THE CLEAN LABEL MOVEMENT
WITH GROWING DEMAND, WHAT ARE THE CHALLENGES AND OPPORTUNITIES AHEAD?
ALSO INSIDE
NOVEMBER/DECEMBER 2013
GOING WITH THE FLOW
PROFITING FROM IBC BLENDING
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CONTENTS
NOVEMBER/DECEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
8
PROCESSING
•
PACKAGING
•
FLAVOURS & ADDITIVES
www.apfoodonline.com
•
40
The Clean Label Movement
STORAGE & HANDLING
volume 25 no.8
28 Automation Leads The Way
46 PACKAGING & PROCESSING 28
Automation Leads The Way
38
A beef product manufacturer in South Africa has seen great expansion over the last 25 years. The company turned to advanced product packaging system to cater to growing demands. By Annalisa Bellante, Cama Group
Often perceived as heavy investments that only big companies can afford, automated packing solutions have many hidden benefits that small and medium companies can enjoy as well. By Valeska Haux, Multivac
32
Case-Study: Next Step In Meat Packaging
Going With The Flow
INGREDIENTS & ADDITIVES
Recent technological advances in continuous-process cooking and cooling have allowed food processors to significantly reduce their energy and water consumption, while achieving improved equipment and process return on investment. By Jim McMahon, Zebra Communications
40
The Clean Label Movement The clean label movement is taking off around the world with increasing number of product launches over the years. The next big challenge is ensuring taste, visual and textural quality with fewer additives. By Thomas Schmidt, Beneo Asia-Pacific
42
Baking With WHEY
The Clean Label Evolution Clean label is a clear trend across global food markets and new product launches in the clean label space have steadily increased over the last decade. By Edwin Bontenbal, Corbion Purac
HEALTH & NUTRITION 46
Baking With Whey The gluten-free market has caught the imagination of health conscious consumers and has been expanding steadily. Whey isolates offer an alternative to gluten-free recipes that helps overcome traditional limitations. By Craig Sherwin, Davisco Foods
Enquiry Number
3513
CONTENTS
NOVEMBER/DECEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
10
PROCESSING
•
PACKAGING
•
FLAVOURS & ADDITIVES
•
STORAGE & HANDLING
www.apfoodonline.com
volume 25 no8
14
Refer to Advertising Index on Pg
for Advertisers’ Enquiry Numbers
BEVERAGE 50
All In A Can The demand for aluminium beverage can in Asia, particularly China, is on the rise, fuelled by innovative packaging design and growing awareness on environmental sustainability. By Jozef Salaerts, Crown Asia Pacific
54
62
64
50 All In A Can
66
Tapping Into China’s Meat Market China’s meat industry has been experiencing strong growth, leading to greater demands on safety and freshness. New packaging solutions can help manufacturers stay ahead of their game as well as reduce costs. By Daniel W Kearny, Bemis
EXHIBITION WATCH
68 70 74 75 76
DEPARTMENTS 12 14 16 24 79 80A 80B
Editor’s Note Advertiser’s List Business News Product Highlights Calendar Of Events Reader’s Enquiry Form Subscription Information
Case-Study: Profiting From IBC Blending Flavour producers’ have never considered intermediate bulk container (IBC) blending as a viable alternative to their conventional, static mixers. Technology advancements have made this method a good option and a single blender can make a difference. By Hans Pettersson, Matcon
Case-Study: The Force Behind Without proper back-up power plants, manufacturers will be exposed to highstake risks in the event of power outage. A brewery in Sri Lanka decided to install diesel power generator to safeguard its production. By S Kusumapala, Cummins Power Generation
Case-Study: Mechanical & Pneumatic Approach To Powder Handling As a UK biscuit and snack product manufacturer finds out, mechanical and pneumatic conveyor systems can cater to different powder handling needs during production. By David Boger, Flexicon
Getting It Right From The Ground Up Flooring is an aspect of production that is often conveniently overlooked, but can have great impact on efficiency and safety. There are many considerations to be made and options to choose from depending on the manufacturing requirements. By Dave McNeece, Flowcrete
60
FEATURES
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EDITOR’S NOTE 12 managing director Kenneth Tan
Economic intEgration FlipsidE The holidays are upon us and 2013 is coming to an end. Looking back, the industry has made great strides in recovering from the economic downturn of years earlier. One notable trend, driven by increasing affluence and health awareness of the region, is the sustained growth in product segments that used to be considered niche markets. Factors such as organic, natural and clean label are getting much more attention as consumers are slowly beginning to understand the price differentiation with conventional products and their benefits. As the economy recovers and people look forward to an optimistic year ahead, many manufacturers have shifted their focus on increasing productivity. One approach is definitely through the adoption of automated solutions, something which the Southeast Asian region is slowly warming up to. Next year is shaping up to be a promising year with lots of opportunities. Emerging markets in Asia are not showing any signs of slowing down. However, the competition within the region is set to increase as well with more companies dedicating more efforts and resources in creating products that cater to special needs of the market. There will be more changes ahead, especially as Southeast Asia prepares itself for the harmonisation in 2015. However, at the moment, the signs suggest that 2014 will be a good year. The APFI team would like to take this opportunity to wish you happy holidays and a great year ahead!
editor Wong Tsz Hin wongtszhin@epl.com.sg assistant editor Sherlyne Yong sherlyneyong@epl.com.sg editorial assistant Audrey Ang audreyang@epl.com.sg assistant art director Ahmad Halik
ahmadhalik@epl.com.sg
business development manager Randy Teo randyteo@epl.com.sg publication manager Peh Sue Ann sueannpeh@epl.com.sg senior circulation executive Brenda Tan brenda@epl.com.sg contributors Annalisa Bellante Craig Sherwin Daniel W Kearny Dave McNeece David Boger Edwin Bontenbal Hans Pettersson Jim McMahon Jozef Salaerts S Kusumapala Thomas Schmidt Valeska Haux board of industry consultants Dr Aaron Brody Managing Director Packaging/Brody, Inc Dr Alastair Hicks Adjunct Professor of Agroindustry Mae Fah Luang University, Thailand Professor Alex BĂźchanan Professional Fellow Victoria University Dr Nik Ismail Nik Daud Head, Food Quality Research Unit Universiti Kebangsaan Malaysia/ President Malaysian Institute of Food Technology Kathy Brownlie Global Program Manager Food & Beverage Ingredients Practice Frost & Sullivan Sam S Daniels Consultant World Packaging Organisation
Executive Board chairman Stephen Tay
Wong Tsz Hin
group executive director Kenneth Tan executive director Lum Kum Kuen
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TradeanMedia Pte Ltd Eastern Holdings Ltd company
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ASIA PACIFIC FOOD INDUSTRY ADVERTISING INDEX ENQ NO
ADVERTISERS
PAGE
ENQ NO
ADVERTISERS
PAGE
3508
ALMOND BOARD OF CALIFORNIA
49
3476
HEAT AND CONTROL PTY LTD
17
3507
BASF
OBC
3436
HUGHSON NUT INC
IBC
3431
BENEO ASIA PACIFIC PTE LTD
53
3501
IGUS SINGAPORE PTE LTD
55
3517
BERICAP ASIA PTE LTD
39
3373
ISHIDA CO LTD
37
3511
BUECHI LABORTECHNIK
21
3343
KALSEC INC
31
3516
CARGILL MALAYSIA SDN BHD
IFC
3514
MATCON LTD
51
3518
CENTRAL FILTER MFG CO LTD
33
3502
MULTIVAC PTE LTD
35
3403
CLEARPACK SINGAPORE PTE LTD
5
3504
PALSGAARD
63
3503
CONNELL BROS
43
6052
PIAB ASIA PTE LTD
80
3521
DSM NUTRITIONAL PRODUCTS ASIA PACIFIC
1
3523
PROPAK ASIA 2014
78
3510
EVERGREEN PACKAGING
19
3522
PROPAK VIETNAM 2014
69
3513
EXXON MOBIL INDUSTRIAL LUBRICANTS
9
6060
R & D ENGINEERS
80
3512
FISHER NUT CO
45
3500
SANDVIK SOUTH EAST ASIA PTE LTD
59
3433
FLEXICON CORPORATION (AUSTRALIA) PTY LTD
3
3389
SCHAEFER SYSTEMS INTERNATIONAL PTE LTD
2
3515
FLOWCRETE GROUP LTD
13
3505
SIDEL GROUP
25
3483
FOOD & HOTEL ASIA 2014
71
6053
TCP PIONEER INCORPORATED
80
3491
FOOD INGREDIENTS CHINA 2014
73
3519
TECSIA LUBRICANTS PTE LTD
23
3520
FORTITECH ASIA PACIFIC SDN BHD
6&7
3453
URSCHEL ASIA PACIFIC PTE LTD
57
3506
GEBO CERMEX (THAILAND) CO LTD
27
3509
WACKER CHEMIE AG
47
3475
HEAT AND CONTROL PTY LTD
15
3486
WATERS CORPORATION
11
This index is provided as an additional service. The publisher does not assume any liability for errors or omissions.
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BUSINESS QuickBites
Asia Pacific’s Top News at a glance
Fonterra Invests NZ$72 Million In Cheese Plant Strong growth from the foodservice catergory driven by Asia is part of the motivation for the investment. SPA Hosts Food Productivity Conference Singapore’s food industry is told to collaborate as a whole to increase competitiveness.
Nestlé Invests In Egyptian Ice Cream Factory The US$28.86 million investment will help extend the company’s services in one of its biggest markets. Del Monte Pacific Acquires Consumer Food Business Operator of one of the largest pineapple plantations in the world, the company will benefit from wide access in the US. MAFF Brings Japanese Culture To Singapore A series of events will be organised in Singapore to raise the profile of Japanese cuisine and culture. Barentz Opens Philippines Office Operating from Manila, the company will focus on establishing itself as a supplier to food and nutrition companies in the country. Survey Shows Consumers Affected By Food Prices Eighty-five percent of global consumers say rising food prices will affect their choice of grocery products. IMCD & Network Nutrition Join Forces The move will extend the reach of Network Nutrition in key target markets like Europe and Asia. Kalsec Shows Strong Interest In Spice Recent postings suggest that American and European consumers continue to seek out hot and spicy goods and beverages.
Food Technology Served
FRESH!
www.apfoodonline.com
Prince Roy, Virginia, US
Unilever Food Solutions Launches Academy Training programs will be developed by the academy to increase productivity from frontline to back-end.
Fonterra To Invest NZ$72 Million In Cheese Plant AUCKLAND, NEw ZEALAND: Fonterra has announced its plans to invest NZ$72 million (US$59.35 million) at its Clandeboye mozzarella plant as it further expands its global foodservice capabilities. The foodservice category includes full and quick service restaurants, institutions, hotels, airline catering facilities and other commercial kitchens. The investment is the final stage of a technology upgrade that will double the capacity of the plant in Canterbury to produce individual quick frozen (IQF) grated mozzarella. When fully implemented, this will increase the company’s IQF mozzarella capacity across its two plants in New Zealand to over 50,000 metric tonne per annum. Additional capacity is required to meet growing international demand, primarily in global fast food restaurant chains, supported by growth in regional fast food and fine dining restaurants. The plant uses a manufacturing process that was developed by the company’s research and development centre that enables frozen natural shredded mozzarella to be made straight from milk in one day, rather than two months taken by conventional mozzarella processes. According to the company’s director of foodservice, René Dedoncke, the growth in the global foodservice category is being driven by emerging Asian markets where the category is estimated to grow at around 13 percent annually to 2016. The plant upgrade will begin in mid-2014 and is due to be completed by September 2015. ________________________________________ Enquiry No: 0800
ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DECEMBER 2013
SPA Hosts Food Productivity Conference on-machine seasoning system
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SINgAPOrE: As part of the effort to increase productivity across different industrial sectors in Singapore, Singapore Productivity Association (SPA) has organised a Food Productivity Conference, a knowledge and experience exchange platform for professionals in the food industry. The theme of the conference is ‘Improving Productivity across the Value Chain’, which signifies the growing need for the industry to collaborate as a whole. “Food businesses today face increased competition and new challenges such as labour constraints and rising business costs,” Dr Ahmad Mohd Magad, president of the association says in his opening address. “It has become increasingly important for companies to adapt and be equipped with the knowledge of productivity, how to apply them and how to innovate, to keep up with competition.” More than 850 food companies have embarked on productivity and service upgrading projects since the launch of the Food Services and the Food Manufacturing Productivity Plans in 2011. In addition, a Food Automation Unit was launched in October last year to help food companies with their automation needs. The automation unit has since reached out to over 170 food manufacturers. In May this year, a joint Call for Collaboration to outsource the preparation of non-core food items to food manufacturers was made in an effort to free up restaurants’ food preparation time and help food manufacturers scale up and invest in automation. More recently, the Singapore Productivity Centre has been set up to address the needs of the food services sector through consultancy, training, study missions, benchmarking, conferences and applied research.
4/09/2013 10:04:23 AM
BUSINESS NEWS
QuickBites NOVEMBER/DECEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
18
INDUSTRY & MARKET
SINgAPOrE: Unilever Food Solutions has announced the launch of the Chefmanship Academy in Singapore to help food and beverage (F&B) establishments stay on top of their game amidst increasing competition and rising food costs. The first-of-its-kind initiative in Singapore is designed to meet the diverse needs of food professionals working in restaurants, catering, hotels, local eateries and school canteens. Supported by SPRING Singapore under the Partnerships for Capability Transformation (PACT) program, the academy is a partnership with the Restaurant Association of Singapore (RAS) for mutually beneficial outcomes. For a start, it will develop a training program to train F&B operators on improving productivity from frontline to back-end operations. This program is developed in close consultation with F&B industry experts, incorporating global expertise with local insights. The training will be delivered via a mix of classroom and real life best practice sharing sessions by industry experts. Participants will also have practical hands-on sessions to enhance learning. The first module will commence on late November this year and it will touch on how F&B establishments can maximise efficiency and profits via optimising key internal operations such as menu planning, kitchen management and front-line service. Academy training program in Singapore is now open for registration. ______________________ Enquiry No: 0802
“A British business owner has created a glow-in-the-dark ice-cream using protein from jellyfish.”
< James Bowe>
James Bowe
Unilever Food Solutions Launches Chefmanship Academy
Did you know?
