APFI November/December 2012

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NOVEMBER/DECEMBER 2012

Established since 1985 | www.apfoodonline.com

Freshness In EvEry Sip Pg 40

The

Evolution Pg 56

LabeLLing

Decoration,

For

Information&Tracking Pg 28

Fill one bulk bag per week or 20 per hour at the lowest cost per bag Flexicon’s extra-broad model range, patented innovations and performance enhancements let you exact-match a filler to your specific cost and capacity requirements FILLER FOR PALLET JACK BAG REMOVAL Low profile version of patented TWIN-CENTREPOST™ filler allows removal of filled bags using a pallet jack, eliminating the need for a forklift or roller conveyor.

Low cost standard models offered with many performance options.

BULK BAG FILLER USES PLANT SCALE Full length forklifting tubes allow positioning of this TWINCENTREPOST™ filler model on a plant scale as needed, allowing you to fill by weight without investing in load cells and automated controls.

FILLERS WITH AUTOMATED FEEDING SYSTEMS Every Flexicon filler is offered with pneumatic (shown) or mechanical (bottom right) feeding/weighing systems, as well as inlet adapters to interface with optional overhead storage vessels.

COMBINATION BULK BAG/DRUM FILLER Patented SWING-DOWN® filler features a fill head that lowers and pivots down for safe, easy bag spout connections at floor level, and a swing-arm-mounted chute for automated filling and indexing of drums.

PATENTED SWING-DOWN® FILLER Fill head lowers, pivots and stops in a vertically-oriented position, allowing operator to safely and quickly connect empty bags at floor level and resume automated filling and spout-cinching operations.

CANTILEVERED REAR-POST FILLER Offered with performance options including: powered fill head height adjustment, pneumatically retractable bag hooks, inflatable bag spout seal, dust containment vent, roller conveyor, and vibratory bag densification/deaeration system.

BASIC FILLER FOR TIGHTEST BUDGETS A lighter-duty version of the economical TWIN-CENTREPOST™ filler, the BASIC FILLER reduces cost further still, yet has an inflatable bag spout seal and feed chute dust vent as standard, and a limited list of performance options.

PATENTED TWIN-CENTREPOST™ FILLER Two heavy-gauge, on-centre posts boost strength and access to bag hooks while reducing cost. Standard manual fill head height adjustment, and feed chute vent for displaced dust.

Numerous performance options. First filler to receive USDA acceptance.

+1 610 814 2400 +44 (0)1227 374710 +27 (0)41 453 1871 +56 2 415 1286

©2011 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.

Z-1087

USA UK SOUTH AFRICA CHILE

Enquiry Number

AUSTRALIA sales@flexicon.com.au +61 (0)7 3879 4180

2936

See the full range of fast-payback equipment at flexicon.com.au: Flexible Screw Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag Conditioners, Bulk Bag Fillers, Bag Dump Stations, Drum/Box/Container Tippers, Weigh Batching and Blending Systems, and Automated Plant-Wide Bulk Handling Systems

y ! p s p y a a d H Ho li Thank you for supporting us this year and we would like to wish you a prosperous 2013!

More than meets the eye At DSM, we offer much more than just single ingredients.

Quali®-Blends – our premium quality premix service – offers support across your entire value chain to reduce complexity and add value to your brands.

From concept generation and product development to logistics and quality control, DSM’s nutritional solutions help you respond to the latest consumer demands. Backed by strong science, our premixes can be delivered to you anywhere through our global presence. quali-blends.com dsm.com qualityforlife.com Quali® is a trademark of DSM

WE SERVE VIRTUALLY EVERY INDUSTRY Ingersoll Rand Industrial Technologies provides products, services and solutions that enhance our customers’ energy efficiency, productivity and operations. Our diverse and innovative products include Ingersoll Rand compressedair systems, tools, pumps, and material and fluid handling system.

AIR Air Compressors & Blowers Reciprocating Rotary Screw Centrifugal - Durable, high efficiency Air Compressors - Low noise level - Simple installation - Energy saving variable speed drive (VSD) - American Petroleum Institute (API) standard design

TOOLS Impact Tools - Ergonomic designs

FLUID HANDLING

- Up to 3.5 inch square drives

Air-Operated Pumps

MATERIAL HANDLING

AFTERMARKET NEEDS

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Double

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- Maximum flow rate up to 1041 litres/min

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Drills

Piston

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- Individual pump & full packages

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Air Starters (Engine) - Inertia and pre-engaged models

- Carbon steel & stainless steel construction (Maximum corrosion resistance)

- Left and right hand rotation

- Multiple pressure/ratios/flows

- Desiccant Air Dryer - Filters - Air Receivers

- Pistol and straight - Needle scaler kit

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- Man lifting winches for offshore applications - Certification by ABS, DNV, Lloyds, etc

- Preventative Maintenance - Tools, Fluid and Material Handling, Servicing & Overhauls - Diagnostic and Auditing Services - Remanufacturing Technology Centre - Installation Work - Low Pressure Blower Services

Parts & Accessories Condensate Mangement - PolySep Condesate System - Pneumatic No-Loss Drain (PNLD) II - Electric No Loss (ENL) - Water Separators

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Controls

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System Components - Intelliflow™ - PaCE

Installation - Simplair Evolution - Receiver Tanks

Consumables

42 Benoi Road Singapore 629903 Tel: 6861 1555 Fax: 6862 2086 Sales Hotline: +65 6860 6734 | Service Hotline: +65 6860 6857 Air: irair@irco.com | Tools, Fluid & Material Handling: irtools@irco.com

www.ingersollrandproducts.com

Enquiry Number

Ingersoll-Rand South East Asia (Pte) Ltd

3092

- Filtration - Lubricants

Multi-page Labels

Self-adhesive Labels

Advanced innovation and high quality for self-adhesive labels, sleeves, labelling and coding systems as well as convincing software solutions for productidentification and integrated data management.

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3193

Label Applicators

Labelling Systems

Marking & Tracking Software Solutions

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Sleeves

Your worldwide leading Partner for Labels and Labelling Technology

CONTENTS 6

PROCESSING

•

PACKAGING

•

FLAVOURS & ADDITIVES

•

www.apfoodonline.com

28

volume 24 no. 8

PACKAgINg & PROCESSINg 28

48

STORAGE & HANDLING

Labelling For Decoration, Information & Tracking

In today’s demanding market, selfadhesive labelling technology offers great opportunities in terms of quality decoration, varied information and product tracking.

By David Saluz, Pago International

36

The Barcode Perspective Despite competition from other forms of tracking technologies, the barcode has held its own for the past few decades. The correct implementation of barcoding technology can increase efficiency and eliminate almost all aspects of human error. By umesh Cooduvalli, Datamax-o’neil

INgREDIENTS & ADDITIvES 40

Freshness In Every Sip

The beverage industry is a competitive, dynamic and innovative segment that is constantly on the lookout for the next big thing. To stay ahead, manufacturers will have to create a ‘fresh’ and sensational experience with their products. By Angie ng and vv Lee, DuPont nutrition & health

44 44

The Power Of Bran With its plethora of benefits, rice bran is taking a leaf from whey protein in becoming a valuable ingredient from a waste by-product. The second of this two-part series will discuss some possible applications of rice bran. By henk hoogenkamp

48 32

Reducing the amount of fats in ice cream without compromising on texture and taste is a challenging affair. Mono- and diglycerides emulsifiers may just be the trick. By Claus Prior hansen, Palsgaard.

Accountability Tracking With Complete Vision Law enforcers and manufacturers alike can turn to imagebased technology to keep out counterfeit products and trace supply chain violations to the source.

By Didier Lacroix, senior vP, Cognex

Equal Richness With Less Fats

HEALTH & NuTRITION 52

Nature’s Answers To Cardiovascular Health Antioxidants found in olive oil and pomegranate extracts have been proven to be effective in maintaining cardiovascular health. These natural ingredients may be the supplements people need with their hectic lifestyles. By vicente Marti, sales manager, Probeltebio

32

CONTENTS

ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DECEMBER 2012

8

PROCESSING

•

PACKAGING

•

FLAVOURS & ADDITIVES

•

STORAGE & HANDLING

www.apfoodonline.com

volume 24 no. 8

12

Refer to Advertising Index on Pg

for Advertisers’ Enquiry Numbers

DEPARTMENTS

52

70

10 12 14 22 79 80A 80B

Editor’s Note Advertiser’s List Business News Product Highlights Calendar Of Events Reader’s Enquiry Form Subscription Information

BEvERAgE 56

The Dairy Evolution healthier dairy beverages are in fashion today, but tomorrow could bring completely unexpected innovations in product portfolios. By Rudy Kartono, International flavors & fragrances

60

Bottle Of Opportunities using bottles to package dairy products is a great opportunity for manufacturers aiming to gain market share in mid-range to premium products segments. By fabienne Chériaux, Serac

FEATuRES 64

A Food Grade Makeover using nSf h1 or hT-1 registered lubricants can help minimise the potential for product contamination and protect brand integrity.

Converting a facility to use these food grade lubricants is not as daunting as it seems. By Peter Bird, ExxonMobil Lubricants & Specialties

70

The Press For Smooth Flow Air compressors are critical components of machines used in the food and pharmaceutical industries. Choosing the right food grade lubricant will ensure less downtime and better overall efficiency. By Mark Phang, Tecsia Lubricants

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EXHIBITION & EvENTS

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Review: Fi Asia Preview: SIAL Middle East Preview: Worlds of Healthy Flavors Asia

ThE CIRCuLATIon of ThIS PuBLICATIon IS AuDITED By BPA InTERnATIonAL ThE ADvERTISERS’ ASSoCIATIonS RECoMMEnD ThAT ADvERTISERS ShouLD PLACE ThEIR ADvERTISEMEnTS onLy In AuDITED PuBLICATIonS

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work with us & GEt a BEttEr Match Contact us now at beer@sidel.com

www.sidel.com

Enquiry Number

Get a production solution tailored to your specific needs & optimize your performance We perform over 60 line audits per year delivering recommendations, which once implemented through close cooperation with our clients, improve productivity by up to 20%. We can do the same for you. Our beer know-how and engineering expertise – proven in 7,000 installations in 100 countries – means we can customize your packaging line, improve flexibility and optimize productivity without ever compromising on reliability.

3204

tastE thE changE Enjoy thE th DiffErEncE

EDITOR’S NOTE 10 managing director Kenneth Tan editor Wong Tsz Hin

wongtszhin@epl.com.sg

writer Sherlyne Yong

sherlyneyong@epl.com.sg

editorial assistant Audrey Ang

audreyang@epl.com.sg

assistant art director Ahmad Halik

ahmadhalik@epl.com.sg

IN a flash, we are at the last stretch of the year 2012. November, or Movember as more and more people refer to it as, has arrived. The Movember campaign hopes to raise awareness of prostate cancer and other male cancer initiatives by urging men to grow their moustaches for a month. In encouraging men to get involved, it aims to increase early cancer detection, diagnosis and effective treatments, and ultimately reduce the number of preventive deaths.

The successful movement also serves as a good reminder that despite the growing awareness on health and nutrition, the public still requires drives and initiatives to be educated on the potential health risks and ways to prevent them.

In fact, ingredients manufacturers have reflected on the pressing demand by the people of Asia for more relevant scientific data. Suppliers like BASF, Beneo and DSM have noticed that the people want to see more regional experiment conducted as they understand that differences in lifestyle habits and diets may cause different results.

Overall, the year 2012 has been a solid year. Despite the economic uncertainty surrounding the US and Europe in the early part of the year, and the slowing down of China’s growth, the market did not hit rock bottom as many have predicted.

Although it was a slight dimple on the recovery trends shown in the last couple of years after the 2009 financial crisis, the stability no doubt offer optimism for everyone.

As many have expressed in their interviews, the year 2013 would be a challenging year, but also a year which we can stay cautiously hopeful for.

The APFI team would like to take this opportunity to wish you happy holidays and a great year ahead! Don’t forget your moustache!

business development manager Randy Teo randyteo@epl.com.sg

publication manager Peh Sue Ann

sueannpeh@epl.com.sg

advertising sales manager Kelvin Leong kelvinleong@epl.com.sg

senior circulation executive Brenda Tan brenda@epl.com.sg

contributors Angie Ng Claus Prior Hansen David Saluz Didier Lacroix Fabienne Chériaux Henk Hoogenkamp Mark Phang Peter Bird Rudy Kartono Umesh Cooduvalli Vicente Marti VV Lee 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 Büchanan 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 group executive director Kenneth Tan

etm Wong Tsz Hin

Eastern

TradeanMedia Pte Ltd Eastern Holdings Ltd company

Head Office & Mailing Address Eastern Trade Media Pte Ltd 1100 Lower Delta Road, EPL Building #02-05, Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2805 Email: apfood@epl.com.sg

Enquiry Number

3201

CAMA HIGH TECHNOLOGY AND SAFETY, A GUARANTEED RETURN ON YOUR INVESTMENT.

Cama Group is a leading supplier of advanced technology secondary packaging systems, continuously investing in innovative solutions. Cama engineers design and develop packaging lines following a well developed and adopted motto: “Technology with Added Value”. www.camagroup.com CAMA ASIA PACIFIC - saleschina@camagroup.com - Tel. +662 207 2364

ASIA PACIFIC FOOD INDUSTRY ADVERTISING INDEX ENQ NO

ADVERTISERS

3199

ALMOND BOARD OF CALIFORNIA

3191

BASF

3201

PAGE

ENQ NO

ADVERTISERS

PAGE

55

3206

PAUL LEIBINGER GMBH & CO KG

35

OBC

3210

PROPAK ASIA 2013

80

CAMA GROUP

11

3209

PROPAK VIETNAM 2013

69

3167

CERMEX SIDEL GROUP

13

3203

PURAC ASIA PACIFIC PTE LTD

53

3212

DSM NUTRITIONAL PRODUCTS ASIA PACIFIC

3

6051

R & D ENGINEERS

73

3187

FI CHINA 2013

76

3137

SATS

IFC

2936

FLEXICON CORPORATION (AUSTRALIA) PTY LTD

1

3173

SCHAEFER SYSTEMS INTERNATIONAL PTE LTD

31

3196

FORTITECH ASIA PACIFIC SDN BHD

IBC

3182

SHANGHAI CHANGLONG

3208

GERICKE PTE LTD

51

3051

GUANGDONG WANTTONE FOOD CO LTD

21

3204

SIDEL GROUP

3192

HEAT AND CONTROL PTY LTD

27

3202

SINO-PACK 2013

23

3200

HYDROSOL

41

3028

SYSTEM LOGISTICS SPA

17

3205

IDI SAS

15

3190

TATE & LYLE SHANGHAI CO LTD

3092

INGERSOLL-RAND SOUTH EAST ASIA (PTE) LTD

4

3197

TECSIA LUBRICANTS PTE LTD

63

3195

INTERNATIONAL FLAVORS & FRANGRANCES

43

3211

THAIFEX - WORLD OF FOOD ASIA 2013

78

3063

KALSEC INC

47

2781

TUV SUD PSB PTE LTD

25

3198

MUEHLENCHEMIE GMBH & CO KG

59

3034

UNITECH INDUSTRIES LIMITED

61

3193

PAGO

7

3207

YAMATO SCALE CO LTD

67

3194

PALSGAARD A/S

19

3183

ZEBRA TECHNOLOGIES ASIA PACIFIC PTE LTD

39

INDUSTRIAL EQUIPMENT CO LTD

37 9

5

This index is provided as an additional service. The publisher does not assume any liability for errors or omissions.

HEAD OFFICE

SINGAPORE EASTERN TRADE MEDIA PTE LTD 1100 Lower Delta Road #02-05 EPL Building Singapore 169206

Contact Peh Sue Ann Kelvin Leong Tel: 65-6379 2888 Fax: 65-6379 2805

MEDIA REPRESENTATIVES CHINA Wan Xin Xian Tel: 86-20-3411 4806 Fax: 86-20-3411 4805

JAPAN Ted Asoshina Tel: 81-3-3263 5065 Fax: 81-3-3234 2064

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Booking deadline for advertisements is no less than FOUR WEEKS prior to publication date.

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3-DIMENSIONAL EXPERTISE Newtec Case Palletizing is now part of Cermex www.cermex.com/newtec/

u SHRINK-WRAPPING

u CASE PACKING

u PALLETIZING

18th Floor Zone B, Thanapoom Tower, 1550 New Petchburi Road, Makkasan, Ratthewi, Bangkok 10400 THAILAND Tel.: +66 (0) 2 207 0720

sales.asia@cermex.com

CERMEX – Headquarters 87, route de Seurre - B.P.3 - 21910 Corcelles-lès-Cîteaux - France Tel.: +33 (0) 380 707 100 - E-mail: contact.us@cermex.com

Enquiry Number

3167

www.cermex.asia

BUSINESSNEWS

Tit Bonač, Ljubljana, Slovenia

INDUSTRY & MARKET

Purified Lactic Acid Effective For Natural Colour Stabilisation Gorinchem, The neTherlands: Research completed

by Purac has demonstrated the effectiveness of purified lactic acid for natural colour stabilisation in acidified foods and drinks.

The study showed that purified lactic acid can reduce the fading of anthocyanins (natural red-purple colours) in acidified finished products by up to 50 percent, compared to commonly used citric acid. As colour fading is perceived as a quality defect by consumers, the ability to retain fresh and vibrant colours throughout a product’s shelf life is a valuable benefit for formulators and brand owners.

The use of natural colours in the food industry is booming, underpinned by health concerns and a return to ‘natural’ products. The global natural food colours market grew by 35 percent to US$525 million between 2005 and 2009. Already accounting for 36 percent of the total food colours market, natural products are expected to increase their share further.

Red, pink, purple and blue are popular colours in

NOVEMBER/DECEMBER 2012

Khmer Brewery Commissions Ziemann For Brewery Extension

Phnom Penh, cambodia: Khmer Brewery has commissioned Ziemann to expand its current production capacity from 750,000 hl per year to 1.3 million hl per year.

Besides providing the brewing technology, Ziemann was responsible for the integration of a complete filling and packaging plant. Furthermore, the company also handled the architectural and structural design of the brewery. In addition, the company also supported Khmer Brewery in recipe development.

