghurt fruit pulps & syrups Milkshake syrups

Bakery and Catering Industry

Fruit pie fillings, Toppings, Jam Caramel treat, Lemon curd, Salad dressings, Mayonnaise & Sauces

Sweeten the deal : Bake and freeze/thaw stable Selection of different fruit content Natural & Preservative free product range Standard products with longer shelf life

FSSC 22000 Certified Halaal and Kosher approved

Celebrate life’s sweet moments!

Phone +27 (0)11 4526730 Email info@vivit.co.za www.vivit.co.za

NEWS

Centralised control tower takes logistics to a new level ID LOGISTICS SOUTH Africa has installed a centralised control tower at its Boksburg, Gauteng head office to manage operations. Adrien Faye, national transport planning and execution tracking manager was responsible for rolling out and supporting similar projects for the global group in France, Belgium and China. ‘We started planning the centralised control tower in South Africa in July 2017. The company deployed Zeno mobile software. This is an online web scheduler for same and next day planning of vehicles and deliveries, with built-in workflow management. ‘This helps to manage planning and execution with real-time events by alerts and automatic adjustment of existing schedules following events. It integrates with handheld mobile devices and a back-end financial system. It enables our mobile workforce to receive alerts, downloadable schedules,

signatures-on-line, and offers a lot more functionality,’ Faye explains.

The company’s optimisation programme is based on Plato. This suite of enterpriselevel planning software modules provides superior transport management, route optimisation and resource utilisation.

Major benefits of a centralised facility is visibility of clients’ orders through its entire journey from collection to delivery, real-time track and trace capabilities and effective monitoring of drivers and vehicles. ‘This managed transport service means we can totally orchestrate operations, and receive real-time analysis, which can result in enhancements and cost savings. In addition, communication between all parties, including clients, has improved,’ he concludes.

An excited ID Logistics team look forward to another chapter in company history

DuPont Nutrition & Health divests alginates business to JRS Group THE COMPANY HAS received approval from the European Commission (EC) to divest its heritage DuPont N&H Alginates business to JRS Group, a leading manufacturer of functional additives from plant-based raw materials. The divestiture is expected to close in Q3 2018.

‘The receipt of regulatory approval to divest the heritage DuPont N&H Alginates business is an important step in finalising our integration of FMC’s Health & Nutrition Business. Our team is dedicated to creating value for our customers through the integration of our new DuPont N&H product portfolio, which combines the heritage portfolios of DuPont N&H, FMC H&N and Dow Food & Pharma to deliver a unique offering in the food ingredients and pharma excipients market,’ says DuPont N&H business president Matthias Heinzel.

DuPont N&H will continue to be active in the alginates market after the transaction closes through the FMC H&N alginates portfolio.

Conference signals strong growth for SA’s macadamia industry

Sunspray bids farewell to managing director Dave Watson A CHEMICAL ENGINEER by profession, Watson is retiring after 39 years in the food industry, 28 of them at Sunspray.

Pictured with Rene Cross and Christopher Seabrooke - CEO of Sabvest, at a cocktail function held in his honour at the Wanderers Club in Johannesburg recently.

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Food Review | June 2018

THE 2018 WORLD Nut and Dried Fruit Conference hosted in Seville, Spain, cultivated an exchange of insights into the global macadamia industry as well as the latest farming trends and global forecast for fruit and nuts. Reports signal a strong growth trajectory with the forecast for 2018 estimated at 2 11 101 metric tonnes worldwide – the highest ever global supply.

South Africa will be the biggest macadamia producer with 54 000 tonnes followed by Australia and Kenya.

With the growth trend set to extend far into the future, Valley Macadamia chairman, Alan Sutton, fostered close alliances with industry experts and positioned the Valley Macadamia Group for big future expansion in sub-Saharan Africa. The group is looking ahead to future markets like India, whilst continuing to service China, the US and Europe.

Sutton shared feedback on the INC’s annual report and discussed key statistics on the growth and global supply of macadamias. Production in China will be 19 000 tonnes in 2018 with a set growth of 10 per cent per annum thereafter and the Australian crop forecast for 2018

NEWS

Ithemba Trust launched Exeo Capital backs Zambian

food distributor

AFRICA-FOCUSED PRIVATE equity manager, Exeo Capital, has announced an investment of US$6.4 million into Capital Fisheries – a market-leading Zambian food distributor that specialises in the cold-chain distribution of animal proteins.

Kennett Sinclair, partner at Exeo Capital, says the decision to invest in Capital Fisheries was driven by the market prospects for this line of business in Zambia and the proven business model of Capital Fisheries.

More than half of animal protein consumed in Zambia consists of fish, Sinclair explains. ‘Capital Fisheries has a large market share in fish distribution in Zambia. The company’s innovative model of wholesaling frozen products from reconfigured, refrigerated shipping containers placed permanently at markets, small shopping centres and areas where people congregate, has been tremendously successful.’

Capital Fisheries’ Zambian founding shareholders, Damian Roberts and Gavin Thomas, say consumer spending is expected to accelerate the company’s current growth. ‘Zambia’s population is forecast to grow at 2.8 per cent per annum by 2030, with an urbanisation rate of 4.8 per cent. We plan to double our wholesale depots and the supporting cold-chain logistics over the next two years.’

Sinclair echoes this sentiment, adding that Zambia’s GDP per capita is forecast to increase by 2.1 per cent by 2030. ‘You have all the ingredients necessary for excellent further growth prospects for this company,’ he explains. Capital Fisheries sells fish, sustainably harvested in Zambia, Zimbabwe and Namibia, mainly tilapia or bream and horse mackerel. More recently, it added smoked fish, and different cuts of Zambian beef and sausages produced from locally sourced fresh meat and certain imported products. Value-added products are processed in a modern fish and meat plant in Lusaka.

Sinclair is confident that this investment will build on Execo’s previous investments in food and agribusiness in sub-Saharan Africa via their Agri-Vie Fund I.

is estimated at 44 500 tonnes at 1.5 per cent moisture.

Australia currently exports 70 per cent of their crop and is said to be developing an additional 3 500 hectares of macadamia trees in 2018.

‘Increased plantings on a global scale is set to continue.

Hopefully this will stabilise supply for what is seemingly an insatiable demand for macadamias worldwide. Generic marketing currently undertaken by the INC is an example of our industry body hard at work to perform the expansion of our product,’ Sutton notes.

The Valley Macadamia Group is expanding capacities and market capabilities to cater for exciting new trends.

It will join the Australian Macadamia Society as an international member from which to gain key knowledge on macadamia marketing for the benefit of African macadamia exports. The knowledge sharing culture of Valley Macadamia furthers the success of local farmers and processors by serving as a go-to platform for the latest trends and insights into the macadamia nut farming and trading industry.

BUREAU VERITAS SOUTH Africa (BVSA) a leader in testing, inspection and certification has launched The Ithemba Trust, an independent body, as part of its transformation journey. Aligned to the BVSA strong social awareness ethos, the trust focuses on empowering females from previously disadvantaged backgrounds with an emphasis on educating young black women in the STEM disciplines: science, technology, engineering and mathematics.

After graduation, the company will absorb the young ladies into the business and upskill them with soft skills on work readiness.

Enterprise development assistance will be provided to those that wish to launch their own businesses and work will be subcontracted to them to ensure they can sustain their businesses and achieve success. The Trust will focus on beneficiaries hailing from areas in which BVSA employees live and work.

District legal counsel for Bureau Veritas Southern and Eastern Africa, Hennie Knight says, ‘Bureau Veritas has many longestablished programmes investing in people and skills, training, socio-economic investments and procurement. Beneficiaries will include young black females who will ultimately grow and develop in the fields of science, technology, engineering and mathematics. We are proud to announce that our journey has culminated in us being 51 per cent black owned and 30 per cent black female owned.’

Independent trustees include Yvonne Busisiwe Kgame and Zwelakhe Onwell Msomi, long-standing members of the South African business communities and highly respected and passionate about education and the transformation of women. The trustees have enjoyed leadership roles in local and international corporates and the education sector; bringing a powerful combined experience set to the trust. They have also been heavily involved in non-profit organisations and charities on local and global scales.

Commenting at the announcement, vice president – Southern African region, Sal Govender concludes, ‘BVSA is committed to the region and continues to support local legislation. We are proud to launch the Ithemba Trust to make a difference in our society by empowering females within the STEM disciplines through education and enterprise development. We are creating a sustainable women empowerment programme that continues to create legacies and build a nation. We are poised to improve the lives of women; the backbone of society. It is our vision for South Africa to constantly exceed our client expectations through world class professionalism from a diverse and highly motivated team.’

Beatrice Scharneck, Hennie Knight, Sal Govender Onwell Msomi and Yvonne Kgame

June 2018 | Food Review

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SIAL Paris 2018 Perpetual hotbed of innovation In a world characterised by stiff competition, there can be no doubt: you need to show originality to stand out from the crowd! Hence the importance of innovation. To find new sources of inspiration - and subsequently whet the appetites of consumers - nowhere can beat SIAL Paris! From 21 to 25 October 2018, at Paris-Nord Villepinte, SIAL Paris will be receiving more than 7,200 exhibitors from 109 different countries, in a space comprising 21 sectors: a 360° product offering making Paris the world capital of food innovation! Over its 5 days, enjoy privileged access to the greatest laboratory on Planet Food: from ingredients to equipment, wines & spirits to soft drinks, seafood products to meat products, by way of fine foods, dairy products and catering products, not to forget organic, dietary and grocery products, preserves and frozen foods.

What is the ambition of SIAL Paris? In a dynamic context for the food sector, proposing genuine growth drivers through innovation and openness to the world, and supporting you in underpinning your business! In 2018, SIAL Paris will once again be offering multiple events within the event, such as SIAL Innovation, Future Lab, SIAL TV, Alternative Food Forum… as well as, for the first time, cooking courses with La Cuisine, multiple theme trails with expert guides (including one trail on store brand trends), and a matchmaking app to make the most of your opportunities to meet and mingle!

Conception: www.stockfood.com © Images by

*Save 15% off the on-site rate by ordering your visitor badge at www.sialparis.com

Now, more than ever, SIAL Paris is a perpetual hotbed of innovations!