Nestlé Invests In Egyptian Ice Cream Factory VEVEy, SwITZErLAND: Nestlé has invested CHF 26 million (US$28.86 million) to extend its ice cream factory in Egypt, one of the company’s biggest ice cream markets in the world. Ice creams produced at the factory are distributed locally as well as being exported to Northeast Africa—to countries including Jordan, Libya, Lebanon, and Tunisia. The factory also produces Mövenpick products, which are exported to Malaysia. The investment at the ice cream factory also includes the introduction of some of the most advanced food production lines out of all the company’s ice cream plants. The factory extension was inaugurated in the presence of Nandu Nandkishore, executive VP Zone Asia, Oceania, Africa, Roger Stettler, senior VP Zone Asia, Oceania, Africa and Suresh Narayanan, market head North East Africa region. The company currently has three factories and seven distribution centres in the country and employs more than 3,000 people. ________________________________________________________________ Enquiry No: 0803
ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DECEMBER 2013
SINgAPOrE: Del Monte Pacific has entered into a definitive agreement to acquire, through a new subsidiary, the consumer food business of Del Monte Foods, a privatelyowned US corporation, for US$1.675 billion. The closing of the transaction is subject to regulatory approvals and customary closing conditions. Under the terms of the purchase agreement, the company will purchase the brands and certain assets, and assume certain liabilities related to the consumer food business in the US, as well as equity interests in certain South American subsidiaries of the US company. As the operator of one of the largest pineapple plantations in the world, the company expects to benefit from wider access to the processed pineapple business in the US, one of the largest packaged fruit segments in the American market. With greater access for its products, the company expects to realise synergies by leveraging its vertical integration, benefitting from economies of scale and valueadded expansion and optimising operations over time. The acquired consumer food business will be managed under a separate platform and will be led by a US-based CEO and management team. It is expected that the operating organisation of the consumer food division will be largely transferred to the company together with the assets and operations of the business. ________________________________________ Enquiry No: 0804
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3510
Del Monte Pacific Acquires Consumer Food Business
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BUSINESS NEWS
NOVEMBER/DECEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
20
INDUSTRY & MARKET
MAFF Brings Japanese Culture To Singapore SINgAPOrE: Japan’s Ministry of Agriculture, Fisheries & Forestry (MAFF) has announced a concerted campaign, ‘Celebrate Japanese Cuisine and Culture!’, to bring together a series of trade and consumer events to raise the profile of Japanese cuisine and culture in Singapore. The campaign will include a trade exhibition for industry professionals, as well as three new consumer events. Singapore saw a 2.7 percent increase in
Japanese food and beverage imports to 14.5 billion yen (US$147 million) in 2012. According to Masayuki Yamashita, director-general of the ministry’s Food Industry Affairs Bureau, there are around 55,000 Japanese restaurants in the world, which is more than double the figure from ten years ago. In addition, the number of Japanese restaurants in Singapore has increased to reach 880 from 180 over the last five years. ___________________ Enquiry No: 0805
Barentz Strengthens Asia Presence With Philippines Office HOOFDDOrP, THE NETHErLANDS: Barentz International, a company involved in sales, marketing and distribution of food ingredients, has opened an office in the Philippines. This new office is a logical step in the rapid expansion of the company, which has been working with global and local leading food and nutrition companies in the region through its Singapore regional head office and other local Asia Pacific teams. “Being in the Philippines is a logical step for us,” says Kees Schepers, VP of Barentz Asia Pacific. “It fits right into our strategy of wanting to be close to our customers to develop premium and innovative ingredients solutions together. In the last two years, we saw a substantial growth with our Asian customers, making it essential for us to be here, to work on innovative products for the Asian market together.” Operating from Manila, the company will focus on establishing itself as a supplier to food and nutrition companies in the Philippines, before developing the ingredients and additives business for the pharmaceutical and personal care industries. With over 100 million people and one of the highest GDP growths in the region in 2012, the Philippines is a key market for the company and its major suppliers. Through freight forwarding and 3PL agreements, the Philippines office will offer a full range of solutions to the food & nutrition market. The opening of the Manila office is part of an Asia Pacific expansion plan, which also includes further moves to Malaysia, Vietnam and Australia. In 2012, the company has solidified its presence in the Asia Pacific region through opening a regional head office and a Vitablend production plant for nutritional premixes and antioxidant blends in Singapore. _______________________________________________________ Enquiry No: 0806
Survey Shows Consumers Affected By Rising Food Prices NEw yOrK, US: Eighty-five percent of global consumers in an online survey say rising food prices will affect their choice of grocery products, according to a new study by Nielsen, a global provider of information and insights into what consumers watch and buy. The Nielsen Global Survey of Inflation Impact surveyed more than 29,000 internet respondents in 58 countries to understand how respondents around the world of all income ranges adjust to rising food prices. When asked about likely spending changes to specific food categories, 14 percent of global respondents indicated they would buy more loose, unpackaged, unbranded cereal (such as rice, wheat and grains). Meanwhile, 11 percent said they would stock up on fresh or frozen fruits and vegetables, and eight percent said they would buy more canned fruits and vegetables. More than half of global respondents had no plans to change their spending on staple categories like dairy products (68%), meat and poultry (62%), bread and bakery goods (60%), packaged foods (55%) and fish and seafood (52%). Half of all respondents said they would buy fewer products such as candies, cookies and other sweets (59%), chips and other snack foods (58%), carbonated beverages (53%), alcoholic beverages (49%), prepared meals (48%) and convenience foods (45%). During times of rising food prices, 41 percent of global consumers surveyed said they would purchase only salepriced items. Thirty-two percent of respondents said they would look for deals online, and 29 percent said they would purchase larger pack sizes. ___________________ Enquiry No: 0807
ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DECEMBER 2013
BUSINESS NEWS 21
IMCD & Network Nutrition Join Forces rOTTErDAM, THE NETHErLANDS: IMCD Group has announced that Network Nutrition, a Sydney headquartered distributor of botanical, nutritional and plant enzyme based raw materials, will be joining the group. The integration of the businesses of both companies, along with the recent acquisition of Capitol Ingredients Australia, will amount to one of the largest specialised natural ingredients providers in the region. René den Hertog, MD of IMCD Australia & New Zealand, says: “The IMCD operation will extend the reach of the Network Nutrition range in key target markets like Europe and Asia, where the value proposition they have demonstrated in the Australian & New Zealand market can also be leveraged. By aligning Network Nutrition’s strength in herbal extracts with the breadth of IMCD’s focus in the natural healthcare market,
we are perfectly positioned to provide a comprehensive portfolio of products and innovative solutions to the market both here in Australia & New Zealand and internationally.” Ryan Gorman, CEO of Network Nutrition, added that by merging the company’s activities into the IMCD structure, the opportunities for growth and development of the existing portfolio are significantly amplified. “This is an important stage in the evolution of our brand and our partner brands. It presents our customers with even greater advantages and benefits.” All Network Nutrition products will continue under the same brand names while employees will transfer to IMCD Australia & New Zealand. The two companies are committed to making the transition completely seamless, and are excited to deliver on the ambitions of the new and improved natural healthcare business unit. ________________________________________ Enquiry No: 0808
www.apfoodonline.com FOR EVERYTHING YOU WANT TO KNOW ABOUT FOOD TECHNOLOGY
www.buchi.com/nirfood AD_halfpage_NIR_F&B_171x122.indd 1
Quality in your hands 14.10.2013 06:48:10
Enquiry Number
BUCHI NIRSolutionsTM guarantee rapid, affordable and precise results. They enable real-time decision making for enhanced quality and higher productivity and support you in mastering your daily challenges from incoming goods inspection to finished product release.
3511
NIRSolutionsTM for Food & Beverage Maximize your efficiency and safety
BUSINESS NEWS
NOVEMBER/DECEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
22
INDUSTRY & MARKET
Will Clayton, Blackburn, UK
Kalsec Shows Strong Interest In Spicy Food
Did you know?
“Seattle entrepreneur Dan Newman and his friend Bryan Summersett have created an app for people to share leftovers.”
MICHIgAN, US: American and European consumers continue to seek out hot and spicy foods and beverages, according to recent postings by the US and EU HeatSync Heat Indexes. The indexes by Kalsec are measurement tools that follow usage of more than 30 different peppers. In collaboration with market data from Mintel’s Menu Insights and the Global New Products Database (GNPD), the US index evaluates more than 2,400 restaurant food and drink menus, while the EU index measures retail product introductions in Europe. In the first six months of 2013, the US and EU indexes both posted strong increases, with the US index up 38 percent and the EU index increasing 26 percent over the previous six months. In the European market, sweet chilli, piquillo and cayenne peppers showed the strongest increases. The European index has continued its climb since 2007. The popular jalapeno and cayenne peppers led the strong growth in the US for the first half of 2013. The banana and pepperoncini peppers also contributed to the increased US demand. “The significant increase in demand and diversity of pepper types supports a global trend toward the consumer’s desire for a more complex and flavourful heat experience,” says Karen Buczek, product director of the company’s natural spice and herb flavour extracts. The index is named after the company’s HeatSync Systems, designed to control the timing, intensity and location on the palate of heat (pungency) to be delivered for specific application requirements. ______________________ Enquiry No: 0809
Enquiry Number
3519
PRODUCT HIGHLIGHTS
NOVEMBER/DECEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
24
Heat & Control: Accumulation Conveyor Heat and Control’s SwitchBack conveyors provide in-line accumulation of delicate snacks, baked products, frozen meals and other goods. Gentle horizontal motion conveying and unique sloped pan configurations prevent product damage by eliminating abrupt drops and stops. Composed of two independent FastBack conveyors, the system automatically stores the product in the lower unit while conveying it in the opposite direction in the upper feed conveyor. Available for capacities up to 1.47 sq m, the system requires less floor space than comparable accumulation conveyors. The patent-pending design requires no photo eyes, product detection devices, gates or trolleys, making it ideal for operation in wet wash down environments. The gentle horizontal motional conveying prevents the loss and build-up of product coatings in the conveyor pans and eliminates the need for mid-shift cleaning downtime. ___________________________________ Enquiry No: P810
Cama: Cartoning Machine Cama has recently produced a complete electronic cartoning line that can pack up to 160 baby milk powder pouches per minute into cartons, with an individual flow wrapped dosing spoon and booklet. Pouch loading into the cartoning machine is provided by two electronic hopper units which phase, collate and load the products into the cartoning machine conveyor. The machine can work with one or both of these loaders. Two flow-wrapped spoon dispensers are also integrated. They cut and load the spoons into the cartoning machine pockets in phase with the pouches. No bag-no spoon-no loading into cartons, is a standard feature of the machine control. The line features a clean and hygienic design that is lubricant free with no product retention. In addition, it has an accessible operator’s interface and ample visibility on four sides. ___________________________________ Enquiry No: P811
Lactalis Ingredients: Dairy Powders
Jennifer, Vancouver, Canada
Lactalis Ingredients has introduced Caralac, a range of dairy powders with an authentic and unique taste: a combination of caramel, toffee and biscuit notes. The powders are obtained through a process based on the Maillard reaction. They are composed of milk powders and whey powders. The 100 percent dairy powder has no added sugar or flavourings, and does not contain any additives or preservatives. The range’s low moisture content makes the powders easy to handle. In addition, it offers several advantages to chocolate applications such as bars, toppings and fillings, including taste differentiation, costsavings, formula optimisation and flavour improvement. __________________________________ Enquiry No: P812
GEA: Condensers Due to enhanced configuration of their heat exchanger tubes, the GEA Searle condensers from the RF range (for synthetic refrigerants) and the NF range (for ammonia) require a smaller refrigerant charge. They are also lighter than their predecessors. The RF range is available for the capacity range of five to 1,342 kW (as per EN 327:2000), in flat-bed or vertical configurations. As a result of extensive testing, two tube patterns have been implemented for this particular range of condensers: one with 12 mm tubing, and the other with 3/8 inch tubing. The air-cooled condensers in the NF range are designed on the same basic principle as those in the RF range and they offer identical configuration possibilities, fans and accessories. The NF models, however, are designed for operation with ammonia as refrigerant, and they have heat exchanger tubes and headers made of stainless steel. Models under this range cover the capacity range from 5 to 1,330 kW (as per EN 327:2000). _________________________________ Enquiry No: P813
Speed iS one thing Flexibility iS everything
diScover carbonated SoFt drinkS the proven poSSibilitieS
Discover all the proven possibilities for carbonated soft drinks at sidel.com/CSD
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The proven possibilities of the revolutionary Sidel Matrixâ&#x201E;˘ system provide a better match for your needs and help you boost your margins. Experience the benefits of line flexibility, production efficiency, product integrity and reduced consumption. It lowers your total cost of ownership and optimises your performance today and for years to come.
3505
Demand among carbonated soft drinks consumers is high. The consumers request greater beverage sophistication and variety, as well as healthier drink attributes, unique shapes, more value for money and a brand they can trust. You need to deliver all of this on one line.
PRODUCT HIGHLIGHTS
NOVEMBER/DECEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
26
Videojet: Thermal Transfer Overprinters
Arla Foods Ingredients: Functional Milk Proteins
The thermal transfer overprinters, DataFlex 6320 and DataFlex 6420, by Videojet are designed to address a range of flexible packaging and labelling applications in the snack foods, bakery, meat and poultry, and confectionery markets, among others. The DataFlex 6320, available in both 32 mm and 53 mm print width formats, is designed for low cost of ownership and is ideal for moderate speed applications including vertical form, fill and seal. The high performance DataFlex 6420 offers higher throughput to provide more capability for faster marking applications. Offered in both 53 mm and 107 mm print width formats, the model’s application range spans ultrafast horizontal form, fill, seal and wide format coding applications requiring a significant amount of content.
Arla Foods Ingredients has launched Nutrilac HiPro Improvers, a range of functional milk proteins that boost protein levels in dairy products to as high as 10 percent without negatively impacting taste and texture. Made from natural milk proteins, the improvers make it possible to pack a bigger protein punch into yoghurts and dairy beverages, as well as ice creams—tapping into the increasing popularity of premium, high protein products among mainstream consumers. The improvers facilitate the creation of delicious and nutritious products with increased protein content without damaging the sensory properties of a product, and with no dryness or graininess—previously a major challenge for manufacturers of high-protein products. When using the improvers, dairy companies can maintain complete control of texture, whether they are producing a thick, spoonable yoghurt or a refreshing dairy drink.
_____________________________________ Enquiry No: P814
_________________________________ Enquiry No: P815
Krones: Centrifugal Pump Krones has launched its own pump series called the Evoguard, with the first product being a single sta ge, normal priming, hygienic centrifugal pump. The pump is available for delivery flows of up to 100 cubic metres an hour, delivery heights of up to 80 m and operating pressures of up to PN 16. It has a new interface with the motor, plus a new seal concept for maximised dependability even when exposed to ultra-tough process conditions that has concomitantly extended useful lifetimes. In terms of operating costs, high-efficiency motors coupled with optimised pump design ensure low energy consumption. Meanwhile, its minimised service routine has reduced the time and manpower required for their cleaning and maintenance, which means there are significantly fewer production interruptions for purposes of the requisite servicing routines. _________________________________ Enquiry No: P816
Hi-Cone: Picking & Palletising System Hi-Cone and ITW Warehouse Automation have launched Vertique, a case picking system that specialises in ‘mixed case’ picking and palletisation. It is used with Hi-Cone’s orientation system, which provides orientation benefits that include 360 degrees communication, improved recognition of on-can promotions, accurate multipack pricing, savings in merchandising cost at retail outlets, as well as packaging with higher impact and added value with no extra packaging material cost. The high-speed system works by optically scanning the label, which is then compared to the stored data in the created database. The amount of rotation is then calculated and communicated to the servo motor, and the container is physically moved to the desired orientation. _____________________________________ Enquiry No: P817
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3506 Enquiry Number
Line performance can always be improved. But not everyone can do it.
At Gebo Cermex, we have more than half a centuryâ&#x20AC;&#x2122;s experience in improving the performance of production and packaging lines everywhere. Our experts design and install innovative solutions that set new standards of performance for our customers in terms of operational efficiency and cost of ownership.
PACKAGING & PROCESSING 28
NOVEMBER/DECEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
AutomAtion LeAds the WAy
Often perceived as heavy investments that Only big cOmpanies can affOrd, autOmated packing sOlutiOns have many hidden benefits that small and medium cOmpanies can enjOy as well. by Valeska Haux, seniOr directOr Of cOrpOrate marketing, multivac AutomAtion is a key factor in industrial-scale manufacturing for achieving high production volumes. Packaging automation also creates other benefits, and it can therefore, be an interesting alternative for small and medium-sized production companies as well. Partial or full automation is common in industrial-scale production of consumer products, in which a large proportion of the process stages is taken over and completely controlled by machines and automation components. However, despite the sophisticated technical possibilities available, there is still a range of simple or very monotonous tasks within the whole packaging procedure, which is still performed manually in many companies. These include, for example, the infeed and loading of products into the pack, the converging of packs or their later loading into boxes as outer packaging. The efficiency of packaging procedures can be increased significantly through the automation of these part-stages. In contrast to a companyâ&#x20AC;&#x2122;s personnel, machine modules for infeeding, loading, converging and box packing are permanently available. They handle the products with speed and precision which cannot be achieved manually and they are much more flexible than the employees in a company, as well as capable of being used for longer and without interruptions due to sophisticated system intelligence. Denesters load trays with the correct spacing into the traysealer. Loading systems fill the trays reliably in a matter of seconds and consistently with the same product volume. Even pliable meat products are accurately loaded by handling modules into thermoformed pack cavities, which are formed with mm precision. Robots and box packing systems slide the individual finished packs into outer boxes in a precise and space-saving way. HigHer Output, Fewer Faults The cycle output of the packaging solutions can be increased through the automation of process
stages in upstream and downstream equipment and part-processes in the packaging line. Automation components make these process sequences and part-processes precisely reproducible and therefore significantly more reliable. This enables companies to ensure a consistent standard in packaging and end-of-line handling. In integrated packaging lines, it is possible to store recipe data in the line control itself, which means that the data no longer has to be entered manually. It can therefore, be called up at any time. A significant time-saving results from this, particularly with the increasing diversity of pack and product versions and with smaller batches. The data is also consistent at all times. Fewer faults arise when the data transfer
ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DECEMBER 2013
PACKAGING & PROCESSING 29
from one process stage to the next is automated. Administrative effort overall is reduced. In addition to this, largely automated procedures can be documented more easily and traced at any time as required by the directives for a particular industry. Automation also ensures that procedures and products can be tracked. Conversions of the machine or line can also be automated to a certain degree, or they can be supported through the machine control of the packaging machine. The quicker and more efficiently the machine and other equipment can be converted to the next batch, the longer the productive time of the overall line. The runningup time for the equipment is reduced, and the danger of damage to dies and machines is largely eliminated. imprOVed FOOd Hygiene The automation of packaging procedures also brings food companies significant benefits with regard to food hygiene. Automation reduces the effort required for the hygiene of personnel. People are potential germ carriers in every production environment. There are good reasons, why there are far-reaching regulations in the food area concerning protective clothing and hand hygiene. Thanks to the automation of tasks, such as the
loading of food into the pack cavities, manufacturers can have a very great influence on food hygiene. This improves the quality and safety of the food. reduced space requirement Automation components also contribute to the fact that the length of the loading area of the packaging machine can be significantly shorter and the space required for box packing considerably smaller than if these process stages were being performed manually by a number of people. This means that several part-processes can be carried out at the same time in the smallest space, without compromising safety standards. The operating range of handling systems can be precisely limited to the cm. That is to say one can have two robots working immediately next to each other without the two systems getting in each otherâ&#x20AC;&#x2122;s way. The dimensions of the equipment can therefore be designed to be smaller. respOnsibility FOr emplOyees If simple and monotonous tasks are taken over by automation components, this frees up manpower resources for more demanding activities. This means that the motivation of employees can be raised and motivated employees improve the atmosphere within the company, which, as experience has shown, has a positive effect on sickness levels. A further benefit of the automation of part-processes is that companies can also exercise their social responsibility better towards their employees, since the pressure for
The automation of packaging procedures also brings food companies significant benefits with regard to food hygiene.