The expansion will see the number of brews increase to 14 brews per day and additional vessels will be installed in the brewhouse area. In addition, an energy-recovery-system will be installed to further optimise energy consumption.

For the increased raw material requirements, a silo plant will be installed to accommodate the related capacity increase in the milling area. In order to handle the increased capacity of an additional 550,000 hl per year, eight new larger fermentation and storage tanks with a volume of 4,300 hl per tank and two additional Bright Beer tanks, each with a volume of 780 hl per tank will be installed. The filtration area and utility area will also be extended in order to meet the increased production capacity.

The completion of the expansion is scheduled for mid of 2013. _______________________________________ Enquiry No: 1001

many confectionery, jams, jellies and beverage products.

These colours can be found in anthocyanins, which are present in numerous vegetables and fruits, including blackcurrants, grapes and purple carrot.

Natural colours are inherently unstable and factors including pH, temperature, oxidation, light and the presence of sugar or salt can all affect stability in the end product. Acidulants have been used for many years for anthocyanin stabilisation and various other purposes.

This latest research opens up new opportunities for formulators to stabilise colours more efficiently in acidified applications such as beverages. _____________________________________________ Enquiry No: 1000

NOVEMBER/DECEMBER 2012 ASIA PACIFIC FOOD INDUSTRY

LOOKING

FOR?

INDUSTRY & MARKET

Creaminess enhancement

Nutritional profile improvement

Clean label solutions

Krones Wins Bavarian Energy Prize

__________________________________________ Enquiry No: 1002

Innovative functional ingredients for

Greek Yogurts

TECHNICAL SUPPORT TAILOR-MADE SOLUTIONS

3205

KNOW-HOW

INGREDIA Pte Ltd. Phone: +(65) 6753 4980 ingredia-asiapacific@ingredia.com

Enquiry Number

neUTraUblinG, Germany: Krones has won the Bavarian Energy Prize for 2012 with its EquiTherm brewing system. The award was presented to the company by Martin Zeil, Bavaria’s minister of state for economic affairs, infrastructure, transport and technology.

A total of 167 entries were submitted for the energy award, which is initiated by ‘Bayern Innovativ’, the Free State of Bavaria’s Society for Innovation and Knowledge Transfer. In addition to the main prize, twelve recognition prizes were awarded.

In the production process for beer, substantial quantities of thermal and electrical energy are required, which (due to technological stipulations on the part of the breweries and quality requirements for the finished beverage) cannot be readily reduced.

The system has been developed to take energy out of the brewing process itself at an appropriate point and puts it back again somewhere else. The energy recirculation capability can achieve savings of up to 30 percent in terms of thermal energy and 20 percent for electricity.

This is the second time the company has won this award.

BUSINESS NEWS

ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DECEMBER 2012

16

INDUSTRY & MARKET

Tetra Pak Invests For Growth & Innovation Singapore: As demand for food processing and packaging solutions in the region rises, Tetra Pak has invested an additional e42 million (US$54.45 million) into its Singapore site to support growth.

Being the company’s largest packaging material factory in terms of production volume, the Singapore plant currently accounts for about 10 percent of the total global production value and caters mostly to customers in South and Southeast Asia.

The investment includes plant machinery and upgrades that will increase production capacity by 25 percent from 15 billion to 20 billion packs a year. In a move to drive innovation, the company has also opened the Coconut Knowledge Centre in response to the rising global consumption of coconut water. It aims to build knowledge on the characteristics of coconut water, develop new flavours, and establish a strong international network for knowledge sharing.

“The Coconut Knowledge Centre’s objective is to build market and technology expertise that will extend our leadership in coconut beverage innovation.

This will be very important for us and for our customers in the region who are growing their local markets and expanding sales abroad, particularly in the US,” said Rusty Kekuewa, VP, SSEA, Tetra Pak. __________________________________________ Enquiry No: 1003

LycoRed Continues Expansion In China Shanghai, China: LycoRed has continued its growth in China by securing a multi-million US dollar agreement with Shanghai Lithy Foods Material, a distributor of botanical extracts and nutrient pharmaceuticals for dietary supplements.

In this partnership, Shanghai Lithy Foods will provide acess to longstanding distribution channels in China’s nutraceuticals industry and focus on a number of important emerging market segments for LycoRed. LycoRed hosted its first Shanghai Seminar, with speeches on its natural tomato lycopene complex by prominent

overseas academicians.

The complex is extracted from phytonutrient-rich tomatoes and can be used for natural lycopene fortification and natural red colouring of foods and beverages.

Speakers at the seminar included professor Esther Paran, professor Joseph Levy and professor Yoav Sharoni. Professor Paran presented her latest findings in natural tomato lycopene complex and vascular health, while professor Sharoni and professor Levy shared their findings on lycopene and its impact on women’s a n d m e n ’s h e a l t h . ______ Enquiry No: 1004

BUSINESS NEWS

NOVEMBER/DECEMBER 2012 ASIA PACIFIC FOOD INDUSTRY

17

INDUSTRY & MARKET

Tung Lok Boosts Productivity With Technology

rscadv.it

sinGaPore: Restaurant chain Tung Lok Group organised a tour around one of their three central kitchens to demonstrate

____________________ Enquiry No: 1005

Produc

tion

The secret of a successful operations management nowadays, is the right balance between production and shipping operations. The right amount of product, in the right place, at the right time. System Logistics is your partner in creating innovative supply chain solutions. We design and manufacture your system to meet your specific needs. Storage solutions rationalization, lean order preparation, just in time distribution systems, flawless and robust WMS software. Faster operation time and cost reduction thanks to a smooth, fluid and waste free operation flow. Our innovation and commitment makes your supply chain simpler and your flow nothing less than perfect.

System Logistics

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Shipment

3028

Partnership. Innovation. Creating Supply Chain Solutions.

systemlogistics.com

Enquiry Number

how productivity can be enhanced with technology.

Central kitchens are ideal for food service companies with multiple outlets, as a consolidation of the food preparation process helps to optimise resources, leading to increased productivity and costs savings.

The group achieves this with the use of automation and specialised equipment. For instance, its ‘Char Siew Bao’ maker can produce about 1,000 pieces per hour with only six employees, while 20 highly trained employees were required for the manual method.

Its pressure and automatic cookers have also cut cooking time considerably while allowing for large volume production.

“Our operations and bottom line have improved greatly since our central kitchen was set up. This has helped expand production capacity to look for new business opportunities.

Overall manpower costs have also come down and we now enjoy savings on production time, utility consumption, improvement and consistency of product quality. This is the way to go,” said Andrew Tjioe, executive chairman of the group.

Is your supply chain flow as lean as this?

BUSINESS NEWS

ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DECEMBER 2012

18

INDUSTRY & MARKET

Everjean, Antwerp, Belgium

DSM Invests In Quality Assurance

Cargill Extends Sustainable Cocoa Program To Indonesia JakarTa, indonesia: Cargill has officially extended its sustainable cocoa program to South Sulawesi province, Indonesia — an important step in developing sustainable cocoa production and increasing the yields of farmers in Indonesia, the world’s third largest producer of cocoa beans.

This launch in Indonesia builds on the company’s ongoing effort to develop sustainable cocoa supply chains in Côte d’Ivoire, Cameroon, Ghana, Brazil and Vietnam. It strengthens the company’s intention to scale up its efforts and develop its cocoa operations in Indonesia to help meet the increasing demand for cocoa across Asia.

The first step in the program will establish farmer field schools to teach farmers good agricultural practices to help improve yields, enhance the quality of cocoa and increase their incomes. The schools will also train farmers on best practices for pest and disease control — an important element in Indonesia where it is estimated over 50 percent of the cocoa crop is lost

to pests and diseases. Initially, the aim is to train 1,000 farmers to reach independent sustainable certification for either UTZ or Rainforest Alliance certification.

The program will initiate the setup of farmers’ organisations, which will play a crucial role in the administration and certification of the cocoa crops. They will also offer farmers a platform to share expertise as well as an outlet to sell their crops at the best possible price. The program will start in South Sulawesi with the aim of extending to other regions in Indonesia over the next few years.

The launch of the sustainable cocoa program in Indonesia is supported by the Sustainable Trade Initiative (IDH) and by a partnership with the South Sulawesi local government. The company is also working closely with field implementation partner, Swisscontact, to promote local development of farmers and to stimulate cooperation. _________________ Enquiry No: 1006

sinGaPore: DSM Nutritional Products has unveiled a new laboratory at its Senoko premix plant in Singapore. The laboratory represents an investment of US$1.2 million that aims to meet the demands of growth within the Asia Pacific region by enabling faster response times to the company’s customers, with increased testing capabilities chemical and sample retention and production facilities.

The new 380 sq m facility features a quality assurance and quality control unit that includes a laboratory with microbiological testing capabilities.

The following features can be found in the improved laboratory: • Fume cupboards, certified in accordance with EN 14175, equipped with automatic sashes to enhance safety, ensure excellent ergonomics and maximum economy with the integration of the air flow to the ventilation system of the whole laboratory.

• Ducted chemical storage cabinets to prevent the formation of potentially dangerous explosive atmosphere in the workspace.

• Adequate chemical storage based on chemical compatibility to prevent inadvertent mixing of incompatible chemicals, which can produce harmful gases/vapours, heat, fire and explosions.

• Energy efficient LED lighting and automated light controls at locations with low human traffic.

• Underbench chemical waste disposal units connected to a permanent exhaust air system and equipped with safety trays and electronic level indicators _________________ Enquiry No: 1007

BUSINESS NEWS

NOVEMBER/DECEMBER 2012 ASIA PACIFIC FOOD INDUSTRY

19

INDUSTRY & MARKET

vitablend

Vitablend Opens Production Plant In Singapore

closer to their growing customer base in the Asia Pacific region. Just like the plant in The Netherlands, this facility will provide nutritional premixes, antioxidant and functional blends, mainly for the infant and clinical nutrition industry.

______________________ Enquiry No: 1008

Enhanced emulsion stability, mouth-feel, texture and viscosity. Improved stability, whippability, foam structure and water retention... Palsgaard’s emulsifier & stabilizer systems help you achieve it all.

Our technical teams around the world are experts in emulsifiers and stabilizers for various dairy products and know how to create products matching local tastes and preferences.

Visit www.palsgaard.com to find out how we can help you in your product development.

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Emulsifiers and stabilizers for dairy

Palsgaard Asia-Pacific Ltd. Singapore Phone +65 64 68 69 05 pap@palsgaard.com.sg

Enquiry Number

hooFddorP, The neTherlands: Vitablend, a provider of nutrition fortification and protection solutions, has opened a production plant in Singapore.

Having a production facility in Singapore allows the company to be

“Being in Singapore is a logical step for us,” says Marc Duchene, GM of the company in Singapore. “It fits right into our strategy of wanting to be close to our customers to develop premium and innovative protection and fortification solutions together.

In the last year 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.”

T h e s e t - u p o f t h e p re m i x production lines offer flexibility in producing complex, high care formulations containing vitamins, minerals, nucleotides and amino-acids.

The company made sure to include a dedicated dry clean room at the facility in Singapore to meet microbiological requirements.

BUSINESS NEWS

ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DECEMBER 2012

20

INDUSTRY & MARKET

DaveBleasdale

SPRING Singapore Hosts Productivity Conference

Novelis Opens Can Recycling Plant aTlanTa, Us: Novelis has announced the opening of an aluminium recycling and casting centre at its Yeongju, South Korea, facility.

The Yeongju recycling center is part of a multi-year, US$400 million expansion of the company’s operations in Korea. Asia is the world’s fastest growing market for rolled aluminium used to create beverage cans, cars and consumer electronics.

As a key component of its sustainable business model, the company has committed to increasing the recycled content of its rolled aluminium products to 80 percent by 2020. This project represents the first major step in the company’s plan to increase its recycling capacity to 2.1 million tonnes by 2015.

The new facility will have an annual capacity of 265,000 tonnes, and will increase the company’s total consumption of recycled aluminium to over 1.4 million tonnes per year. Other significant recycling expansions are already underway in Brazil and Germany, along with additional investments worldwide. _________________________________________________________________ Enquiry No: 1009

sinGaPore: SPRING Singapore recently organised the first food manufacturing productivity conference to help local manufacturers deal with the challenge of low automation adoption and lack of economies of scale.

In his opening address, Lee Yi Shyan, Singapore’s senior minister of state for trade and industry and national development, shared the results of a commissioned international benchmarking study that compared Singapore’s food manufacturing industry with 12 other countries, including Australia, Hong Kong, Japan, Taiwan and the UK. He also announced the establishment of the Food Innovation & Resource Centre (FIRC) at Singapore Polytechnic, which will provide food automation solutions and advisory services to food manufacturing companies.

During the conference, Valerio Nannini, MD of Nestlé Singapore, introduced innovative strategies for a sustainable business. Wade Cruse, Southeast Asia head of industrial goods and services practice of Bain & Company shared the benchmarking study results in greater details, while Yoshiteru Wantanbe, chief executive of Watanabe Professional Engineer Office illustrated ways to promote efficiency and automation.

The session wrapped up with a case study provided by Dr Sombat Thiratrakoolchai, VP of Charoen Pokphand Foods.

____________________ Enquiry No: 1010

BUSINESS NEWS

NOVEMBER/DECEMBER 2012 ASIA PACIFIC FOOD INDUSTRY

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company also offers an extensive range of after-sales services. These include the maintenance and overhaul of used machinery, the supply of spare parts, the validation of filling lines, and training programs for machine operators. The company also acts as general contractor for complete filling and case packing lines. ______________________ Enquiry No: 1011

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sTUTTGarT, Germany: Bosch Packaging Technology has closed its acquisition of Ampack Ammann, a filling and packaging machine specialist.

The antitrust authorities have approved the appropriate documents. The contract governing the purchase had been signed in July this year.

Ampack Ammann develops, manufactures, and sells filling and packaging machines for paste-like and liquid food. Employing some 250 associates, the company has generated average sales of some â‚Ź35

million (US$45.36 million) over the past few years. It has been agreed that the purchase price will not be disclosed. The company will remain an independent unit and will be operated as a subsidiary. Its products will in future continue to be marketed under its current name.

Equipment developed by the company includes cup and bottle filling machines, as well as dosing systems and peripheral machinery.

The equipment is mainly used to fill and package highly sensitive food such as dairy products, baby food, drinks, and hospital food, but also dosable food products such as cereals.

Apart from manufacturing its own machines and equipment, the

Enquiry Number

Bosch Acquires Ampack Ammann

Jeremy Keith, Brighton and Hove, UK

INDUSTRY & MARKET

PRODUCT HIGHLIGHTS

ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DECEMBER 2012

22

B&H: Glue Extrusion System B & H Labeling Systems has introduced a patent-pending extrusion glue system (GES) roll-fed labelling.

The GES is comprised of four key components: extrusion tower assembly, dedicated PLC / HMI, all-metal GES vacuum drum, and melt-on-demand glue tank. It can run at speeds up to 600 cycles per minute.

Its closed system reduces glue recirculation by over 90 percent, which eliminates overcooking the glue and damaging its bonding properties.

The PLC-controlled extrusion technology offers accurate control over the placement of the adhesive on a label, the size of the leading and trailing edge glue patterns and the amount of adhesive applied to the label. The GES controls glue laydown weights within +/- 10 percent of the programmed target weight.

It controls the glue pattern placement on the label within +/0.254 mm (0.01 inch) and the glue temperature within +/- one deg F (0.56 deg C). ______________________________ Enquiry No: P1020

Doehler: Brown Flavours Doehler has developed a range of ‘brown’ flavours, ranging from chocolate, cocoa, nut, nougat and coffee to caramel and vanilla. Each of these flavours is available in a diverse range of nuances.

In addition to extracts and natural flavours, a number of compositional flavours are also offered. The product range features a regional focus which appeals to country-specific flavour preferences.

The brown flavours are also available for beverage applications. The spectrum ranges from carbonated soft drinks with lemon-caramel flavour to beer mixes refined with chocolate-cherry-chili-spice, to even a coffee-chocolate energy drink. ______________________________ Enquiry No: P1022

Flexicon: Bulk Bag Conditioner

Piab: Conveyor Line Piab has introduced piFLOWp, a conveyor line that can meet the demands of the food and pharmaceutical industries. The vacuum generated by the line is produced in an energy efficient way by utilising cartridges.

The cartridges are smaller, more efficient and more reliable than conventional ejectors, which allows for the design of a flexible, modular and efficient vacuum system. A vacuum system based on the technology can provide three times more vacuum flow than conventional systems, while reducing energy consumption.

The conveyor line is designed according to USDA and GMP guidelines. All materials are FDA approved and all configurations can be delivered with an ATEX Dust certificate. ______________________________ Enquiry No: P1021

Flexicon’s Block-Buster bulk bag conditioner features a hydraulically-actuated, variable-height turntable for automated in-frame bag rotation and conditioning of bulk bags at varying heights. The number and pressure of hydraulic ram actuations, the height of the turntable, and the degree of rotation are user-programmable.

Two hydraulic rams with specially contoured end plates press opposing sides and corners of bulk bags, loosening material that has solidified during storage and shipment, enabling bulk bag unloaders to discharge it through bag spouts.

The conditioner is recommended for bulk bags containing hygroscopic chemicals, certain spice blends, heat-sensitive products, and other materials prone to solidifying to the point at which pneumatically-actuated flow promotion accessories integral to bulk bag dischargers are inefficient or completely ineffective. ______________________________ Enquiry No: P1023

Enquiry Number

3202

PRODUCT HIGHLIGHTS

ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DECEMBER 2012

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Stable Micro Systems: Linear Indexing System Stable Micro Systems has launched an automated linear indexing system (ALIS). The system automates the testing process, increases productivity, eliminates operator errors and improves operator safety.

The ALIS enables the loading of multiple test samples prior to testing and does not require constant supervision by the user during testing. It can be set up quickly and easily and sample mounting is fast. The system can accommodate and evaluate samples even if they are not spaced regularly.

The system is available in two platform lengths — 250 mm and 600 mm — and has two modes of operation. The platform can either be moved and paused for the testing of each sample, or can be moved constantly at the same speed as the texture analyser’s arm, which is ideal for peel testing, for instance.