SIAL, a subsidiary of Comexposium Group

For any question, contact our agent: Mr. Alexandre LASSERRE Business France Johannesburg Tel: + 27 (0) 11 303 7192 Mob: +27 (0) 84 554 5066 Email: alexandre.lasserre@businessfrance.fr

5

reasons to visit SIAL Paris

1> A range of products popular with more than 9 out of 10 visitors (Source 2016) 2> 78% of exhibitors unveil their new products here (Source 2016) 3> Exclusive content to give you sources of inspiration 4> Multiple opportunities to exchange with your peers from around the world 5> The biggest retail brands are there

I N D U S T RY U P DAT E

NEW

ON THE SHELF Albany’s new

Bread-A-Betix Suitable for the health-conscious and those who want to manage blood sugar levels and control body weight. Bread-A-Betix contains fibre, which is essential to control blood sugar and cholesterol. It reduces the risk of heart disease and bowel cancer, helps to maintain bowel health, aids in achieving a healthy weight and increases the feeling of fullness. These nutrients include carbohydrates, protein, and micronutrients such as vitamin A, iron, zinc and some B vitamins.

Superfood

goes mainstream Fria’s Superfoods has branched out to include a variety of delicious and nutritious nibbles. Items are now supplied to the mainstream health market. The range includes lemon bliss balls, matcha mint and liquorice balls, sweet potato brownie balls, black bean truffles, a coffee chocolate workout bar, banoclate cake cups, peppermint mousse cake cups and, its best-seller, Snickers cake cups.

The perfect gastronomic mouthful Although a large proportion of the Spanish olive harvest is used to produce olive oil, an exclusive selection makes it to processing and bottling as table olives. A small selection of those prized table olives is marketed to South Africa under the Staffords brand name. The range’s outstanding quality and flavour is sure to tantalise local foodies.

Scottish

jamspiration Stafford Bros & Draeger, leaders of fine food in South Africa for over 90 years, has acquired local distribution rights for Mackays handmade preserves and marmalades. All strawberries, raspberries and blackcurrants for its preserves come from the berry fields of eastern Scotland.

The bitter oranges in its marmalades come from Seville, the home of the marmalade orange. Mackays do not add colours or flavours to any of its products, and use only whole berries in its preserves.

New edition to

legendary rusks Lemon Cream is the latest flavour in the Ouma Rusks range. The brand is currently the number one player in the rusk market (valued at R283 million), and commands a 55.5 per cent control of the segment. Ouma Rusks’ Special Edition Lemon Cream is currently on retail shelves across the country in a 450g pack. If you’re a morning, afternoon or midnight dipper, this wholesome treat is just for you.

Trusted by moms,

loved by kids Danone’s Yo-Jelly is South Africa’s only yoghurt and jelly snack and combines the best of both worlds. This makes it a better and tastier treat that kids can enjoy any time of the day, guilt-free. Made with 11 added vitamins, 30 per cent more milk and 30 per cent less sugar, moms get peace of mind of knowing their kids are getting the nutrients their growing bodies need.

June 2018 | Food Review

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C O M PA N Y F O C U S

Flexibility through CONSISTENT DIGITALISATION The soft drinks market is characterised by frequently changing and often short-lived trends.

To stay ahead of competition in the long term, soft drink manufacturers must rapidly adapt production to new requirements, work efficiently and produce optimal quality.

Digitalization for D softdrinks igitalisation offers flexibility while boosting energy efficiency.

Solutions tailored specifically to soft drink production requirements, ensure reliable production processes and reproduced product quality.

products at the same price as mass to speed up processes and optimise produced products. These must be available production operations. immediately. Different flavours and product Siemens technology creates digital variants are growing - not least because of twins of soft drink products, plants, and increased health and fitness awareness. production lines to simulate and optimise Other food trends can be identified such as the entire workflow. It enables integration low fat, low carb, personalised nutrition and of individual machines in plants (known DIGITALISATION CHANGES products ingredients like engineering, as a bottom-up approach) and a top-down Both discrete and process workflows in thefree-from softdrink indus- without After design and the digital twins allow for EVERYTHING lactose or gluten. allows central engineering try can benefit from digitalization. At Siemens, we call our virtual commissioning,approach so that that all previous development New technologies provide industry with an the Digital This Enterprise. increases the amount product an entire plant.

Both approaches portfolio for digitalizing the industry stepsofcan be efficientlyofvalidated.

Production process and initial impression about the possibilities variants, recipes and brands that must ensure comprehensive digitalisation of It is based on a holistic approach that transforms the tradibottling also benefit from simulation and optimization with of producing of the The into an integrated be developed, produceddigital and managed engineering processes. tional valuefood chain of afuture. product product twins. –Machines and production lines connected to world population islifecycle growing fast and food makingtotypical mass production much more After design and digital and production – from product design producMindSphere, our open, cloud-based IoTengineering, operating system, must be produced on a large scale.

The complex.

When producing any type of food twins allow for virtual commissioning, tion planning, engineering, execution, and services. Only enable an entirely new dimension of transparency, resultdigital revolution can significantly affect or beverage, it is mandatory to consistently which validates all previous development a fully digitalized business model with a consistent digital ing in additional opportunities for optimizing processes and change food and beverage markets. monitor raw materials and products over steps. Production process and bottling thread has the power and flexibility to speed up processes with added value for the client: shorter time-to-market, Consumers are also changing the way they the entire production process. Managing benefits from simulation and optimisation and optimize production operations. more flexible engineering, optimal product quality, and order groceries, asking for individualised a huge product variety, and smaller batch with digital twins. Machines and production greater plant availability and efficiency.

With our solutions it’s possible to create digital twins of sizes with consistently high quality levels, lines connect to MindSphere, an open, the softdrink products, plants, and production lines to change in the way food requires a major cloud-based IoT operating system, enabling a new dimension of transparency. This simulate and optimize the entire workflow.and Webeverages also en- are produced today.

PRODUCTS AND SOLUTIONS provides additional opportunities for able the integration of individual machines in the plant TO MAKE YOU COMPETITIVE DIGITALISATION IN ACTION optimising processes with added value for (also known as bottom-up approach) as well as the topDiscrete and clients: shorter time-to-market, flexible FOODapproach AND BEVERAGE manufacturers down that allows the central engineering ofprocess the workflows in the must plant. consider many factors: a ensure the comprehensive soft drink industry can benefit from engineering, optimal product quality, entire Both approaches consistent and high level of product digitalisation or, as Siemens refers to greater plant availability and efficiency. digitalization of the engineering process. quality; maximum plant availability; it, the Digital Enterprise. The system optimum resource efficiency; and the is based on a holistic approach that PRODUCTION PLANNING greatest possible flexibility to meet transforms traditional value chains of a Challenge: individual customer requirements. product into an integrated product and New products are continuously being Mastering all these challenges is production lifecycle – from product design introduced and production factories are possible with digitalisation. Siemens to production planning, engineering, often located in different countries that offers products and solutions to fully execution and services. Only a fully use different raw materials. Food and or gradually integrate and digitalise the digitalised business model with consistent beverage manufacturers must ensure the entire value chain. digital thread has the power and flexibility taste and quality of the product is the

Third party applications Cloud-based, open IoT operating system: MindSphere

Product design

Production planning

Production engineering

Production execution

Collaboration platform: Teamcenter Suppliers and logistics The holistic approach to optimize the entire value chain

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Food Review | June 2018

Services

C O M PA N Y F O C U S

same and fulfil national regulations when marketing a brand in a different country.

CHALLENGES IN THE SOFT DRINK INDUSTRY:

Solution: Simatic’s IT R&D Suite defines product composition and simulates product performance. This enables you to meet product requirements. R&D Suite supports formula optimisation processes and includes a regulatory assessment to ensure compliance to national and international law. With Teamcenter NX you can create digital twins of product package and simulate and stress-test packaging. In this way, you find the right fit between a cost-efficient and attractive and appealing design.

Challenge: After a product has been designed, you need to produce it on a large scale. This is a typical challenge for many industries, since R&D and production departments are often disconnected. Digitalisation is the key to close the gap between digital formulation and production. This ensures the same product and quality can be produced at different sites, to verify production planning and assess capacities before investing.

Increased variety of products and recipes

Complex coordination between customer demands and filling orders

Cost-pressure

Global and regional regulatory compliancy

Manual production scheduling

Solution: Comos and Tecnomatix meets this challenge with efficient planning and simulation capabilities. The creation of a digital twin of the entire plant will help simulate critical processes, check material and product flows, validate production capacity, identify bottlenecks and overcapacities. It allows you to simulate what-if scenarios to find the right concept before committing resources.

PRODUCTION EXECUTION Challenge: Engineering is built on the foundation of production planning. During this phase, mechanical and electrical components and automation steps are engineered in detail.

Integrated workflows increase engineering efficiency for the production process and for filling and packaging.

Solution: Totally Integrated Automation Portal (TIA Portal) controllers, distributed I/O, HMI, drives, motion control and motor management are seamlessly integrated into a single engineering environment.

Its integrated library concept supports global standardisation. TIA Portal opens the door to the world of Totally Integrated Automation. It includes powerful and scalable automation hardware that works seamlessly with other elements of the

3

High quality demand.

3

system. Virtual commissioning makes it possible to simulate and validate engineering before start of production.

3

3

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Challenge: Production execution links the virtual world of planning with the real world of production. Manufacturers must synchronise manufacturing operations with business processes.

3

Solution: Simatic IT Preactor offers the possibility to plan and schedule orders based on cost, energy consumption, availability of material, equipment, employees and other process related constraints like cleaning in process (CIP). Siemens technology ensures transparency of production assets, calculates and reports KPIs like OEE and reacts with line balancing algorithms to avoid downtime. This is possible with food and beverage specific concepts based on Simatic and Simatic IT technology. •

Siemens – www.siemens.com/food-beverage

June 2018 | Food Review

11

CONVENIENCE FOOD PROCESSING

Add value to RTEs Africa is one of the largest and most diverse food regions in the world and a popular market for future expansion. A rise in consumer income is seeing growth in demand for convenience meals. Customers are becoming time poor and require convenient meal preparation options.

A

s consumer tastes and preferences change, food service providers must be more proactive in their response to growing trends within markets.

Adding value to convenience food products will continue to be a much sought after commodity. One area of growth is pre-packaging fully cooked products.

Meat, seafood, poultry and vegetables are cooked, packaged and frozen so customers only need to heat before serving.

An important part of RTE meal production is the way the product is finished. Consumers like products to have the same grilled finish and visual enhancement as something they would cook at home. Many producers use branding and searing technology, which gives meat brown surfaces, applies grill marks to vegetables and enhances food with a just-grilled flavour and appearance.

Heat and Control’s Rotary Brander or combined Searer/Rotary Brander is ideal for applying an appetising, just-grilled finish to products such as meat, poultry, seafood, vegetables and bread. A gas-fired open flame brander continuously imparts grill marks on the top, bottom or both sides of food items. Independent direct flame searing burners brown surfaces and add fresh-off-the-grill accents; they are grilled for authenticity and no imitation caramel branding strips are applied.

The Rotary Brander has a variable speed branding wheel. This adjusts to accommodate different product thicknesses and can be raised clear when branding is not required.