PACKAGING & PROCESSING
NOVEMBER/DECEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
30
Conveyor systems and handling modules can offer an efficient way of converging and box packing the packs after the sealing and cutting process. They connect directly into the packaging machine or labeller and provide a continuous pack flow to downstream line components. Handling modules undertake the loading into boxes, including all the handling of interleaving layers and separating wall inserts. All types of loading patterns can be defined, so that the volume of the secondary packaging is used to the optimum degree. The cycle output of the modules can be scaled precisely to the requirements of the upstream and
tHe inVestment in autOmatiOn cOmpOnents can alsO be justiFied by tHe resulting HigHer leVel OF equipment eFFectiVeness. quick return On inVestment The use of automation components does of course require a certain level of investment. From the economic point of view, this investment is however, sensible, since the automation of procedures contributes to reducing faults, increasing productivity and giving longer productive times. The investment in automation components can also be justified by the resulting higher level of equipment effectiveness of the packaging machine. The interface between the infeeding and the upstream manufacturing procedures has to be very exact, so that there are no product jams or empty spaces. In order to ensure a continuous product flow, it is sensible in many cases to create redundant systems as well. This means that procedures continue to run, even if one of the infeed components is briefly out of operation.
downstream systems. Both equipment versions can also eject faulty packs from the packaging procedure. As part of the integrated automation concept, there is also tracking of the entire procedure, since the individual modules are integrated in the machine control of the packaging line. The automation of individual process stages serves to optimise the whole packaging procedure. Todayâ&#x20AC;&#x2122;s solutions provide more flexible automation with intelligent systems, so they can continue to meet changing requirements. Thanks to automation, the productive time and output of packaging equipment can be very positively influenced.
For more information, ENTER No: 0820
Robert Couse-Baker, Calfornia, US
Handling modules undertake the loading into boxes, including all the handling of interleaving layers and separating wall inserts.
output, which often burdens these employees, is reduced by automation. All modules in automated packaging lines can be controlled centrally via the human-machine interface, and they can be tracked in real time. Since all the line components follow the same logic, their operation is very visible. The automated part-processes, which are supported by the machine control, can be monitored easily and tracked in real time. This creates space for opportunities with optimisation throughout the entire automated process chain. These optimised sequences also lead to considerably fewer faults along the whole process chain.
Enquiry Number
3343
PACKAGING & PROCESSING
NOVEMBER/DECEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
GoinG With the FloW Recent technological advances
in continuous-pRocess cooking and cooling have allowed food pRocessoRs to significantly Reduce theiR eneRgy and wateR consumption, while achieving impRoved equipment and pRocess RetuRn on investment. By Jim mcmahon, ZeBRa communications The cooking and cooling of prepared foods is an area of particular interest for food processors that incorporate pasta, rice, vegetables and dry beans into their food products. Uniformity in cooking and cooling is critical to achieve a refrigerated, frozen or canned meal that will have the desirable texture and taste when it is later reheated for consumption. The blanched pasta cannot be too stiff or too soft. The fettuccine, linguine, tagliatelle and spaghetti cannot be stuck together or damaged. The cooked rice should keep its texture, have the right amount of free starch or stickiness and maintain its kernel integrity. Dry beans should not be bursting or split. And vegetables should have the desired firmness and consistency. Without a highly effective cooking and cooling capability, these products cannot be obtained with a high degree of uniformity.
Along with improving the precision of cooking and cooling parameters, food processors are always looking for ways to reduce process costs, and, more recently, achieve a higher level of sustainability in their operations. There are many processes in food manufacturing that can be addressed to reduce operating costs, while at the same time improving sustainability. One of the most critically important objectives to achieving this is reducing process energy and water consumption. Implementing energy- and water-efficient practices and technologies should be a senior priority at system levels in food manufacturing plants. With the continual increase in energy and water costs, optimising energy and water usage in food processing has never been a stronger issue. Embracing these sustainability initiatives is the continuous-process cooking and cooling method for pasta, rice and vegetables. This process has experienced continual improvements to its technology over the past four decades in the reduction of energy consumption, through improved system designs and streamlined automation. Recent technological advances in continuous-process cooking and cooling have made significant improvements in reaching critical energy and water efficiency levels. continuous-Process cooking & cooling Continuous-process cooking and cooling evolved from the batch method, which has been a standard in commercial cooking and cooling systems. However, the batch method has its drawbacks.
Christian Cable, Lancaster, UK
32
PACKAGING & PROCESSING
ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DECEMBER 2013
33
Carl Milner
age of the product, and adequate agitation to keep It is somewhat limited in maintaining precise pasta, rice and vegetables separated during the temperature and time parameters of the pasta, rice What E mizu cook and chill cycles, products tend to be unevenly or vegetable foodis products in theKiller？ cooking and coolThe pH value of the sodium hypochlorite solution is adjusted from 5 to 6 (acidulous) using carbon dioxide cooked and theby cooling process insufficient to uniing process. The batch process is also limited in its What is E mizu Killer？ (CO2) and so, strong sterilizable water that contains a large amount of HOCl is manufactured. formly halt cooking. agitation capability to keep these products sepaThe pH value of the sodium hypochlorite solution is adjusted from 5 to 6 (acidulous) by using carbon dioxide These conveyor-based systems have been rated during and chill processes, (CO2)the andcook so, strong sterilizable waterwhich that contains a large amount of HOCl is manufactured. Feature E mizuinKiller superseded by rotary drum continuous-process facilitates consistentof temperatures the product. which utilise an auger method to The◎ first generation continuous-process Rotary drum Carbon dioxide completely dissolves to water becausecooker/coolers, of using the membrane. Feature of Eofmizu Killer move food products through an enclosed, watercooking/cooling systems used conveyors to move cooker/ ◎ chlorine gas nordissolves the hydrogen gasbecause are generated. ◎ Neither Carbon the dioxide completely to water of using the membrane. fi lled drum. food products through the processes in series. For coolers have ◎ running cost is cheaper thanhydrogen electrolysis the medicine. ◎ The Neither the chlorine gas nor the gasand areusing generated. Considered the industry many years, water-spray conveyor systemsand were signifi cantlycan be chosen ◎ The device of a safe, cheap easy handling according to the standard usage. for continu◎ The running cost is cheaper than electrolysis and using the medicine. ous-process cook and chill methods, rotary drum the standard for cooking and cooling food prodimproved the ◎ The Flow〉 device of a safe, cheap and easy handling can be chosen according to the usage. 〈Basic 〈Sterilization Effect Test Results〉 cooker/coolers have significantly improved the ucts, but these systems have their drawbacks. processing of Bacterial counts before 30 seconds Bacteria processing of pasta, rice and vegetables. Cookers and coolers are only as good as their pasta 〈Sterilization and rice. CO2 NaClO treatment Test （pcs./ml） 〈Basic Flow〉 Effect Results〉 These have ensured more ability to precisely control the prodBacterial counts improvements before 30 seconds 4.3×10⁵ ＜10 Bacteria coli Escherichia CO2 NaClO treatment （pcs./ml） uniform processes and allowed cookers and uct’s exposure to time and temperature Hollow 7.2×10⁵ ＜10 Salmonella 4.3×10⁵ ＜10 Escherichia coli coolers to handle even higher throughputs. parameters throughoutFiber the processes. Mixer 7.7×10⁵ ＜10 Water Staphylococcus aureus Hollow 7.2×10⁵ ＜10 Salmonella Step-blanching, for example, enables increConveyor-based systems, Membranehowever, pH:5.48 Residual chlorine concentration:32ppm Temperature ：20℃ Mixer Fiber 7.7×10⁵ ＜10 Water Staphylococcus aureus mental temperature increases to be made are prone to variable production Sterilizable rates, Water Membrane pH:5.48 Residual chlorineBefore concentration:32ppm Temperature ：20℃ Bacteria：Bacillus subtilis 1 minute 3 minutes 5 minutes throughout the process. which introduces variations in product Sterilizable Water temperature resulting in inconsistent 7.8×10⁵ 3.1×10⁵ ＜10 Cl 80ppm, pH 5.42subtilis Bacteria：Bacillus Before 1 minute 31.3×10⁵ minutes 5 minutes CO 2 control systems product quality. CO 2 Cl 188ppm, pH 9.20 7.4×10⁵ 7.8×10⁵ 6.6×10⁵ 4.3×10⁵ 7.8×10⁵ 3.1×10⁵ 1.3×10⁵ ＜10 Cl 80ppm, pH 5.42 CO 2 Gentle mechanical agitation can be imparted Lacking uniform water spray cover(Japan Food Research Laboratories) thienzieyung
CO 2
Cl 188ppm, pH 9.20
7.8×10⁵
E mizu Killer
Water
CE NT RA CO L
2
CO2
6.6×10⁵
4.3×10⁵
Electrolusis 〈Comparison of Manufacturing Method〉 Dissolved CO2
CO 2
Water CO 2
7.4×10⁵
〈Comparison of Manufacturing Method〉 (Japan Food Research Laboratories)
CO 2
pH
Dissolved CO2 E mizu Killer 5.0～6.0
Water
Cl concentration （ppm） pH
Water
Electrolyzed Acidulous Electrolusis W ater
CENTRAL FILTER MFG. CO., LTD.
CO
Hollow Fiber 2
5.0～6.0 Acidulous
Electrolyzed 8.0～ W ater
10～100 5.0～6.0
10～30（80） 5.0～6.0
80～ 8.0～
Safety （ppm） Cl concentration
◎ 10～100
△ 10～30（80）
△ 80～
Corrosivity Safety
No ◎ Unnecessary No ◎ Unnecessary ◎ ◎
Yes △ Necessary Yes △ Necessary △ △
Yes △ Necessary Yes ○ Necessary △ ○
セントラルフィルター工業株式会社
Dissolved CO2 Hollow Fiber Dissolved CO2
Treatment of Chlorine gas and Hydrogen gas Corrosivity
Running cost gas Central Filter MFG Co., LtdTreatment is aof Chlorine comprehensive filter manufacturer and Hydrogen gas Initial cost covering the full spectrum of the fi ltration business requirements ranging Running cost 80 Cl 100 from reverse osmosis (RO)Initial equipment to large mesh strainers. 2 cost ◎ △ △ 〈Specification〉 Rate Rate Rate ％ ％ ％
100
60 80 Cl 2
E mizu Killer Sterilizable Water
OCｌˉ
HOCl E mizu Killer
60 40
Water E MIZUSterilizable KILLER
200 0
OCｌˉ
HOCl Acidulous Sterilizable Water System
20 40
1
2
3
4
1
2
3
4
5 pH
5
CCK500
Cap. ℓ/ｈ
500
7
8
9 10
6
7
8
9 10
1,000
2,500 CCK2500
500 1,000
500×1,500 ×600 2,500
CCK500 CCK1000 UF SYSTEM 300×500 400×800×
Size ×400 500Water Cap. ℓ/ｈ Natural-Mineral W×H×D
Manufacturing Device 300×500
6
CCK1000 CCK2500 〈Specification〉
Size ｐＨ W×H×D
×400
400×800× 500
Ｃｌ (ppm） ｐＨ
CCK5000
CCK10000
5,000
10,000
CCK5000 CCK10000 BIOPLORER 650×1,600 600×1,700
×700 Counting ×700 5,000 10,000 Rapid Microbe System Complete high-precision microbe 650×1,600 600×1,700 ×700in only about ×700 counting easily, 6 minutes
500×1,500 5.0～6.0 ×600
20～100 5.0～6.0 ※ The above specifications are subject to change without notice.
Ｃｌ (ppm） 20～100 ○ We offer apH total system from design and manufacturing through to maintenance and contribute to the society.
※ The above specifications are subject to change without notice.
Shinjuku Estate Bldg. 1 -34-15, Shinjuku, Shinjuku-ku, Tokyo 160-0022 Japan ForFukushima, more information, please contact MF Nishi-Umeda Bldg. 5-1-26, Fukushima-ku, Osaka 553-0003 Japan Shinjuku Estate Estate Bldg. 11-34-15, -34-15, Shinjuku, Shinjuku, Shinjuku-ku, Shinjuku-ku, Tokyo Tokyo 160-0022 160-0022 Japan Japan Shinjuku 102E Pasir Panjang Rd#02-06 Ctilink W arehouse Compalex Singapore 118529 MF Nishi-Umeda Bldg. 5-1-26, Fukushima, Fukushima-ku, Osaka 553-0003 Japan info@central-filter.com.sg Shinjuku Estate Bldg. 1 -34-15, Shinjuku, Shinjuku-ku, Tokyo 160-0022 Japan http://WWW .central-filter.co.jp/english/index.html http://www.central-fi lter.com.sg 102E Pasir Panjang Rd#02-06 Ctilink W arehouse Compalex Singapore 118529 info@central-filter.com.sg http://WWW .central-filter.co.jp/english/index.html
SINGAPORE BRANCH
Tel 81-3-3350-0091 Fax 81-3-3350-0095 Tel 81-6-6345-3531 Fax 81-6-6345-3500 Tel 81-3-3350-0091 81-3-3350-0091 Fax Tel Fax 81-3-3350-0091 81-3-3350-0095 Tel 65-6272-1191 81-6-6345-3531 Fax 65-6272-0170 81-6-6345-3500 Tel 81-3-3350-0091 Fax 81-3-3350-0091 Tel 65-6272-1191 Fax 65-6272-0170
Enquiry Number
Tokyo Head Office Osaka Branch Technical Center Tokyo Head Office Singapore Branch Osaka Branch E-mail Technical Center W ebsite Branch Singapore E-mail W ebsite
Technical tei-up with DAICEL CORPORATION CENTRAL FILTER MFG. CO., LTD. CENTRAL FILTER MFG. CO., LTD. SINGAPORE BRANCH
3518
Please TECHNICAL CENTER about the test necessary the selection the filter elements. ○ We offer aconsult total system from design and manufacturing through to for maintenance andofcontribute to the society. Technical tei-up with DAICEL CORPORATION Please consult TECHNICAL CENTER about the test necessary for the selection of the filter elements.
PACKAGING & PROCESSING
NOVEMBER/DECEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
34
Rool Paap, Rotterham, the Netherlands
PLCs enable uniform cooking temperatures and control volume of water flow, achieving a consistent end process.
to the food products as they progress through the cook and chill processes. A system called Hydro-Flow applies a combination of air and water injection which physically and buoyantly supports heavier loads, more evenly distributing food products in cookers and coolers. Controls automation integrated into rotary drum continuous-process cooker and cooler systems has largely made these improvements possible. Their programmable logic controllers (PLCs) provide precise automated control of process functions, including recipe management, and enable uniform cooking temperatures and con-
cooker/coolers enables them to process the same volume of pasta, rice or vegetables in less time, using significantly less energy to heat the water required for the processes. Monitoring energy and water usage, and managing process systems in these rotary drum cookers and coolers has played an important role supporting sustainability efforts in food processing plants. recaPturing heat & Water With conventional rotary drum continuous-process cooking, the cooker is filled with ambient-temperature (approximately 65 deg F) water and heated to 200 to 205 deg F. In the processing of pasta, rice or vegetables, the water needs to be continually heated to compensate for the constant addition of ambient-temperature product. This requires energy. Additionally, in the processing of pasta and rice, because water is absorbed into the products during cooking, ambient-temperature make-up water needs to be continually added into the rotary drum. This adds to the heat load requirements of the cooker. This also requires energy. During a process run of pasta, rice or starchy vegetables, which may continue for 20 continuous hours, as much as 10 gallons of water can be overflowed per minute to reduce the build-up of starch in the water. This means an equal amount of make-up water needs to be added. The volume of overflow and make-up water varies depending on the size of the cooker, and the type and volume of
the latest technology in continuous-Process rotary drum cooking caPture and reuse heat energy. trol of water flow, achieving a totally consistent end process. These control systems minimise the time required to perform complex tasks and increase efficiency in cooking and cooling process operations. They reduce operator error and process cycle times, enable improvement in product quality and consistency, and increase production throughput and equipment return on investment (ROI). The benefits from these automated process technologies have also minimised energy and water consumption. Compared to batch systems and conveyor-based cooker/coolers, the latest improvements in rotary drum continuous-process
pasta, rice or vegetables being run. The overflow water is discarded as wastewater, and is taking the 200 to 205 deg F heat energy out along with it. For every gallon that comes out of the cooker at 200 to 205 deg F as overflow, a gallon of make-up tap water at approximately 65 deg F needs to be added. The cooker, then, has to heat that water back up to 200 to 205 deg F to continue the cook process. This requires energy. In essence, not only is the overflow heat energy from the cooker being wasted, new energy now has to be added to reheat the water in the cooker to 200 to 205 deg F. The latest technology in continuous-process
PACKAGING & PROCESSING
ASIA PACIFIC FOOD INDUSTRY OCTOBER NOVEMBER/DECEMBER 2013 2013
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rotary drum cooking is now capturing and reusing the heat from the 200 to 205 deg F overflow water. Leaving the cooker, the overflow water, instead of being put down the drain, is moved to an adjacent storage tank where it is pumped through a heat exchanger. The heat is transferred from the hot overflow water to a reservoir of ambient-temperature make-up water before it is put into the cooker. With this process, the make-up water can reach 125 deg F, considerably higher than the approximately 65 deg F tap-originated make-up
Rotary drum cooking significantly reduces the heating load requirements of the cooker.
energy recuPeration In rotary drum cooking and cooling, the pasta, rice or vegetables come out of the cooker at 200 to 205 deg F. The product then immediately goes into a chiller where it is cooled in 35 to 40 deg F water. Initially, the water put into the chiller is tap water with a temperature of about 65 deg F. To bring the chillerâ&#x20AC;&#x2122;s water temperature down to the 35 to 40 deg F range needed for cooling product, energy has to be expended.