It is suitable for a wide range of products, including dairy, bakery, confectionery, meat and poultry, fruit and vegetables, supplements and tablets. _______________________________ Enquiry No: P1024

Meech: Static Bar Meech International has launched a static elimination bar that is designed for labelling, packaging and converting applications, and as an ionised air rinsing system tailored for the food and beverage industry.

Featuring the pulsed DC technology used by the existing 976 bar, the Hyperion 971 is more resilient to the build-up of contamination which naturally occurs during use, and therefore, allows for easier cleaning. Available in a choice of lengths up to 4 m, the bar operates up to 15 KV as a standard and provides effective long range ionisation typically from distances of 200 to 1,000 mm.

The IonRise is a fan-driven system that combines AC ionisation, an airflow distributor and an inner filtration. The control of the airflow coupled with the neutralisation of static charges releases contamination from the container’s inner walls. Contamination is then caught by the vacuum airflow and extracted to an inline HEPA filtration system, capable of capturing 99.99 percent of particles at 0.3 microns. _______________________________ Enquiry No: P1026

tna: Vertical Form Fill & Seal System

Acal BFi: IR Spectrometer

tna has launched robag 3ci, a vertical form fill and seal rotary polyethylene packaging system. The machine can offer efficiencies of up to 99 percent of target output while reaching the speed of 150 bpm.

The rotary jaw design uses advanced impulse sealing technology to deliver quality and consistent packaging with high levels of accuracy. Product waste is reduced due to the optimised product transfer from the multi-head scale through to the jaws. The rotary double flat jaw configuration doubles the throughput in comparison to the standard single jaw packaging systems.

The system offers enhanced ease-of-use as no mechanical adjustments are necessary when changing product or film for a wide range of applications and bag sizes. With a small footprint due to its compact design, the system requires minimal floor space. It also helps to meet sustainability goals through minimal air and power consumption, as well as standby options within the software.

A high-resolution device with response from 1,100 – 1,900 nm, NIRQuest512-1.9 is suitable for applications ranging from monitoring changes in food production and chemical processing to characterising lasers for semiconductor assembly and medical treatment.

The device has a 512-element Hamamatsu Indium Gallium Arsenide (InGaAs)-array detector and is available with multiple grating and optical bench options. The standard version comes with a 150 lines/mm grating, 25 micron entrance slit and a non-fluorescing longpass filter that transmits >1,000 nm. The filter helps to mitigate second-order effects.

The low dark noise characteristics of the device make it possible to integrate the spectrometer (or expose the detector in the spectrometer to light) for longer durations, which is useful in low light level environments. Signal to noise ratio at full signal is >15,000:1 at 100 ms integration time. High gain mode operation is available for applications where sensitivity is paramount.

______________________________ Enquiry No: P1025

______________________________ Enquiry No: P1027

TUV速

Enquiry Number

2781

PRODUCT HIGHLIGHTS

ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DECEMBER 2012

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Mettler Toledo: CO2 Sensor The InPro 5500i offers carbon dioxide (CO2) measurements for brewery and carbonated soft drinks applications. An intelligent sensor management (ISM) functionality has been added to enhance the thermal conductivity CO2 measurement principle.

ISM simplifies sensor handling and increases reliability, leading to increased operational uptime. In addition, a package for combined O2 and CO2 measurements with a multi-channel transmitter is available. This package optimises processes, maintains product quality and controls costs by providing accurate, real-time, continuous measurements.

The device can be installed easily with a choice of process connections. Its hygienic and simple membrane design reduces maintenance efforts, while the absence of moving parts ensures a reduced failure rate and high operational uptime. Immunity to background gases such as oxygen and nitrogen means carbon dioxide measurement is highly selective. ______________________________ Enquiry No: P1028

Baumer: Optic Sensor Baumer has launched a performance category of optical sensors with three sensor types: a diffuse sensor with background suppression, SmartReflect — light barrier without a reflector and a retro-reflective sensor also for reflective surfaces.

The O500 series was developed with a focus on optimising total overall costs without compromising on performance, reliability or convenience. As a result, the sensors feature compact dimensions, through holes and control elements for all sensor principles and technologies within the series.

The light beam is aligned to the fixing holes by design, therefore, minimising adjustment operations. Both provide flexibility to machine and construction companies because the sensor principle and light source can be specified at a later point in time.

The sensors can be taught-in just by touching them with any ferromagnetic tool, such as a screwdriver. ______________________________ Enquiry No: P1030

Cama: Loading Unit RC Cola: Cola Flavours Royal Crown Cola International has launched of an array of flavours in its beverage portfolio for its global bottler network.

RC Kick Cola adds a punch of guarana, an exotic fruit that gives a natural energy boost, to the original cola flavour. Along with guarana, the drink also features an advanced blend of sugar and sweeteners to deliver a taste with fewer calories. Its preformatted packaging designs can be tailored for any market and are available for two and 0.5 litre bottles, as well as 16 ounce cans.

Formulated with exotic refreshments in mind, the RCQ Special Edition Flavors line offers an assortment of flavours including ‘Guava Melon’, ‘Cranberry Acai’, ‘Sicilian Lemonade’ and ‘Guarana’. Each flavour’s packaging incorporates a unique creature character that identifies the specific variant to generate attention in stores and forge recognition. Preformatted package designs are available for both 0.5 litre bottles and 16 ounce cans. ______________________________ Enquiry No: P1029

Cama has developed a range of advanced technology packaging systems specifically engineered to meet the requirements of the food and non-food markets.

The Triaflex series have been added the the company’s Delta robots to enhance its existing range of robotic solutions.

Delta four axis robots with carbon fibre arms are suitable for fact product handling.

The ‘IF’ Monoblock loading unit, a combination of integrated packaging machines and four axis robots, offers reduced footprint, flexible size changing with increased reliability. It is equipped with a simple or multiple conveyors to group and load products into boxes and small cases.

The dynamic box phasing device ensures gentle package handling combined with fast product loading. The robots are guided by an intelligent vision system, which guarantees automatic recognition of various products, according to their type.

The multi-robot application utilises a single controller for the entire line. Consequently, all functions are integrated in one control system, while the number of interfaces and component costs are reduced. ______________________________ Enquiry No: P1031

Progress through innovation

Complete Snack Processing Systems

heatandcontrol.com

Enquiry Number

• Potato Chips; from hard bite to classic • Corn & Tortilla Chips • Taco Shells, Corn Tortillas & Tostadas • Fabricated Chips • Pellet Snacks • Extruded Snacks • Roasted Nuts, Peas & Legumes • Namkeen [Traditional Indian savoury snacks]

3192

Heat and Control is one of the world’s leading manufacturers of snack food processing systems with 60 years food industry experience. Complete systems are provided to deliver the highest quality food products and a combination of experience and expertise and the commitment to innovation and quality, will guarantee world class solutions for product requirement.

PACKAGING & PROCESSING 28

ASIA PACIFIC FOOD INDUSTRY november/december 2012

Labelling For Decoration, Information & Tracking in today’s demanding market, self-adhesive labelling technology offers great opportunities in terms of quality decoration, varied information and product tracking. by david Saluz, project manager of corporate marketing, Pago international

Self-adheSive labelling technology is characterised by a clean and precise application, even at high speeds on the packaging line. Self-adhesive labels offer almost unlimited opportunities in terms of highquality decoration, varied information, functional support and product safety.

These advantages, coupled with precise and efficient labelling, have impressed the hair and body care industry, the demanding p h a r m a c e u t i c a l s i n d u s t r y, the chemicals and household goods industry and the food and drink market.

Self-adhesive labelling brings together high-tech product labelling and product decoration into one package — a combination that few companies throughout the world are able to provide with a high level of quality and service.

Self-AdheSive lAbelS S e l f - a d h e s i v e l a b e l s w e re developed in the US in the 1930s.

After roll goods made machineprocessing possible in the 1950s, self-adhesive labels became a

triumphant success in the packaging world.

In contrast to cardboard and paper labels, which had to be attached using pins, string, staples or wet glue, self-adhesive labels could be manufactured by means of a working process and applied directly to products.

Although card and paper substrates were used to begin with, a wide range of plastic materials quickly came into use. These are equipped with a very thin layer of adhesive and placed on a siliconised backing material.

Soon, the traditional paper and card processing industry developed its own range of label printers. At first significantly influenced and dependent on the textile industry, the self-adhesive label conquered all markets and industries in quick succession. identificAtion lAbelS Self-adhesive labels have long played a much more significant role than that of mere labelling

and identification, although these, the most widely distributed of labels, are used primarily in the logistics and retail sectors.

A wide range of substrates and adhesives enable the labelling of even challenging packages and substances. Various types of information are printed onto thermo material or using thermo transfer coloured ribbon, and can be reliably collected and processed by data management systems.

Even integrated electronics, radio frequency (RF) and radio frequency identification (RFID)

november/december 2012 ASIA PACIFIC FOOD INDUSTRY

PACKAGING & PROCESSING 29

haptic, golden or silver relief structures are just a few of the many quality finishing options for decorative labels. informAtion lAbelS Various kinds of information labels enable extensive user information to be permanently attached to the product in a space-saving way.

Multi-page booklets enable instructions for use, hazard information, consumer information and corporate data to be clearly and concisely displayed in a number of languages.

Leaflet labels or Leporellos can be unfolded easily and offer space for information or promotional campaigns.

implementations are now state of the art. decorAtive lAbelS High-quality decorative labels are characterised by a range of finishing techniques. The art lies in combining various printing processes, such as relief printing, intaglio printing, screen printing, offset and digital printing, onto a wide range of materials with embossing, painting, lamination and layering.

The no-label look, metallic effects, shimmer and shine, holographic and 3D effects and

Shrink SleeveS In addition to self-adhesive labels, shrink sleeves have also been a primary means of decorating products since the 1960s.

This involves printing on film, forming it into a tube and then placing it around the products.

The sleeves are shrunk to fit the package using warm air or steam, thus giving the products attractive decoration all the way round. lAbelling technology At the same time as the shift from standard labels to self-adhesive labels in the 1950s, there was also a revolution in application methods.

Product labels, that had up until then been mainly applied by hand, could now be affixed precisely and efficiently thanks to self-adhesive labelling technology. In contrast to wet glue applications, the dispensing

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ASIA PACIFIC FOOD INDUSTRY NOVEMBER/DECEMBER 2012

System controls enable the labelling system to be individually configured with regard to machine handling and integration into comprehensive packaging systems.

30

process for self-adhesive labels was cleaner and left no sticky residues in the packaging area or on the product.

LABELLING SYSTEMS In linear labelling systems, the products are transported around the system in a linear fashion.

This usually takes place using a conveyor belt and a variety of support systems.

Labelling that takes place

u s i n g s u i t a b l y c o n f i g u re d systems will label the product from above, below, at the sides or all the way round. Various machine configurations can be used, depending on the product characteristics, the labelling requirements and the desired service.

For the labelling process itself, additional product labelling and efficient handling of the label rolls are key process steps when operating a labelling system.

Regardless of whether it is the complete or partial all-round labelling of cylindrical products or the labelling of asymmetrical product shapes that is required, the top priorities are always precise product transportation and accurate, targeted application of the labels.

System controls enable the labelling system to be individually configured with regard to machine handling and integration into comprehensive packaging systems.

In the case of rotary systems, the products are transported in a rotary star. Fixed in place on rotating plates, they are configured precisely and can be labelled from the sides, thanks to the rotary star.

Labelling from below and above is not possible with this kind of product conveyance.

However, the transportation and rotation of the products on the rotary star offers optimal performance when labelling.

This is a crucial competitive advantage, especially in the drinks industry and the hair and body care industry.

MARKING & TRACKING SOLUTIONS The linking up of the labelling process with specific control or serialisation requirements is becoming increasingly important in industries where quality is paramount.

International regulations are mandatory in the pharmaceuticals industry, food and drinks sector and also for technical chemical applications. However, tracking and tracing is also incredibly important in terms of the logistics for the flow of all kinds of goods.

The trackability and identification of products is a major requirement in the industry.

Complex data management and open system solutions require extensive software expertise in packaging and logistics.

Software solutions for the flow of goods, combined with corporate resource planning tools, are increasingly forming a complementary part of labelling and identification technology.

For more information, ENTER No: 1040

Fast beats slow Effective warehouse design means short routes for goods and staff. Using containers in conjunction with intelligent conveyor systems speed up and optimise logistics operations. We show you how to become fast, flexible and efficient. Contact us, we will gladly advise you.

P: 65/6863 0168 路 E: regionalmktg@ssi-schaefer.sg 路 www.ssi-schaefer-asia.com

Enquiry Number

3173

PACKAGING & PROCESSING 32

ASIA PACIFIC FOOD INDUSTRY November/December 2012

AccountAbility Tracking WiTh compleTe Vision law enforcers and manufacturers alike can turn to image-based technology to keep out counterfeit products and trace supply chain violations to the source.

By didier lacroix, senior VP, Cognex

EarliEr this year, toxic fresh produce made the headlines in China in a string of food scandals that rocked the country’s food industry. Inhabitants in Shandong province were surprised to discover that cabbages sold in the market had been tainted with formaldehyde, according to a report by China Daily Mail in May. It was later discovered that farmers had sprayed the vegetables with the chemical to keep them from turning bad in the hot weather.

HealtH Hazard The toxic compound is known to cause cancer and is commonly used as a disinfectant and for embalming, as explained by BBC News. Formaldehyde

is also a skin irritant and can cause other health-related issues like difficult breathing and digestive problems.

The same month saw another scandal take place, with the culprit this time being fake stewed pig ears, as reported by China Daily. The food item is a popular snack that was sold at a market in Ganzhou, a city in Jiangxi province. Investigations revealed that the pig ears were made from gelatin and sodium oleate. The latter is a banned substance for food, while the former could be poor-grade or industrial gelatin — given the low price of the pig ears.

While these examples are stark reminders of the need for stronger law enforcement and harsher

penalties to be meted out to offenders, technology too can help play a pivotal role in keeping food from dubious sources out of the supply chain.

By adopting barcode technology, the different parties at various levels in the chain can help to establish accountability to ensure that only legitimate products enter the supply chain.

A small-scale project has been conducted to demonstrate the effectiveness of barcode technology in the supply chain.

One of the goals of the project was to create a system to track beef from farm to fork. It has been reported by AGWeek that the University of Michigan supplied a small herd of cows, which were slaughtered for their

PACKAGING & PROCESSING

November/December 2012 ASIA PACIFIC FOOD INDUSTRY

meat. The frozen meat packages were tagged with barcodes and made their way back to the residence halls.

Besides serving as a means of authenticating the source of the meat, it was also noted that shoppers in future could use a smart phone or kiosk to determine whether the meat came from grain-fed, grass-fed or hormone free animals. Furthermore, steps are being taken to apply 2D barcodes, which contain more information on the animal and how it was processed.

This case study demonstrates how a food supply chain can be set up to ensure traceability and accountability, while adopting technology to support these goals. By implementing these mechanisms on a larger scale, barcoding food products from the source could, at least to some degree, provide a means of preventing substandard products from entering the supply chain.

KeePing traCK Besides applying the technology upstream at the supplier level to allow manufacturers to trace sources of ingredients and raw materials, it can also be adopted within the manufacturing facility to track production progress.

An image-based barcode re a d i n g s y s t e m c a n h e l p manufacturers to determine the location of a product, raw material or work-in-progress in the facility. Besides location tracking, the system is able to capture and store data pertaining to the processes and production stages that an item has already passed through.

A n i m a g e - b a s e d re a d e r acquires the image of an entire package’s readable surface and locates the barcode. This means that the position and orientation of the code are no longer a

Barcodes can be printed directly on a package, which eliminate the need to manually apply a label on each item.

roadblock to a successful read.

In comparison, it often requires multiple laser scanners to be configured together to read barcodes in applications where orientation is not repeatable.

Barcodes can also be printed directly on a package, which can save the manufacturer time by eliminating the need to manually apply a label on each item. Since the code can be positioned at any location on the package, it is possible to meet specific customer requests to place the code in a specific position.

2d Vs 1d Food manufacturers are making the transition to 2D codes, such as Data Matrix or QR Codes.

Compared to 1D barcodes, a greater amount of information can be encoded in 2D codes to help with product traceability throughout the manufacturing process and the supply chain.

In certain situations, 2D codes are used in conjunction with 1D barcodes in the production process. For manufacturers who have invested in a laser scanner based system, this becomes a problem as their system cannot understand Data Matrix or QR

codes. In contrast, image-based readers can effectively and reliably read both types of codes as well as 1D barcodes.

Some of the most challenging to read 2D codes are those that are printed directly onto a part (also known as direct part mark or DPM). By using laser etching or dot peening methods, these codes are marked onto the part to create a permanent DPM. Even codes that may be difficult to read due to poor marking, or marking on a curved surface, can still be reliably read with advanced reading algorithms.

Another advantage of imagebased readers is that the system can be programmed to store images of codes that have been read. Images of failed reads can be analysed later to determine the causes and be used to improve the barcode printing processes.

ComPlete VisiBility A certain facility processes meat products such as pork, beef and chicken in a range of packaging options. The meat is processed, packed into boxes and moved down a conveyor line into a refrigerated warehouse. For the manufacturer, it is vital for

ricardo, London, UK

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Contract manufacturers of food products can benefit from a vision-based code reading system.

them to have complete visibility of the product as it moves out of the building and into the storage area.

A 1D linear barcode was previously applied to each package at the slicing station.

A l t h o u g h a l a s e r b a rc o d e reader was used to track the movement of products in the facility, the system suffered high rejection rates.

A contributing factor to this problem is the speed at which the line runs — about 200 feet (60.96 m) per minute. Furthermore, the packages come in many shapes and sizes and could present themselves at different angles to the scanner. Since the labels themselves could be placed at different locations on the box as well, this made it difficult for the laser scanner to accurately read all the packages.

Despite making adjustments such as investing in barcode printers and readers and changing the process for applying labels, a successful read rate beyond 93 percent could not be achieved.

There were also situations where the scanner failed to read a label

even when the latter appeared to be letter-perfect to the human eye.

Given the production capacity of about 25,000 boxes per day, a rejection rate of seven percent was unacceptable. solution in sigHt The facility owner eventually decided to try out image-based code reading technology. Readers were deployed to read existing linear barcodes and successful read rates saw an immediate improvement to 98 percent.

After switching over to 2D barcodes and tuning some of the hardware, the facility managed to achieve 99.99 percent read rates.