The Rotary Brander can be used in combination with a Direct Flame Searer.

The searing section uses multiple heightadjustable burners to provide a variety of surface finishes, from char-grilled accents to overall browning.

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Food Review | June 2018

Grilled for authenticity

VALUE ADD PROCESSING TECHNOLOGY Food output increases in response to the introduction of new technology. Highspeed production lines have dramatically increased overall production levels for food processors. One major trend in the marketplace is the capability to fully and efficiently cook a wide range of products on the same line.

“A major poultry processor uses the AirForce oven to cook breaded breast fillets in just 1.8 minutes, compared to 4.5 minutes in a competitive impingement oven” Processors are always trying to maximise yields and product quality while being flexible in what they can produce. It is becoming a rare luxury to have a single line dedicated to a single product. Most new processing lines installed need to be as flexible as possible to allow for the widest range of products produced. This can require a line to include batter and breading capabilities, frying (full and par-fry) and oven capabilities to produce high quality convenience meals.

Equipment needs to be either portable or easily included or excluded within the line when not needed.

Heat and Control’s AirForce impingement oven cooks dramatically faster than comparable ovens as it quickly and evenly transfers heat across the full width of the product conveyor. Yields are higher due to AirForce’s patented moisture-controlled

AirForce oven technology

heating system, and uniform cooking across the width and not ‘over-cooking’ product on one side of the oven.

A major poultry processor uses the AirForce oven to cook breaded breast fillets in just 1.8 minutes, compared to 4.5 minutes in a competitive impingement oven. Another processor’s AirForce oven cooks breast chunks in almost half the time required by a rival impingement oven.

Reliable and uniform breading and coating applications are other ways convenience food processors can add value to production lines. Customised or standard, a breading application can accelerate productivity and trim maintenance and sanitation costs. Breading is the final finish of many prepared food products. Visually it can be the largest coating component of a product. Breading must have the appropriate texture, taste, mouth-feel and quality to align this product with desired consumer markets.

Heat and Control’s SureCoat Breading Applicator can uniformly apply pre-dust, breading and flake coatings to meat, poultry, seafood and vegetable products.

Breading is quickly transferred by large diameter, adjustable-speed augers. Top and bottom coating can be adjusted independently for superior coverage of all product surfaces using flour or batter pre-dust, granular and non-free-flowing breadings – even delicate Japanese-crumb and flake coatings.

There are many ways in which processors of convenience food can add value to products. Keeping production lines lean and using efficient processing and packaging technology will reduce downtime, boost speed of product output and increase yield. •

Heat and Control – www.heatandcontrol.com

Innovation In Action

Innovations that deliver superior equipment and performance

Heat and Control’s complete Corn Product Systems can make the highest quality corn chips, tortillas, taco shells and tostadas. As a single source supplier, we have all the equipment you need for masa production, forming, processing, toasting, seasoning, inspection, weighing and packaging the best corn based products.

With manufacturing facilities and sales offices worldwide, Heat and Control supports manufacturers with experience, expertise and resources to develop the most value driven and efficient solutions for any food production challenge.

Put our innovation to action in your plant today!

Preparation | Cooking | Coating + Conveying | Inspection | Weighing + Packaging | Controls + Information

www.heatandcontrol.com | info@heatandcontrol.com | Cape Town +27 21 948 5934

CONVENIENCE FOOD PROCESSING

An end to water ingress Ishida Europe has introduced an internal moisture sensor and monitoring system for its latest range of multihead weighers.

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he technology enables fresh and frozen food producers to control and prevent water ingress into critical production equipment. Coupled with Ishida’s advanced Sentinel monitoring and reporting system, the system ensures enhanced performance and long term reliability.

Water ingress is a common problem in fresh and frozen weighing and packing.

While models for these applications typically have appropriate IP ratings and waterproof washdown designs, these cannot prevent incidents such as doors and drive weigh units being loosely torqued or doors left open.

Air purge systems, designed to push out moist air may be poorly maintained and lead to humid air being used.

Excessive water or humidity within a multihead weigher will cause loss of machine performance and significant damage - resulting in expensive downtime and repairs.

Ishida’s solution is three dew and temperature sensors, which are placed

“Excessive water or humidity within a multihead weigher will cause loss of machine performance and significant damage”

at key points within the weigher: under the top cover, in the turret and the main body. These provide constant monitoring of humidity levels within the weigher and sends out a series of escalating alerts to operators if levels become too high.

There are three stages of alerts.

A humidity level of between 70 and 79 per cent triggers a yellow alert. This type of humidity can typically be cleared using the air purge system to remove moisture from the machine.

Humidity levels between 80 and 89 per cent, which could occur if the air purge system itself is compromised, creates a red alert that results in the weigher’s remote control unit’s power being automatically switched off.

It cannot be switched back on until moisture levels have dropped below the 80 per cent threshold.

Anything above the 90 per cent critical level will see a bespoke input/output module come into operation. This can be configured to customer requirements such as an audible alarm or a series of beacon warning lights to indicate that critical moisture levels have been reached. •

Ishida – www.ishida.com

Data management tool launched With the new tna intelli-sys iPS 3 software, food manufacturers can use a single, standardised platform to collate, visualise and evaluate live and historical information from every part of the production chain and across multiple locations.

I

ntegrating data from every process and at every site in a single-plant management system, increases visibility, reduces administrative tasks, optimises processes and improves traceability. This results in a smarter, transparent and profitable manufacturing process.

Compatible with both PLC and PC-based technology, tna’s integrated Production System (iPS) easily integrates with all existing tna and third party equipment. The tna intelli-sys iPS 3 is scalable, transparent and cost-effective software that provides users with ultimate visibility over every step of the production line, locally or remotely, through a simple, user-friendly web-capable interface.

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Food Review | June 2018

Thanks to the system’s real-time data acquisition capabilities, faults are detected quicker, ensuring downtime and waste are kept to an absolute minimum, while food safety and product quality are maintained.

Collation of detailed historical data, such as batch scheduling, tracking and tracing can be used for internal communication purposes, but also as an external tool to prove regulatory compliance.

‘Inefficiencies in the food processing industry are vast and can occur at every stage of the production cycle,’ comments Chris Jones, product manager - controls, tna. ‘A lot of times, these efficiencies are caused by miscommunication between plant management and the production floor. Our new tna intelli-sys iPS 3 is a huge

Real time data manag

ement

step up in the evolution of real-time data management technology as it ensures that all departments have access to the same set of data. By using a single tool to monitor and report on production efficiencies, managers and operators can quickly identify which areas require attention, act and ensure all products and processes are within specification. The platform’s ability to collect detailed, standardised and reliable data from every part of the production process provides advanced control over the entire work flow for a safer and more efficient production process, making it a real asset to any plant.’ •

Tna – www.tnasolutions.com

CONVENIENCE FOOD PROCESSING

Marlen Carruthers Auto Shredder

INNOVATIVE SOLUTIONS for further processing Marelec Portio is a high precision and economic portion cutting machine.

It is suited for fresh boneless products in the poultry, red meat and fish industries.

P

TRUSTED END-TO-END PROCESS SOLUTIONS

ortion cutting is based on scanning technology. Products are placed on an infeed belt through a laser line, which follows a product’s contour. A highspeed camera takes 150 images per second of the changing laser line. Software then transforms the item to a 3D object with volume. Information, in combination with density, allows the machine to cut exactly for required weight.

After scanning, product moves towards a cutting station over a well-defined distance at a very high speed. For the machine to know the density of products, it is enough to scan and weigh three different pieces.

It calculates density and keeps this in its memory. When a specific product needs to be portioned, density is taken from the memory programme and large volume production can start. Where density varies between products, an infeed weighing unit can be connected.

To portion different types of product, different knives are used. For softer types of meat, thin knives of 1.5mm are used.

Two millimetre heavy duty knives are used for harder or thicker products. Changing between products, programmes or knives takes a few1396_DFS seconds.ADVERT.pdf 1 12/03/2018

Marlen International, a global manufacturer of highly engineered food processing equipment and systems has acquired Unitherm Food Systems. The acquisition adds a new set of thermal processing technologies to Marlen’s existing offering and maximises food product quality, production efficiency and safety. Customised continuous thermal and chilling food processing equipment further strengthens solutions in the meat and protein sector.

Unitherm has been serving a wide range of food processors since 1985. It is known for its innovative approach to developing thermal food processing equipment, which assists processors to maximise yield while enhancing product safety and profitability.

The company designs and manufactures advanced hygienic cooking, chilling, pasteurising and freezing equipment. Its water cook systems, spiral chillers and freezers, complete frying lines and pre- and post-package pasteurisation complements existing thermal solutions. The latter includes batch ovens, chillers, industrial smokehouses, dehydrators, individual breading and frying machines. In terms of continuous solutions, it offers four separate machines for pre-dusting, battering, breading and frying. Units can be used as standalone systems or in a fully automatic line. Each machine comes in four different belt widths to cater to capacity requirements.

Unitherm’s pre-duster is an automated solution. It applies a thin coating of dust or flour to a product to enhance batter adhesion and improve yield. The Batter Enrober takes 09:09

the hassle out of marinating and battering a variety of products, from meats and seafood to ethnic products and produce. It is available in waterfall and dip styles for maximum flexibility. It easily switches between batters.

The Unitherm Breader can handle numerous types of crumb with ease - ideal for a wide variety of breading applications.

It is easy to adjust the thickness of the crumb bed and curtain for tight control over product quality.

With four sizes and eight belt configurations, Unitherm’s Fryer provides a versatile, cost-effective frying solution for processors of all sizes. Want to flash fry spring rolls and falafel or fully cook fish sticks and chicken nuggets? The fryer uses digitally controlled heating and a continuous conveyor system to guarantee every product achieves a consistently high standard.

Marlen International builds innovative solutions in vacuum stuffing and pumping, portioning, size reduction, thermal processing and food handling. Sold under the brand names of Marlen, Carruthers and Unitherm, products have long set the standard for quality and performance.

Marlen’s Carruthers brand is an industryleader in size reduction equipment. This includes slicers, meat dicers, shredders and jet knives. State-of-the-art, continuous flow, fresh or cooked product machines allow customers to take control of processing with less handling, improved hygiene and reduced labour costs. •

DFS Process Solutions – www.dfs.za.com

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CM

MY

CY

CMY

PROCESSING SOLUTIONS FOR POULTRY, MEAT, FISH, PROTEIN RECOVERY AND EFFLUENT WATER.

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+27 (0)87 238 1873 • sales@dfs.za.com • www.dfs.za.com

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Food Review | June 2018

CONVENIENCE FOOD PROCESSING

Infrared technology

tells the inside story

K

eeping production equipment strictly on schedule in the food and beverage industry means downtime is not an option. Comtest, Fluke’s local representative advocates the use of infrared inspections (IR) into the maintenance mix.