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MULTIVAC Pte Ltd 25 International Business Park #01-61/63 German Centre Singapore 609916 Office: (65) 6565 3919 Fax: (65) 6566 9798 Email: multivac@sg.multivac.com www.multivac.com
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water used in all prior continuous-process cooker systems. This significantly reduces the heating load requirements of the cooker. A sizable difference in energy savings can be realised when heating water to 200 deg F from a starting point of 125 deg F, rather than from 65 deg F. Additionally, the starch laden overflow water, which has previously been discarded, is then screened to remove the particulates and reused as make-up water to compensate for product absorption, providing significant water savings.
PACKAGING & PROCESSING
NOVEMBER/DECEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
As hot food products are released into the chiller, the water has to be continually cooled to take the heat out of the product and bring its temperature down to a safe 40 deg F range quickly, to reduce the potential of bacterial growth. This requires energy. Bacteria predominantly grow in an environment that is between 40 deg and 140 deg F. During the cooking process, raw ingredients are brought up past 140 deg F as quickly as possible to the final cooking temperature, thus minimising the time that food products can be influenced by bacterial growth. The same is true on the other end of the process line, with the cooling of the productâ&#x20AC;&#x201D;reducing its temperature as quickly as possible to below 40 deg F is essential. The energy usage in this cook and cool process has been considerably improved upon with the addition of a mid-process quench step, adding a small reservoir between the cooker and the cooler. Instead of moving the product directly from the 200 to 205 deg F water temperature of the cooker and into the 35 to 40 deg F chiller water, a mid-process quench cycle with unheated ambient-temperature tap water (65 deg F) can capture much of the productâ&#x20AC;&#x2122;s heat before it enters the primary chill cycle. Since the quench tap water is not preheated, it requires no energy input. Quenching reduces the temperature of the pasta, rice or vegetables down to 110 to 120 deg F, capturing 45 to 50 percent of the cooked productâ&#x20AC;&#x2122;s heat energy in the quench water. The 110 to 120 deg F water in the quench can then be used in the cooker for make-up water to re-hydrate the product, instead of bringing in the usual 65 deg F tap water to reach the 200 to 205 deg F temperature cooking range. This sizably reduces the energy draw normally needed to heat the cooker water. The quench then releases the product into the chiller, which now only has to bring the product temperature down 70 to 80 deg F to reach the targeted 40 deg F, instead of needing to bring the temperature down 160 to 165 deg F if the quench cycle was not in place. The energy savings in the chiller from the reduced refrigeration load is significant. The quench system, called Easy-Flow, developed by Lyco Manufacturing, maintains 100 percent uniform product cooling with less than one percent product damage. Rice, most varieties of pasta, and select vegetables can be cooled in the quench to 110 to 120 deg F before entering the chilled water cooler. The system uses a patented plenum technol-
ogy to achieve its high-speed cooling without damaging the product. The pasta, rice or vegetables are pulled through the cooling plenum at the bottom of the tank by Venturi effect, which increases the velocity of the fluid without pump impeller contact. The Venturi effect creates a pressure differential that pulls the water and product through at a high speed with the capability of moving 300 gallons of water and product through the plenum per minute. reduced energy & Water consumPtion These recent technological advances in continuous-process cooking and cooling have allowed food processors to significantly reduce their energy and water consumption, while achieving improved equipment and process return on investment (ROI). Compared to conventional rotary drum continuous-process cooking, recapturing heat and water from cooker overflow and quench systems can result in considerable savings. When recapturing heat and water from cooker overflow, British thermal units (BTUs) can be reduced by 60 percent, kilowatt hours (kWh) can be reduced by 72 percent and water usage can be reduced by 25 percent. With the quench system in place, for a continuous-process rotary tank cooker, BTUs and kilowatt hours can be reduced by 35 percent compared to an identical rotary tank cooker without the quench system. For the chiller under the same conditions, with the quench system in place, BTUs, tonnes of cooling required per hour, and kWh can be reduced by 41 percent. embracing sustainability Waste reduction, resource and energy management, improved process controls and throughput efficiency are key factors that have influenced the acceptance of the latest continuous process cooking and cooling systems. These are critical functions for achieving sustainable practices in the processing of food products. These latest developments save energy, increase productivity, and reduce environmental impacts. Advanced continuous process cooking and cooling of pasta, rice and vegetables has emerged as an innovation in sustainable technology within the food processing industry. As government agencies and food manufacturers steadily, but surely, embrace the sustainability initiative, continuous-process technology in food processing will continue to occupy a prominent position in the evolution of sustainable processing. For more information, ENTER No: 0821
Joel Kramer
36
CCW-RV
Engineered for maximum productivity Technology for unparalleled performance
Ishida Korea Co., Ltd. Tel: 82-32-661-4144 Fax: 82-32-661-4156 44 SANNO-CHO, SHOGOIN, SAKYO-KU, KYOTO, 606-8392 JAPAN Tel : 81-75-771-4141 Fax: 81-75-751-1634 URL: http://www.ishida.com E-mail: webood@ishida.co.jp
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Ishida Systems (M) Sdn. Bhd. Tel: 60-3-56333602 Fax: 60-3-56333680 No. 34 & 36 (Ground Floor), Jalan PJS 11/20, Bandar Sunway, 46150 Selangor Darul Ehsan, Malaysia Ishida (Thailand) Co., Ltd. Tel: 66-2-681-9990-93 Fax: 66-2-681-9994 123/13 NonseeRoad, Khaweng Chongnonsee, Khet Yannawa, Bangkok 10120, Thailand Ishida India Pvt. Ltd. Tel: 91-124-385-4392 Fax: 91-124-385-4393
382,Ground Floor, Udyog Vihar, Phase-2, Gurgaon - 122 016, Haryana, India
Ishida Vietnam Co., Ltd. Tel: 84-8-5417-1243 Fax: 84-8-5417-1246
R4-51, Hung Phuoc 4 Complex, Tan Phong Ward, District 7, Ho Chi Minh City, Vietnam
PT Ishida Indonesia Tel: 62-21-29-078-912 Fax: 62-21-29-078-815
Gading Bukit Indah, JI. Bukit Gading Raya SA-30, Kelapa Gading Barat, Kelapa Gading, Jakarta Utara 14240, Indonesia
PACKAGING & PROCESSING 38
NOVEMBER/DECEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
Case-study:
Next Step IN Meat packagINg
A beef product mAnufActurer in South AfricA hAS Seen greAt expAnSion over the lASt 25 yeArS. the compAny turned to AdvAnced product pAckAging SyStem to cAter to growing demAndS. by annalisa bellante, mArketing & communicAtion mAnAger, cAmA group Karan Beef is a supplier of the beef and beef products in South Africa. Ivor Karan established his feedlot on the family farm in 1974 with less than 100 head of cattle. Over the years, the capacity of the feedlot has increased to accommodate over 130,000 head of cattle—making the company’s feedlot one of the largest in Africa. The purchase of three adjoining farms increased the overall size of Karan Beef estate to 2,330 hectares—not only accommodating the growing feedlot, but also allowing for the evolution of the facilities into a fully integrated business unit. The processing plant is part of the abattoir complex situated in Balfour; the abattoir has the licensed capacity to process 2,000 head of cattle per day. The meat processing plant utilises trimmings generated from the on-site deboning plant, producing 22 tonnes of meat products per shift. At the facility, the company manufactures and packs a range of value added products including marinated, pickled, par-cooked products and hamburger patties. All products are produced with international consumers in mind. The products are exported to Hong Kong, Indian Ocean Islands, Middle East, African countries. They are also sold nationally to the food services market in a variety of pack sizes and to the retail market, under their own house brands or under the company’s brand. In the past few years, customer demand for its products has been well above the company’s sustained annual compound growth rate. Throughout its growth, the company’s priority has been not only to meet the market demand, but also to maintain a high quality standard of its products and processes. The company consequently turned to Cama Group, a supplier of advanced technology secondary packaging systems, to engineer its packaging lines to allow the company to meet the exceeding market demand. To meet the beef manufacturer’s needs, the packaging line is composed of a box forming machine and four in line Triaflex Delta Robots,
The easy handling of irregular hamburgers can guarantee insignificant waste of products.
which by means of a ‘smart’ vision system can pick flow-wrapped frozen hamburgers, and load them into three flaps lid boxes with different configurations and sizes. Loaded boxes are then transferred outside the loading unit and transported to the three flaps closing machine. The maximum infeed rate is 300 packs per minute. Subsequently, the products are packaged in retail cartons or catering cartons with different size changings. The packaging supplier developed and designed a specific box with gusset type reclosable feature to suit the specific demand of the ‘catering’ sizes. The gentle handling packaging solution has been studied, so as not to damage delicate products. The easy handling of irregular hamburgers can guarantee insignificant waste of products. The smart vision system can optimise management of the product by automatically selecting products, according to pre-established dimension and arrival speed. The unique approach of this new multi robot application is that a single controller for the entire system is adopted based on a standard technology and can therefore be managed by a trained engineer. Consequently, all functions are integrated in one control system, while the number of interfaces and component costs are reduced. For more information, ENTER No: 0822
BERICAP
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Healthcare
INGREDIENTS & ADDITIVES
the Clean LabeL MoveMent The clean label movemenT is Taking off around The world wiTh increasing number of producT launches over The years. The nexT big challenge is ensuring TasTe,visual and TexTural qualiTy wiTh fewer addiTives. by Thomas schmidT, inTerim md, beneo asia-pacific According to internationally respected food trends expert Julian Mellentin, ‘naturality’ is the biggest trend in key Asian markets this year. Consumers are demonstrating a preference for what they perceive as ‘natural’ products, with an inclination towards fewer and simpler ‘wholesome’ ingredients that have a natural and intrinsic health benefit. They are actively looking for products that are free-from chemicals or genetically modified and e-number additives, and showing a fondness for organic, ‘safe’ ingredients, equating their definition of ‘natural’ with ‘healthier’. Recent high-profile scares in Asia, including baby milk scandals, have made Asian consumers especially concerned over the integrity of food and what features on product labels. This demand has resulted in many local food manufacturers looking to natural solutions, prompting the growth of what has been coined the ‘clean labelling’ movement in Asia. Recent statistics show that the number of products launched on a clean label
platform in Asia increased from 1,235 in 2003 to more than 7,675 by 2013, and the numbers show no sign of slowing down. cleaner labelling compromise The rise of the clean label movement presents food manufacturers with an opportunity for new products or the reformulation of existing ones with natural ingredients. The down side is this can cause manufacturers numerous challenges as traditionally, products with fewer additives can lack the taste, visual and textural appeal of artificially modified products. However, with careful natural ingredient combination and an experienced partner, manufacturers can master the art of balancing technological issues with a cleaner label and a good taste profile. Worldwide, manufacturers are making changes towards clean labelling, viewing the clean label movement not as a consumer fad or short-term trend, but as a long-term industry development.
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naTural baby Food The baby food market is an especially sensitive market when it comes to natural ingredients. Protective parents are prioritising simple, natural ingredients in infant formula and baby foods, often with organic-certified labels. A European study shows that 72 percent of consumers accept higher prices for naturally produced foodstuffs without additives. This is especially true for children’s products where 17 percent would pay a surcharge of about one third for more ‘natural’ baby food. As a natural ingredient that is highly digestible, rice has proven itself in this stringent infant food market environment over the past few years, proving especially popular in the infant jar application, with 75 percent of all European product launches in the 12 months to the end of September 2012 containing rice starch ingredients. Rice starches can replace artificial ingredients as a natural texturiser and qualifies for hypoallergenic, clean
INGREDIENTS & ADDITIVES
ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DECEMBER 2013
Steven Depolo, Miami, US
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label, organic, as well as non-GMO products. In addition, test trials have shown that vegetable and fruit jars that contain food rice starch have improved product stability in terms of viscosity, syneresis control and shelflife. The small particle size of rice starch also creates a creamy texture without any effect on the end product’s taste or colour. SatiSfying the Sweet tooth The natural trend is also gaining influence within the confectionery market. Nearly 10 percent of all confectionery launches between September 2011 and September 2012 used either
However, as ‘naturality’ gains importance in consumer mindsets, the industry is looking to replace the chemical compound in white coatings. Rice starch can be used, offering a natural, clean label alternative with no undesired impact on taste or appearance. Rice starches enable confectionery manufacturers to achieve exceptional whiteness in their products, without any yellow or grey tinge to the finished shine—a problem that often occurs when using other starches such as corn or wheat starches. Test trials have also shown that rice starch is extremely stable and will
The rise of The clean label movemenT presenTs food manufacTurers wiTh an opporTuniTy for new producTs or The reformulaTion of exisTing ones wiTh naTural ingredienTs. natural or additive/preservative-free claims, or both, making ‘clean label’ related claims, the most popular assertion overall. For example, titanium dioxide has long been used by confectionery manufacturers to achieve a bright white coating in products like sugar coated candies, gums or pastilles.
preserve the brilliant white colour of the end product for months. Staying ahead towardS Clean Western Europe might currently dominate the global trend towards naturality, with 40 percent of new clean label launches taking place
in the continent, but Asia is also performing well, sharing the same percentage as the US when it comes to clean label launches at 17 percent.
lamantin
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As a natural ingredient that is highly digestible, rice has proven itself in the stringent infant food market environment over the past few years.
Titanium dioxide has long been used by confectionery manufacturers to achieve a bright white coating. Consumer understanding of ingredients and their functions differs around the world, as does the ability to afford their benefits. With Asia’s rapidly growing middle class, projected to account for two-thirds of the world’s middle class population by 2030, more Asians are expected to seek healthier, additive-free, natural ingredients in the foods they purchase. The demand for food manufacturers to provide clearer, more transparent claims on packaging is also expected to increase. For more information, ENTER No: 0830
INGREDIENTS & ADDITIVES 42
NOVEMBER/DECEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
The Clean label evoluTion
Clean label is a Clear trend aCross global food markets and new produCt launChes in the Clean label spaCe have steadily inCreased over the last deCade. by Edwin BontEnBal, direCtor of market development food, Corbion puraC In the quest for healthy, tasty products, modern consumers attach increasing importance to the origin of the ingredients used to produce their food. From oils to fats, to seasonings and condiments, they want authentic taste through natural flavour ingredients. In their annual trend-spotting, research groups Mintel and Datamonitor identified natural and clean label flavours and ingredients, as well as low salt, fast innovation, adventurous and ethnic tastes, stability of quality and mitigation against fluctuations. Mintel further reports that consumer
focus is definitely on ‘natural’ nutrition and products incorporating inherently natural, fresh, wholesome, balanced nutrition are increasingly popular in the savoury goods sector. Leading the way towards natural foods across the Asia Pacific region is China, a country known for its lax food safety standards but is now working to shake off the negative image. Earlier this year, China conducted a consumer research study in the three major cities of Beijing, Shanghai and Guangzhou. The results showed that more people are now considering buying foods with ‘natural’ or ‘green’ labels and that natural ingredients are more likely to be ac-
cepted than chemical or synthesised ingredients. Close to 85 percent of those surveyed said that they check the ingredient list before buying packaged food. Food with natural ingredients is also perceived to be the safer and healthier choice. Chinese manufacturers, as a result, are taking a closer look at production technology and processing to cater to the local demand for clean labelled products. In the global marketplace, retailers are key influencers in the clean label movement, judging by the entry of new products. In the past five years, 30 percent of total new products launched had a clean label positioning. In Asia, the number of products launched on a clean label platform increased from 1,235 in 2003 to more than 7,675 in 2010. The growing mega-trend towards clean label products spans across all food and beverage segments and creates unlimited opportunities for reformulation and new product development. However, there are implications to the use of natural ingredients depending on the food product and the proposed natural solution—the taste will change and the shelf life could shorten and/or costs might increase. Manufacturers not only have to contend with the expense and time of reformulation and product development, but also increasing prices of functional ingredients, natural colours and flavours. Additional challenges facing manufacturers and marketers include labelling requirements and market differentiation, technical issues such as shelf-stability and processing and delivering the taste and texture consumers demand. dEfining ‘ClEan laBEls’ As with many trends in the global food industry, clean label is difficult to define. Consumers, retailers and the industry have different understandings of the term.
INGREDIENTS & ADDITIVES
ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DECEMBER 2013
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Does clean-label mean organic, natural, ingredients, simple ingredient lists or GM-free? Ultimately, it all comes down to credible ingredients in a food product, so that the consumer understands the logic behind the use of different ingredients in the food. In Europe, many companies have been able to reduce the e-numbers on the labelâ&#x20AC;&#x201D;the question is how many e-numbers are still acceptable for a specific product? In the US, the chemical sounding ingredients are under pressure regardless of whether they are natural or not. For certain categories, the number of ingredients is being reduced, whether they are natural or chemical.
turers and brands, rather than major retailers. The clean-label trend in the US is spreading across the market sectors as manufacturers move to counteract negative perceptions of processed foods that include salt, saturated fat and sugar. In the UK, much of the clean label trend has been driven by major retail-
ers and supermarkets, which have been quick to respond to increased consumer interest in what goes into their foodâ&#x20AC;&#x201D;leading to many brands moving to reformulate their products in order to meet retailer specifications. Even some naturally sourced ingredients with names perceived to be artificial or chemical are being removed from ingredient lists. Japanese consumers, like their counterparts in the UK, Europe and US, are increasingly concerned with what goes into their foods, prompting manufacturers to find natural alternatives. This, combined with the tradition of seasonality in Japanese culture that has long demanded constant product variation from Western
Ideas to Grow With
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gloBal trEnds The push for clean-label products in Europe is led primarily by manufac-
The push for clean-label products in Europe is led primarily by manufacturers and brands, rather than major retailers.