In the final installation, the decision was made to implement two reader units to achieve c o m p l e t e re d u n d a n c y a n d to ensure 100 percent reading success. The only boxes that cannot be read now are those where the codes are missing or severely damaged.

Contract manufacturers of food products can also benefit from a vision-based code reading system. A producer of canned soup for example, makes large

volumes of a particular product, such as chicken soup. The soup is packaged into unlabelled cans, which are moved into a warehouse until a customer order is received.

Once this happens, the cans are labelled with the corresponding customer’s private brand label just prior to shipment. As the frequency of cans moving on the production line is one can every 60 ms, conventional human-eye inspection is not feasible.

Initial efforts at applying machine vision to the setup involved connecting a camera to a frame grabber board on a computer. The problem was that the hardware was not designed for a factory environment, as the cameras and frame grabber boards were susceptible to heat and dust. A considerable level of expertise is also required to set up and maintain this type of system — expertise that is typically not found in a canning plant.

A vision system was eventually implemented to inspect product codes against the bright reflective background of the cans, at a rate of 1,000 products per minute. The pattern matching tool inspects the product code and recognises a pattern regardless of where the barcode is located.

Instead of trying to read individual characters, the application is configured to simply look for an image that matches the three-digit product code.

Matching the images of the product codes has proven to be a more reliable and robust solution than attempting to convert the images into characters.

New product codes can be configured by simply putting a can carrying the new code, in a position where it can be viewed by the vision system. After this, a rectangular box is positioned

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LE I B

ligHt influenCe Machine vision systems create images not by studying the object itself, but by analysing the light that is reflected from an object. It is therefore important to understand how light is reflected from an item that is being inspected.

Light that strikes the object and that is reflected towards the camera, causes the object to look bright. When light is reflected away from the camera or absorbed by the object, the latter appears dark. A machine vision system typically focuses on the differences between light and dark areas to make conclusions about edges, textures or markings that are critical parameters in an inspection process.

Since different surfaces can affect image creation, it is necessary to understand the properties of the material that the object is made from, such as its size, shape and surface finish.

The colour of an object also affects the image, even if the inspection system is monochromatic (eg: a red surface

will reflect light differently from a pink one). Since these characteristics af fect how light is reflected, they could present challenges in creating a good image. Determining the correct amount of light for the application can provide the solution to a seemingly difficult application.

A good image is the result of proper focus and illumination.

Images with poor contrast and uneven illumination require greater effort for the imaging c o m p u t e r p ro c e s s , w h i c h eventually increases the processing time, and can result in a larger number of incorrect image analyses. In most cases, high contrast images are the easiest to process.

A good image processing system would be capable of recognising images of varying contrast levels. The issue here is repeatability, the ability to consistently recognise images of a much lower contrast. Once illumination can be properly controlled, the machine vision system should be able to process the images easily and with a high degree of reliability/repeatability.

For more information, ENTER No: 1041

- high performance in small space 14 for all kinds The industrialDaimlerstr. inkjet printer of non-contact marking and coding

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around the product code. The vision system is able to detect the product code even if it is in a different position or at a different angle, as long as it is in the camera’s field of view.

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A good image processing system would be capable of recognising images of varying contrast levels.

NG E R

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The

Barcode PersPecTive

Despite competition from other forms of tracking technologies, the barcode has held its own for the past few decades. The correct implementation of barcoding technology can increase efficiency and eliminate almost all aspects of human error.

By Umesh Cooduvalli, senior product manager, DatamaxO’Neil When ‘traceability’ is mentioned in the context of food safety, the issue of product recall often comes to mind. The response is understandable considering the fact that cases of salmonella contamination and E coli outbreaks make it to the news quite regularly these days. The ability for manufacturers to track

and trace the origin, movement and destination of ingredients or products is therefore increasingly important, so that they can quickly identify the source of a breakout and promptly fix the problem.

For the most part, food & beverage (F&B) manufacturers do see the need and take the responsibility (whether or not

the law requires it) to ensure their products are labelled properly with the right technology for tracking. However, the challenge that some face is in finding the best equipment to take care of creating the actual labels.

BarCODe BasiCs One of the primary tools that is most commonly used by food manufacturing enterprises as a track-and-trace solution is the barcode technology. Within the food industry, companies typically use thermal transfer printing technology to create barcodes, as barcodes printed on product labels will last through food expiration dates.

Having been in use for nearly 40 years, barcoding has gone through many stages of development.

Though newer technology such as RFID tagging exists, barcoding still dominates, and is by far the simplest, yet perhaps most effective form of labelling in the food manufacturing sector.

While several standard barcoding systems exist on the market, one format is more predominantly used by food manufacturers — the GS1 DataBar. GS1, an international not-forprofit association, has managed

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37

to ‘unify’ supply chains globally by getting businesses to adopt its system of barcode standards.

The predominance that the GS1 DataBar has gained is largely due to the fact that its barcodes hold more data in a smaller code when compared to other standards (such as the Universal Product Code (UPC) or European Article Number (EAN) barcodes).

For the food manufacturing industry, GS1 DataBar allows for GTIN (Global Trade Item Number) identification on variable-measure and hard-to-mark products such as fresh produce. The barcode can also hold GS1 application identifiers like serial numbers, lot numbers, and expiration dates. This supports product authentication and traceability for not just the fresh food products,

but for marketing coupons as well. The use of the barcode has fundamentally helped to improve efficiency and visibility of supply and demand chains.

PriNTer TreNDs & esseNTials Across Asia, a majority of food manufacturers are small to medium enterprises (SMEs) that do not require high-end

Portability ranks high in key features of industrial barcode printers.

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Plate Heat Exchanger

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industrial printing equipment for creating barcode labels. In this respect, it is important for these manufacturers to consider their true needs in terms of functions and benefits for selecting an industrial barcode printer.

For the F&B industry, the best industrial barcode printers possess a number of key features, and portability ranks quite highly amongst the top few. Portability tends to be a key concern for many food manufacturing SMEs, since variability and changes in production line processes can be the norm. Manufacturers look for portable printers that have rugged construction and that can withstand multiple location changes, which may sometimes happen within a day.

Another essential characteristic is heat management. As lots of heat is produced in a manufacturing setting, a barcode printer used for F&B applications needs to automatically adjust to optimum heat and speed levels, yet still be able to produce prints of top quality. Printers that consume less power are less likely to overheat as well.

Of late, more barcode printers are featuring lower power consumption, with some using up to 25 percent less energy than others in the same class and category. Furthermore, some printers feature print heads that are made with durable coating material, have better abrasion resistance, and that can last longer before replacement is necessary.

In the fast-paced food manufacturing industry, it is no wonder that speed needs to be factored in as well when choosing a barcode printer. Industrial printers that offer faster processing speeds with larger memories will be preferred over slower counterparts.

For ease-of-connectivity with other systems in production lines,

In a busy factory setting, a printer should enable user-friendly label configuration set-ups.

barcode printers with a wide selection of communication ports ranging from serial, to parallel, USB, LAN and W-LAN will be most popular with food companies. laBels & iNfOrmaTiON CaPTUre Tracking and tracing to a food source can take time, so when time is of the essence due to supply chain complexity, labels need to contain enough pertinent information that will allow the shortest track for food manufacturers to locate the right product as quickly as possible. In this respect, product identification information, expiration dates and time stamps, as well as shipping labels, all need to be printed well and clearly affixed onto food and food packaging alike.

Where printers are concerned, ease-of-use to change label designs or edit information on labels will be important considerations for food manufacturers. Within a busy factory setting, even seemingly unimportant features such as the graphical display on a printer should be easy to read and should enable user-friendly label configuration and set-up.

Since barcode readers also come in varying shapes and functions, it is important that

and quickly.

barcode labels are printed in highenough resolution and quality to ensure that whatever barcode reader is used at the products’ destination will be able to capture the right information a c c u r a t e l y

fUTUre Of fOOD TraCiNg Despite the emergence of newer and better technology (such as RFID tags), barcoding has remained the de facto standard across many industries worldwide. The food industry, in particular, has reconciled barcodes and RFID as complementary technologies even though there are slight overlaps in their functionalities.

Ultimately though, what defines the value of barcoding for any application will be its implementation. If used correctly and with the right equipment on hand in food manufacturing facilities, barcoding has the ability to increase efficiency and eliminate almost all aspects of human error, simply by automating the full data collection process in food tracing.

What’s left for the industry to do then, is to push for faster, more portable, power-efficient, and user-friendly barcode printers and related equipment than ever before.

For more information, ENTER No: 1042

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3183

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IN

EVERY SIP

the beverage industry is a competitive, dynamic and innovative segment that is constantly on the lookout for the next big thing. to stay ahead, manufacturers will have to create a ‘fresh’ and sensational experience with their products. By angie ng and vv lee, regional product managers, dupont nutrition & health THE beverage industr y is a competitive, fun, energetic and innovative segment that is always on the lookout for the next big consumer trend. In recent years, the increased awareness of health and well-being, as well as rising incomes, especially in the developing markets, have become important factors in driving the beverage market to new heights of innovation.

Beverages are excellent vehicles to deliver functional ingredients and market new and exciting product concepts, possibly due to the high convenience factor and availability of beverages to purchase on the go. emerGinG marKet trends Consumers are constantly looking for new beverages with added value in this novel segment,

particularly relating to health, nutrition and wellness. Some of the emerging market trends driving the beverage sector are listed below.  Natural and ‘naturally rich in’ continue to grow (antioxidants, fibres, etc.)  ‘Light’ and ‘low sugar’ products continue to rise  Added fibre is increasingly popular  Juice-type beverages formulated with real fruit and pulp are also popular, usually perceived to be better-for-you  Focus on mental functions (energy, relaxation, brain activity, etc.)  Anti-ageing, anti-tiredness health claims  Satiety and weight control (fat burners, blockers, appetite suppressants)

staBilisers in BeveraGes Beverages need to be visually appealing in addition to providing excellent taste, regardless of the kind of fruit, pulp concentration or flavours used. The consumer’s experience of the beverage prior and during consumption is very important because it affects the overall impression of the beverage. This means that the sensory experience must be able to meet the consumer’s expectation of the beverage.

Adjustment of sensor y properties could involve the fine-tuning of body and fullness, freshness, clean mouthfeel properties and flavour release.

Regulating these parameters relates to controlling viscosity at various shear rates. This is because when a beverage is consumed, it is exposed to different mechanical actions in the mouth. Some of the commonly used stabilisers include xanthan gum, pectin, cellulose gum, guar gum and microcrystalline cellulose. All of these can be included in the

 particles can be suspended while the beverage is being filled at higher temperatures  allowing bigger and denser particles to be used in the formulation  ability to suspend the particles in reduced solids recipes Such customised solutions can also be developed to suit Asia’s predominantly tropical climate, where suspension performance is under particular stress.

developinG palataBle Functional BeveraGes Traditional beverage manufacturers may use sucrose as the major sweetening agent and these products are considered the gold standard for flavour delivery and mouthfeel. Sucrose provides sweetness, mouthfeel/ body and flavour characteristics that are not easily imitated by substitutes. Health and cost concerns have led to increasing interest to remove sugars from drinks and replacing them with non-nutritive sweeteners.

The use of high-intensity sweeteners alone in sugarfree beverages is widespread.

However, compared to full sugar beverages, such sugar-free versions often lack mouthfeel.

Stabiliser systems or single hydrocolloids are often used to replace the loss of mouth-feel in a cost-effective way. Apart from stabilisers, bulk sweetener ingredients also offer food manufacturers an alternative to replace sugar, yet remain competitive by maintaining cost of use. In addition, such ingredients can also improve the nutritional profile of the products.

Fructose is a naturally occurring sugar, sometimes referred to as ‘fruit sugar’, and is 1.4–1.8 times as sweet as sucrose. It has great sweetening and flavour enhancing properties.

Fruit, chocolate and coffee flavours are all enhanced by the addition of fructose.

Partial replacement of sucrose with crystalline fructose in the formulation is a straightforward but effective way to reduce energy and sugar whilst enhancing f l a v o u r, b o d y ( s w e e t n e s s mouthfeel) and maintaining cost of use in beverages. Fructose is also metabolised independently of insulin, making it a very useful

Enquiry Number

formulation depending on what functional properties and end beverage type are desired.

The highly competitive fruit beverage market segment has raised consumers’ expectations for a more ‘natural’ feel with higher nutritional value for products containing fruit pulps and fruit bits. The sedimentation of pulp, particles and cloud material is a common phenomenon in beverages with high fruit pulp solids content.

This occurs over a certain storage period and the result is a nonhomogenous product with an unattractive appearance.

This trend has called for m o re ro b u s t s o l u t i o n s t o help suspend the pulps and particles, without compromising the viscosity of the finished product during transportation and while products are on the retail shelves.

Stabilisation and suspension can be achieved using stabiliser systems with a high yield value.

Stabilisers are able to create a three-dimensional network in the beverage liquid phase and this helps to promote the suspension properties.

There are various solutions available to help meet the needs of the beverage processor to allow flexibility in production, where:

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relative sweetness

Flavour enhancement properties of fructose.

Flavour release is enhanced

Fructose

sucrose can help mask bitter offnotes

time ingredient in the development of low glycaemic index (GI) products that are suitable for diabetics.

I n a d d i t i o n , t h e U K ’s Leatherhead Food Research has found that crystalline fructose also shows synergistic effects with sucrose. The greatest synergistic effect was seen at 30 percent reduction of sucrose and replacing it directly with fructose, with an increase in sweetness intensity of 45.5 percent.

Although crystalline fructose is typically more expensive than sucrose on a per kg basis, due to its sweetness enhancing abilities, there are opportunities in maintaining the overall cost of product formulation by substituting some of the sucrose with crystalline fructose.

The mouthfeel profile can be improved through the addition of small amounts (as low as <0.5 percent) of polydextrose.

Polydextrose is a randomly bonded polymer of dextrose. It is non-crystalline, but its high solubility and low viscosity in solution makes it a valuable ingredient for providing mouth feel and fibre content. With an energy value of just one kcal/g, it can be used in sugar free and low calorie beverages. Polydextrose is also suitable for incorporation into diabetic products.

While it adds bulk and provides a fuller mouthfeel to enhance taste perception, polydextrose has a clean taste and helps to enhance the taste profile of the final product by masking

relative sweetness

Sweetness profile of fructose and sucrose blend.

50% Fructose and 50% sucrose a blend of fructose and sucrose can increase sweetness perception and flavour intensity.

time

some unpleasant aftertaste.

Furthermore, polydextrose is considered as a dietary fibre and prebiotic in most markets.

Faced with growing calls to play a more active role in tackling the global obesity epidemic, m a n u f a c t u re r s c a n re t a i n maximum formulation flexibility when using polydextrose. It is an extremely straightforward ingredient to formulate with due to its high solubility and stability.

It is very well tolerated and has been used in the food industry for over 30 years, recognised for its ability to facilitate nutrition and health claims in a diverse range of food and beverage applications, without negatively impacting taste and texture and therefore, the end product appeal too.

‘Fresh’ & sensational experience It is imperative for beverage manufacturers to constantly look for ideas to innovate and renovate so that they can offer consumers t h a t ‘ f re s h ’ c o n s u m p t i o n experience. The potential of functional beverages cannot be underestimated and this is the demand of many consumers today.

Functionality is definitely here to stay, but consumers are also increasingly looking for drinks that are ‘natural’.

The challenge for beverage manufacturers today is to create drinks with the desired nutritional benefits and flavour profile, whilst still providing a pleasant all-round organoleptic experience. There are various solutions and alternatives available to help processors innovate and sensationalise their beverages to taste as well as look good.

For more information, ENTER No: 1050

With IFF’s FlavorFit™ portfolio of custom technologies, our experts use proprietary ingredients, sodium-reduction technologies and umami enhancements to create healthier soups, snacks, and prepared meat and chicken products with the authentic, savoury flavours people crave — and keep coming back for.

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less.

Consumers may want less sodium, fat and added MSG in their diets, but it’s taste that still excites them.

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delightfully

44

Power of

theBran

McKay Savage, London, UK

With its plethora of benefits, rice bran is taking a leaf from whey protein in becoming a valuable ingredient from a waste by-product.

The second of this two-part series will discuss some possible applications of rice bran.

By Henk Hoogenkamp From a technological point of view, the stabilising properties of rice bran are very interesting and have shown capabilities in a wide range of further processed meat products. In most cases, adding a relatively small percentage allows this all-natural ingredient to wholly or partially replace materials commonly used, such as carrageenan, soy protein, modified polysaccharides and starches, while eliminating chemical-sounding E-numbers on labels which concern more consumers.

The combination of these ingredients, while maintaining all its natural origin, results in the ability to control purge in formulated meat products, increase water retention, and improve cooking yields throughout the thermal processing cycles.

There is no need to mention confusing E-numbers or chemically sounding names on product labels. Rice bran is a label-friendly, ecologically sound healthy ingredient that provides low-cost,

ASIA PACIFIC FOOD INDUSTRY November/December 2012

sustainable nutrition and applications for a rapidly increasing world population. US-harvested rice bran is GRAS, non-GMO, all-natural, hypoallergenic, kosher-parve and halal. It is expected that in the future, rice bran stabilisation facilities will be built in the major rice producing regions like China, Vietnam and Thailand.

From moisture management to being an unimposing carrier in seasoning blends, the ability of rice bran to outperform other ingredients while maintaining similar water activity levels is unparalleled. Subsequently, rice bran can be considered an essential ingredient for moisture management and nutrition across a wide variety of applications, while delivering high quality, great taste and least-cost options In its very basic condition, defatted rice bran is a cost-effective option for use as filler in processed meat products and a stable source of fibre in whole grain foods such as cereals, crackers and batters.

Defatted rice bran is also used as a fermentation accelerator, which can generate pre-and probiotics.

Rice bran is increasingly seen as an inexpensive ingredient to create or prepare trans fat-free foods, such as ‘healthy’ mayonnaise, salad dressings, batter and breading for coated foods.

Rice FiBRe Rice fibre is a carbohydrate polymer with three or more monomeric units. The characterising elements of fibre are that they are neither digested nor absorbed in the human small intestine.