Its range of high performance, thermal imagers makes year-round spot-testing possible on-site. It focuses specifically on troubleshooting and monitoring transformers, switches, disconnects and MCCs. By performing quick infrared spot checks, maintenance technicians can

uncover potential failures. This allows for timeous repairs. The line can be kept in motion by frequently scanning and troubleshooting critical equipment.

Traditional troubleshooting using trial and error can be effective, but time consuming and costly. What is critically important is to pinpoint an issue within a mass of sprawling production lines, quickly, as every second of downtime is expensive.

Equipment cost has historically forced plant managers to outsource annual infrared inspections and in many cases, limits scope of work. Annual scans certainly uncover problems, but users shouldn’t have to hope for the best until next year’s scan.

Food and beverage production demands reliability, so annual spot checks just Infrared can be used to evaluate pipe integrity, proper flow and build-up. Here the abrasive material in the pipe has started to erode the pipe wall at the elbow joint

By comparing similar bearings, infrared easily spots a problem. In this image, two bearings on these rollers are nearing failure, which could shut down this line

aren’t enough. The production line monitor can narrow down and rule out possible problem causes faster by seeing the whole picture with infrared, allowing varying temperatures of components to tell the inside story. •

Comtest – www.comtest.co.za

EXTREME EFFICIENCIES WITH THE LOWEST OPERATIONAL COST AND THE WIDEST PRODUCT OFFERING WITHIN THE FOOD AND BEVERAGE INDUSTRY.

MCP3 Series

FP2+ Series

VPCP Range

General Hygienic Application

Sterile Hygienic Application

Specialised Hygienic Applications

The Packo range of General Hygienic pumps offer a deep diversification of pump offerings in terms of:

The Packo range of sterile type hygienic sanitary pumps are:

Packo specialises in specific product design and custom product requirement:

• Flow rates 40m3h to 1200m3h • Various impellor designs, closed, open and vortex.

• Completely clean and certified to EHEDG, 3A and FDA Standards • All Internal welds are hand polished • Hygienic fittings • Self priming • Air handlings • High pressure units, • Multistage up to 16bar

• VPCP solids handling pump designed for fruits, vegetable etc. capable of handling solids up to 213 mm with the lowest damage to product rate in the industry.

• Sealless vertical cantilever design, capable of pumping hot frying oil and numerous other applications where the pump needs to be submerged.

• Packo has also revolutionised the era of mixing pumps with the patented design SFP2 & SFP3 capable of sheer rates of 40000 s-1.

• Custom design and manufacture • The RMO design for sensitive product handling and transfer from trucks where hydraulic motors are required.

• Vast product diversification and design.

• Flow rates 40 m3h – 2000 m3h • Various impellor designs, closed, open and vortex • Wide range of flanges, BSP fittings, 1092-1/01 & 02 ANSI and smooth tubes • Electropolished • Closed coupled designs • Multiple sealing solutions

+27 (0) 11 704 7500 • info@verder.co.za • www.verder.co.za

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Food Review | June 2018

CONVENIENCE FOOD PROCESSING

Move with the times In October 2017, IRP Engineering Plastics brought its Johannesburg-based divisions together under one roof in a modern 2 000m2 office and factory in Lanseria. Food Review spoke to managing director Kris Kibble about the future of the company.

Q: TELL US WHAT THIS MOVE MEANS FOR THE COMPANY AND ITS CLIENTS A: Bringing together all divisions has resulted in significant cost-savings. This makes us even more competitive. Other advantages include increased collaboration between divisions, better communication, sustained service and overall quality control of goods and services. Our new head office integrates the Johannesburg office, administration, CAD Design and sales staff.

It also houses the belting assembly, workshop, jobbing, injection moulding and stores holding divisions.

Q: HAVE YOU EXPANDED YOUR CAPACITY AND CAPABILITY? A: We have increased capacity in our workshop and jobbing division, while our injection moulding division incorporates new machinery. We have enhanced capabilities by being together under one roof making collaboration and communication far better and easier.

Q: WHAT MAKES YOUR COMPANY UNIQUE? A: IRP Engineering Plastics supplies conveyor component products to the food, beverage and packaging industries. It is our expertise in the field and our solutions that make us unique to our competition. The company has been in operation for more than 30 years and locally manufactures the majority of our conveyor component products, which is another differentiating factor.

Q: HOW DO YOUR PRODUCTS IMPACT FOOD SAFETY? A: Products that come in contact with food substances are FDA approved. To further guard against bacteria and listeriosis build up, we incorporate and use Microban on all units. Our products are manufactured locally and are readily available. This gives us a major advantage over local distributors and overseas competitors that supply the same conveyor components, but with an increased lead time. Breakdowns cost production plants a lot of money. Obtaining the same locally manufactured conveyor components is a must for any production plant.

Q: THE WAY FORWARD? A: IRP Engineering Plastics continues to invest in developing, innovating and increasing its conveyor component product range. Three brand new product offerings and four product enhancements will hit the market in 2018. We encourage all major food processing, beverage and packaging plants to continue to support local manufacturers. •

IRP Engineering Plastics - www.irp.co.za

June 2018 | Food Review

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R O B O T I C S & AU T O M AT I O N

Protect yourself against

voltage sags

A

leading dairy company purchased a 750 kVA PCS100 AVC40 to protect bottling and sterilisation machines in its production line. The technology will help solve voltage sag problems, which caused several complications for the processor.

Any power event or interruption is a threat to the sterile environment of a dairy production line. Costs can be significant with disposal of wasted product and the extended time it takes to clean a system prior to recommencing production. Increased automation means conveyors of increased speed are being used.

Bottling interruptions are usually caused by voltage fluctuations, which cause sensors, drives or controls to malfunction. Besides the physical damage to product or tools, it can also cause timeouts for cleaning or repair work.

“Any power event or interruption is a threat to the sterile environment of a dairy production line” Following the trend of higher automation levels and increasing demands for production continuity in the dairy industry, stable power quality has become a major issue for the dairy producer to increase operational efficiency. To this end, the company decided to upgrade and transform its production line to ensure important loads are immune to voltage sag, with a power protection device.

THE TOTAL SOLUTION The ABB solution that keeps this dairy company protected from voltage sags is the PCS100 AVC- 40. The AVC is used to protect critical loads, which include bottling and sterilisation machines.

ABB’s active voltage conditioner has typical applications including high-speed bottling, packaging, dairy processing and other food and beverage production lines. •

FAST FACT THE PCS100 AVC-40 is a high-performance power electronic system specifically designed for industrial and large-scale commercial applications. It responds instantly to power quality events by correcting voltage sags, phase angle errors, unbalance and surges, while providing continuous voltage regulation. At the time of voltage sags and swells, the PCS100 AVC- 40 can respond within milliseconds and inject up to 40 per cent correction voltage. With a compact design, it can be easily installed in a machine room or other confined spaces.

This reduces demand for additional floor space during design and construction. It is featured with a redundant internal bypass system that ensures continuous power supply to loads from the utility grid.

ABB – www.abb.com/ups

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Food Review | June 2018

— A plant of infinite possibilities.

Talk to us.

Are you constantly striving for increased efficiency? Working to integrate processes? Seeking to optimize every aspect of production? Our comprehensive portfolio and consultative approach runs from power to palletizing. So whether you need total traceability or simply higher efficiency, we have the answer.

Discover the infinite possibilities at new.abb.com/food-beverage

R O B O T I C S & AU T O M AT I O N

Data and the smart machine revolution How can manufacturing efficiency be improved?

Bringing smarter automation into the workplace offers an innovative solution, but it all starts with data.

T

ake a look at Forpheus, Omron’s table tennis playing robot. It symbolises the company’s 3-i philosophy for machines – integrated, interactive, intelligent. How can a machine like Forpheus play a sport? While Forpheus combines several technologies to create a robot with human-machine interaction, the fundamental element to making any machine smarter is data.

The first step is collecting data, from individual machines or entire production lines. This can result in tremendous amounts of data. Analysis can be handled effectively and cheaply using today’s processing power and cloud storage. Clean data is essential to enable efficient processing.

Displaying collected information on a screen, in an easy-to-understand way, can help operators identify and respond to process anomalies.

DATA ANALYSIS HELPS OPERATORS Displaying process operation data in this way can result in a 20 to 30 per cent efficiency increase. As data amounts escalate, humans become less capable of interpreting it or perceiving patterns. Incorporating large data analysis software, computers offer an accurate and tireless tool to

Achieve flexible production

USING DATA TO INCREASE AUTOMATION Automation can be taken a step further. Smart systems could identify an issue or potential issue, flag it and then automatically adapt parts of the production line to compensate for any shortfall while problems are being fixed. This occurs within safe operating parameters, resulting in better production efficiency.

Let us consider this at the level of an individual machine.

Smart machines, equipped with data analysis capabilities, can optimise behavior for any given situation because they know how they are supposed to work normally. They monitor their own performance and ensure it matches expected behavior.

If a defect or divergence from a standard pattern occurs, the machine reports the issue to the entire system and, if possible, compensates for issues by amending its operation. From a system viewpoint, alterations must be balanced throughout the line to ensure consistent operation between machines.

with integrated robotics solutions

Delta Parallel robot Quattro and Hornet

Articulated robot Viper

SCARA robot eCobra

support humans in the task of analysing big data. These tools can identify irregularities in performance data and flag potential issues to the operator.

Instead of just identifying an issue, systems can locate exactly where problems are on the line and what needs to be done to fix it.

Collected data is often taken offline for advanced processing and pattern recognition. Resulting patterns are transferred back to the factory to be implemented in real-time by the machine.

Mobile robot LD Series

The new Omron Robotic Automation enhances the most demanding manufacturing lines. Realize faster line start-up & change-over, implement easier to use technology & vertical line integration, and facilitate faster data capture & analysis to increase your in-line efficiency.

SMART FACTORY AUTOMATION Data complexity is one of the items that makes moving to a smart factory a major challenge.

Omron is implementing these smarter systems into its own processes. Applying what they have learnt to to bring the benefits of smart automation to customers. With several selected customers, they are carrying out experiments in smart automation, learning where bottlenecks occur. Only by performing research in real factories, can real value be uncovered. •

Our industrial robotics range from articulated, SCARA, and DELTA to collaborative (mobile) robots that optimize the handling of varying lot sizes and diverse products, formats and qualities. Achieve flexible production with integrated robotics solutions that give you a competitive edge!