INGREDIENTS & ADDITIVES
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manufacturers, seems likely to drive the desire for clean label further. innovativE ingrEdiEnt solutions Across the globe, clean label research has demonstrated that what matters most to consumers are the ingredients. Consumers are seeking products made with simple, wholesome ingredients with minimal processing. The focus on natural for savoury goods is also becoming increasingly popular and in line with overall trends in the broader food category, where freshness has gained ground as a point of difference as consumers look for more natural products. The food industry is faced with the challenge to find natural ingredients that can deliver on food quality and integrity without compromising on taste or shelf life. Under such pressure, food companies are working on the double with ingredient specialists to provide consumers with foods that are safe, tasty, and of top quality, with ingredients lists as ‘clean’ as can be. Ingredients suppliers are developing solutions such as functional native starches, functional flours, nutritional ingredients and naturally based sweeteners to help manufacturers develop clean label products without dramatically increasing costs. I n re s p o n s e t o t h e s e c l e a r market trends, Corbion Purac recently launched their Verdad line of label-friendly ingredient solutions to preserve the freshness, integrity and flavour of a wide variety of foods that include bakery products, prepared refrigerated meals, and meat and poultry products. Based on the natural fermentation processes of sugar cane, the latest addition to the line, the Verdad Powder F80, is permitted to be labelled as ‘fermented sugar’ to meet consumer demand for natural, fresh and authentic-tasting products.
ConsumErs arE sEEking produCts madE with simplE, wholEsomE ingrEdiEnts with minimal proCEssing. Using the latest fermentation and spray-dying technology, this multipurpose powder minimises the need for heavy processing (for example, sterilisation) and contains components that enhance savoury notes, such as tomato, spices, and herbs. The powder can easily be applied to a wide range of fresh and readyto-eat products, such as sauces, salads and breads, and now offers food processors a greater choice of label-friendly ingredients and more flexibility in applications. Fermentation is an age-old process that imparts multiple benefits to a finished food product, including enhanced flavour, improved texture, and greater microbiological stability. The addition of ferments to food products yields all of these advantages without fermenting the product itself. on thE horizon In terms of driving market expansion, retailers continue to refine their private label strategies, with packaging playing an essential role. The latest package designs put the ‘brand’ in
store brands, with smart looks that convey differentiated quality. Active packaging technologies, for example, effectively reduce the need for food additives and preservatives without compromising on a product’s shelf life. They also create an opportunity for cleaner product labels. Manufacturers and retailers will continue to collaborate with ingredient suppliers to help formulate clean label products given the inherent challenges that exist in clean label formulation. When working with the right partner, manufacturers can produce clean label products that match consumer taste and texture expectations at a reasonable cost. As consumers become increasingly informed about the foods they eat, it will become even more important to them to be able to access the products they want with ingredients they recognise and trust. Manufacturers will need to find innovative solutions to incorporate new ingredients that deliver on consumers’ desire for simplicity and transparency. For more information, ENTER No: 0831
Enquiry Number
3512
HEALTH & NUTRITION
NOVEMBER/DECEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
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Baking With Whey
The gluTen-free markeT has caughT The imaginaTion of healTh conscious consumers and has been expanding sTeadily. Whey isolaTes offer an alTernaTive To gluTen-free recipes ThaT helps overcome TradiTional limiTaTions. by CraiG SherWin, direcTor of proTein Technology cenTer, davisco foods In the past, gluten-free was thought of as a niche market for the less than one percent of the world population that suffers from celiac disease. But in the last 5-10 years, there has been a surge in awareness of this autoimmune disorder and diagnoses within the entire spectrum of gluten sensitivities. In increasing numbers, consumers have chosen to cut back on wheat or remove the wheat protein known as gluten from their diet entirely. As food companies get more skilled at delivering gluten-free products, these diets will be more sustainable for consumers that choose them and many food companies are betting that this shift in dietary patterns is here to stay. Nothing highlights the functionality of gluten like a traditional French baguette. The protein complex known as gluten has a unique ability to transform under the forces of mixing into a fine-stranded large molecular network. A developed gluten network has the ideal balance of strength and elasticity to support expanding bubbles of gas and steam during baking. In skilled hands, a baguette can leaven and bake into an open porous structure full of aroma and tender to chew.
â&#x20AC;˘ Dough hydration When gluten doughs are mixed, they hydrate and hold on to the water within the large protein matrix. A gluten-free dough with only a starchy ingredient replacing the flour will be sticky, hard to handle, and the baked product will be dry and crumbly. Gums such as xanthan and egg whites have often been incorporated in some gluten-free formulas to serve this hydration purpose. Whey proteins can also manage moisture during mixing, forming and baking to get just the right performance. â&#x20AC;˘ Dough strength and elasticity In order to work with dough to shape it, hold pizza toppings or simply to hold gas during baking, the gluten-free baker needs a replacement for glutenâ&#x20AC;&#x2122;s
unique strength and elasticity profile. As in the French baguette, dough needs to be able to stretch and deform without losing its cohesiveness. This is the most challenging property of gluten to match. Gum and protein systems are sometimes used to replicate these properties. Whey protein isolate is another good option. Once hydrated, whey protein can provide strength to the dough to aid in handling without sacrificing elasticity. During baking, the gas cells expand, and as the dough heats, whey proteins will denature and form inter-molecular bonds. Along with the starch, this protein network will stabilise the bubbles and support the baked volume.
Gluten-Free BakinG
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When bakeries remove the glutencontaining wheat flour from their formula and substitute with another starch source, they are left with several important properties they still have to meet. Whey protein isolate (WPI) is a particularly good option to meet all these challenges, with clean flavour, an attractive nutrient profile and a clean label.
ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DECEMBER 2013
• Baked texture After baking, many gluten-free products are known to have a dry and crumbly texture. A gluten-replacer must be able to hold on to water as a plasticiser while also contributing to strength. Whey protein’s disulphide-stabilised networks provide strength to the crumb structure.
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• Flavour Whey proteins are able to provide the functionality of protein in a clean-flavoured package. Some whey protein isolates can be used at 10 percent in foods and beverages with negligible flavour impact. • Colour The colour of baked goods is not only a cue for palatability for the consumer, but is also the visual cue for adequate baking. Dough that does not brown the same in a commercial oven will be a challenge for a baker to optimise.
Consumers who choose gluten-free diets are inherently a health-conscious population. Perhaps the greatest advantage a whey protein-enhanced gluten-free formula can provide is an opportunity for consumers to get the protein levels they need throughout the day. Research has demonstrated the importance of getting the right amount of protein at every eating occasion for the body to metabolise nutrients in the optimal way. As summarised by the Dr RL Walzem of Texas A&M University for the US Dairy Export Council, whey proteins are well-known to be among the highest quality protein
Wacker Chemie AG, Germany, info.biosolutions@wacker.com Asia Representative Office: Wacker Chemicals (China) Co. Ltd. Tel. +86 21 6100-3535
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It is well known that the right protein, sugar and pH can optimise the Maillard browning reaction. What is often overlooked is how inter-related oven performance is with colour development. A gluten-free dough that does not rise in the oven and lose moisture at the same rate as wheat dough would not have the same heat transfer properties at the surface. Holding on to too much water will extend baking times and result in a more pale colour. Releasing water too quickly, will result in a darker colour as well as a dryer, more crumbly texture. The best way to match the baking profile of wheat dough is to find a gluten-replacer that hydrates and holds water in a similar way as gluten. This is one advantage that whey proteins have over gum systems, which have very high water-holding capacities. A protein-based gluten-replacer can replicate both the hydration as well as dehydration kinetics of baking to optimise oven performance and yield the right texture, colour and finished product moisture.
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HEALTH & NUTRITION
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the World oF Gluten-Free BakinG PreSentS Some exCitinG BuSineSS oPPortunitieS and teChniCal ChallenGeS.
British Mum
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Kurt Nordstrom, Maryland, US
Rebecca Siegel
When gluten doughs are mixed, they hydrate and hold on to the water within the large protein matrix.
nutritional boost in return. Best of all, whey proteins are accepted on food labels as a natural and wholesome source of protein. For more information, ENTER No: 0840
jeffreyw
sources available, with a complete amino acid profile, high in branched chain amino acids, and high digestibility (WPI has a PDCAAS >1, while gluten is only 0.4). Most notably, whey proteins are among the highest sources of the amino acid leucine, the molecular trigger for muscle protein synthesis. Consuming adequate leucine levels is the best way to ensure the protein you consume at any meal is put to use in the body to maintain muscle mass. At any stage of life or on any diet, maintaining muscle mass is important for health. For child development, adult weight management, sports nutrition and slowing the loss of muscle with ageing known as sarcopenia, optimising muscle protein synthesis is a key part of a healthy diet. As an example, four of the glutenfree cookies below made with 10 percent whey protein isolate provides 10 g of protein and about 1.1 g of the 2.5-3.0 g of leucine recommended per eating occasion. The world of gluten-free baking presents some exciting business opportunities and technical challenges. A little bit of knowledge of the principles of hydration, protein network formation and oven performance allows us to pick the right ingredients and conditions to make the best gluten-free baked goods we can. High protein whey protein isolates are able to meet these challenges without sacrificing flavour, and can give a
Because when you’re creating snacks consumers clamor for, no ingredient
gives you the ability to add more goodness than almonds. They’re tasty and crunchy, and when compared gram for gram, they are the tree nut highest in protein, fibre, calcium, vitamin E, niacin and riboflavin. Learn more about the essential almond at AlmondBoard.com/snacking.
3508
[ ALMONDS, OF COURSE. ]
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© 2013 Almond Board of California. All rights reserved.
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DEMAND for beverage cans is on the rise in China. As consumers enjoy higher disposable incomes, there is a corresponding increase in demand for convenience and quality, especially when it comes to food and beverage products. While North America and Europe have traditionally recorded the highest consumption rates of canned drinks, emerging markets such as China will drive the future growth of the industry. We have already seen the shift from traditional returnable glass bottles to beverage cans as brands seek to modernise their packaging mix and differentiate their products on store shelves. In 2013, the global beverage industry is seeing a greater variety of options proliferate existing segments like natural energy drinks, ready-todrink cocktails with multi-flavoured vodkas, regional craft brews and hard ciders.
In Asia specifically, growth in market segments such as energy drinks, ready to drink coffees and teas, wine and nutraceutical beverages like juices is expected to continue and the ongoing popularity of nutritional teas and beverages, such as Jia Duo Bao and Tian Di Yi Hao, can be expected in markets where there is a large Chinese consumer base. The introduction of new drink flavours, including fresh fruit (especially tropical fruits) will also be prevalent. Fruit and vegetable juices are growing in popularity due to increased interest in preventive healthcare and awareness of the benefits of consuming such beverages. This growing global awareness is reflected in a recent report from Global Industry Analysts that estimates that the global fruit and vegetable juices market will reach 72.29 billion litres by 2017. Expanding on this trend towards health and wellness drinks, Chinese Emerging markets such as China will drive the future growth of the canned drink industry.
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THE DEMAND FOR ALUMINIUM BEVERAGE CAN IN ASIA, PARTICULARLY CHINA, IS ON THE RISE, FUELLED BY INNOVATIVE PACKAGING DESIGN AND GROWING AWARENESS ON ENVIRONMENTAL SUSTAINABILITY. BY JoZeF salaerts, PRESIDENT, CROWN ASIA PACIFIC fruits-only beverage consumption will move to include vegetables in 2013. Likewise, the Chinese beverage industry will see continued demand for healthier beverages as concerns about obesity continue to rise, according to research firm Mintel. To retain market share or win new consumers, manufacturers must ensure that they can meet this increased demand. Besides introducing natural, diet or low-calorie versions of mainstay beverages, they can also look to alternative packaging formats to cater to different lifestyle needs. For example, manufacturers are increasingly required to address the demand for smaller package sizes or single-serve packs, as the trend of ‘indulging without guilt’ persists. Similarly, as a growing number of consumers pursue more active, healthy lifestyles, beverage packaging needs to be more durable in order to minimise the risk of accidental breakage as people bring their drinks outdoors or on-the-go.
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innovation is Key The beverage industry is characterised by change and innovation, ranging from the shift from three-piece to two-piece beverage cans in emerging markets, to the recent increase in the production and introduction of specialty cans in mature markets like the US. The focus for can manufacturers is to enhance the convenience cans offer consumers, as well as introduce innovations that can help brands stand out in the crowded retail landscape. An example of a recent packaging innovation is a full-aperture beverage end, which was first launched at the 2010 FIFA World Cup. A variation of the technology was introduced in China last year. The can allows the entire lid to be removed, effectively turning the packaging into a smooth-edged drinking cup and eliminating the need for pouring or extra glassware.
metal in sUstainaBle BrandinG Sustainability has continued to be a hot topic, even in emerging markets. Local Chinese authorities are starting to pay more attention and passing environmental legislation, such as the amended Law on the Promotion of Clean Production that will eventually ban excessive packaging in the city of Shanghai. C h i n a ’s P a c k a g i n g R e c y cling Master Plan aims to reduce excessive packaging by enforcing mandatory legal standards and specifications—for example, packaging must not have more than three layers. Non-compliance will lead to stiff penalties, including hefty fines and/or confiscation of non-compliant products. In serious cases, it may even result in the loss of the company’s operating license.
In keeping with overall environmental efforts, the global beverage industry is moving towards the use of sustainable packaging. Metal contributes to sustainability savings in several ways, and as a packaging material, offers significant advantages over alternative formats. Cans protect the quality of beverages by providing a powerful barrier against light and oxygen, helping extend shelf life and preserve freshness and taste. At the heart of metal’s sustainability story is the fact that it is 100 percent and infinitely recyclable. Beverage cans are also the most recycled drinks pack in the world—according to 2011 statistics, the recycling rate of aluminium cans was 58.1 percent, a rate nearly double that of all other beverage containers, according to the Aluminum Association and other industry associations.
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Craig Sunter, Manchester, UK
Patrick Denker, Athens, Greece
Wojciech Kulicki
52
Modern technology allows canmakers to reduce wall thickness while providing high performance. The durability of metal also means that little to no secondary transport packaging is required during shipping, and some of the inherent benefits of metal mentioned earlier, such as the long shelf life afforded by the materialâ&#x20AC;&#x2122;s ability to block light and oxygen, means that beverage cans also help minimise product waste, another important aspect of sustainability. Compared with 20 years ago, aluminium beverage cans are now 28 percent lighter. The lightweighting of cans adds another dimension of sustainability to metal packaging. Modern technology allows canmakers to reduce the thickness of can walls but still provide a high-performance container. A specific transition within the Chinese market is the move from the 206 neck diameter cans traditionally used to package beverages to 202 neck diameter cans. The smaller diameter reduces metal use during the production process.
Constant innovation will remain an indUstry standard.
Unlimited Potential Beyond sustainability contributions, the beverage can has unlimited marketing potential, as both a long-term investment and for special shortterm selling opportunities. For many brands, the power of packaging has been overlooked. An ideal vehicle for either refreshing or enhancing an existing or new brand, constant innovation will remain an industry standard, with both canmakers and brand owners contributing towards the generation of versatile and sustainable packaging solutions. In the years to come, it would not be a surprise to see more and more brands embrace and introduce metal into their packaging portfolios. For more information, ENTER No: 0850
Matching todayâ&#x20AC;&#x2122;s expectations. Smart ingredients for healthy lifestyles. As part of their modern lifestyles, consumers expect their food to be tasty, healthy, convenient and functional at the same time. BENEO offers smart ingredients that help you meet these expectations. Our products cater for energy and weight management, improved digestion and healthy ageing as well as better taste and texture, just to name a few. Beyond that, your product development will be inspired by our insights and expertise!