Therefore, fibres belong to the following categories:  Edible carbohydrate polymers naturally occurring in food and beverages  Edible carbohydrate polymers that have been derived from food sources by enzymatic, physical or chemical treatment or processing  Fibres should have a beneficial physiological effect and are wellresearched for long-term use and benefits Rice bran oil is generally considered to be on the higher end of the quality spectrum of vegetable oils in terms of colour, cooking stability, cooking temperature, fatty acid

McKay Savage London UK

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INGREDIENTS & ADDITIVES 45

composition and high levels of antioxidants, including tocotrienols and phytosterols. Along with oleic and linoleic fatty acids, these compounds are linked to lower cholesterol levels.

William Neuheisel, Washington, US

Pain RelieF Beyond its potential applications in the food chain, rice bran has many bioactive extracts and components that show potential in health foods, cosmetics and pharmaceuticals.

Increased intake of whole grains and bran, in particular, may reduce the incidence of hypertension. Compelling indications show that rice bran and its fractionated extracts or compounds will move beyond the explorative stage within a few years and develop into serious remedies for conditions like inflammatory relief associated with osteoarthritis and rheumatoid arthritis, immune boosting and anti-viral effects.

Arthritis is especially targeted since it is a debilitating disease that affects one in five adult Americans or about 42 million people. By 2020, that number may reach 60 million and the European Union will not lag far behind.

Rice bran extracts and compounds show inhibitor y activities against the key proinflammatory enzymes cyclooxygenase (COX) and lysyl oxidase (LOX). Arthritis is an inflammation of the joints that can develop into a chronic condition involving swelling, pain and restricted movement.

Osteoarthritis or rheumatoid arthritis may result from a deregulation of pro-inflammatory cytokines as well as COX and LOX enzymes.

Rice bran extracts show strong promise for safe and effective treatment of arthritis. There is little doubt that specially formulated lifestyle foods targeting the growing numbers of arthritis sufferers will become an important new category.

inTRiguing SoluTion Rice bran is a hypoallergenic, cold water functioning and performing solution that boosts stabilising and texturising properties. It also offers cost optimisation that helps food formulators upgrade to a clean label and additive free positioning for their products.

Rice bran protein offers instant viscositymodulation properties, stability and texture to a broad range of processed food and meat products.

The powdered functional ingredient rapidly hydrates and disperses in water without lumping to deliver a unique harmonisation with other support ingredients, such as added protein and starch. Its process tolerance ensures good resistance to a wide pH spectrum, shear and heat variations during processing.

Rice bran has a slight nutty, honey-like flavour that allows the richness and diversity of flavours to prevail in a range of quality convenience foods.

Food and meat processing today is confronted with a number of health considerations and emerging challenges: sodium reduction, fat replacement, meat protein alternatives, protein fortification and green-label messaging. Rice bran provides at least some of the answers.

The ingredient has solid authenticity and is globally recognised, ranking among the most consumer-friendly ingredients. Rice branâ&#x20AC;&#x2122;s natural origin will become a significant marketing tool as the trend towards clean and environmental-friendly labelling intensifies. Already popular in dietary supplements and functional foods, rice bran is now increasingly crossing over into mainstream foods.

Rice bran protein offers cost-effective functional properties like enhancing and stabilising meat emulsions and coarse-ground meats, such as burgers and patties. Equally important, the ingredient has a friendly eco-footprint and environmental image that is reflected in label declarations on food packaging.

Because rice bran protein retains moisture, it improves the shelf life of meat products, enhances the nutritional profile, and adds fibre.

Both soluble and insoluble fibres are naturally present in rice bran, making it likely to become the choice ingredient for products targeting a health-conscious niche. Along with helping meat processors develop healthier formulations, the use of rice bran protein can generate significant cost savings, compared with expensive alternatives such as soy protein and mustard flour.

Rice BRan oil The crude rice bran oil is composed of 88 percent

INGREDIENTS & ADDITIVES

ASIA PACIFIC FOOD INDUSTRY November/December 2012

Southern Foodways Alliance, Mississippi, US

mathiasbaert, Brussels, Belgium

Deb Nystrom, Michigan, US

46

Rice bran has potential to be used in a wide range of applications.

neutral lipids, four percent unsaponifiables, and two to four percent free fatty acids. The unsaponifiable fraction is of great interest since these include a mixture of naturally occurring antioxidant compounds, such as vitamin E and gamma oryzanol.

Hexane is usually utilised as the solvent to extract the rice bran oil from the rice bran. Furthermore, short chain alcohol like ethanol and isopropanol can be used as an alternative to hexane. In general terms, alcohol extracted or ethanol extracted rice bran oils yield higher amounts of unsaponifiable compounds and tocopherols (vitamin E) and vitamin B. By limiting the free fatty acid content in rice bran oil, the colour can be improved. Hence, it is likely that hexane extraction ultimately has too many drawbacks. It can then be expected that ethanol or alcohol extraction will be used in combination with enzymes to improve yield and quality.

Rice bran oil includes highly valuable minor components, such as gamma oryzanol, tocopherols, tocotrienols and phytosterols. The recovery yield of these minor components is greatly influenced by the method of refining, ie: chemical or physical refining. During deodorisation, the highly volatile fractions like phytosterols and tocotrienols are removed while the non-volatile gamma oryzanol is further fractionated.

Physical fractioning or refining will be the

method of choice for premium rice bran oil production. Physical fractioning is a process that is not only free of environmental impact but also safe and simple, providing quality oil with good colour and virtually no odour.

Gamma oryzanol contains ferulic acid esters and is known to be a very effective antioxidant even at high temperatures. It has been demonstrated that gamma oryzanol is four times as effective as vitamin E at inhibiting cellular oxidation.

Rice bran oil has hypocholesterolemic influence with decreased low density lipoprotein (LDL). This effect is due to the presence of high concentrations of unsaponifiables including phytosterols, oryzanols and tocotrienols. The potent antioxidative properties of gamma oryzanol also act as a protective agent against UV light.

The ferulic acid present in oryzanol prevents or slows down skin damage or ageing. Also, the presence of tocotrienols has a very positive effect on skin and can be considered a first line of defense, as they neutralise or stabilise the free radicals generated in the skin when exposed to UV rays.

Because these compounds can penetrate the skin quickly and get absorbed rapidly, they can help in skin repair.

For more information, ENTER No: 1051

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WITH LESS FATS

IN recent years, there has been an increased focus on the amount of saturated fats present in food products, both from an economical point of view due to taxation on saturated fats and for health reasons. This has put a demand on the producers to develop ice cream with a healthier profile, by using healthier ingredients or by reducing the content of the less healthy ones.

Emulsifiers, mono- and diglycerides, can be used to help manufacturers reduce the amount of saturated fats in ice cream. fAt tyPes Fat is a key ingredient in ice cream. It plays a major role in building the internal structure of the ice cream, as well as providing creaminess and smoothness.

Traditionally, coconut and palm kernel oils have been used for the production of ice cream.

These oils have a high content of saturated fat â&#x20AC;&#x201D; coconut, 92

Janet McKnight, Oxford, UK

Magnum ice cream

reducing the amount of fats in ice cream without compromising on texture and taste is a challenging affair. Mono- and diglycerides emulsifiers may just be the trick. by claus Prior Hansen, application scientist, Palsgaard.

Extruded ice cream 1 - layered

eQuAL ricHness

percent, and palm kernel, over 80 percent.

This high level of saturated fat gives the fats a good ability to form the internal structure of the ice cream. However, when the level of saturated fat is reduced, the fat becomes softer. This makes it more challenging to produce ice cream with a good structure and the desired eating quality, without making adjustments in the rest of the ingredients, such as the emulsifier and stabiliser systems used.

The fat and the emulsifier

used in ice cream both play a role in building the internal structure that stabilises the ice cream. The emulsifier is added to reduce the stability of the ice cream emulsion. This makes it easier for the emulsion to partly break down and for the fat globules to make a partially coalesced structure once the ice cream emulsion is being whipped in the ice cream freezer.

This partially coalesced fat structure stabilises the air bubbles inside the ice cream, making the ice cream more smooth. Additionally, this partially coalesced fat structure has a great influence on the melting properties of the ice cream. set uP A study has recently been performed to investigate the effects of different types of mono- and diglycerides on the stabilisation of ice creams with reduced levels of saturated fat.

In the study, three different types of mono- and diglyceride systems were tested: fully saturated mono- and diglycerides (FS), partly unsaturated monoand diglycerides, containing trans fatty acids (PuS-T), and partly unsaturated mono- and diglycerides, without trans fatty acids (PuS-nT).

The different vegetable fats used in the study were all without trans fatty acids: vegetable fat with 92 percent saturated fat (reference fat), vegetable fat with 50 percent saturated fat (Fat 50) and vegetable fat with 40 percent saturated fat (Fat 40).

The heat shock (HS) method was applied on the specimens, which were stored at -10 deg C for four days before undergoing further storage at 20 deg C. The combination of the three different mono- and diglyceride

INGREDIENTS & ADDITIVES

November/December 2012 ASIA PACIFIC FOOD INDUSTRY

49

systems with the three different types of fats meant that nine trials were made for the study.

AnAlyses In the study, three different analyses were performed in order to evaluate the effect of the emulsifier:

A mix viscosity of 300 to 500 cps was measured for the nine different ice cream mixes. Hence, all nine mixes were within the common viscosity range used by the ice cream industry.

PArticle size Distribution The aged ice cream mixes were also subjected to a particle size distribution measurement. All mixes show two peaks, at 0.1 – 0.5 μm and at one to two μm, with the main peak at one to two μm. For the reference fat, the emulsifier system giving the narrowest particle size distribution at the main peak was PuS-T. For Fat 50, all three emulsifier system gave very similar particle sizes for both peaks, with PuS-nT being slightly narrower at the main peak than the two other systems. For Fat 40, like for Fat 50, the main peaks were very similar in their particle size distribution, but FS gave the narrowest particle size distribution.

The particle size distribution of the ice cream mixes indicate that they can be used for the production of ice cream.

Pressure to reduce saturated fats in food products has led to numerous research in this area.

40

35

30

Volume %

 Viscosity of aged ice cream mix using Brookfield DV-III, spindle 2, 20 rpm  Particle size distribution of ice cream mix after ageing and of melted ice cream using Horiba LA 950  Melting resistance of ice cream before and after heat shock. Melting was monitored for 90 minutes at 25 deg C.

25

20

15

10

5

0 0.01

0.1

1

10

100

P art icle s iz e, µ m FS

P uS - T

Pu S -nT

Particle size distribution of melted ice cream.

For ice cream produced with the reference fat, there is a significant difference in the particle size distribution of the melted ice creams. The emulsifier system, FS, gave a very narrow particle size distribution compared to the two unsaturated emulsifier systems, indicating that the unsaturated emulsifier creates a larger sized partially coalesced fat structure.

For ice cream produced with Fat 50, there is a difference in the particle size distribution for the melted ice cream. Like reference fat, the emulsifier system, FS, gave a narrower particle size

distribution compared to the two unsaturated emulsifier systems.

When comparing the main peaks of the ice creams containing the emulsifier system FS for the reference fat and Fat 50, it can be seen that the particle size distribution of the reference fat is smaller than for Fat 50, indicating that the combination of the emulsifier system FS and Fat 50 are better at making a partially coalesced fat structure.

The ice creams containing the two unsaturated emulsifiers are again containing particles of a larger size. This indicates that these emulsifiers are better

INGREDIENTS & ADDITIVES

ASIA PACIFIC FOOD INDUSTRY November/December 2012

Melting resistAnce The melting resistance of the ice creams produced with the reference fat is strongly influenced by the type of emulsifier used. Ice creams made using the emulsifier system FS lose 25–30 percent of its weight after 90 minutes, whereas the ice creams made with unsaturated emulsifier systems only lose up to five percent after 90 minutes.

This correlates well with the particle size distribution of the ice creams produced with the reference fat as discussed earlier.

The unsaturated emulsifier systems gave much larger particles than the emulsifier system FS. The melting resistances of the ice creams made with Fat 50 are very similar. All the ice creams lose up to five percent of their weight after 90 minutes.

Process used for the production of the ice cream mix:

1

Mixing of all ingredients at 40°C



at making larger sized partially coalesced fat structures.

Ice creams produced with Fat 40 have a similar particle size distribution with the emulsifier systems FS and PuS-T, whereas the emulsifier system Pus-nT creates larger particles than the two other systems.

2

HoMogenisation: 140 bar at 75°C

Production Process

5  4

ageing overnigHt at 5°C

3

Pasteurisation: 85°C for 5 seC.



Sarah Buckley

OhioStateEngineering

Mono- and diglycerides can be used to reduce the amount of saturated fats in ice cream without compromising on texture mouthfeel.

From the results of the particle size distribution of the ice creams, one would expect that the combination of Fat 50 and emulsifier system FS would offer the least melting resistance.

This is due to the more narrow particle size distribution of the ice creams made with FS than with the unsaturated emulsifier systems.

However, this is not the case, indicating that the ability to make a partially coalesced fat structure in the ice cream is less sensitive to the type of emulsifier used in combination with Fat 50.

The melting resistance of the ice creams made with Fat 40 are influenced by the type of emulsifier used. The ice creams produced with PuS-nT lose up to 12 percent of their weight after 90 minutes, whereas the ice creams produced with emulsifier systems FS and PuS-T only lose up to five percent after 90 minutes.

When comparing these results with the particle size distribution for Fat 40, it was expected that these ice creams would give very similar melting resistances.

However, the fact that PuSnT offered the least melting resistance, but had the largest particles, suggests that these partially coalesced fat structures are more coalesced and therefore, are not participating in building



Robert Neff, US

50

Cooling to 5°C

INGREDIENTS & ADDITIVES

November/December 2012 ASIA PACIFIC FOOD INDUSTRY

51

benefits of unsAturAteD fAts

Ice cream recipe used: Ingredient Vegetable fat Skim milk powder Sucrose Glucose Syrup, 42 DE Stabiliser system (E410, E412) Mono- and diglycerides Water

NEDSMELTNING-NY

saturated fat has been linked to an increased risk of heart disease, which is why the WHo recommends that the intake of saturated fat should be restricted to maximum 10 percent of the daily energy intake. reducing the amount of total fat or switching to a fat with reduced levels of saturated fat has an effect on the cost of the final ice cream in countries where there is a taxation on the amount of saturated fat in the ice cream, like in Denmark.

As an example, the Danish tax is DKK16 (us$0.35) + 25 percent VAt per kg of saturated fat.

% 10.00% 11.40% 11.50% 3.35% 0.16% 0.40% 63.20%

Ice cream production:  Continuous ice cream freezer: Gram Equipment GIF 400 Overrun: 100%

Powder Processing ...

Powder Processing ...

 Storage at -20°C

• Feeding, conveying and

the internal structure of the mixing systems ice cream.

The• study shows that an Full service worldwide adjustment of the mono- and diglyceride systems used in ice • Test Centre cream production will have to be considered when switching to fats with a lower amount of saturated fats.

For more information, ENTER No: 1052

• Feeding, conveying and mixing systems • Full service worldwide • Test Centre

Gericke Multiflux® Mixer GMS ECD

Gericke Pte Ltd. Singapore 787813 T +65 64 52 81 33 gericke.sg@gericke.net

Gericke (Shanghai) Pte Ltd. Shanghai 200020, PR. China T +86 21 5382 0108 gericke.cn@gericke.net

Gericke Multiflux® Mixer GMSwww.gericke.net ECD Anzeige20_12.indd 1

23.04.12 11:25

3208

 Hardening at -35°C for 24 hours.

Enquiry Number

 Ice cream outlet temperature: approximately -5.5°C

HEALTH & NUTRITION

ASIA PACIFIC FOOD INDUSTRY November/December 2012

margo555111100045

52

Natureâ&#x20AC;&#x2122;s aNswers to CardiovasCular HealtH Antioxidants found in olive oil and pomegranate extracts have been proven to be effective in maintaining cardiovascular health. these natural ingredients may be the supplements people need with their hectic lifestyles. By vicente Marti, sales manager, Probeltebio Natural antioxidants are present in many foodstuffs that we consume. Among some of the most important ones are red wine, broccoli extracts, red fruit extracts, cocoa, cherries, tea and soya beans.

However, some of the most potent antioxidants present in food are derived from pomegranate and olives.

Recent discoveries have shown that natural antioxidants have a role to play in the prevention of many biological ailments and diseases, including cardiovascular diseases.

C a rd i o v a s c u l a r d i s e a s e s continue to be a leading cause of morbidity and mortality among adults in many developed economies, and are becoming an issue in developing countries due to rapid changes in food habits.

T h e f a c t o r s f re q u e n t l y

associated with this problem are atherosclerosis and high blood pressure, eating and other unhealthy habits, such as cigarette smoking, and high cholesterol levels linked to improper diets and obesity.

According to the World Health Organization (WHO), approximately 17 million people die of cardiovascular diseases, particularly heart attacks and strokes, every year. Furthermore, WHO estimates that by 2020, heart disease and stroke will become the leading cause of both deaths and disabilities worldwide, with the number of deaths projected to increase to over 20 million a year and by 2030, to over 24 million a year.

These statistics are a reflection of how this situation is affecting global populations and the strains it is creating on health and government institutions worldwide. The world population is increasingly concerned about the need to address the problem both collectively and individually.

Prevention Individually, people are increasingly aware of the

ruslan081100148

November/December 2012 ASIA PACIFIC FOOD INDUSTRY

Nature’s best solution for texture & taste Some of the most potent antioxidants present in food are derived from pomegranates.

Purac has 80 years experience with ingredients solutions for food and snacks.

Purac Adds Kick to Any Snack!

Whether it comes down to controlling the crispiness or improving the flavour profile of snack seasonings, Purac is your go-to partner.

Our Puracal® line interacts easily with pectins to put the “crisp” in snacks.

For extruded snacks, Puracal extends shelf life and improves texture.

And that’s not all!

Our Purac® Powder works wonders to enhance the flavour profile of savoury and dairy-based seasonings.

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Talk to our food specialists now or visit: www.purac.com/snacks

Purac Asia Pacific, 3 International Business Park #06-19 Nordic European Centre, Singapore 609927 Phone: +65 63491350

Enquiry Number

need to improve their habits and cardiovascular health. Population wide strategies for healthier living practices are being implemented both on a national and local level. As they become more evident, people are more conscious about their efficiency.