Discover how to improve your flexible production, contact us: +27 (0)11 579 2600 info.sa@eu.omron.com industrial.omron.co.za

Omron – www.omron.co.za

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robot_88,5x130_p&c_review_ad_enza_01.indd 1 Food Review | June 2018

20-07-17 12:52

R I S K M A N AG E M E N T

A case for product recall and contamination insurance High-profile product recalls focus an uncomfortable spotlight on failures of product safety and contamination prevention processes. It highlights the need for comprehensive risk management and insurance to manage reputational, financial and legal repercussions of a large-scale product recall.

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his type of insurance is relatively The biggest impact associated with a common among most large product recall is reputational damage. ‘Social commercial and multinational media can rapidly exacerbate and escalate operators. Tony Webster of insurance any product recall situation, unless handled brokerage and risk advisors, Aon South Africa properly.’ It’s critical to respond rapidly explains, ‘Most small to medium-sized in an emergency and to take commercial businesses care with the message being have not kept pace with communicated to customers. the need for this essential This may ultimately influence cover. They are at huge the severity of loss and financial and legal risk if consumer sentiment post a product they supplied, recall. It could also impact even a component of a on business interruption final product, is subject to a aspects associated with a product recall due to material product recall where a site risks posed to consumer or production line may health and safety. The reality completely shut down due er is most small operators only to contamination.’ st Tony Web think about how to manage Product recall insurance a product recall when it’s too on its own is not sufficient late. For a smaller company to address multifaceted risks in the food without the financial and marketing backing supply chain. There are liability aspects of a large parent company, consequences to consider, including the potential for could be dire.’ Every operator in the supply legal class action in severe cases. An allchain, from farm to fork, must take due encompassing liability insurance programme care of products and ingredients - from is essential. growers, processers to logistics providers, ‘If a product causes harm to a person, wholesalers, distributors and retailers. there are two additional scenarios that ‘A thorough risk identification process is at the heart of establishing exactly where risks are and what your business is liable for. This is a task best undertaken with the aid of a professional insurance broker to formulate a holistic view of all risk; what measures are in place to manage and mitigate potential exposure and appropriate insurance plans that will respond favourably in any given situation,’ Webster notes.

Product recall and contamination insurance provides cover for unforeseen and accidental events that can jeopardise product integrity and safety. ‘The insurance policy covers the cost of withdrawing and recovering stock from shelves, transport costs, staff overtime, costs to repair, replace or destroy products, subsequent loss of profits and crisis communication needed to keep brand integrity in check. It will also advise consumers of a product recall,’ Webster notes.

come into play from a liability point of view,’ Webster explains. ‘Product liability cover would provide a solution to any injury or damage the product may cause, for example a product that is incorrectly labelled, i.e. not listing nuts as an allergen. Directors and officers (D&O) insurance would also come into play where a person in a supervisory position did not practice due diligence in their role, and faces being held liable in their personal capacity for any legal claim that may arise.’

It is crucial for all role players in the supply chain, large and small, to fully interrogate the extent of exposure and all potential sources of risk. ‘Even a seemingly small ingredient or component supplier could be drawn in as a co-defendant if there is a liability claim. The Consumer Protection Act provides significant protection and recourse for consumers against all role players in the supply chain. Legal defence costs alone have the potential to bankrupt smaller operators, hence the imperative to have comprehensive insurance to protect the business from those risks that simply cannot be mitigated or foreseen,’ Webster notes. ‘The most important consideration is the total cost of risk. This is where the costs of recall insurance are dwarfed by potential catastrophic consequences for a business or a recall that threatens human life or limb,’ Webster concludes. •

Aon South Africa – www. aon.co.za

“The Consumer Protection Act provides significant protection and recourse for consumers against all role players in the supply chain”

June 2018 | Food Review

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R I S K M A N AG E M E N T

How to get rid of the world’s most expensive pest When dealing with risk management in food production facilities, pest control should be high on the priority list. Disruptions caused by pest infestations will result in an increase in operating costs and a decline in revenue.

T

he term ‘stores product insects’ (SPIs) covers several types of insects including beetles, weevils, moths and mites. These are normally found in stored food products such as grains, cereals, dried fruit, nuts, seeds and even tobacco.

First signs of a problem include seeing small beetles crawling across counter tops, moths flying around or small caterpillars crawling across walls or ceilings. This is the adult stage of an SPI infestation. The more adult stage insects one sees, the older and more widespread the infestation. You may also notice larvae, pupae or silken webbing

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Food Review | June 2018

R I S K M A N AG E M E N T

on food storage bins, on the outside of packets or bags, in cracks and crevices around shelves or on machinery, beams and windowsills or paper and cardboard packaging.

WHY IS THIS THE MOST EXPENSIVE PEST? A single SPI infestation can result in enormous economic losses through damage and contamination of food products and packaging.

Not only do the feeding habits of SPI’s cause damage as they eat food they infest, but their breeding habits also contaminates products. Larder beetles lay their eggs in a food source. When eggs hatch, larvae will consume food products by burrowing into food materials and consuming them from the inside out. They also contaminate food materials with waste products.

Contamination caused by SPI will make food unfit for human consumption.

Infested products must be found and destroyed immediately. SPIs can also cause damage to packaging, making some food products susceptible to accumulating food-borne diseases, while reducing shelf life.

WHAT DOES THIS MEAN FOR BUSINESS? A study conducted by Rentokil found that 60 per cent of businesses, which suffered from a stored product pest infestation, reported an annual revenue loss of between one and nine per cent. Nearly half of businesses surveyed (45 per cent) with a stored product insect problem, reported replacement costs for contaminated raw ingredients. Approximately 10 per cent of businesses reported

additional costs from an SPI infestation through fines or closures.

Risk management in the form of preventative pest control measures is critical. The ability to prevent a costly infestation through integrated pest management practices and high standards of hygiene and sanitation (including stock rotation practices) makes sound financial sense. •

Rentokil Initial – www.rentokil.co.za

Infestations of Stored Product Insects

can cost businesses huge amounts in both downtime and stock loss

Get in touch with us!

0800 736 86545 or www.rentokil.co.za

June 2018 | Food Review

25

R I S K M A N AG E M E N T

OPTIMISE EFFICACY of antimicrobial application There is no room for risk-taking when it comes to food safety. The challenge isn’t whether to protect product against pathogens, it is to identify the best approach for your processing operations.

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here are four equipment options for treating meat and poultry for pathogen protection. Each relies on different technology.

ULTRA PASTEURISATION

Antimicrobials should ideally be applied during packaging

The process thermally heats packaged meat at elevated temperatures.

Exposure to these temperatures must occur at the meat surface for a set length of time. This will ensure potential contamination is exposed to treatment. Under the right conditions, ultra-pasteurisation is very effective. The method doesn’t work with overlapped products and requires a prolonged exposure to heat. Depending on the type of product, organoleptic properties could be affected.

four to eight log reduction. Equipment includes a large chamber where product is placed for processing. HPP, while highly effective, can limit production as it is a batch process.

The effect of HPP on organoleptic properties with readyto-eat meat is not usually an issue, but some products may undergo changes.

HIGH PRESSURE PASTEURISATION

MODIFIED ATMOSPHERIC PACKAGING

The technology utilises high pressure of between 15 000 to 88 000psi to kill pathogens. The method is extremely effective and typically achieves

MAP is effective for shelf life extension and has no effect on organoleptic properties. The effectiveness of the process is dependent on packaging. Only bacteriostatic effects are possible with MAP. The use cost of MAP is generally twice the cost of traditional vacuum packaging.

SPRAY APPLICATION OF ANTIMICROBIALS Antimicrobials are often applied in the package, but can occur prior to packaging. The system enables easy adjustment of the column of antimicrobial applied. Alternative 1 Status can be obtained with some antimicrobials that contain bacteriostatic and bactericidal properties since both are applied in one step.

Certain antimicrobials must be contained when sprayed, so factor this in when evaluating.

BEST PRACTICE IN SPRAYING ANTIMICROBIALS · Applying antimicrobials in the package is ideal. The package is the last point of intervention after exposure to other potential sources of contamination such as conveyors, tables and personnel. · When spraying prior to packaging, choose a point where contact surfaces of the product are accessible. Ensure surfaces have been sanitised in the event product comes in contact with other surfaces after antimicrobial application. · Trim and other products that are going to be ground should be sprayed with antimicrobial prior to grinding. Exposed product surfaces that could have potential contamination are lowest at this point. Antimicrobial is typically sprayed into a blender or mixer. · Any type of equipment that comes in contact with products should be sprayed periodically with sanitisers. This is to limit the spread of contaminants. · Consult with experts. Spraying antimicrobials require a high level of precision and is not attainable with workers using spray bottles or holes drilled in pipes. •

Monitor Engineering – www.spray.co.za

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Food Review | June 2018

BeverageREVIEW SOUTH AFRICAN

www.foodreview.co.za

New cultivars to beat the drought Cape Vintner Classification launched Local label nabs export award

June 2018 | Volume 8 | Number 6

NEWS

Thandi Wines seals deal to export wine to China WESTERN CAPE’S THANDI Wines secured a oneyear contract with a Chinese distributor to export its range of premium wines to China. This contract was signed at the 19th SIAL China International Trade Fair. A total of 23 South African agroprocessing companies showcased local products and services. Managing director of Thandi Wines, Vernon Henn says the contract value sits at more than R700 000.

‘We will commence the contract with a shipment of two containers containing 26 000 bottles. We will then follow that with another two containers. The contract will be renewed on an annual basis,’ Henn notes.

The main export destination is Europe, which accounts for more than 85 per cent of sales.

‘We started experiencing saturation in Europe and growth stagnation. This compelled us to repackage our marketing strategy and explore other markets. In this instance, the Asian market. The decision presented us with welcome rewards - especially as this is a growing market with a lot of potential customers.

The main ingredient required is timing and the Department of Trade and Industry nailed it on the head by bringing us to this stage. People are looking to make purchase in preparation for the Chinese New Year, which will be during the end of February next year,’ he explains.

Thandi Wines was established in 1995 as South Africa’s first agricultural Black Economic Empowerment (BEE) project. It is owned by 250 farm worker families who hold 62 per cent shares in the company.

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Beverage Review | June 2018

Uitkyk wine estate

Uitkyk sale creates focus for Distell’s wine business DISTELL, AFRICA’S LEADING producer and marketer of leading fine wines, ciders, spirits and RTDs, has entered into a sale agreement with Warwick Wine Estate, to acquire Uitkyk wine farm.

Speaking after the announcement, Richard Rushton, Distell’s managing director, said the sale of Uitkyk was part of the company’s efforts to streamline its asset portfolio, in a way that allows it to re-invest further into its business and achieve its growth aspirations.

The sale is consistent with Distell’s strategy to focus and increase its investment on a select portfolio of wine brands and assets.