Enquiry Number
3431
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BEVERAGE
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GettinG it Right From the gRound up
Alicia Nijdam,Vancouver, Canada
Flooring is an aspect oF production that is oFten conveniently overlooked, but can have great impact on eFFiciency and saFety. there are many considerations to be made and options to choose From depending on the manuFacturing requirements. by Dave Mcneece, international marketing and business development manager, Flowcrete
EvEry year, the world produces approximately 1.5 million pints of milk, which is consumed by six billion people in a ÂŁ250 billion (US$400.45 billion) industry. To satisfy this massive demand, milking facilities have to be efficient, reliable and hygienic in order to cope with the numerous challenges of an arduous workload. Every day the dairy environment will undergo traffic from rubber boots, cattle and forklift trucks, it will have to deal with heavy machinery, lactic acid spillages and intense cleaning routines, all while having to simultaneously factor hygiene levels and employee safety concerns into the mix. The choice of flooring in a dairy is a crucial aspect in dealing with all these challenges and ensuring the farmâ&#x20AC;&#x2122;s success, and there are many types of hard flooring systems available to the dairy industry to help maximise the potential of their buildings. Benefits Of Resin flOORs The seamless finish of a resin floor creates a shield against the damaging corrosives that would otherwise compromise concrete, and it will provide a smooth, easy to clean surface that will work with a cleaning regime to eliminate germs from the milking area. The robustness of a resin floor also means that dairy farmers can subject it to heavy trauma from cattle, staff, machinery and vehicles without concern for its integrity. The sturdy and level surface is also ideal for coping with internal transport from forklift trucks that will be frequently braking and turning on the floor. Should even further resilience be required, aggregates such as quartz sand, aluminium oxide and bauxite can be added to the resin layer to enhance its strength and slip resistance profile. One of the most popular hardwearing resin flooring systems able to provide these benefits is cementitious polyurethane. This material combines cement and water-based technologies to produce a mortar with a high cross-
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linked density, making it a good choice for areas that undergo abusive attacks from chemical, thermal and impact sources. The material is trowel applied on site and creates a very strong and seamless matte finish. The non-porous and difficult to penetrate nature of cementitious polyurethane helps to avoid bacterial contamination as pathogens cannot seep into the floor and are much easier to remove during cleaning. This solution is better than epoxy alternatives at resisting bacterial excretion on the floor. Most importantly, cementitious polyurethane is much better at coping with thermal shock than other types of resin flooring, as it has a thermal coefficient of expansion similar to that of concrete. This means that when it is applied over concrete, it is able to expand, contract and move with the substrate when subjected to large temperature changes without cracking. Resin floors have varying chemical and bacterial resistance profiles depending on the specific make up of
the system, which affects the floor’s ability to protect itself from corrosive chemicals that would otherwise lead to the floor failing from erosion, softening, embrittlement, blistering or delamination. Polyurethane floors in particular are very good at resisting organic acids, including lactic acid, which is one of the main chemical corrosives in a dairy. Hygiene iMpORtance Maintaining a high standard of hygiene and cleanliness is essential, and an effective cleaning regime is vital to ensuring this. If not acted upon, contaminant build up could not only lead to corrosion of the floor but also damage the health of the animals, contaminate the milk and ruin the dairy’s reputation. To maintain a hygienic milking area, many dairies will undergo cleaning sessions after the milking that take between 30 to 60 minutes. If there are two or three milking sessions per day, then just cleaning the dairy can take
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Substances can penetrate splits in a concrete floor which can be hard to clean. up a significant amount of time and energy. All this cleaning presents two issues for a floor. Firstly, the floor needs to be smooth and level to allow for an effective cleaning regime, but it also needs to be durable enough to withstand intense maintenance. Regular thermal shock from hot water cleaning is likely to degrade an unprotected concrete floor and power washes in particular will eat into the surface layer. Harsh cleaning chemicals will also damage concrete over time and make it porous. If a floor coating is not able to cope with the strains of the environment it will start to crack, meaning that the facility will face an increased contamination risk that their cleaning regime will find difficult to cope with. Substances can penetrate splits in a concrete floor which can be very hard to clean. This could result in microbial growth and the spread of bacteria from pathogens that are able to thrive in broken flooring. All of this could adversely affect the sanitation of the dairy and raises the risk of contaminates entering into the extraction and storage processes. anti-MicROBial flOOR sOlutiOns Resin flooring systems are highly adaptable and additives can be included to cater for specific challenges.
By cOMBining aDDitives intO tHe Resin MatRix Of a pOlyuRetHane systeM, HaRMful MicROORganisMs aRe DestROyeD. Anti-microbial agents can be included into the finish to give an enhanced hygiene performance that actively works to inhibit the growth of bacteria. By combining these additives into the resin matrix of a polyurethane system, harmful microorganisms are destroyed as soon as they encounter the floorâ&#x20AC;&#x2122;s surface. And because it is created from a resin, the floor retains the hard-wearing properties required in a dairy. When looking into the best antimicrobial floor solution, it is important to bear in mind that some will have the additive spread throughout the resin whilst others will only have it on the surface. The practical difference is that should the surface layer ever be cracked or worn down, then the solutions that have an agent throughout the mixture will still attack pathogens in the cracks. DRaining in a DaiRy Liquid from dung, cleaning fluids, lactic
acid spillages and many other sources can create substantial excess water in a milking facility. The pooling of too much water in a dairy farm can be a serious hygiene concern as it is a prime site for bacterial growth. A non-porous, well drained floor is important to making sure that water does not stagnate and lead to unhygienic conditions. A resin floor is impervious to water and facilitates good draining, which will make removal of any unwanted matter or liquid much easier and more effective. This is especially important when coping with the large amounts of faecal matter that build up during milking, as blocked dung channels or long standing effluence pose exceptionally dangerous hazards. Dairy facilities can be so wet that a flooring system without an extremely low water absorption rate faces inevitable discolouration if not disintegration. Resin floors can be fitted to include designs that will not fade, which is ideal if clear lineage is an
Enquiry Number
3453
BEVERAGE important aspect of the dairy floor for safety or operational reasons.
fast cuRe flOORs Many operators of dairy farms may be concerned that refurbishing their floors will lead to damaging downtime and a problematic halt in day to day operations. However, resin finishes that use methyl methacrylate (MMA) can offer an extremely tight turnaround in installation to minimise production losses. These fast-cure acrylic resin solutions drastically reduce disruption by creating a fully trafficable flooring surface that is usable hours after application instead of days or weeks. Dairy operators would not compromise strength, life span or durability to achieve this fast turnaround—in fact, an MMA system provides a floor that is double the strength of traditional
epoxy quartz screed (a common type of industrial flooring). Because this product can be installed at extreme temperatures, from -20 degrees to +35 degrees, it can be installed in the dairy’s cold storage rooms without having to shut the room down, so it can remain at its optimum temperature throughout the floor’s application process. This trait also means that the refurbishment can take place at any time of year and so can be applied when it is most convenient. While MMA floors have a high resistance to a range of acids and alkalis, it is not as good as cementitious polyurethane at withstanding corrosive chemicals or thermal shock from steam cleaning and hot water wash downs. Milking aRea While the main focus of attention will be on the milking area, a dairy operator should not overlook all the other buildings that make up the facility. Epoxy resin surfaces are ideal for non-processing zones such as offices, entrances, staff rooms, corridors, warehousing and most areas exposed to less rigorous service conditions. Like the other systems, they can have anti-slip additives included into the mix to limit the risk of falls across the dairy complex. A resin floor is useful in storage rooms in particular, as they especially need to be kept clean at all times. Ideally placed away from all the obvious sources of contamination, the room’s design should help to maintain a hygienic environment by having impervious floors which are free drained to a suitable trapped drain and walls that are smooth and easy to clean.
An epoxy solution would not be as effective as cementitious polyurethane in the milking areas as the high level of organic chemical attacks and thermal shock that cementitious polyurethane is able to withstand would make an epoxy floor crack or de-bond. installatiOn cOnsiDeRatiOns Before you decide to install a resin floor, it is important to weigh up a dairy’s specific requirements. Talk to a resin flooring specialist about the individual demands of a facility to understand what solutions will work best. For example, do you need a very high-level of anti-slip flooring? Will the floor be exposed to thermal shock? Where is hygiene the biggest priority? What type of chemicals will the floor be exposed to? Once you have come to an informed conclusion, make sure the specialist resin floor is installed by appropriately qualified tradespersons to ensure that the coating adheres properly to the substrate with a seamless finish able to provide a strong and impervious surface. After installation, the finish needs to be properly cleaned and maintained. If you are introducing a new cleaning product, conduct a small spot test on an inconspicuous area as a precaution. Most special purpose cleaning materials would not damage a resin floor, but to get the most out of a new surface and to maintain any properties that may have been added, clean the floor in accordance with the manufacturer’s instructions. For more information, ENTER No: 0851
liz west, Miami, US
WORkeR HealtH & safety Contamination is not the only danger that can stem from excessive water, as slippery conditions are a danger to the health and safety of any workers or visitors in the area. According to industry figures and the UK’s Health and Safety Executive, slips on wet floors is one of the most common causes of accidents within the dairy industry. In any facility with areas prone to wet conditions, the site’s risk management needs to minimise the risk of slippery surfaces. This may not just be in the main milking zone, so the storage rooms, staff areas, corridors and walkways should all be considered. Effective draining is important in tackling this hazard, but to further decrease the chance of falling, special aggregates can be added into the mixture of a resin floor to create an anti-slip surface which actively enhances grip underfoot. Again, hygiene requirements need to be brought into the decision-making process, as the ease of cleaning needs to be judged against the level of grip required because coarsely textured surfaces are harder to clean than smooth surfaces.
Samuele
58
NOVEMBER/DECEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
Sandvik steel belts for hygienic processing of chocolate and confectionery Hot or cold, solid or perforated, carbon or stainless, thereâ&#x20AC;&#x2122;s a Sandvik steel belt for every confectionery processing application, from simple conveying of sugar or cocoa mass to in-line freezing, forming, cooling, casting, conditioning, drying and baking. The flat, smooth and hard surface enables efficient cleaning for maximum hygiene and product safety, and every Sandvik steel belt benefits from the support of our Business Class service network.
Enquiry Number
3500
n Easy cleaning for maximum hygiene n Durable steel provides an excellent ROI n 24/7 technical support, global service n Ask for a copy of our confectionery brochure
Sandvik South East Asia Pte Ltd Process Systems Division 50, ALPS Ave, #04-00 Sandvik Building Singapore 498782 Tel: +65 64773736 | Fax +65-64773785 Email: sea.sps@sandvik.com
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Case-study:
the ForCe Behind Without proper back-up poWer plants, manufacturers Will be exposed to high-stake risks in the event of poWer outage. a breWery in sri lanka decided to install diesel poWer generator to safeguard its production. by s KusumaPala, territory manager, cummins poWer generation
According to research by contingency planning organisations, the cost of an electrical outage can exceed US$1 million per hour for the average large business. In manufacturing industries, losses may reach US$2-3 million per hour or higher. Given these high-stake risks, facilities managers across all industries are being forced to evaluate new options for providing a continuous supply of power. Major outages in different parts of Asia in recent years have focused more attention on the devastating business impact that extended power outages can have. For example, in 2011, 60 companies in South Korea lost an estimated 100
billion won (approximately US$89.4 million) resulting from a loss of power that lasted 16 minutes. In the last two years, countries like Sri Lanka, Thailand, Indonesia and Philippines have all seen some form of widespread power outage. It does not help matters that Asia tops the list as the most disaster-prone region in the world, according to the United Nations Office for Disaster Risk Reduction (UNISDR). It is clear that 24/7 dependence on electric power virtually necessitates that every business has some level of standby power. Providing your business with electrical power in the event of a utility outage is the role of every standby power systemâ&#x20AC;&#x201D;whether it is a backup
generator to keep the lights and computers running in a small office or a multigenerator power system for a manufacturing plant. Diesel PowereD Generators Diesel engines are typically the top choice for standby power generators because of their reliability, durability and performance under load. Diesel powered generators are depended on for back-up power systems in the most critical locations: hospitals, airports, government buildings, telecommunications facilities, and of course manufacturing plants. In standby power applications, diesel generators can start and assume full-rated load in less than 10 seconds and they typically can go 30,000 hours or more between major overhauls. To prevent disruptions to the beer brewing and bottling process in the event of power outages, Sri Lankaâ&#x20AC;&#x2122;s beer manufacturer Lion Brewery decided to invest in a reliable standby power system consisting of diesel powered generators. Currently, the company produces 800,000 hectolitres of beverage per annum, running a fully automated sophisticated plant that utilises German packaging and bottling technology. The brewery which has a local
Electrical outage can cause great losses to manufacturing plants.
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market share of 82 percent produces several global brands, including Carlsberg, under license from Carlsberg International Denmark and Corona beer from Mexico, in addition to its proprietary beer brand Lion, Sri Lankaâ&#x20AC;&#x2122;s most popular beer. Apart from its local dominance, the flagship brand is exported to several countries including the US, Canada, Australia, UK, Japan and the Maldives. Power For seamless ProDuction The companyâ&#x20AC;&#x2122;s operations are fully computerised, using technology like enterprise resource planning solutions, sales force automation systems, computerised maintenance management systems and data warehousing solutions within its production and networking infrastructure. Power support is crucial to ensure minimal downtime. Because of expansion requirements, it was necessary for the company to increase its power generation capacity by adding two 1,000 kVA units and have them work harmoniously with the existing 1,000 kVA unit. The manufacturer also wanted all three generator sets running from the same brand of controls to avoid interfacing problems. Cummins Distributor Trade Promoters proposed the installation of two units of QST30G4 gensets (at 1,000 kVA capacity each) with PCC3100P controls, as well as a PCC3300 control-
ler to link up the other machine. The DMC1000 was also proposed for utility paralleling to synchronise all three units of generator sets with the utility and one another, in addition to coordinating every aspect of the power system. Integrated paralleling in the generator sets controls offers fast synchronising. Any number of generator sets can be synchronised in less than 15 seconds in most applications. What is particularly interesting is that the PCC3300 controller had never been used on a hydro-mechanical engine powered generator set from a different manufacturer prior to this project. maintenance is Key Maintenance is of particular importance for the company as it ensures that the generators will start and run when needed. There is no point in investing in a standby power system if it does not do its job during an outage.
Maintenance is of particular importance for the company as it ensures that the generators will start and run when needed.
Because of the durability of diesel engines, most maintenance is preventive in nature. Preventive diesel engine maintenance typically consists of general inspection, lubrication service, cooling system service, fuel system service, servicing and testing starting batteries, as well as regular engine exercise. This maintenance procedure plays a critical role in maximising reliability, minimising repairs and reducing long term costs. By working closely with the suppliers to maintain their standby power system, the company is assured that it will start and run when they need it most. For more information, ENTER No: 0852
FEATURES
NOVEMBER/DEcEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
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Case-study:
Mechanical & PneuMatic ApproAch to powder hAndling As A UK biscUit And snAcK prodUct mAnUfActUrer finds oUt, mechAnicAl And pneUmAtic conveyor systems cAn cAter to different powder hAndling needs dUring prodUction. by DaviD Boger, vp sAles & mArKeting, flexicon
Burton’s Biscuit, a UK biscuit and snack product manufacturer, is best known for their ‘Jammie Dodger’ sandwich made of two shortbread biscuits with jam in the centre. To build on the product’s success, the company decided to market a ‘Chocolate Dodger’ version, made of chocolate biscuits with chocolate cream in the centre. To produce the chocolate cream, the plant installed a batching/blending system consisting of flexible screw conveyors that transport cocoa powders to a horizontal paddle mixer and a pneumatic conveying system that delivers finely milled sugar to the mixer. A PLC controls the gain-in-weight batching/blending process, in which the cocoa powders, milled sugar, palm oil and liquid chocolate are
added in sequence to the mixer. Load cells supporting the mixer transmit weight gain signals to the controller, which starts and stops the conveyors and the mixer, and opens/ closes valves, to automatically batch and blend the chocolate cream. Dual FlexiBle Screw conveyorS Cocoa powder has a bulk density of approximately 560 kg/cubic metres and is non-free-flowing. The material has a tendency to pack, cake and form deposits on conveying equipment surfaces, particularly if exposed to moisture since it is also hygroscopic. In addition, it fluidises readily and generates dust. To move the troublesome material consistently while containing dust, the company specified two flexible
screw conveyors with screw geometry suited for the application. The chocolate cream recipe calls for 15 kg of one type of cocoa powder and 25 kg of another, both of which are manually dumped from 25 kg bags into a twin floor hopper that keeps each type separate. The twin hopper consists of two narrow hoppers joined at a centreline, from which a hopper lid hinges to cover the opening of one hopper or the other. The lid also doubles as a shelf to support bags during slicing and dumping. A wire screen with 50 mm square apertures spans both hopper openings to prevent the passage of bag scraps. Dean Miles, the company’s engineering projects manager, explains that a vacuum extraction system connected to both hoppers withdraws any fugitive dust generated from dumping activities. The hoppers are also equipped with an electromagnetic vibration system that promotes flow of material into the inlets of flexible screw conveyors that transport cocoa to the mixer. Each conveyor consists of a stainless steel flexible screw, housed in a three m long, 90 mm OD plastic tube that is inclined at 70 degrees. From the discharge spouts of both conveyors, material flows to a common wye fitting and then through a single downspout that discharges into the mixer. The screw is driven by a 2.2 kW motor located above the discharge point of the tube, thereby preventing powder from contacting drive seals. The screw is engineered with special geometry to minimise radial forces and maximise longitudinal flow of the material to prevent pack-
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ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DEcEMBER 2013
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ing of the compressible material. As the flexible screw rotates, it selfcentres within the tube, providing clearance between the screw and the tube wall to minimise grinding or heating/melting of the powder. The conveyors are started and stopped by the PLC to move 15 kg of one cocoa powder, and then 25 kg of the other, to the mixer. Each conveyor moves material at the full feed rate of 1.85 cubic metres/h and then steps down to dribble feed rate before stopping once the accurate target weight is gained by the mixer. PneuMaTic conveyor Unlike cocoa powder, the sugar powder needed for the process is free-flowing (when dry) and is sourced from a distant plant location, leading the company to specify a pneumatic conveying system. The plant receives sugar in gran-
ulated form, which is milled to a fine powder, and then fed from a hopper through a rotary valve into a 200 m long, 75 mm diameter stainless steel pneumatic line. Powered by a blower located upstream from the sugar intake point, the pneumatic conveyor has a capacity of 2,110 kg/h. Since the fine powder will readily agglomerate and block the line in the presence of moisture, a key requirement is to keep the sugar warm and dry—achieved by means of a dehumidification system. Miles points out that this is especially critical because the pneumatic line contains four 90 degree elbows and four 30 degree elbows where plugging would otherwise occur. A 915 mm diameter filter receiver separates the sugar from the air stream, before it enters a 500 kg capacity receiving hopper, located
above the mixer. Four air-jet fluidisers in the bottom of the hopper promote the flow of material as it is fed into the mixer by a rotar y valve under PLC control, according to weight gain input provided by the mixer’s load cells. Just before entering the mixer, the sugar passes through a 915 mm diameter vibratory screen with 1.0 mm openings, which retains oversized material. Once palm oil and liquid chocolate are added to the batch, the PLC cycles the mixer, opens a discharge valve, and pumps the chocolate cream blend to the sandwich production line. For more information, ENTER No: 860
Experts in emulsifiers and stabilizers for · Yoghurt/yoghurt drinks · UHT milk · Chocolate milk · UHT whipping creams · Soy beverages Enhanced emulsion stability, mouth-feel, texture and viscosity. Improved stability, whippability, foam structure and water retention... Palsgaard’s emulsifier & stabilizer systems for dairy help you achieve it all. And with application centres on three continents we can help you throughout the entire process of preparing a new product for production or adjusting an existing recipe.