Preventive measures are always more cost efficient compared to interventions. Therefore, it is important to constantly remind people to adopt a healthy lifestyle. People have come to realise that healthy eating habits and the right amount of exercise are beneficial to the heart. Among the eating habits that have been linked to good health is the much flaunted Mediterranean diet.

In its origin, the Mediterranean diet is rich in fish, fruits, vegetables, legumes, cereals and olive oil. It has been tested over time and clearly shows benefits in lowering the risk of coronary and chronic diseases that are traditionally linked to poor diets.

One of the pillars of the Mediterranean diet is olive oil. When consumed in moderation, it has multiple beneficial properties linked to cardiovascular health.

However, in today’s stressful societies, it is very difficult to sustain a healthy lifestyle. Work related stress, complicated schedules and other issues are some of the pressures we face.

Among the most visible consequences of this is a poor dietary intake with an excess of saturated fats (fast living = fast foods) and less vegetables, fruits and natural antioxidants consumption.

Improving dietary habits is a good way to begin preventing cardiovascular diseases, as well as other conditions, such as diabetes, obesity, metabolic syndrome, hypertension and high cholesterol,

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Pomegranates and olives have two of the most potent polyphenols present in nature.

all of which are linked to a hectic lifestyle. The lack of time is forcing people to go for unhealthy quick fixes.

This situation can be reversed by following certain habits that can lead us to better wellbeing. Scientific studies have demonstrated the important role that antioxidants play in maintaining a balanced human metabolism, by reducing oxidative stress and other related effects. nAtUrAL PoWer Pomegranates and olives have two of the most potent polyphenols present in nature. Natural olive and pomegranate fruit extracts can be manufactured based using eco-friendly technologies on an ultrapure water based extraction process that does not use any organic solvents.

This is one of the most natural ways to obtain valuable polyphenols (antioxidants) from fruits, which can then be used to manufacture healthy foods According to studies conducted at the Spanish Research council and Hospital La Paz in Madrid, consumption of olive oil enriched with hydroxytyrosol proved to be highly beneficial in preventing cardiovascular disease.

A 28 day human intervention clinical study has shown that a daily consumption of 10 g of olive oil, representing a dosage of 5 mg of hydroxytyrosol, can reduce the percentage of low-density lipoprotein (LDL) cholesterol oxidised particles by up to 35 percent.

Oxidation of LDL cholesterol particles is the first step in plaque formation and has been identified as one of the biomarkers used to diagnose metabolic syndrome.

An experiment conducted on laboratory animals shed an interesting conclusion: a regular intake of the hydroxytyrosol present in extra virgin olive oil has proven to be effective in significantly minimising the risk of high cholesterol levels in blood.

Recently, the European Food and Safety Authority has confirmed the scientific claim that the ‘consumption of olive oil polyphenols contributes to the protection of blood lipids from oxidative damage’ and as a result, olive oil polyphenols have been included in the permitted health claim list by the European Commission. In order to substantiate this claim, the daily intake must be of at least 5 mg of hydroxytyrosol and its derivatives in oil.

PUniCALAGinS in PoMeGrAnAteS Equally, pomegranates are rich in punicalagins, some of the most powerful antioxidants present in nature. Punicalagins are known for their capacity to neutralise free radicals that are responsible for cellular oxidation.

Scientific evidence has suggested that punicalagins are very effective in the treatment or prevention of hypertension through its vasodilator properties and has a beneficial effect on endothelium cells.

Using the clinical data from the study with hydroxytyrosol rich olive oil extracts, it was concluded that pomegranate extract has beneficial effects on arterial blood pressure. Animals that were fed the extract showed anti-hypertensive activity which could help prevent the occurrence of cardiovascular problems.

At the same time, pomegranate extracts can alleviate pain and inflammation of the joints, as well as loss of mobility associated with joint diseases.

It also has an important role in maintaining proper intestinal health as it helps stimulate the growth of healthy bacteria and inhibits the growth of pathogenic ones.

These studies show that pomegranate and olive oil extracts may well be considered as health promoting dietary supplements, and can be used as a successful strategy to produce functional foods and beverages with antihypertensive qualities that can prevent atherosclerotic plaque build-up as well.

For more information, ENTER No: 1060

SAVVY SNACKING

6 grams of protein power

Crave-worthy crunch

Energy that lasts

© 2012 Almond Board of California. All rights reserved.

A natural complement to sweet and savoury tastes

A variety of flavour possibilities

3.5 grams of satiating fibre

AND YOU THOUGHT YOU WERE JUST ADDING ALMONDS.

A lot goes in with a little almond. We’re talking 13 essential nutrients to give health-conscious consumers a snack they can feel good about, and feel fulfilled after eating. Then there’s the tasty, satisfying crunch that keeps everyone reaching for handful after heart-healthy handful. Not to mention the natural, lasting energy,

Enquiry Number

One serving of almonds is 28–30 grams.

3199

global appeal and unmatched versatility. A snacking success story? We think so.

BEVERAGE 56

ASIA PACIFIC FOOD INDUSTRY November/December 2012

THE

DAIRY EVOLUTION Healthier dairy beverages are in fashion today, but tomorrow could bring completely unexpected innovations in product portfolios. By Rudy Kartono, regional category manager, International Flavors & Fragrances

WHILE other product categories are trying to hitch a ride on the health bandwagon to attract more consumers, dairy beverages have traditionally been associated with health and nutrition. By its very nature, a dairy beverage would promote fortification and bodily functions, such as improving digestion and bone health.

Some of the most popular health-related benefits for a dairy beverage include less or no sugar and fat in that beverage. We have seen products that combine these health benefits to attract more consumers, for example, a Thai yoghurt drink with zero fat and added calcium for bone health.

Manufacturers are also marketing dairy beverages to time-pressured consumers who may not have enough time to get a nutritious meal. Consumers want products that are designed to provide their nutritional needs instantly.

Consider the beverages in Japan that are designed to replace breakfast as they contain several different foods ---- one hits the spot with milk, coffee and banana all in one. In addition, Australia

has several products containing cereal and milk together in a drinkable on-the-go format.

Sensorial experiences have come to the fore in some countries in the Asia Pacific region. Manufacturers have been keen to explore new flavour combinations or new flavour ideas for dairy products. One way has been to modify the all-time

global favourite flavours for dairy products: strawberry, vanilla and chocolate.

For instance, one Australian manufacturer has introduced a ‘wild’ strawberry flavoured milk.

More local flavours provide a different perspective to the same trend. Red date (jujube) flavoured milk in China and azuki (red bean) flavoured milk in Japan are some cases in point.

The delivery of indulgence is another aspect of the sensorial approach. It is a major consumer driver and area of innovation for brands, as seen in the success of Greek yogurt in the US. Indulgence has also come to dairy beverages in this region, with one manufacturer going with the indulgence theme through a limited edition launch of a caramel fudge flavour in its milk product range in Australia, and integrating cheesecake or crème caramel flavours into yoghurt.

HEALTHIER BEVERAGES With numerous brands available in the market however, dairy beverage manufacturers still need to enhance their portfolio on a frequent basis in order to get that competitive edge. Leveraging on the health and wellness movement is one of the most effective ways of doing so. While descriptions such as ‘less sugar’, ‘low fat’, ‘no sugar’ or ‘zero fat’ are not new, they are still a very good way to attract consumers.

Consumers can relate to these terms easily with personal goals to reduce fat and sugar intake.

The US Department of Agriculture (USDA) has supported this trend with new recommendations that were introduced in the middle of last year. In conjunction with a new plate-based visual that replaces the iconic food pyramid, the

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November/December 2012 ASIA PACIFIC FOOD INDUSTRY

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HEALTH VS TASTE Health and wellness concepts are everywhere, influencing consumer mindsets, lifestyles and needs. However, even though the average consumer is trying to apply these concepts in his or her daily life and should accept that a healthier product will not taste like the original, we have found that consumers are simply unwilling to compromise on taste.

Low fat milk generally does not taste as good as full fat milk,

Similarly, it is equally important to restore the sugary mouthfeel which contributes to the body of the overall taste after sugar has been removed. This is often missing when sugar is replaced with artificial sweeteners or other sweetness enhancement systems.

The challenge is to restore what has been removed in such a way that it retains the original sweetness and creaminess of the milk. Fortunately, flavour modulation solutions for both

Consumers are expecting their dairy beverages to deliver more in terms of sensorial experience and nutritional values.

given that some of the fat has been removed and the perception of creaminess is also reduced.

The fats that usually contribute creaminess and provide a mouthcoating effect are absent, resulting in a thin and watery-tasting dairy product. This challenge is what manufacturers encounter when producing lower fat products.

sweetness and creaminess have been developed for health and wellness that can recreate the required perceptions, enhancing the taste and mouthfeel of the healthy product.

FAST FORWARD While it is still important for dairy manufacturers to make sure that Flavour modulation solutions for sweetness and creaminess have been developed.

ricardo, London, UK

ADDITION OR REMOVAL A healthier dairy beverage can be created in two ways. The first is by adding ingredients that are already known to have a specific positive function or could improve overall health. Examples are DHAfortified milk for children’s brain development, calcium-fortified milk for bone health, and milk with pre- or probiotics to promote good digestion.

Another option is to introduce a new ingredient into a dairy beverage, but more consumer education would be required. It would probably be a better idea to ‘borrow’ a well-known ingredient in other categories (like an energy drink or an isotonic drink) and put that into dairy products.

Not only can this save efforts on consumer education, it can also generate excitement and lead to more innovative products.

The second way to create a healthier dairy beverage is by removing undesirable ingredients, which is how we arrive at low- and non-fat milk, as well as low-sugar or sugarless milk.

Karl Baron, Malmö, Sweden

USDA advises drinking fat-free or low fat (one percent) milk and avoiding ‘empty calories’, such as the sugar found in sweetened drinks.

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IFF_yoghurt_vanilla

Out of the box concepts include bringing energy drink flavours to yoghurt.

EmsiProduction

Some manufacturers have put cereal and milk together in a drinkable on-the-go format.

they are catering to the current needs of their consumers, it is equally important that they look ahead towards the next big thing in dairy. Consumer research can provide some of the insights needed to begin planning new directions in research and development, and is a critical step to understanding how consumer tastes and needs are changing over time.

Another trend we see is the rise of the middle class in the developing countries. This means higher disposable incomes and more money to spend on items such as dairy products. This group, which is growing, is travelling more and also more connected online.

In the past, there was a much bigger gap in lifestyles between developed markets and developing markets. As a

result, trends from the developed markets moved to the developing markets relatively slowly. With travel, the internet and social media, however, consumers around the world can access information and are adopting trends from virtually anywhere.

The developing world no longer follows the developed world. Countries like Japan and Korea are a hotbed for innovative new products and these are being embraced all around the world.

New products and ideas can also come from cross-fertilisation of concepts, with ideas borrowed from other dairy products such as yoghurt and ice cream or even other food categories. Out of the box concepts include bringing energy drink flavours to yoghurt.

For example, in Japan, one yoghurt product contains vitamin B1 and B6 and is topped with a flavour more usually associated with energy drinks. The Japanese can also buy a salty milk ice cream with salted chocolate coating, while there is a bacon sundae on a limited edition summer dessert menu in the US. These fusion foods could well be the basic tastes we ask for in future. It makes you wonder: will milk in the future still taste like milk?

For more information, ENTER No: 1070

Adult Eurygaster Integriceps (Puton) feeding on a wheat spike

Harvest damage?

Mühlenchemie fixes problem wheat.

When bugs infest unripe, green wheat grains during extremely long periods of dry weather, they damage the gluten by exuding a protein-degrading enzyme. Although products baked from such lots of wheat in no way constitute a health hazard, bug-damaged flour has always been considered difficult to process. Depending on the degree of damage, the doughs lose their elasticity and become soft and weak.

Recent research and baking trials at Mühlenchemie’s applications laboratory have pointed the way to a solution: special compounds of active substances can be used to strengthen the gluten, reduce the activity of protein-degrading enzymes to a minimum and enhance the baking properties of the dough in general. In particular the Mühlenchemie additives EMCEbest BugStop BE and EMCEbest BugStop WT1 produce excellent results in respect of dough properties, larger volume and enhanced crumb characteristics.

Extensive research has proved that the balanced interaction of enzymes, ascorbic acid and acidity regulators makes it possible to use a large proportion of bug-damaged flour together with good flour to make marketable bakery products.

Stern Ingredients Asia-Pacific Pte Ltd Singapore Phone: +65 / 6569 2006 info@sterningredients.com.sg www.sterningredients.com.sg

A member of the Stern-Wywiol Gruppe

Flour without improvers

Flour with the addition of 0.2% EMCEbest BugStop WT1

The addition of only 0.2% EMCEbest BugStop WT1 to bug-damaged flour from the Bulgarian harvest resulted in optimum volume and crumb formation in this series of tests.

BEVERAGE 60

As far as dairy product packaging is concerned, purpose, use and habits differ greatly from one country to another. According to Euromonitor International, statistics on milks, drinking yogurt and other fermented milks show that in countries such as the Philippines, Australia and Indonesia, bottles are the preferred choice, whereas in others, cartons still make up the lion’s share.

Such differences can be explained by the disparity in consumers’ tastes in terms of products (fermented or not) and the supply chain organisation within each country (cold or not). However, with the exception of India, major countries in this geographical area have shown a rather low utilisation of flexible pouch packaging.

Just like Europe, consumption of dairy products in Asia follow changes in consumers’ lifestyles and purchasing power, induced by accelerated urbanisation.

With farms being further away and the explosion in numbers of supermarkets, shelf life needs to be longer.

The urban lifestyle creates new eating habits, like snacking, and a higher level of stress calls for functional food. In this context, the numerous opportunities offered by plastic bottles will certainly lead to an increase of its shares amongst other types of packaging.

Versatile Packaging MediuM A bottle is a versatile packaging for liquid dairy products. Suitable for any kind of product (such as milk, yogurt and probiotics) and all distribution channels (refrigerated or not), it also offers unique benefits to the consumer in terms of convenience (easy to handle, re-sealable and shockresistant). Enhancing the quality

ASIA PACIFIC FOOD INDUSTRY November/December 2012

Bottle Of OppOrtunities

using bottles to package dairy products is a great opportunity for manufacturers aiming to gain market share in mid-range to premium products segments. By Fabienne chériaux, marketing manager, serac

of the product it protects, a bottle is a good means to stand out from competition on the shelves.

With all the design possibilities it offers, the bottle, in consumers’ mind is a sign of quality. This is why in countries like the US, France and the UK, the bottle has become the number one packaging for liquid dairy products, especially in the premium segments.

This type of packaging should therefore be considered by any manufacturer who is willing to demonstrate superior quality for its product, whether in America, Europe or Asia. Bottles can

replace existing packaging or be used as a supplement, which is often the case, in order to reach out to different target groups.

Bottles can provide answers to processing constraints and consumers’ demands. Bottling solutions can be tailored to any project a manufacturer has in mind to add value to its product. Material is no longer an obstacle. Progress made in barrier technologies has allowed HDPE and/or PET to be used in conjunction with common heat treatments that are applied to dairy products.

November/December 2012 ASIA PACIFIC FOOD INDUSTRY

one For each Project There is no standard when it comes to defining a bottling line for dairy products. Each project is different and leads to a specific solution, with food safety as the ultimate objective.

Nutritional Beverages Premixes Precision Powder & Liquid Blending Tablet Manufacture Sachet Packing Product Design Services Unitech Industries specialise in the custom manufacture of nutritional beverages and premixes for the New Zealand and International food, dairy, beverage, bakery and pharmaceutical industries.

Unitech can assist with the provision of a range of services surrounding the supply of your product including; formulation design, product validation trials, regulatory and or label claim compliance, sourcing materials, manufacture, quality assurance and delivery.

Contact Unitech to determine the possibilities for improving and developing your quality products to create new market opportunities.

innovation • Precision • trust • commitment •

Each type of product has its own bottling requirements.

Everything starts from the product that has to be bottled: what kind of product it is, how viscous and homogeneous it is, what the qualitative and organoleptic properties that must be preserved. Then, there are the distribution constraints: chilled or ambient distribution and desired shelf life.

The machine manufacturer has to carry out a complete study on hygiene risks to recommend the proper bottle material, machine components and packaging treatments to achieve safety requirements. With growing consumer protection legislation, dairy filling machine specialists have developed a wide range of solutions and technologies for clean, ultra-clean and aseptic applications. The next step is to select a line that is best suited for the particular product.

sales@unitech.co.nz www.unitech.co.nz

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ProFitaBle inVestMent A bottling line can be regarded as a costly investment by dairy product manufacturers, especially for medium sized companies. However, such an investment must be considered with an overall picture and balanced with the revenues and savings it can generate, as well as the freedom it can give to the company.

Bottles can generate new revenues by enabling manufacturers to target markets with higher added value, where profit margins are greater.

They also contribute to brand awareness and brand image, with a higher appeal than traditional packaging medium.

With regard to savings, one should consider the performance of weight filling rotary machines.

These machines offer outstanding features in terms of production speed and filling accuracy. They are also reliable and have a long service life.

Initial investment is therefore repaid over time by the capability to produce faster and with greater precision, the amount of product to be filled in every container.

Time is another criterion that may tip the balance in favour of investing in a machine rather than choosing a solution where investment is integrated in the unit packaging price. In the long run, independence may prove to be a cheaper and less restrictive option considering that product

evolution demands the market to renew itself constantly.

Enquiry Number

These materials can also compete with cartons on extended shelf life projects for products stored in chilled conditions or at ambient temperature. Shape is not a factor either. Dairy products can be presented in curvy packaging that evokes the femininity associated with this product category.

UnitecH indUstries

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The filling system and its surrounding area must be kept sterile.

From our experience, having in-depth knowledge of the dairy industry and working closely with customers are two key factors of success in designing a bottling line, without neglecting the quality of the equipment and the variety of options available. iMProVed shelF liFe With consumers’ growing demand for fresh products with longer shelf life, dairy filling specialists have worked out a complete range of packaging treatment solutions to ensure maximum decontamination.

Wet or dry treatment can be applied to the bottle and/

or the cap, as well as to the aluminium foil. Dry treatments combinations such as HDPE bottle neck trimming and pulsed light decontamination of caps can prove useful as an answer to new market requirements such as freshness. They offer full compliance with the shelf life requirements of chilled products without any risk of chemical residue on the packaging.