‘Our key focus brands, like Nederburg, Alto, Fleur du Cap, Plaisir de Merle and Durbanville Hills, have shown strong performance for the financial yearto-date. This reinforces the benefits of our more focused approach,’ Rushton notes.

Distell remains committed to growing the South African wine industry by playing a key role in the wine category.

Slash energy consumption TETRA PAK HAS reduced the energy use of its separators by 40 per cent using breakthrough Encapt pressure management technology. The system lowers atmospheric pressure around the spinning bowl, using a lowpressure pump. Sensors monitor the system to minimise air friction, which ensures it uses less energy.

Combined with a unique AirTight design inside the bowl, the entire system is hermetically sealed to ensure no air enters. There are inlets at the bottom and an outlet at the top to promote the flow of air thereby conserving energy. The two technologies combined make the machines the most efficient on the market.

Tetra Pak product manager, Ulrika Rehn says, ‘We want to help customers meet the challenge of achieving superior product quality with lower operational costs, and a lower environmental footprint. The technology is most commonly used to separate milk or whey.

Tetra Pak separators with Encapt technology

EVENT

Cape Vintner Classification site-specific wines introduced More than 50 of South Africa’s most outstanding sitespecific wines were hosted at a function held at Vergelegen cellar in May.

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he tasting was the result of several years of hard work and collaboration by the Cape’s top wine producers.

They established an independent association to build South Africa’s reputation as a producer of world-class wines and to promote the Cape’s distinctive site-specific wines.

Michael Fridjhon and Danie de Wet

Known as the Cape Vintner Classification (CVC), it currently has 22 members and an additional eight are in the process of accreditation.

Accordingto CVC chairman Neil Ellis, the organisation aims to ensure quality Cape wines are recognised as some of the best in the world. ‘We’ve developed a system for vintners and wines. This system will allow for accreditation, governance and promotion of distinctive Cape sitespecific wines and assure customers of the integrity of CVC members.’

The organisation operates within the structures of the Wine of Origin scheme.

All CVC members meet its criteria for ownership of vineyards or management of vineyards through registered, long term leases.

CVC members are subject to independent audits to ensure they adhere to four association cornerstones. These are based on robust technical and environmental criteria, cellar door facilities, ethics and wine quality.

The exceptional wines tasted at the CVC event represented less than five per cent of the vineyard area of members by volume.

Selection follows a rigorous process, under the guidance of Ellis. CVC members submitted wines for blind tastings by independent judging panels.

‘The overarching objective of establishing South Africa as a leading producer of world-class wines and promoting the Cape’s site-specific wines, a key factor is the CVC’s ability to identify and accredit wines, which clearly

Katherine Miller, Propper Gundwa and Natalie van Almenkerk

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Beverage Review | June 2018

reflect quality, consistency and sense of place,’ Ellis explains.

The Wine and Spirit Board has authorised CVC to accredit wines that meet these standards as site- or site-specific wines.

Wine writer Michael Fridjhon compared the CVC showcase to creating art, ‘Some people create works of art in mixed media, others in one single medium such as marble or oil. With this CVC selection, it is a restricted medium and the best expression of it.’

Ellis concurs, ‘To achieve our goal, we will need patience and persistence. This kind of winemaking needs hard work, perseverance, self-denial, dedication, discipline and respect for authority. There is an African saying that if you want to go fast, go alone. If you want to go far, go together.’ •

KEY CRITERIA FOR CVC MEMBERSHIP •T echnical and environmental: Members must clearly demonstrate that wines are crafted taking full cognisance of the importance of its facilities and its impact on the environment.

• Cellar door facilities: Members of the public must be able to visit these CVC estates and enjoy exceptional levels of hospitality.

•E thical matters: All members must have a recognised and acknowledged ethical accreditation based on the International Labour Conventions’ Ethical Trading Initiative, incorporating South African labour legislation.

•W ine quality: The wine maker will present the wines to an independent committee and will be required to articulate the uniqueness of the vineyard’s terrain and the impact of the winemaking intervention.

WINE

Grape harvest delivers promising quality

BOOK YOUR

FOOD LOSS, WASTE SUMMIT

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Distell’s head winemaker, Niël Groenewald says the 2018 wine grape harvest delivered healthy, good quality grapes. Crop output is about 30 per cent down on last year’s intake, although yields differ across regions.

T

he company’s substantial footprint across wine growing areas of the Cape gives it ready access to grape and wine supplies, helping offset drop in yields this year. ‘We have a very flexible sourcing policy and maneuverability to respond to a variety of climatic outcomes.

‘It was definitely one of the most challenging harvesting seasons in recent years. Dry growing conditions had a relatively favourable impact on the quality of our premium quality grapes, depending on growing area,’ Groenewald notes.

Top-grade white fruit showing vibrant, concentrated ripe fruit flavours includes Sauvignon Blanc and Chardonnay from Stellenbosch; Durbanville Sauvignon Blanc and Pinotage; Chenin Blanc from Darling; Chardonnay from Paarl and Ceres Riesling.

These white wines feature an average alcohol percentage of approximately 12 per cent.

Reds with intense depth of colour, full, ripe flavours and soft tannins can be observed in Cabernet Sauvignon, Petit Verdot, Pinotage, Merlot and Cabernet Franc from Stellenbosch; Cabernet Sauvignon, Merlot, Cabernet franc, Petit Verdot, Carignan and Grenache from Paarl – as well as Ceres Pinot Noir. ‘We are satisfied with alcohol levels at around 13.5 per cent across the board for our red wines. Wine drinkers globally are seeking out wines with slightly lower alcohols, while offering spectrum and intensity of flavour.

Our 2018 vintage wines will be capitalising on this worldwide trend,’ Groenewald enthuses.

Poor set (millerandage) is a viticultural challenge in which grape bunches present berries that differ in size and maturity. It’s caused by cold and rainy or otherwise bad weather during the flowering stage of the vines. While poor set will in most instances, cause a drop in yield, its potential impact on wine quality varies.

Crushing across cellars was evenly paced across the months of February and March, with uneven ripening experienced almost across the board in the case of white wines. A portion of premium Sauvignon Blanc and Chenin Blanc had to be harvested two to three weeks earlier at lower sugar levels to retain freshness, spectrum and intensity of aroma and flavour. This resulted in a lower alcohol level.

Premium Sauvignon Blanc and Chenin Blanc tonnage are down, while early predictions on eventual wine quality seems outstanding. Chardonnay came in on par with expected volume and excellence grade, due to its innate ability to weather harsh conditions. Vineyards situated at higher altitudes proved resilient, like the Pinot Noir vines situated at the top of the Matroosberg close to Ceres. It delivered largely stress-free fruit at a good level of phenolic ripeness.

Mogorosi.indd 1

26 & 27 JULY 2018 BIRCHWOOD HOTEL, BOKSBURG

OBJECTIVES: • To highlight what food waste constitutes • To discuss strategies to prevent food waste and loss • To open a platform to network

SOME OF THE TOPICS AND SPEAKERS CONFIRMED: • Household food waste disposal in South Africa Research on food waste in developing countries is limited.

This study is the first of its kind undertaken in South Africa.

• Food Waste: Reduce then Recycle Gavin Heron Director: Earth Probiotic

Food waste research is important to address food security issues.

Prof Suzan Oelofse Research Group Leader: Waste for Development, CSIR • Nutrient Recycling Gerhard Gous Director: AgriProtein Gauteng

• Why food waste diversion from landfill is so important Challenges commercial kitchens face with food waste Practical solutions for diverting food waste from landfill

Bronwyn Jones Owner: Bokashi Bran

To register call Levi on: 078 103 4461 or email levim@mogorosicomms.co.za

Birchwood Hotel & OR Tambo International Centre

June 2018 | Beverage Review

31

2018/06/13 2:14 PM

WINE

Dry-farmed vineyards, particularly those located in Simondium (situated between Paarl and Franschhoek) and Darling, were harvested earlier than vineyards that received supplementary irrigation. This was done to prevent further vineyard stress and the resulting higher pH values in grapes.

In contrast, some reds such as Cabernet Sauvignon and especially Shiraz are being harvested later than expected. Flavours are subdued, with recent rains and cooler temperatures following an extensive stretch of hot, dry months.

Fermentation of reds is a bit slower than in previous years, but is managed with frequent, gentle pump-overs to soften tannins, stabilise colour and supply oxygen to yeasts for sound fermentation.

‘What is evident is that South African wine grape growers and producers need to accelerate efforts to adapt to conditions of the drought. This is the new normal,’ Groenewald stresses. ‘Grape suppliers were compliant with the South African wine industry’s socially sustainable programme run by the Wine and Agricultural Ethical Trade Association (WIETA).’

Distell continues to implement water saving strategies from soil to cellar. It uses techniques such as deficit irrigation and recycled water for cooling towers in cellars,

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Beverage Review | June 2018

applying more efficient chilling processes and rigorously following water-wise cleaning regimes to eliminate water wastage.

In addition to production site-based water savings, Groenewald says the company is focusing on the judicious use of water in many of its vineyards. The vineyard initiative forms part of Distell’s water management programme, honouring the company’s commitment to reduce the amount of water used to produce its range of beverages, with impressive progress made since 2009.

“Distell continues to implement water saving strategies from soil to cellar” The goal is to curtail 25 per cent of water consumption per litre of total packaged product across its full range, including wines, spirits, ciders and RTDs by 2020, using 2009 as the base year.

During its past financial year, Distell invested more than R200 million in its water management programme. Plans are in place to guide the company to full sustainability in water, with negligible reliance on municipal

resources within the next three years. Small portable pressure chambers or pressure bombs have been in use since the 2011 harvest to gauge the leaf water potential in vines as a basis for determining optimal irrigation strategies. Certain vineyards saw savings of up to 40 per cent as a result.

Distell uses infrared technology called ‘Fruitlook’ to gauge growth and progress of vines and to determine differences in growth of portions within a vineyard, and between different vineyards.

Advances in vine planting programmes will include more drought-resistant grape varieties. Nederburg winery in Paarl has been experimenting with Mediterranean varietals well-suited to changing climatic conditions for more than a decade. Tempranillo and Graciano were established at its Simondium farm in 2004, and Carignan and Grenache were planted at the Nederburg property in Paarl in 2008, as was Chambourcin, Vidal Blanc and Seyval Blanc in late 2016.

Distell continues to collaborate with its network of suppliers to find ways to enhance production and infrastructural efficiencies.

‘We look at viticultural protocols, the optimisation of resources such as water and energy and even the location of production sites to eliminate unnecessary transport costs,’ Groenewald concludes •

PackagingREVIEW SOUTH AFRICAN

June 2018 | Volume 43 | Number 6

www.foodreview.co.za

Metal proves its mettle

Bosch’s auger machines can save on your bottom line

Paarl Labels moves to digital

NEWS

Will metal lead the way to economic growth?