Asia Palsgaard Asia-Pacific Ltd. Singapore Phone + 65 6468 6905 Pap@palsgaard.com.sg
Enquiry Number
Headquarters Palsgaard A/S Denmark Phone +4582 7682 Direct@palsgaard.dk
3504
Visit www.palsgaard.com to learn more about how we can help you in your product development
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Case-study:
Profiting from iBC Blending Flavour producers’ have never considered intermediate bulk container (ibc) blending as a viable alternative to their conventional, static mixers. technology advancements have made this method a good option and a single blender can make a diFFerence. by Hans Pettersson, business development director, matcon The rising population, standard of living and desire for diversity of taste are all reasons why the flavouring industry is growing rapidly. This therefore generates the need to become more efficient and flexible to cope with this demand. The ‘industry standard’ for mixing of powder is to use some kind of static hopper (conical, cylindrical or trough shaped) with a large rotating tool to provide the main mixing action. This mixing action is often further enhanced by applying a fast rotating agitator or intensifier to break up lumps and/or dispense a liquid or fat into the mix. In order to achieve a homog-
enous mix it is often required to ‘sequence’ or ‘stage’ the ingredients in the correct order, sometimes with time intervals, thereby occupying an operator throughout the complete mixing cycle. These mixers come in a wide range of sizes. It is typical that many operations start with small unit(s), around 500 kg batch size, but over time, grow in number and size, often up to two tonnes or more. The actual mixing time (once all ingredients enter the hopper) is often very short—just a few minutes. But the filling (including staging), emptying and thereafter, cleaning between recipes, are all very time
Inventory To make matters worse, the classic response to the poor overall equipment effectiveness is often to mix more volume of a given recipe before changeover in order to reduce relative downtime for cleaning. This results in large amount of stock which ties up capital as well as a significant amount of space. Part of the stock is also wasted since the fashion of taste changes very quickly, meaning a product which was in heavy demand six months ago may no longer be sellable—so the stock has to be scrapped. Eventually, additional floor space is required in order to cope with the increasing inventory—resulting in major capital expenditure in a new building and infrastructure. This ultimately puts the business under immense pressure to increase the turnover, perhaps at the expense of profitability? Cost savIngs A static mixer as described above will typically achieve four to six batches per shift including down time for cleaning every other batch. An intermediate bulk container (IBC) blender is decoupled and will achieve three batches per hour, independent of recipe changes. Therefore, one IBC blender will do the same job as five static mixers and thereby, dramatically reduce the floor space required. Furthermore, because there is no longer an incentive to mix more than what is ordered, the work in progress will be reduced, saving hundreds of square meters. Finally, and most importantly, now that ‘make to order’ is achiev-
TheDeliciousLife
Taz, Vancouver, Canada
consuming operations, leading to poor efficiency and OEE, typically around 5-25 percent. As demand for capacity and flexibility continue to increase, more factory space is required.
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Andrea Nguyen, Los Angeles, US
tHe blender Is a sIMPle, Proven and robust teCHnology PrIMarIly used In ProvIdIng HoMogenous blends of free floWIng PoWders.
able, there is no longer a reason to hold excessive amounts of finished goods in warehouse, meaning that investing in one blender can save anything from 150-1,500 sq m of floor space, subject to how it will be utilised. When more capacity is required; another IBC blender will provide the same saving again. WorkIng MeCHanIsM The IBC blender is a simple, proven and robust technology primarily used in the pharmaceutical industry providing hundreds of companies with homogenous blends of free flowing powders. However, it is not able to handle sticky powders or liquids within the recipe.
Matcon have, therefore, developed an ‘intensifier’ to overcome this limitation. This has proven to be efficient and is already in operation at 25-30 factories around the world. The smallest ingredient inclusions are down to 0.01 percent and CV-values of two percent or less can most often be achieved. As a positive ‘side effect’, many of the staged blends using traditional mixers can now be performed as a single run, which further improves throughput (OEE) as well as reducing complexity and risk of errors. The IBC blender is suitable to blend IBCs with volumes between 300-3,000 litres and a single machine can be made to accommodate al-
most that complete size range. Furthermore, the IBCs can typically be filled to between 25-75 percent of the air volume, giving an ever greater range of batch sizes that are possible to produce with a single blender. It is therefore not uncommon for a client to blend batches from 150-1,500 kg with the same IBC blender. The IBC technology is being implemented into the manufacturing facilities of many global flavouring producers in the Southeast Asia region. For more information, ENTER No: 0861
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NOVEMBER/DEcEMBER 2013 ASIA PACIFIC FOOD INDUSTRY
tapping into China’s Meat Market China’s meat industry has been experienCing strong growth, leading to greater demands on safety and freshness. new paCkaging solutions Can help manufaCturers stay ahead of their game as well as reduCe Costs. by Daniel W Kearny,Vp market and teChnology deVelopment-asia paCifiC, bemis
Tom Booth, Hong Kong
The meat industry in China continues to experience significant growth in a variety of sectors. It is undergoing a structural transformation from smaller artisanal operations to large scale companies. There were 79.57 million tonnes of pork produced in China in 2011— equivalent to 49 percent of the total amount produced globally. In the same year, China produced 6.48 million tonnes of beef and 3.99 million tonnes of mutton, equivalent to 14 and 31 precent of the total amount produced globally. Total revenues for the meat industry in 2012 were
estimated to be RMB1.0319 trillion (US$169.26 billion) in 2012 with a profit of RMB55.9 billion. Further evidence of the industry’s expansion is the number of slaughtering and meat processing companies which has increased 4.21 percent in the past year and is still rising. Investment is up with the total assets of slaughtering and meat processing companies increasing by a staggering 19 percent to almost RMB68 billion. While fresh meat remains the largest segment of sale, industry experts at the forum discussed the
huge potential for growth in frozen and Chinese-style processed meat product segments. A c c o rd i n g t o e s t i m a t e s b y Euromonitor, in terms of volume, the Chinese market for packaged processed food such as ready-made meals, snacks and meat will surpass America’s by 2015. China is estimated to consume as much as 107 million tonnes of packaged food by then, compared to 102 million tonnes in the US in 2015. This forecasted demand will impact heavily on the packaging industry as manufacturers will have to develop and introduce more innovations, technologies, applications and packaging solutions which can benefit both manufacturers and consumers. With such fierce competition, companies will have to improve their systems and innovate in order to differentiate themselves. The ability to meet fast growing consumer demand for convenience and the capability to deliver fresher and safer meat products at every stage of the chain will have a strong impact on the success of most businesses. These overarching trends in the meat industry are affecting the way in which manufacturers are designing packaging for this sector. In the next few years, processed meat is set to grow in market share and assume a greater role in the meat industry. In addition, chilled fresh meat is growing rapidly with meat processors increasingly concerned and focused on food safety throughout the entire product cycle from sourcing to processing, storage, shipment and display. Supply chains have also been improving rapidly, alongside cold chain products. These industry trends have meant that most businesses are increasingly looking for four main things in their packaging when it comes to meat—extended shelf life, material efficient packaging, how to drive excitement at retail,
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Problem of freshness & shelf life Apart from the basic function of protecting meat from contamination, meat processors from around the world have been grappling with the issue of maintaining meat’s fresh red appearance and extending its shelf life. In the last few years, several innovative film solutions have been introduced in the market, including a fresh case film for fresh meat packaging applications. The fresh case film vacuum package uses substantially less packaging material than alternative packaging formats, thereby decreasing shipping costs and increasing efficient use of retail shelf space. The ‘freezer-ready’ package also occupies less space in the consumer’s refrigerator or freezer. In today’s conventional technology, there is tray and overwrap packaging that gives a standard meat product three or five days of display life, but with the fresh case, it would extend this shelf life to thirty days. Thirty days in the supply chain in a high-value product such as red meat or poultry is a big number that adds significant value to the whole process. This active material technology took years to develop and is a game-changing breakthrough for the face of the meat market and opens new possibilities for processors and retailers alike. While the application has already been in use in America for the last two years, it will be made available in China and Asia over the coming months, providing more options for longer lasting meat products in the region than ever before. Creating exCitement To meet the higher demand for packaged fresh meat as well as high and low temperature meat products
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and improved convenience for the consumer.
As a result of rising demand in the domestic market, processed meat output in China reached US$66 billion in revenue in 2012. companies, more efficient packaging solutions have been developed that can help optimise packaging for a range of different meat products and help ensure products look appealing to consumers at retail. Western manufacturers have utilised these packaging solutions that are engineered for optimum performance on high-speed shrink wrap machines. The films maximise potential of equipment to triple productivity and lower total costs compared to rotary chamber shrink systems, providing a strong example of how packaging manufacturers can work together to create better solutions for customers that also appeal to consumers. The films provide better gloss and clarity, as well as higher shrink, than competitive films, creating tight, crystal-clear packages that deliver a superior branded presentation in the meat or dairy case. The forming films also create a superior package for high-profile foods like half hams because they allow deeper draw than competitive films. Features of the films include low curl plus high shrink and excellent formability to conform tightly to the product, creating an attractive package without dog ears. The films’
high-barrier properties and exceptional puncture resistance extend shelf life and minimise damage and waste throughout distribution. In addition, the roll stock offers easier product loading than shrink bags to minimise labour, and requires less shipping and warehousing space, reducing distribution costs. Wi t h a g ro w i n g n u m b e r o f Chinese, especially urban residents preferring to purchase meat products at supermarkets and hypermarkets for convenience, there is much higher demand for store ready fresh as well as high and low temperature meat products. As a result of rising demand in the domestic market, processed meat output in China reached US$66 billion in revenue in 2012. Over the five years through 2012, the industry has been growing strongly at an annualised rate of 19.6 percent. The dietary patterns of the Chinese have changed significantly since the government implemented economic reforms in the late 1970s. In particular, meat consumption has been rising steadily, in line with higher incomes. For more information, ENTER No: 0862
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Vitafoods AsiA
According to Euromonitor, the Asia Pacific region saw sales of health and wellness products worth US$217.4 billion in 2012, the largest across all regions. As consumer education of health beneficial ingredients rises, interest has turned to fortified/functional products and milk formula and juice in particular.
The show welcomed over 170 exhibitors showcasing a wide range of health food ingredients, raw materials and services.
VitAfoodS ASiA Where AsiaWorld-Expo Center Country Hong Kong Date September 4-5
Vitafoods Asia 2013 was held at the AsiaWorld-Expo Center in Hong Kong from September 4-5, 2013. The show welcomed over 170 exhibitors showcasing a wide range of health food ingredients, raw materials and services to over 2,200 visitors, buyers and distributors from across Asia. Over 30 countries were represented with most attending from China, Hong Kong, Japan, India, South Korea and Malaysia. Another indicator of growth and opportunity across Asia was the wellattended sessions in the Seminar Theatre, which was the most popular show feature this year and attended by over 30 percent of visitors. A workshop by EAS Strategic Advice on the forthcoming harmonisation process for health supplements in ASEAN opened the seminar programme, providing insight into the forthcoming changes. The key message was that companies need to understand the regulations and must start preparing early.
“thE hArmoniSAtion will givE oPPortUnitiES SUch AS for PlAcing ProdUct with onE common StAndArd in mUltiPlE mArkEtS And mAking hEAlth clAimS.”
“A number of developments in the area of health supplement standards and regulations harmonisation are underway in ASEAN and will be implemented by the ten ASEAN member states within the next five years,” Wai Mun Poon explains. “While the harmonisation will give opportunities such as placing products with one common standard in multiple markets and making health claims, companies should be aware that regulatory requirements are expected to be tougher. Companies should understand the new requirements and plan their business strategies
accordingly, to maximise the opportunities that the harmonised ASEAN arena will bring.” Other business-led presentations include ‘How to do business in China’, ‘Understanding the regulatory environment in Hong Kong’ and ‘Opportunities in winning health trends’. There were also keynotes by Euromonitor, Datamonitor, Hong Kong Food Science and Technology association, as well as product presentations by some of the exhibitors. The show is scheduled to return from September 3-4, 2014, at the same venue. _________________ Enquiry No: 870
Enquiry Number
3522
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drinktec 2013
According to a survey by Canadean, 46 percent of respondents in the global beverage industry are optimistic that revenue growth in 2013 will surpass that of 2012, primarily due to a focus on new products and services, improving operational efficiency and expanding into emerging markets.
This year’s edition of the show unveiled technological developments focusing on flexibility, health and safety, sustainability and productivity.
drinktec 2013 Where Messe München Country Munich, Germany Date September 16-20, 2013
Go with the flow — if the turnout for drinktec 2013 was anything to go by, those who were concerned over the global recession and its repercussions need not have worried. Held over a period of five days from September 16-20 at Messe München in Munich, Germany, the trade fair saw a 14 percent increase in visitor numbers from the previous edition. In line with increasing globalisation and the rise of emerging markets, the fair saw a vast congregation of exhibitors and visitors from all over the world. There were 1,445 exhibitors from 77 countries displaying a variety of solutions for the beverage and liquid food industry, and the same diversity could be seen in visitor figures. Visitors came from 183 different countries, up from 172 in the previous edition. There was a significant growth in visitors from Asia and the US. Visitors from Japan doubled and those from
Driven by ConvenienCe AnD heAlth, Consumers Are not only seeking proDuCts thAt lAst longer, but Also those thAt Are nAturAl AnD fresh. China and Thailand saw increases of 45 percent and 71 percent respectively, while the US rose to become the fourth country in visitor rankings. The top spot was taken by Italy, followed by Russia and Switzerland. Other countries that made up the top ten include the UK, Austria, France, Belgium and Japan. Simple Flexibility Catering to an international crowd, flexibility was one of the main themes seen throughout the show. “Flexibility, I’m sure in a few years, will not even be an option. We see it,” said Marc Aury, president and MD of newly
formed Gebo Cermex, a packaging line engineering firm under the Sidel Group. The company follows a philosophy that is at the core basis of its existence —integration. What this results in is a segregation of needs by process rather than process lines, characterised by low capital expenditure (CAPEX) and a greater emphasis on operational expenditure (OPEX). Such a model helps to mitigate capital-related challenges that local suppliers in emerging markets might face. Mature players will also be able to keep up with the ever changing demands of the industry without
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Working in tandem towards this goal are the ingredient suppliers, where the natural trend is most evident. Common sights at the show include natural sweeteners (mostly stevia based), natural colours derived from fruits and vegetables, as well as new flavours from indigenous fruits. For instance, Döhler introduced
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FreSh, Natural taSte Another trend that permeates the show is hygiene and safety. “Apart from some very minor differences which different types of beverages bring into the game, everybody wants to have a safe and microbiologically stable bottle, and that is the same across the world,” said Dr Erasmus Vogl, VP of APAC, MPP–Beverage Technology, Lanxess. Achieving this has become a growing challenge due to the rise of ambient drinks with extended shelf life. Driven by convenience and health, consumers are not only seeking products that last longer, but also those that are natural and fresh. According to Kathrin Klein, head of Marketing & Planning from the same company, this is a need that looks set to continue in the future. “That is basically the centre of our approach, fulfilling customers’ demand in five years time,” she said. The tangible effect of that approach is the Velcorin DT Touch, a dosing pump for new or existing filling lines that requires only minor modifications.
The pump is used for dispensing a compound—Velcorin (dimethyl dicarbonate)—that enables the cold sterilisation of beverage. It is used for “basically all beverages which benefit from a fresh and natural taste,” said Ms Kein, where examples include wine, cider, fruit juices, over-ice teas and flavoured water among others.
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worrying about being tied down by assets that are losing their relevance. In tandem with this vision, the company has unveiled the Evoflex, a range of high speed palletiser that processes up to 12 layers per minute. It utilises a single column design that allows the machines to switch automatically between different products and packaging, while its floor level infeed eliminates the need for a pack elevator or platform and improves ergonomic efficiency and work safety. “The vision we have is in one factory. We want to have the same technology for one application, no matter if you run glass, metal, PET, or tomorrow, something that we don’t know, and that is the strength of the Evoflex. You don’t need to adjust it, everything is automatic. You can run glass in the morning, cans in the afternoon, PET in the evening, and you have the same machine,” Mr Aury explained.