Container sterilisation is another key step in aseptic filling systems which can guarantee the absence of contaminants and therefore, the longest shelf life. In such systems, the dairy product and the container are sterilised before they enter the filling process.

The filling system, as well as all components in contact with

Liquid dairy packaging — 2011 Unit Sales Share by Key Pack Type 100% 90%

% Unit Volume

80% 70% 60% 50%

Stand-Up Pouches

40%

Other Packaging

30%

Flexible Plastic

20%

Liquid cartons

10%

Bottles

Vi et na m

Th ai la nd

Ph ilip pi ne s So ut h Ko re a

In do ne sia

In di a

Ch in a

Au st ra lia

0%

Notes: Bottles include rigid plastic and glass bottles; Other Packaging includes metal, paper-based, and other flexible packaging as well as thin wall plastic containers.

Source: Euromonitor International

the product and the area around the machine, is kept sterile. This requires the minimalising of the amount of elements in the aseptic filling zone, and the filling turret to be designed without bug-traps, so that it is easy to clean and sterilise. Electronic systems can also be isolated from the sterile zone to remain accessible during production.

Packaging trends As in Europe and North America, milk bottling projects have been increasing in the Asia Pacific region over the past few months.

Among the most active countries are China, Indonesia, and Vietnam, where bottles are showing its benefits compared to cartons and flexible packaging. Even in India, where flexible packaging is deeply rooted in consumption habits, milk manufacturers are investing in HDPE and PE bottling lines.

Bottles are fast becoming the packaging container of choice, especially for fresh milk and ESL milk, two products which account for the highest number of projects. Interest in these product categories, probably driven by quality, food safety and a desire for a fresh-tasting product, is propelling aseptic systems and PET bottles forward.

PET bottles are now able to protect milk from UV radiation and can be processed through air-blown injection, with benefits such as reduced bottle weight and a more rigid neck finish. Combined with aseptic systems, PET bottles with UV barriers can be stored at ambient temperatures — a great opportunity in countries where cold chain monitoring is an issue.

For more information, ENTER No: 1071

FOODGRADE GRADE FOOD LUBRICATIONSOLUTIONS SOLUTIONS LUBRICATION Easingyour yourlubricant lubricantcontamination contaminationconcerns concerns Easing

Lubricant Lubricant contamination contamination isis aa constant constantthreat threatininthe thefood foodprocessing processing industry because even a minor incident could force a company industry because even a minor incident could force a companyto to undertake undertake aareputation-damaging reputation-damagingproduct productrecall. recall.

Minor Minor lubricant lubricant leaks leaks inin processing processing machinery machineryare arecommon, common,often often avoidable, and not always obvious.

Normal wear and tear seals can avoidable, and not always obvious. Normal wear and tearonon seals can cause a gearbox or compressor to release minute quantities of oil that can cause a gearbox or compressor to release minute quantities of oil that can spoil spoil aa batch batch of of food. food. Prudent Prudent maintenance maintenancecan canminimize, minimize,butbutnotnot eliminate, these threats. eliminate, these threats.

Tecsia Lubricants offer complete range of NSF H-1* registered food grade Tecsia Lubricants offer complete range of NSF H-1* registered food grade lubricants to secure your process while providing outstanding protection lubricants to secure your process while providing outstanding protection and improving your industrial equipment uptime. and improving your industrial equipment uptime. *NSF H-1 lubricants are used in areas where the lubricant may incidentally *NSF H-1 lubricants are used in areas where the lubricant may incidentally come in contact with food during processing. come in contact with food during processing.

Tecsia Lubricants Pte Ltd 2A Mandai Estate #01-01 Tecsia Lubricants Pte Ltd BHL Factories 2A Mandai Estate #01-01 Singapore 729928 BHL Factories Phone: (65)729928 6456 1133 Singapore Fax: (65)(65) 6459 0093 Phone: 6456 1133

Fax: (65) 6459 0093

Tecsia Lubricants (Thailand) Co. Ltd No. 16, Sukhumvit 93(Thailand) (Phung Mi 1) Tecsia Lubricants Co. Ltd Sukhumvit Road, Bang No. 16, Sukhumvit 93 Chak, (Phung Mi 1) Phra Khanong, Bangkok Sukhumvit Road, Bang10260 Chak, Thailand Phra Khanong, Bangkok 10260 Phone: (66) 2 333 1141 Thailand Fax: (66) (66) 2 333 Phone: 2 1145 333 1141 Fax: (66) 2 333 1145

PT Tecsia Lubricants Indonesia Sampoerna Square, PT TecsiaStrategies Lubricants Indonesia South Tower, 30th floor Square, Sampoerna Strategies Jl. South Jend. Sudirman kav.

45-46 Tower, 30th floor Jakarta 12930 Indonesia Jl. Jend.

Sudirman kav. 45-46 Phone: (62)12930 21 2993 0829 Jakarta Indonesia Fax: (62) 21 2993 Phone: (62) 21 0888 2993 0829 Fax: (62) 21 2993 0888

www.tecsialube.com www.tecsialube.com Enquiry Number

3197

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ASIA PACIFIC FOOD INDUSTRY november/december 2012

Grade

A Food Using NSF H1 or HT-1 registered lubricants can help minimise the potential for product contamination and protect brand integrity.

Converting a facility to use these food grade lubricants is not as daunting as it seems.

By Peter Bird, marketing advisor, ExxonMobil Lubricants & Specialties

Recalls of food and beverage products due to contamination concerns have risen significantly over the last decade. Considering that recalled products can be devastating to a brand and are potentially harmful to consumers, it is not surprising that the US Food Processing 2008 Annual Manufacturing Trends Survey indicated that food and beverage processorsâ&#x20AC;&#x2122; number one concern is food safety, more so than energy, labour issues or environmental concerns.

This trend extends far beyond the US, impacting regions all around the world. In the current global climate, food and beverage processors are under more pressure than ever to ensure the safety of their products, protect their brand reputation, enhance their companyâ&#x20AC;&#x2122;s productivity and expand profit margins in the face of tightening economic times.

One of the impor tant areas that food and beverage processors need to focus on to help achieve a food safe and hygienic processing environment is lubrication. Using lubricants that are suitable for use in food machinery where incidental food contact may occur, NSF H1 or HT-1 registered, will not only help to minimise the potential for product recalls and maintain

Makeover

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brand integrity, but can also enhance equipment performance, thanks to advancements in lubricant chemistries.

Food and beverage processing plants often have a wide variety of machinery and converting all of them to an NSF H1 or HT-1 registered lubricant can be an overwhelming task. Here are some tips for plant managers and maintenance professionals to help streamline and simplify the conversion process within their own quality and risk management systems, such as Hazard Analysis and Critical Control Points (HACCP).

By itemising your equipment, properly storing and handling the lubricant inventory, converting the equipment, and establishing a proactive oil analysis program, companies will not have to compromise production goals for incorporating and improving its food quality initiatives.

contact’ with the food or beverage being manufactured.

Such compounds may be used on food processing equipment as a protective anti-rust film, a release agent on gaskets or seals of tank closures, and as a lubricant for machine parts and equipment in locations where there is potential exposure of the lubricated part to food. Equipment such as baking chains, conveyors and mixers, depending on risk of exposure, may require the use of H1 registered lubricants.

NSF H2 registered lubricants can be used in machinery in a food and beverage processing facility where there is no possibility that the lubricant or lubricated part will come in direct or incidental contact with food. Such applications of H2 registered lubricants can include fork lift trucks and transportation

equipment that do not come in contact with the food/beverage product or components, and where cross-contamination with H1 registered lubricants can be avoided.

NSF H3 registered lubricants are soluble oils that are used for rust prevention on trolleys and similar equipment; they must be removed before any contact between food and equipment.

NSF HT-1 registration is specifically reserved for heat transfer oils that may have incidental food contact. As an example, there may be a potential risk that heat transfer oil in a heating jacket could come in contact with vegetable oil used to cook chips, leading to incidental contact between oil and food. NSF HT-2 registered products should only be used in heat transfer applications where there is no chance of the lubricant or the lubricated machinery components coming into contact with food.

It is important for plant managers and maintenance professionals to itemise each piece of equipment and every application and accurately assess the risk of food contamination caused potentially by the lubricant according to local HACCP planning procedures.

NSF H1 registered lubricants are suitable for applications in machinery that could potentially have ‘incidental contact’ with food or beverage.

Rachel Tayse, Ohio, US

EqUiPMENT iTEMiSaTioN For a lubricant to achieve product registration from the National Sanitation Foundation (NSF) for use in a food or beverage processing equipment, lubricant manufacturers need to submit product formulations and labels to be reviewed by a certified NSF toxicologist.

The components used in the lubricant are compared against regulatory requirements including NSF’s Registration Guidelines for Proprietary Substances and Nonfood Compounds and 21 CFR. Based on the toxicologists’ analysis, a lubricant can be registered as H1, H2, H3, HT-1 or HT-2.

NSF H1 registered lubricants are formulated with base oils and components that comply with FDA 178.3570 and are suitable for applications in machinery that could potentially have ‘incidental

Product formulations and labels must be submitted for review.

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Nick Saltmarsh, London, UK

EqUiPMENT CoNvErSioN There are several advisory steps that need to be followed to convert a non-NSF H1 or HT-1 registered lubricant in a piece of equipment to a NSF H1 or HT-1 registered lubricant. Each stage should be clearly documented according to HACCP planning and may vary according to the complexity of the individual equipment and maintenance procedures.

Upon completion, maintenance professionals should then review the list with their lubricant manufacturer or lubricants distributor to select the correct lubricant, oils and greases, and also to potentially consolidate the number of necessary products and accurately access volume.

By minimising the number of lubricants used and only using NSF H1 and HT-1 registered lubricants, plant managers and maintenance professionals can optimise food safety initiatives, expedite the purchasing process, simplify maintenance procedures and minimise the opportunity of improperly lubricating equipment.

ProPEr SToragE & HaNdLiNg Following the proper storage and handling procedures for NSF H1 and HT-1 registered lubricants can help maintain the integrity of the productâ&#x20AC;&#x2122;s formulation, so it can provide the anticipated performance characteristics when applied to a piece of equipment.

First, maintenance professionals and plant managers should thoroughly examine the lubricants upon delivery.

New packaging should not be damaged, especially the package seal. Any damage to the seal could indicate that the lubricant has

Lubricants must be stored and labelled properly for distribution.

been potentially contaminated and should not be used.

NSF HT and HT-1 registered lubricants should ideally be stored inside a temperature-controlled (40 deg F to 77 deg F; approximately 4 deg C to 21 deg C), dry storage room and segregated from nonNSF H1 and HT-1 registered products. Each product should be properly labelled and new batches of product should not be topped off with the remainder of lubricant from another batch.

It is preferred that maintenance professionals opt for drums of product to maintain stock rotation and throughput.

When dispensing the product, maintenance professionals should use containers clearly marked for the appropriate NSF H1 and HT-1 registered product to avoid any contamination and avoid the need to replace unused oil. Additionally, the use of personal protective equipment is recommended to avoid any unnecessary contact.

As for disposal, food and beverage processors should take all responsible care to dispose of lubricant-related waste properly and ensure that it is disposed of in an approved manner by an authorised company.

Step 1. Operate the system under normal conditions until stabilised operating temperature is reached.

Step 2. While it is still warm, drain as much oil from the system as possible. Breaking of low point flanges and drain points will improve lubricant removal. If possible, manually clean reservoirs and larger piping with clean, lint-free rags, shop vacuum and/or squeegee. Do not use solvents. Visually inspect for cleanliness.

Step 3. Drain filter housings and replace all filters.

Step 4. Fill the system with sufficient NSF H1 or HT-1 registered oil to ensure full circulation. Note: This change of oil should be treated as a flush oil and not a final fill.

Step 5. Operate the system under normal condition for a minimum of one hour. Exercise cylinders and circuits to improve the flush process.

Should the flushing fluid show signs of contamination (excessive solid or water contamination, through visual or used oil analysis inspection), additional circulating and filtering time may be necessary.

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Step 6. While it is still warm, drain as much flush oil from the system as possible.

Breaking of low point flanges and drain points will improve flush oil removal. If possible, manually clean reservoirs and larger piping with clean, lint-free rags, shop vacuum and/or squeegee. Do not use solvents. Visually inspect for cleanliness.

Using lubricants that are suitable for use in food machinery can help minimise recall, maintain brand integrity and enhance equipment performance.

Step 7. Drain filter housings and replace all filters.

Step 8. Fill the system with recommended NSF H1 or HT-1 registered oil. Assume normal operation, monitor filters and conduct regular oil analysis.

Step 9. Clearly label all machinery equipment with the type of lubricant that should be used. Clearly label â&#x20AC;&#x2DC;fill only with NSF H1 or HT-1.â&#x20AC;&#x2122;

EffEctivE AnAlysis ProgrAm Once the equipment is running with the new NSF H1 or HT-1 registered product, it is imperative for maintenance professionals to monitor its performance to ensure the conversion was done properly.

This helps to ensure lubrication performance and system integrity according to HACCP planning.

One of the most comprehensive ways to monitor the condition and performance of an oil is through a used oil analysis program.

This type of condition-based monitoring provides maintenance professionals and plant managers with insight about the condition of the oil as well as the components of the equipment and its lubrication.

Using this data, informed decisions can be made about the remaining life of the lubricant.

In addition, the data can give valuable information about the condition of the equipment and can be used to address equipment issues before they lead to unscheduled downtime.

Applications particularly suitable for a used oil analysis program are hydraulic and gear box equipment, as well as heat transfer systems.

Typically, food and beverage processing companies work with a trusted oil analysis provider and they can help provide advice on oil analysis frequency.

Sam Beebe

Note: For systems containing large complicated internal structures, systems with heavily aged lubricants or lubricants with the presence of significant levels of unwanted heavy metals, additional flushing and oil analysis may be required to achieve adequate cleanliness. This will help ensure the integrity of the system and the lubricant.

Converting an entire food or beverage processing facility to NSF H1 and HT-1 registered lubricants can be a large undertaking.

However, by following the tips outlined in this article, plant managers and maintenance professionals will be better able to turn it into a manageable task within their local risk management systems while helping their company optimise production, promote food quality, and ensure the brand integrity of its products.

For more information, ENTER No: 1080

Enquiry Number

3209

FEATURES

PRESS FOR smooth FLOW

THE

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ASIA PACIFIC FOOD INDUSTRY november/december 2012

air compressors are critical components of machines used in the food and pharmaceutical industries. choosing the right food grade lubricant will ensure less downtime and better overall efďŹ ciency. By mark phang, technical manager, tecsia lubricants

Sean Rogers, Kingston Upon Hull, UK

AIR compressors are considered to be one of the highly mission critical applications for food and pharmaceutical industries. For these applications to function smoothly and properly, they require lubricating oils. Food grade compressor oils are essentially the life-blood of air compressors.

It is necessary for users to manage the common dilemmas arising from compressor oil selection and usage. The common challenges posed to users include: high top up rate and high discharge temperatures, accelerated oxidation and ageing of compressor oil, deposits formation and sludge, and selecting the suitable viscosity of oil based on operating temperatures. typeS oF oilS Vegetable base oils have natural lubricity and are generally regarded as safe for food processing equipment. They are also used in environment sensitive areas such as agriculture and marine that require high biodegradability.

However, it is crucial to understand that vegetable base oils alone are not able to handle high operating demands, heavy loads, extreme temperature range and high speed. Adding approved additives will definitely enhance the

performance, but sometimes this may not be cost effective from a lubricant manufacturerâ&#x20AC;&#x2122;s point of view as compared to synthetic ones. Some examples of vegetable base oils include soy oil, castor oil, palm oil and rapeseed oil.

Highly treated mineral oils, also known as technical white mineral oils, have much better oxidation resistance and thermal stability as compared to vegetable base types. Their long term stability may be of equivalence to some synthetics. With these enhanced performance properties, it is no wonder white oils are popular, especially with air compressors.

These oils have an economical pricing range and are able to meet demanding operating conditions.

On a down side, using these oils requires more monitoring. Unlike synthetics, they tend to break down exponentially when subjected to harsh conditions and eventually, carbonisation occurs.

Therefore, with technical white oils, users are faced with frequent oil change intervals.

Synthetic based oils include esters, polyalkylene glycols (PAGs), silicones and polyalphaolefins (PAOs). Ester base food grade oils are especially suitable for high operating temperature applications such as oven roller chains and

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Small VolUme, high capacity Air compressors used in food industries are no different from those used in industrial plants.

Such compressors are the heart of the industrial system and lubricants are its life-blood.

The compressed medium, within air compressors, may have indirect or direct contact with the end product during production or processing. An example of such a case is compressed carbon dioxide used in beverage carbonation or compressed air used to transfer flour from a tanker.

Modern compressors are increasingly making greater demands on the lubricants used, that is, smaller oil volumes, bigger delivered capacities and higher operating temperatures.

Indeed, there are oil-free compressors available in the market that eliminate potential air/oil contamination and messy oil spills.

These oil-free compressors generally have higher operating temperatures, lower efficiency and a higher maintenance regime.

They still do require lubricating oil for drive trains and support bearings. Although one may argue that replacement of parts can be done economically and easily, untimely down time and excessive wear and damage due to production overloading can be a severe hassle.

Such situations may incur greater costs as compared to oil-flooded compressors.

An oil-flooded compressor ultimately runs cheaper and

Cliff, London, UK

mineral base oils and do not require a thorough flushing system when upgrading to a synthetic PAO from mineral base oils. They are also compatible with most elastomers and seals, thus giving them an added advantage over ester or PAG base oils when making a switch to synthetics and when material compatibility issues occur.

FrĂŠdĂŠric Bisson, Rouen, France

they do not leave behind hard residues after evaporating.

Esters are also formulated for air compressor oils due to their natural lubricity. Ester molecules have properties that allow them to be naturally attracted to metal surfaces, resulting in the formation of a strong lubricating film.

Their natural detergency/dispersancy is an added advantage. This provides a cleaner operation and added stability.