L

AST OCTOBER, STATS SA released figures indicating an increase in manufacturing production by more than one per cent. This was mainly attributed to higher production in basic iron, steel, non-ferrous metal products, metal products and the machinery division. There have also been a number of acquisitions, showing confidence in the metal packaging industry.

Kishan Singh, at the helm of Metpac-SA, shares the sentiment of the industry’s increase in market share through continued innovation.

In his words, ‘Metal packaging will adapt and

accommodate to the requirements of the modern consumer’.

This type of packaging equates for 9.2 per cent of the country’s market value with a recovery rate amounting to 73 per cent. It’s also a main topic of focus in this edition of PACKAGING REVIEW. Turn to page 39 to read more about the challenges and opportunities in the metal packaging industry.

From me and the team at PACKAGING REVIEW, welcome and best wishes to Singh in his new role at the association.

Until next month!

Assistant Editor Aarifah.Nosarka@newmediapub.co.za

Tetra Pak’s evolution in straws THE MULTINATIONAL FOOD packaging and processing company aims to launch a paper straw for its portion-sized carton packs by the end of this year. This is part of a broader programme to help address the issue of plastic straw waste.

Playing an integral role for products in packaging consumed on the go, straws are part of the plastics waste problem.

Tetra Pak has been working to encourage consumers to push straws back in the pack once they have consumed the contents. This is so straws and packs can be s e rl a Ch collected together. d n Bra

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Packaging Review | June 2018

A team at Tetra Pak is working on the development of paper straws suitable for use on the company’s portion-size cartons.

‘It sounds simple, but there are a number of significant challenges to producing a paper straw with the required properties,’ explains Charles Brand, executive VP of product management and commercial operations at Tetra Pak. He says the development team is confident a solution can be found and that a paper straw alternative will be launched in a few months.

The company’s packs are on average made up of 75 per cent paperboard. Developing paper straws would be another important step toward the Tetra Pak’s long term ambition of offering a completely renewable portfolio.

New closures division launched in response to market growth DIVERSIFIED GLOBAL CHEMICALS manufacturer, SABIC introduced its caps and closures segment, launched earlier this year, at the Plastic Closures Innovations Conference. The event was held from 22 to 24 May in Berlin.

The company, headquartered in Saudi Arabia, discussed the latest materials and solutions for the market. It further outlined measures to address issues in the circular economy.

‘With our extensive range of polyethylenes and polypropylenes, SABIC has built a strong position in the production of caps and closures. The market is growing and changing all the time. We are moving quickly to respond to current and future developments,’ says Hans Pierik, SABIC’s global caps and closures segment leader.

The company’s goal is to extend application coverage across food and beverage and non-food areas alike.

Its caps and closures portfolio spans a number of polyethylenes (PE) and polypropylenes (PP). SABIC also engineers polycarbonate plastic.

‘This year we will be adding more innovative materials, including a new HDPE that makes it possible to cut weight in caps for carbonated soft drinks,’ Pierik adds.

The company has developed a new multi-modal grade of HDPE with excellent organoleptic properties.

The SABIC HDPE CCX027C polymer combines excellent environmental stress cracking resistance (ESCR) with good flow characteristics. This allows cap manufacturers to design very lightweight closures. It also exhibits strong shear thinning. This means it has a relatively low MFI (0.8g per 10 minutes, 2.16kg).

Its flow characteristics during injection moulding are similar to those of a unimodal HDPE with an MFI more than three times higher.

Improvements to ESCR and physical properties such as stiffness and impact strength enable extra lightweighting.

Reductions in required processing temperatures help processors save energy and cut cycle times. Better organoleptics assist in meeting the need for caps to have no effect on the taste of packaging contents – especially important for bottled water.

SABIC’s local office is based in Roggebaai, Cape Town.

EVENT

Reduce waste

with new skin packs On 16 May, Sealed Air hosted an event at Emperors Palace in Johannesburg, to address sustainability issues for primary packaging. The event included a number of discussions by company representatives.

I

n the food packaging industry, ground breaking innovation is occurring not only in the development of new packaging designs, but also new technology and applications of existing technologies for better and sustainable packaging performance. This is the driving force behind the company working to produce sustainable materials, extend product shelf life and improve resource and operational efficiencies.

Companies in the food industry need to focus on the entire life cycle of their products. They must ensure new packaging formats respond to key trends that have become increasingly complex. Food packaging must reflect 3.pdf 1 lifestyles 2017/03/31 different consumer and 9:29 AM

expectations, resource scarcity and environmental considerations.

Rob Stockdale, sales director for the African region, highlighted the launch of the company’s Cryovac skin packaging solutions.

These are the Darfresh, Darfresh on tray and on board and new top webs for mono PET and PP trays, amongst others.

The Darfresh packaging process uses specially formulated top and bottom webs to create a vacuum skin consumer pack, which fits around products ‘like a second skin’.

A focus on modern and innovative packaging and solutions for protein and ready meal markets were among the topics discussed.

Didier Marteau, marketing director for EMEA at Sealed Air, said these packaging

The Sealed Air team show the latest skin packs launched with Rob Stockdale alongside Valentino Branchi, sales director for the Middle East and Africa, and Didier Marteau and Jonathan Dunford on the far right

innovations help producers and retailers deliver fresh food, while reducing waste.

‘The right packaging is a key contributor to preserving food during its distribution cycle, meeting consumer demand and avoiding overall waste,’ he noted.

According to Jonathan Dunford, VP for sales and marketing at Sealed Air, webs for skin packs, manufactured by the company, were released in Europe more than 14 months ago.

‘This has become very popular in the food market. Our materials are offered with a recycling base. We offer the bases and materials, which is a great solution for the South African market,’ he concluded. •

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June 2018 | Packaging Review

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C O M PA N Y F O C U S

A digital era

for Novus Holdings Paarl Labels has enhanced its market offering to deliver a broader range of unparalleled quality labels of any run length. Aarifah Nosarka reports on the significance of the company’s recent investment in a narrow web digital printer at its Cape Town facility.

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he HP Indigo WS 6800 was Printing in silver is not commercially commissioned and installed by available yet, but will be later this year.

Kemtek Imaging Systems on 1 April.

The technology can handle a multitude Luke Papadopoulos, MD of Paarl Labels says of substrates from 12 to 400 microns. This the installation will cater to market trends means unsupported films and pressure and customer needs to help food and sensitive labels stocks are available, so beverage products stand out on shelves. printing can be done on any He says the relationship substrate, including carton board. between the company Its liquid electrophotography and its customers is technology delivers crisp symbiotic with the job attractive images and smooth of producing labels vignettes. It applies a thin for customers taken ink layer, which provides a very seriously. uniform gloss between the ‘The function is for ink and substrate. Fade labels not only to serve resistant Magenta expands their purpose of conveying the addressability of information but also achieve applications that require a Luk e the end goal of making high level of light fastness s lo u po Pap a do products stand out.’ in outdoor conditions. It Paarl Labels is the labelling has one shot technology so division of Novus Holdings, all colour separations are transferred Africa’s commercial printing operation. simultaneously in a single pass The company has an arrangement with HP onto substrates. that all machines purchased are in-field A built-in spectrophotometer and tools upgradable. This means current technology simplify colour management and eliminate will be upgraded with the specs of the the need for expensive software, hardware latest machines available, such as the HP and manual calibration processes.

Indigo WS 6900, when it’s released.

Paarl Labels also installed the ABG The HP Indigo WS 6800 offers extended digicon 3 offline finishing solution at the colour gamut and it prints in CMYK, orange, end of the line of the HP Indigo WS 6800 green, violet and white. to provide applications such as hot and cold foiling and flexo overprints on the finishing line.

DELIVERING SATISFACTION

PAARL LABELS’ FLEXO site is an ISO 22 000:2005 and ISO 9001:2008 accredited facility printing self-adhesive labels for the beverage, food, cosmetics and petro-chemical industries. Its gravure printing operation in Montague Gardens is ISO 9001:2008 accredited and produces wet glue and wraparound labels for the beer, soft drink and bottled water markets.

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Packaging Review | June 2018

EFFECTIVE SERVICE PROVISIONS Short print runs, an essential application for the food and beverage industries, can now be done at the Paarl facility, allowing brand owners to order smaller quantities.

‘This is a trend we are seeing in the market. Brands are experimenting with products on shelf. Companies don’t want to print a long run of products, which are still in the experimental phase.’ The digital press is ideal in these instances.

There is an inclination toward premiumisation. ‘We noticed many suppliers trying to differentiate themselves in the market with premium offerings.

This can have a lot of embellishments and different designs added,’ explains Papadopoulos.

Personalisation is also a trend, which is largely driven by social media and interaction on different mediums.

‘Consumers want products relevant to them.’

Papadopoulos exemplifies this by explaining the recent campaign involving mass personalisation where consumers could name and design the elephant that appears on the Amarula bottle before sharing it with friends on social media.

MARKET SHARE Paarl Labels is home to a complete range of printing solutions devoted to creating personalised labels.

‘We have a fleet of UV flexo presses for medium-to-long run and self-adhesive labels. These are dedicated to supplying the food and beverage industries.’ High levels of embellishments such as embossing The HP Indigo WS6800 system

C O M PA N Y F O C U S

and debossing can be done on one line in a single pass. A rotogravure press is also in operation at the company’s Montague Gardens facility. This is particularly suited to the high volume beverage market, which extends to beer, carbonated soft drinks (CSD), bottled water and more. This press is mainly used for high volume printing.

Over the past few years, the company has had strong growth in the beverage label segment.

‘We are very involved in this market using our UV Flexo press in Paarl. We have also been successful in gaining shares in the beer and the wraparound market for CSD.’

DEBUNK MISUNDERSTANDINGS

DID YOU KNOW?

A close up of the HP digital press

Labels are made up of a The HP Indigo WS 6800 was number of layers. These automation and colour launched in 2014. include varnish, ink, matching. HP’s liquid facestock, adhesives and a electroInk technology back sheet, all of which needs delivers high resolution to work in harmony in order to printing and perfect registration. convey the appeal required.

Converters can meet the most stringent Papadopoulos says when consumers see corporate branding requirements using labels on packs, they perceive the labelling up to seven ink stations and a colour process as simple. gamut reaching up to 97 per cent of ‘There is a lot of work, thought and Pantone colours. HP’s SmartStream planning that goes into the design and Mosaic technology enables SKU production of labels to perform and proliferation, seasonal redesigns, and look the way they do on packs. It is a mass customisation for campaigns that technical process.’ boost sales. Coca-Cola, Budweiser, Nestlé, The following aspects need to be taken P&G and Oreo all offer recent branding into consideration when producing labels: and packaging success stories using the • t ype of bottle WS6000 series and SmartStream Mosaic.