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flavours such as brewed elderflower lemon and guarana, along with its ‘Crystal Clear Colours’ range of solutions that allows the use of colours with a neutral taste profile and stability in transparent beverages without the addition of any artificial ingredients. With the recent acquisition of a share in Brazilian firm Amazon Flavors, Wild Flavors is also offering concepts that feature maté and acai extract. EnvironmEntally & Cost FriEndly In light of rising costs and the impending effects of climate change, sustainability has been the buzzword for years. While the goal remains the same, the ways of achieving it have been constantly changing. One of the growing trends is lightweighting, where drinks manufacturers are striving towards bottles that are as light as possible. Singing to this tune, GEA Procomac has introduced a 12 g PET bottle along with its Aseptic Blow Fill (ABF) machine, which is the first rotary aseptic blow moulding machine for PET bottles with an integrated aseptic filler and capper. Used for filling sensitive beverages like milk, milk-based products, teas and juices, the system first uses vaporised hydrogen peroxide (VHP) to sterilise preforms at the exit of the oven and eliminates the need for rinsing. This ultimately reduces the amount of chemicals required—the preform is smaller and has a simpler shape than the bottle—and the weight of the bottle, simply because the preform is made of thicker material. Therefore, temperatures can be increased during treatment without risking shrinkage or affecting the bottle’s shape. Its simpler and smaller layout leads to reduced energy consumption as well. Bottles aside, other developments in su s t a i n a b i l i t y i n c l u d e t h e streamlining of secondary packaging. A result of this is direct printing, which completely does away with labels on bottles. One such example is the Innoprint PET by KHS that
saves as much as 42 metric tonnes of labels per year. The company has also presented a new method of holding bottles in multipacks without the use of banding or shrink wrap film. Instead, blobs of glue are used, where consumers can remove bottles one at a time without affecting the rest of the pack. Similarly, Krones has debuted the EvoLite Bloc—a forerunner in environmental friendliness. According to Volker Kronseder, CEO of the company, being environmentally friendly is something that is very close to his heart. The EvoLite pack strapper achieves this by producing six-bottle packs with an integrated carrying handle, resulting in cost savings of up to 74 percent. Because no shrink tunnel is required, energy consumption is also reduced by up to 90 percent. automation Meanwhile, automation has become a common sight in plants as production increases in scale and complexity. It can
therefore make a tangible difference in productivity when one uses the right tools, in addition to having a smaller carbon footprint. “One of the other major topics during the recent years is obviously the system of energy management and energy savings,” said Gunther Walden, VP of Food & Beverage, Siemens. Echoing his sentiments, Dipl.-Phys Claus Blankertz, lead consultant at the company, added that having the right automation systems “is a really good basis to have influence on the energy efficiency of the plant, because you have all the data.” With the data, plant owners can better optimise processes, such as replacing or resizing applications to those that are more energy efficient, reusing waste energy, and improving predictive maintenance. The next edition of the show will be held at the same location from September 11-15, 2017. _________________ Enquiry No: 871
3491 Enquiry Number
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Food & Hotel Malaysia
A new feature introduced at the show was the Business-to-Business (B2B) sessions which generated more than 2,000 matches and 457 on-the-spot matches between trade visitors and exhibitors.The pavilions actively using the sessions were from Japan, South Korea, Singapore and Taiwan.
A series of special features were held, which included the Celebrity Cooking Demonstration by Chef Sherson Lian and Chef Johny Fua using ingredients from the exhibitors. Food & HoteL MaLaySia Where Kuala Lumpur Convention Centre Country Kuala Lumpur, Malaysia Date September 17-20
Food & Hotel Malaysia (FHM) 2013 was held at the Kuala Lumpur Convention Centre (KLCC), Malaysia, from September 17-20, 2013. The show occupied 13,000 sq m of space spread across over seven exhibition halls, making it the biggest since its inception in 1993. A total of 18,865 trade visitors from 57 nations visited the show, which amounted to an increase of 5.5 percent from the previous show. There were 1,160 participating companies from 47 nations present and six international pavilions from Japan, South Korea, Singapore, Taiwan, Turkey and the US. To add flavour to the exhibition, a series of special features were held, which included the Celebrity Cooking Demonstration by Chef Sherson Lian and Chef Johnny Fua using ingredients from the exhibitors, two days of intensive wine appreciation classes by the Roderick Wong, founder of
a total of 18,865 trade visitors from 57 nations visited the show,which amounted to an increase of 5.5 percent from the previous show. the Wine Academy, and an interesting workshop on Scottish Single Malts and Japanese Sake Shochu by Thomas Ling, a certified specialist of spirits and sake professional. There were also two informative conferences, one of which was a Halal workshop on Malaysian Halal Standards, Certification and Auditing, which provided comprehensive information on proper guidelines and compliances on Halal procedures in Malaysia by the Malaysian Export Academy. The second conference was organised by the ASEAN Hotel and
Restaurant Association and themed ‘New age hospitality a solution for the next generation of hoteliers’. Just like the previous edition, Culinaire Malaysia 2013 was held alongside the show. This year’s competition features 34 categories, more than 1,300 participations and 86 judges from around the world with international culinary and beverage background. The exhibition is scheduled to return from September 29 to October 2, 2015, with the theme of ‘A Perfect Setting For Your Business’. _________________ Enquiry No: 872
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Oishii Japan
According to Japan’s Ministry of Agriculture, Forestry and Fisheries, there are over 55,000 Japanese restaurants in the world, more than double the number a decade ago. In 2012, Singapore saw 2.7 percent increase in Japanese food and beverage imports to 14.5 billion yen (US$147 million).
There were a series of seminars and demonstrations on topics that are linked to the Japanese culture.
OiShii Japan Where Suntec Singapore Country Singapore Date October 17-19
The second edition of Oishii Japan was held from October 17-19, 2013, at Suntec Singapore. The three-day exhibition covered over 4,000 sq m of floor space and featured 230 exhibiting companies from 26 Japanese prefectures. It attracted close to 6,000 trade and public visitors from 23 countries, which is an increase from last year’s visitorship of over 5,000. The three core areas of the show were: classic foods, innovative products and Japanese F&B business. Innovative products and new-to-market brands have been added to the show to introduce variety and raise awareness of diversity in Japanese food and beverage products. T h e J - F o o d Te c h p a v i l i o n showcased 10 leading food machinery companies from Japan and allowed visitors to explore a display of equipment and technology for food processing and related operations
The Three core AreAS oF The Show were: clASSIc FoodS, InnovATIve prodUcTS And JApAneSe F&B BUSIneSS.
to raise productivity, efficiency and consistency. Other highlights of the show include a series of seminars and demonstrations and tastings held at the Presentation Area. Dr Hajime Yasui and Dr Kazuo Miyashita from Hokkaido University gave a talk titled ‘Guide to Japanese Food Culture and Functionality: Hokkaido Hakodate Seaweed’. Shigeru Shiraishi, a chef at the Takumi restaurant, gave a demonstration on ‘The Art of Freshness in Japanese Cuisine’, while the
Livestock Industry Association shared ‘The Anatomy of Japanese Wagyu’. Other demonstrations include ‘The Art of Confectionery-making with Japanese ingredients’ by Janice Wong, a chef at 2am:dessertbar, ‘Let’s Eat “UMAMI”! Taste Japan’ by Akihiro Maetomo, chef at the Chikuyotei restaurant and ‘A Warrior’s Guide to Japanese Liquor’ by Ayuchi Momose of Sake Sumurai. The exhibition is scheduled to return from October 16-18, 2014, at the same venue. _________________ Enquiry No: 873
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AnugA 2013
According to the Federal Association of the German Retail Grocery Trade, turnover in Germany’s food retail trade from January to July 2013 grew by 3.3 percent, from the €160 billion (US$215.81 billion) that was registered the previous year.
Food is becoming less of a need and more of a want. In today’s environment where affluence is increasingly rampant, consumers are demanding more from food products. AnuGA 2013 Where Koelnmesse Country Cologne, Germany Date October 5-9, 2013
TouTed as the Olympic games of the food service industry, the 32nd edition of Anuga was held from October 5-9, 2013, in Cologne, Germany. For five days, around 155,000 trade visitors from 187 countries were treated to the sights presented by 6,777 exhibitors, all of which were revolving under the theme of ‘Food Values’. “Quality and food values are very important for the industry. It also encompasses traceability and food safety—in other words, the sustainability of food,” said Jürgen Roters, mayor of Cologne and chairman of the supervisory board of Koelnmesse. Food is becoming less of a need and more of a want. In today’s environment where affluence is increasingly rampant, consumers are demanding more from food products. With around 65 percent of the participants and 88 percent of exhibitors coming
from abroad, globalisation is very much a growing reality. According to Dr Wolfgang Ingold, chairman of the Federation of German Food and Drink Industries (BVE), it becomes important then, to defend against regionalisation that is propagated by protectionist policies. Consumers should be given the choice to decide their needs for themselves. The crux of this lies in giving consumers sufficient information to make their own choices. driven By HealTH One of the major trends at the show is health, in part driven by growing affluence and education among the population. Despite having been an ongoing trend for a while, it shows no sign of abating but seems to be thriving. Companies are responding to this demand by developing products that are natural or organic-certified, with
many items sporting Germany’s ‘Bio’ label for organic goods. This trend is not just limited to Western Europe however, as many exhibitors from Asia came with similar products as well. For instance, Chinese exhibitors presented organic tea, beans and goji berries among others, while Singaporebased Unisoy introduced its black soy milk powder, which also won the taste13 award. According to Audrey Tan, divisional director of the Food Division under the Lifestyle Business Group, IE Singapore, such products are a core competence of Singaporean firms, where “this trend towards healthier options, organic options, would play very well to our strengths.” Other items that she thinks would resonate well with the German and European market are for example, instant noodles that are baked or steamed as opposed to being fried. She
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adds that having items like this “will be a good alternative to what is out there in the market,” because it serves as a differentiating factor. Food items aside, natural and organic claims are making a splash among beverages, especially energy drinks. Traditionally carbonated and filled with the likes of sugar and caffeine, energy drinks took on a new persona when exhibitors presented options that are tea-based and non-carbonated, where some were combined with juice and others carried organic labels. On the other end of the spectrum, there is an emergence of wellness drinks that aim to combat the stresses felt in today’s high strung environment. This includes 2B Relaxed, another taste13 winner, whose ingredients comprise hops, a fruit mix, stevia, and amino acid L-tryptophan, a precursor to ‘happy hormone’ serotonin.
Ölz Meisterbäcker are in 200 g packs to suit smaller households and individuals. Packaging trends tagged to convenience can also be found in the meat sector where items are individually packed or portion sized, and often in flexible packaging.
GrowinG Urbanisation A result of urbanisation, consumption habits are changing as families become smaller and people are becoming more mobile. To top it off, markets worldwide are experiencing an ageing population, leading to convenience products becoming more widespread. One of the key types of products alluding to this trend is easy-to-prepare items that can be readied in a few minutes or less, most of which can be prepared in the microwave or toaster oven. Examples seen at the show include pizza on a stick, which comes without artificial flavours, additives or preservatives, French fries made for the microwave, as well as pancakes that can be toasted straight from the freezer. Likewise, in the bread and bakery section of the show, it was a common sight to see pastries and breads that are pre-cut, pre-baked, and suitable for going straight to the oven despite being frozen. Another component of the convenience trend lies in packaging and serving sizes. For instance, pastries and breads from Austrian confectioner
ChanGinG Diets With increasing globalisation, European markets are developing a palate for alternative diets. Not only does this include a greater acceptance of international flavours, it has also led to a growing number of people who are adopting alternative diets that are Halal, vegetarian or vegan, leading to the boom in lactose-free, gluten-free products. Particularly among baked goods, there is a significant increase in products that sport the glutenfree claim as awareness of gluten intolerance increases. Dairy or lactose free claims are also rampant as companies cater to intolerances as well as alternative diets like veganism. For instance, Finnish firm Valio introduced its lactose free milk ingredients, which have been picked up not just by the dairy industry but also confectionery and ready meal manufacturers. Meanwhile, Australian firm The Chia Co has also responded by launching the Chia Pod, a non-dairy yogurt alternative. Other examples include soy-based margarine, as well as vegetarian deli slices.
With increasing globalisation, european markets are developing a palate for alternative diets. In the meantime, there is also a greater acceptance of international flavours as people travel more and are exposed to other cultures through digital mediums. As such, there was a strong showing of exotic and authentic flavours that conveyed heritage from other countries. Indigenous items like dates and dried fruits were highlighted at the Turkey pavilion; the Singapore pavilion displayed noodles, instant coffee as well Asian sauces and pastes, Malaysia introduced traditional biscuits and soy sauces with a twist, while the Spain pavilion was dominated by Jamón and other cured meats. With an appetite for international cuisine, Western European markets
like Germany hold great potential for international trade, such that in Singapore alone, the German market catapulted over the last four years with a growth of approximately 14 percent. The next edition of the show will return to the same venue from October 10-14, 2015. _________________ Enquiry No: 874
Enquiry Number
3523
Virag Virag, Budapest, Hungary
LOOK OUT FOR THESE SHOWS CALENDAR OF EVENTS 2013/14 November 18-20: SHANGHAI INTERNATIONAL BIO-FERMENTATION PRODUCTS/ TECHNOLOGIES & EQUIPMENT EXPO Shanghai Everbright Convention & Exhibition Center Shanghai, China China XinShi Exhibition Services E-mail: bioexpo@163.com Web: www.biozl.net ❑ To Exhibit ❑ To Visit ❑ General Enquiry
19-21: FI EUROPE Messe Frankfurt Frankfurt, Germany UBM E-mail: matthias.baur@ubm.com Web: www.foodingredientsglobal.com/ europe/home ❑ To Exhibit ❑ To Visit ❑ General Enquiry
20-22: CHINA INTERNATIONAL BEVERAGE INDUSTRY EXHIBITION ON SCIENCE & TECHNOLOGY Shanghai International Expo Center Shanghai, China China Beverage Industry Association E-mail: CBST@chinabeverage.org Web: www.chinabeverage.org/cbst_en ❑ To Exhibit ❑ To Visit ❑ General Enquiry
20-23 PROPAK INDONESIA 2013 JIExpo-Kemayoran Jakarta, Indonesia PT Pamerindo Indonesia Web: www.pamerindo.com/events/2 ❑ To Exhibit ❑ To Visit ❑ General Enquiry
24-26: SIAL MIDDLE EAST Abu Dhabi National Exhibition Centre Abu Dhabi, UAE Sial Group E-mail: info@sialme.com Web: www.sialme.com
February 27-2: FOOD PACK ASIA BITEC Bangkok, Thailand TBP Publications E-mail: tbp.internet@gmail.com Web: www.foodpackthailand.com ❑ To Exhibit ❑ To Visit ❑ General Enquiry
March 4-6: PROPAK VIETNAM Saigon Exhibition & Convention Center Ho Chi Minh City, Vietnam Bangkok Exhibition Services E-mail: arayabhorn@besallworld.com Web: www.propakvietnam.com ❑ To Exhibit ❑ To Visit ❑ General Enquiry
6-8: FOOD, HOTEL & TOURISM BALI Bali Nusa Dua Convention Centre Bali, Indonesia Pamerindo Web: www.pamerindo.com/events/10 ❑ To Exhibit ❑ To Visit ❑ General Enquiry
31-APR 4: ALIMENTARIA Gran Vía de Fira Barcelona, Spain Fira Barcelona E-mail: alimentaria-bcn@alimentaria.com Web: www.alimentaria-bcn.com ❑ To Exhibit ❑ To Visit ❑ General Enquiry
25-27: FOOD INGREDIENTS CHINA 2014 Shanghai World Expo Exhibition & Convention Center Shanghai, China China Food Additives & Ingredients Association E-mail: cfaa1990@126.com Web: www.chinafoodadditives.com/d_e.htm ❑ To Exhibit ❑ To Visit ❑ General Enquiry
❑ To Exhibit ❑ To Visit ❑ General Enquiry
February 18-21: HCJ JAPAN Tokyo Big Sight Tokyo, Japan Japan Management Association E-mail: hcj@convention.jma.or.jp Web: www.jma.or.jp/hcj/eng ❑ To Exhibit ❑ To Visit ❑ General Enquiry
April 8-10: CHINA INTERNATIONAL ORGANIC FOOD INDUSTRY EXPO China International Exhibition Center Beijing, China Beijing Shibowei International Expo E-mail: foodexhibition11@163.com Web: www.gnfexpo.com.cn/en/ ❑ To Exhibit ❑ To Visit ❑ General Enquiry
*All details subject to change without notice. Please check with organisers for updates.
April 8-11: FOOD AND HOTEL ASIA Singapore Expo Singapore Singapore Exhibition Services E-mail: tsm@sesallworld.com Web: www.foodnhotelasia.com ❑ To Exhibit ❑ To Visit ❑ General Enquiry
27-29: CHINA INTERNATIONAL FOOD EXHIBITION China Import & Export Fair Complex Guangzhou, China China National Food Industry Association E-mail: gzyfzl@163.com Web: www.ifechina.com ❑ To Exhibit ❑ To Visit ❑ General Enquiry
May 6-8: VITAFOODS EUROPE Palexpo Geneva, Switzerland Informa Exhibitions E-mail: maria.sidiropoulou@informa.com Web: www.vitafoods.eu.com ❑ To Exhibit ❑ To Visit ❑ General Enquiry
25-28: TAIPEI INTERNATIONAL FOOD SHOW Taipei World Trade Centre Taipei, Taiwan Bureau of Foreign Trade E-mail: foodtaipei@taitra.org.tw Web: www.foodtaipei.com.tw ❑ To Exhibit ❑ To Visit ❑ General Enquiry
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