• w ill the bottle be dry or moist when the In addition, variable data capabilities for label is applied brands include unlimited designs, bar • are the contents warm or cold codes, text, images and security features.

• w ill packaging encounter label-to-label The press allows converters to produce contact where scuffing occurs and ways any narrow web label, flexible packaging, this can be avoided sleeve, IML, wraparound label or folding • is a peel and read function or other carton jobs. It supports 0.5 to 18pt functional purpose required.

materials, including standard substrates with inline priming. HP Indigo ElectroInk Premium White delivers high-opacity white in a one-pass process.

The colour automation package of the HP Indigo WS6800 features a built-in spectrophotometer and software tools to simplify colour management and eliminate the need for expensive software, hardware and manual calibration processes. The system’s automatic alert agent provides early detection and quality control to help find and highlight inconsistencies between digital files and printed images in real time.

The HP Indigo 8000 digital press was launched in 2016. Described as the label industry’s most productive digital narrow web press, with two WS6800 print engines, it doubles production speeds of the 6000 series by reaching top speeds of 262fpm. •

Paarl Labels – www.novus.holdings/labels.com

DELVING INTO THE RANGE HP’s flagship label press is the Indigo WS6800 digital press. It is the third generation in the HP Indigo WS6000 series.

According to the company, the WS6800 delivers the industry’s highest crossover point versus flexo when it comes to narrow web pressure sensitive label printing.

The WS6800 has top printing speeds of 98 up to 131fpm in enhanced productivity mode. It also has advanced colour

Inside the facility

June 2018 | Packaging Review

37

D RY G O O D S FI L L I N G

Auf Wiedersehen to

overfilled or slack filled bags!

Food waste is an ongoing issue. Manufacturers and suppliers are in search of technologies that enable food waste reduction and filling precision. To keep abreast of competitors, technologies have been developed to meet these demands.

D

ry goods on store shelves have thrived over the past five years, driving the need for systems that reduce wastage and precisely fill bags and pouches.

Bosch has produced a number of powder and granular dry good fillers. Whilst these machines can also fill liquids, the company’s speciality lies in technology to fill dry products.

Through extensive research carried out by the company, it found most dosing manufacturing suppliers volumetric dosing devices could only promise a five to eight per cent variance in over and under filling products into bags. Customers often need to procure check-weighers, which leads to an increase of cost and footprint while trying to balance an inefficient volumetric doser.

Andrea Padayachee, Bosch’s business developer says the company’s auger filler and belt weigher in most cases provides

ACTIVE PARTICIPATION THE INDEPENDENT CONSERVATION organisation, WWF reports the packaging industry recognises the growing problem of food waste and is actively working to lessen it.

“Bosch’s belt weigher was designed to package the ultimate variety of granule-like products ” less than one per cent variance on powder and/or granular foods.

Designed in Waiblingen, Germany, the FVS auger filler is specifically for highspeed and precise volumetric filling of freeflowing powder products.

‘The use of product specific augers and closures ensures very high dosing accuracy for small and big portions. This machine can pack weights as low as 20g up to 10kg.

It has a mechanical output of more than 50 bags per minute, dependent on bag size,’ she explains.

Solid design makes handling easy and quick format changes possible. Filling accuracy is ensured at every stage of the three-step process, which the product undergoes. The procedure involves a hopper, cross-feeding chamber and screw process.

This guarantees efficient and continuous running of products during production.

PRECISE WEIGHT CONTROL Bosch’s FBW belt weigher is a gravimetric filler. According to Padayachee, this is a completely new invention, created to reduce product waste.

‘It was designed to package the ultimate variety of granule-like products such as snacks, rice, grains, seeds, pulses, pet food and even non-food products such as detergents,’ she notes.

The system has two belts that operate simultaneously, is economical and offers high outputs and accuracy.

The compact design of the machine offers accessibility for easy maintenance and simple changeover by means of using parameter settings in the HMI. It can also be mounted to VFFS machines and does not need a platform.

The belt weigher not only saves resources through product waste reduction and filling precision, but also makes use of electronic technology instead of pneumatics.

This ensures faster opening and closing of equipment buckets, which results in compressed air savings.

The machine enables dry goods packing from 200g up to two kilogrammes and has a mechanical output of 100 bags per minute.

‘Bosch’s FVS auger filler and FBW belt weigher have significant benefits. They require little space and offer ease of access to all parts, which ensures easy maintenance and low operational costs. These machines can be viewed in our Bosch showroom in Midrand,’ Padayachee concludes. •

Bosch South Africa – www.bosch.co.za

Bosch Packaging Discover the Benefit of Bosch Dry Goods Filling Solutions with Volumetric Filling Equipment Gravimetric Filling Equipment

Robert Bosch Packaging Technology 96, 15th Road, Randjespark, Midrand | Tel 011 651 9600 Email Aubrey.pharatlhatlhe@za.bosch.com | www.bosch.com

Bosch.indd 1

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Packaging Review | June 2018

Rent a Bosch – Without Capex

2018/06/07 10:11 AM

M E TA L PAC K AG I N G

Pack to the future Poised for growth, the South African metal packaging industry is on the cusp of an exciting era. This is according to the newly appointed CEO of Metpac-SA, Kishan Singh who says efforts to introduce new technology and improve the environmental credentials of metal packaging are yielding positive results.

O

n the topic of global packaging trends, Singh predicts an unprecedented demand for metal and aluminium cans in coming years.

He says as the global population continues to grow, so will demand for convenient packaging.

‘There will be an increase for packaging that prevents food waste, easing supply chain stresses. This packaging will also be recyclable and sustainable. Metal packaging ticks all these boxes.’

This type of packaging equates to 9.2 per cent of the South African packaging market value. It totalled about R65 billion and seven per cent of the approximately 3.3 million tonnes of market volumes (exconverter) in 2016.

Whilst seemingly small compared to some of the other packaging streams, MetPacSA predicts metal packaging is poised to grow its market share owing to its excellent recovery rate.

‘It is infinitely recyclable because of its metallurgical chemistry, composed of iron or aluminium atoms.’

COMPETITIVE RECYCLING STATS When used steel or aluminium cans are recycled, atoms are reconstituted into

DID YOU KNOW? South Africa has one of the highest recovery rates in the world for used metal packaging.

their original atomic arrangements. This completely renews the material for reuse. Singh believes it is this principle, amongst many others, which will continue to position metal as an ‘extremely’ viable packaging material into the future.

South Africa has a 73 per cent recovery rate for metal packaging. This is three per cent more than it was in 2015, according to the 2016 BMI Research Report. There are plans to increase recycling rates to 75 per cent by 2021.

‘In an attempt to improve green credentials, industry has made significant progress in recent years to reduce its environmental footprint. This has been

done by light-weighting products, which resulted in metal packaging becoming significantly more competitive and attractive for product designers.’

OBSTACLES TO GROWTH In spite of breakthroughs with metal packs and attempts to increase recovery and recycling rates, challenges remain.

South Africa’s slow economic growth has resulted in lower packaging consumption.

June 2018 | Packaging Review

39

M E TA L PAC K AG I N G

The lack of separating recyclable materials at source and low collection and recycling awareness are additional challenges along with limited access to landfills by waste pickers.

This results in insufficient access to materials.

Long distances between consumption and recycling infrastructure also prove to be problematic.

Singh says the metal Kishan S packaging industry ingh is aware of these challenges and is in the process of finding solutions to address issues and metal’s improve recovery and recyclability.

‘Our IWMP is being drafted with inputs from industry role players for submission later this year,’ he adds.

FUTURE FORECAST Metal packaging is predicted to grow in market share through continued innovation. ‘The beverage sector in particular holds exciting opportunities for the sector. Metal packaging will adapt and accommodate to the requirements of the modern consumer, through shape, size, functionality and closure changes.

More importantly, adaptation must comprise the unwavering industry quest for mass reduction without compromising packaging efficacy. Metal is known to retain internal pressures of carbonated soft drinks more efficiently than other materials. In addition, closure designs on beverage cans are able to retain internal pressure at almost 100 per cent. This enables a longer shelf life and extended supply chain distances.

Given these exciting developments, it is only a matter

of time before the metal slice of the pie gradually increases as these packs become the preferred choice for supply chain efficiency,’ he explains.

Singh recently delivered a talk at the Australian Institute of Packaging’s biennial National Conference held in Queensland. He was among the 40 international and national experts invited to represent the global food, beverage, manufacturing and packaging industries. He took the opportunity to introduce the international audience to the mission and vision of MetPac-SA.

DEDICATED TO THE CAUSE Metpac-SA is committed to reporting on the actual metal recycling and recovery rates within the country. This is to prove the metal packaging industry is planet friendly.

‘Our vision is to bring together the entire metal packaging value chain in South Africa and promote the interests and recycling of steel, tin plate and aluminium packaging. We do this by keeping a close eye on local and international legislation that can have an impact on our industry.

“Our Industry Waste Management Plan is currently being drafted with inputs from industry role players for submission later this year”

AT THE HELM TO LEAD THE PACK SINGH HAS TAKEN over the helm from Delanie Bezuidenhout as the organisation’s new CEO. He is widely known and respected for his in-depth knowledge, technical and commercial expertise within the metal packaging industry. Singh will be taking a leading role over the next few months in completing and submitting association’s plan for the Industry Waste Management Plan (IndWMP) by the September 2018 deadline.

‘This will probably be the single most important initiative I will drive in the short to medium term as the entire packaging industry, through dedicated Producer Responsibility Organisations (PROs), is working together to achieve this deadline,’ he says.

We therefore urge all raw material suppliers, primary packaging converters, fillers or bottlers, retailers and brand owners to sign up as members. This will enable a greater impact and we will be able to hold our place in the packaging industry in the future,’ he adds.

The metals industry should not underestimate the threat of losing market share to other packaging materials.

‘We should constantly be on the lookout for ways to innovate and promote the message that metal is truly an environmentally sustainable packaging solution. Spreading the recycling message, news of our industry’s ongoing and impressive metal recovery rates, as well as continued innovation to preserve natural resources, are all critical in proving our extended producer responsibility to the consumer, government and other stake holders,’ he concludes.

WHAT IS A SUSTAINABLE POPULATION? It can survive over the long term without running out of resources or damaging the environment in the process. This means a population must not generate more waste than natural processes can manage. It is one where wastage does not generate harmful outcomes for the ecosystem. Resources used should be renewable through natural processes or entirely recyclable. A sustainable population must not grow past the point where those natural limits are breached. At present, the current human population is not sustainable. •

Metpac-SA – www.metpacsa.org.za

40

Packaging Review | June 2018

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Food Review | June 2018

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