One major drawback on this is that ester base oils are often faced with a challenge â&#x20AC;&#x201D; seal compatibility. As such, users must avoid using neoprene, styrene butadiene rubber (SBR), low nitrile (Buna N), as well as acrylic paint.

PAG base food grade oils are typically used in most industrial-made worm gear boxes due to their excellent lubricity and heat transfer properties. PAG has excellent oxidative stability, cleaner operation (varnish free) and a higher tolerance towards water. However it is not compatible with hydrocarbon oils and has compatibility issues with certain types of seal materials and paints.

Silicone base food grade oils have excellent thermal and oxidation stability, are highly resistant to aggressive chemicals and have good material compatibility (with an exception to paints). Unfortunately, it lacks great lubricity, is rather costly and has low solvency that is coupled within additive packages.

PAO base food grade oils are most widely used in the majority of industrial applications or equipment. They have significantly greater oxidation stability and a greater range of operating temperatures as compared to white mineral oils.

More importantly, they are completely compatible with

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more economically with better efficiency, lowering the need for maintenance. Such compressors are extremely appropriate when industries require these applications to run for long hours. This is why many plants still prefer oil-flooded compressors.

Choosing the right food grade lubricants for such compressors is garnering more requirements.

Besides having a food grade certification, customers are now seeking for more approvals and registrations in food grade lubricants such as European Hygienic Engineering and Design Group (EHEDG), Halal and Kosher.

Few of the main reasons involve the facts that food processing control has become increasingly stringent and targeted consumers have also widened. Therefore, this creates a need for food grade lubricants to be able to conform to these respective regulations and practices.

Synthetic compreSSor oilS Synthetic compressor oils are becoming increasingly accepted because food processing parameters are getting progressively challenging in relation to greater loads and high temperature range.

This is the key reason why synthetics are becoming highly preferred over technical white oils.

Desirable properties in oilflooded rotary screw compressor include: sealing effect, cooling or heat transfer, ability to minimise wear, oxidation stability, thermal stability, ability to prevent or have minimal deposits (cleanliness), ability to reduce or completely eliminate potential fire and explosion hazards, and compatibility with elastomers and metals.

Advantages of using synthetics include: better lubricity and heat transfer, excellent thermal and oxidative stability, superb low temperature fluidity, extended

High operating temperatures will accelerate oxidation, which promotes build-up and corrosion.

oil drainage which allows industries to have minimum downtime, longer equipment life span, great reduction on operating costs, prevention of fire and explosion hazards, cleaner operation, less oil disposal, and lower volatility.

Disadvantages of using synthetics include: high initial expenditure, seal limitations, and compatibility with other oils (no mixing should be involved).

The initial cost of switching to synthetic compressor oils may be high but returns are enormous over time. In the long term, with synthetic compressor oils, air compressors will experience improved efficiency and require less energy due to improved lubricity and lower friction losses.

Under full loads, the operating temperature can be reduced, therefore increasing component life and becoming less demanding on the cooling system. The oil change interval is also extended

and will lead to lesser machine downtime. Subsequently, reduced environmental impacts with lower lubricant disposal rates are among the many added advantages of using synthetics.

Some of the challenges highlighted in compressor lubricating oils include: high top up rate and high discharge temperatures, accelerated breakdown of compressor oils, deposits and sludge formation, and selection of appropriate viscosity based on ambient temperatures or machine conditions. challengeS High oil top up rate can be due to ineffective oil/air separation, cloggedscavenger pipes or orifices,leakage in lubrication systems, seals failure, and lubricant levels being too high or when excessive foaming has occurred.

High discharge temperatures, on the other hand, can be

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november/december 2012 ASIA PACIFIC FOOD INDUSTRY

caused by high loading/unloading compression ratios, ineffective coolers, choked air filters, lubricant breakdown, and insufficient or improper lubricant used.

Besides having proper control of oil flow circulation in the lubrication system and cooler water circulation (if applicable), users are recommended to constantly monitor oil levels, leakages, and pressure drops at separator or filter so as to minimise these issues.

The air demand quantity needs to be monitored periodically to ensure that the correct air receiver size is installed. For correct use of lubricants, it is always advisable to engage a lubrication specialist for proper recommendation and help.

High operating temperatures will accelerate oxidation and lead to an increment in acid content in oils and this promotes particle build-up and corrosion. High water content promotes hydrolytic reaction and thinning of oil films and this will result in breakdown of oils and inadequate lubrication.

Synthetic oils have better thermal and oxidation tolerance. Together with their advantageous demulsibility, they have better performance and longer extended lubrication intervals as compared to mineral base oils. Mineral base oils oxidise readily at 93 deg C and the onset temperature of oxidation is lesser depending on the grades.

It is crucial to note that almost all negative deposits are located at thermally-critical locations or bottle necks. This causes a series of problems and over time, oil coolers will lose their heat transfer capacity and efforts to reduce compressor discharge temperatures will become tremendously cumbersome.

Compressors will eventually become clogged with varnish and residues near the differentials, filters, return lines, valves as well as fittings. In such cases, even with frequent oil change and regular thorough cleaning, compressors do not appear to have any issues solved.

Choosing the right lubricant coupled with preventive maintenance practices, such as checking for plugged filters and worn seals, will eliminate unnecessary down time, reduce oil consumption, allow a cleaner operation and extend machine life.

If compressors are located at high ambient temperatures, the operating temperature of oils used may be influenced significantly, especially when no efficient cooling parameters are present. Base oil viscosity will reduce drastically and the necessary lubricating film protection of the application will not be ensured.

To resolve this, the higher viscosity grade should be chosen as this will help cushion viscosity loss at higher ambient temperatures. With this, users will then be able to provide their application with better protection.

Furthermore, age and conditions of the compressor can affect the selection of oil’s viscosity as well.

It is advisable to choose a higher viscosity grade to provide the necessary oil film strength as wear and tear rate is generally higher in older compressors.

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Detergent DiSperSancy This is a fundamental disadvantage of conventional food grade lubricant formulations — they generally possess very minor or no detergent-dispersancy properties. More deposits and sludge tend to form quickly at elevated temperatures. Oil-induced residues may form in machines even under normal operating conditions, in the guise of resinification, lacquer, oil carbons and so on.

Switching to synthetic base oils equipped with detergent-dispersancy properties will clean and minimise sludge formation in compressor systems.

For more information, ENTER No: 1081

Enquiry Number

William Warby, London, UK

73

EXHIBITION & EVENTS

NOVEMBER/DECEMBER 2012 ASIA PACIFIC FOOD INDUSTRY

74

Fi Asia o rnational Exp Jakarta Inte a si ne Jakarta, Indo 5, 2012 October 3 –

Review:

Fi Asia

Indonesia seemed an ideal location for the show given the country’s population of over 237 million people, the fourth largest in the world, and its consumption of 51 percent of the ingredients in the ASEAN region.

OVER 564 exhibitors participated at the event to showcase their food and beverage ingredients, products and innovations over 8,295 sq m of floor space. In addition, over 59 products made their Asian or worldwide debut at the show.

Networking, education and learning were key components of the show. There were over 30 seminars and conferences organised by industry associations, researchers and product development professionals, including the ‘Future of Food Factors’ seminar, free product and business seminars and a half day presentation on Halal certification procedures in Indonesia.

On the first day, HE Mohamad Suleman Hidayat, Indonesia’s minister of industry delivered a keynote speech on policies and support of the government on the development of food ingredient industry in the country.

The rest of the sessions were categorised into ‘nutrition and health’, ‘food safety and quality’ and ‘food security and defence’.

Under the plenary discussion on nutrition and health, Dr John Cavallo of Trilogy Essential In-

gredients illustrated the use of macro- and nano-emulsions as delivery systems for flavour and biologically functional ingredients. Dr Nancy Dewi Yuliana of Bogor Agricultural University shared the use of metabolomics for identification of bioactive compound from plant extract, while Anders Henriksson from DuPont Nutrition & Health gave examples on the use of fermented dairy for improved nutrition and health.

For the food safety and quality segment, Dr Soo Chuah from Kraft Asia Pacifi c detailed the emerging challenges of complying with microbiological criteria. Dr Takashi Kuda of the Tokyo University of Marine Science and Technology shared his research on the effect of food residues against dryness, disinfectants and UV-irradiation on bacteria adhered to surfaces.

As for the food security and defence categor y, Dr Drajat Martianto of Bogor Agricultural University suggested the use of fortification as food factor for food security and defence. Dr Purwiyatno Hariyadi highlighted packaging innovations that can enhance food products, while

Dr Fred Davis of Texas A&M University described plant propagation and nursery production systems of tropical crops that can help secure future food supply.

Besides the international conferences, there were also other focus sessions conducted by ingredient manufacturers to share knowledge and information on the latest ingredient trends. In two of such talks, DSM shared with the audience the global vitamin D deficiency and the importance of nutritional intake in the first 1,000 days of a child’s life starting from pregnancy.

The years 2013 and 2014 will continue to be critical ones for the food, beverage and ingredients industry in Southeast Asia, especially in preparation for the ASEAN Economic Community (AEC), to be formed in 2015. AEC is expected to create a dynamic single market and production base and become a competitive economic region with over 600 million people — the world’s largest trading bloc.

The show will be organised in Bangkok, Thailand, in 2013 before returning to Jakarta, Indonesia, in 2014. ________________________ Enquiry No: 1090

EXHIBITION & EVENTS

NOVEMBER/DECEMBER 2012 ASIA PACIFIC FOOD INDUSTRY

75

INTERVIEW

Tina Low, Director - human nutrition, for BASF in Asia Pacific

The Asian population faces two major issues: over- and under-nutrition. Those who consume too many calories (sometimes nutrient-poor calories) are affected by problems such as obesity, heart diseases and diabetes. On the other hand, there are still far too many undernourished people on our planet.

We are currently combatting over-nutrition with our phytosterols for cholesterol reduction, tonalin conjugated linoleic acid for fat reduction and omega 3 fatty acids for heart and brain health.

While Asia is a diverse collection of cultures and eating preferences, we see a trend to more natural food ingredients. Natural, nature identical and synthetic will all have a clear place in the market, but the trend towards natural ingredients is growing more rapidly than others.

We see a need for health, convenience and wellness solutions, driven by rising incomes, shifting demographics and social transformations. We believe that products delivering health and wellness benefits will grow at a faster pace than the average food and beverage market growth rate. Functional health ingredients are the fastest growing category, driven by weight management, digestive health and wellbeing and lifestyle categories.

For 2013, we see continued growth potential in human nutrition, as we believe that the global market for food ingredients will grow steadily by about four percent per year over the next 10 years. This will be dominated by the emerging markets in Asia Pacific and Latin America, with some countries like India and China at close to double digit growth.

INTERVIEW The year 2012 has not been an easy one, but performance has generally been good. However, a slight slowdown in the markets has been observed in the later part of the year, particularly in China, with clients being more careful with their business decisions.

Digestive health continues to be one of the main focuses of the region. This is especially true for the elderly segment. In places like China, the ageing population has shifted the demographic. We have also received more requests from international clients for ingredients on digestive health that are targeted at elderly people.

Asian customers tend to have a higher requirement on ingredients compared to their western counterparts, as they consider food to be a very important health issue. Asians naturally expect health components to be included in their food and for the food they consume to be healthy.

For example, another major trend in Asia is the cognitive development of children. Asian parents place huge importance on their childrenâ&#x20AC;&#x2122;s education and therefore, are very concerned about their mental performance. One popular ingredient is isomaltulose, which promotes Koen Van Praet, MD, Beneo Asia Pacific energy to the brain in a balanced way. There is data that shows that the inclusion of isomaltulose in diet can help children perform better over time.

Although a wealth gap exists in many Asian countries, such as Indonesia and the Philippines, the cost of adding healthy ingredients into a food product has minimal impact on its price.

Regardless of whether the US and Europe can recover from the current economic uncertainty, the Asia Pacific region is an important market for us where we see our future growth. In future, we would like to integrate more research and development in the region to produce data that is relevant to the people.

Food Ingredients China 2013

FIC 2013

Enquiry Number

3187

Focus on Food Industry Larger and More Exciting

未命名-1 1

2012-9-13 13:19:42

EXHIBITION & EVENTS

NOVEMBER/DECEMBER 2012 ASIA PACIFIC FOOD INDUSTRY

77

e East SIAL Middl ibition National Exh bi ha D bu A Centre UAE Abu Dhabi, – 28, 2012 26 r be Novem

Preview:

SIAL Middle East SIAL Middle East, the region’s professional trade exhibition for the food, drink and hospitality industry, will welcome eight new international pavilions this year, registering a 60 percent growth in overseas market interest.

A total of 21 international pavilions with exhibitors from four continents will participate in the threeday industry showcase, with eight international pavilions making their debuts.

According to a 2011 study conducted by the Economist Intelligence Unit, demand for food imports will double by 2020 to match the growing requirements of residents with higher levels of income, climbing to US$53.1 billion by the end of the decade versus US$25.8 billion in 2010.

Preview:

Worlds of Healthy Flavors Asia

Saudi Arabia, the largest market in the GCC, produces nearly 60 percent of poultry meat and 40 percent of red meat consumed in the country, with the UAE, Oman and Qatar heavily dependent on imports for both segments and currently importing over 75 percent of market product.

Brazilian exports to the UAE totalled US$2.17 billion in 2011, and trade with the Arab world increased by more than 28 percent to US$25.13 billion last year — led by Saudi Arabia at US$3.5 billion — with 2012 expected to see growth of up to 15 percent according to the Arab Brazilian Chamber of Commerce.

The 2011 edition of the show welcomed 466 exhibitors from 43 countries, and 9,707 visitors. The event will also incorporate three new events as part of a co-location agreement, with Rice & Grains 2012, ITCA Abu Dhabi and the Emirates International Date Palm Festival added to the line-up. ______________________________________________ Enquiry No: 1091

s Asia ealthy Flavor Worlds of H Centre n io nt ve on C Raffles City Singapore 12 28 – 30, 20 November

Organised by The Culinary Institute of America (CIA) and Harvard School of Public HealthDepartment of Nutrition, the Worlds of Healthy Flavors Asia will address some of the major nutrition and health issues seen in Asia today, such as the growing diabetes/obesity epidemic.

SPEAKING at this event will be Greg Drescher, the VP of Strategic Initiatives & Industry Leadership at the CIA as well as other representatives from the Harvard School of Public Health-Department of Nutrition, National University of Singapore and the Health Promotion Board

Singapore.

Apart from talks and panel discussions by industry experts, international and local chefs will also be present to give culinary demonstrations and presentations. ________________________ Enquiry No: 1092

www.worldoffoodasia.com/www.thaitradefair.com

Savor the Best in Asia 22. - 26.05.2013 IMPACT Exhibition Center Bangkok, Thailand Enquiry Number

3211

THAIFEX - World of Food ASIA covers • Food & Beverage featuring HALAL & ORGANIC Food • Foodservice • Food Technology Reserve your • Retail & Franchise booth now!

2013 EVENT HIGHLIGHTS Thailand Ultimate Chef Challenge

NEW - Asian Coffee Bean Competition

2013 - we extend our warm welcome to the Indochina Teams from Cambodia, Laos, Myanmar and Vietnam. The competition will be opened to regional teams from the Asia Pacific region.

THAIFEX-World of Food Asia will host the first Asian Coffee Bean Competition. With the support of Barista Association of Thailand, this platform is a unique opportunity for networking and exchanging ideas in this growing industry. Stay tune for more information on our website www.worldoffoodasia.com

• 500 contestants • 20 judges (7 WACS endorsed judges) • Featured category – Mekong Culinary Challenge • New category – World Ocean Seafood Culinary Challenge

Supported by:

Endorsed by internationally recognised World Association of Chefs Societies (WACS) and supported by Thai Chefs Associations (TCA), Thailand Ultimate Chef Challenge will bring you a larger and more impressive competition. If you are up for the challenge, join us to display your culinary skills at the next Thailand Ultimate Chef Challenge!

Jointly organized by Koelnmesse Pte Ltd Ms Lynn How Tel: +65 6500 6712 Fax: +65 6294 8403 l.how@koelnmesse.com.sg

The Thai Chamber of Commerce

Organized by:

Virag Virag, Budapest, Hungary

CALENDAR OF EVENTS 2012/13 November 21 – 24: INTERFOOD INDONESIA Jakarta International Expo, Kemayoran Jakarta, Indonesia Kristamedia Pratama E-mail: info@kristamedia.com Web: www.interfood-indonesia.com ❑ To Exhibit ❑ To Visit ❑ General Enquiry

21 – 24: ALLPACK INDONESIA Jakarta International Expo, Kemayoran Jakarta, Indonesia Kristamedia Pratama E-mail: info@kristamedia.com Web: www.allpack-indonesia.com ❑ To Exhibit ❑ To Visit ❑ General Enquiry

25 – 28: TAIWAN TEA, COFFEE & WINE EXPO Taipei World Trade Center Taipei, Taiwan Chan Chao International E-mail: james@chanchao.com.tw Web: www.chanchao.com.tw/nov/

26 – 28: ASIAN CONFERENCE ON FOOD AND NUTRITION SAFETY Raffles City Convention Centre Singapore ILSI Southeast Asia Region E-mail: acfns2012@ilsisea.org.sg Web: www.ilsiacfns2012.com ❑ To Exhibit ❑ To Visit ❑ General Enquiry

27 – 29 MENOPE Dubai World Trade Centre Dubai, UAE Global Links Dubai E-mail: info@naturalproductme.com Web: www.naturalproductme.com ❑ To Exhibit ❑ To Visit ❑ General Enquiry

28 – 30: WORLDS OF HEALTHY FLAVORS ASIA Raffles City Convention Centre Singapore Culinary Institute of America E-mail: Louisa_soon@nuhs.edu.sg Web: worldsofhealthyflavorsasia.com ❑ To Exhibit ❑ To Visit ❑ General Enquiry

December

❑ To Exhibit ❑ To Visit ❑ General Enquiry

26 – 28: SIAL MIDDLE EAST Abu Dhabi National Exhibition Centre Abu Dhabi, UAE Turret Media E-mail: info@sialme.com Web: www.sialme.com

4 – 6: DUBAI DRINK TECHNOLOGY EXPO Dubai Convention & Exhibition Centre Dubai, UAE Index Conferences & Exhibitions E-mail: drinkexpo@index.ae Web: www.drinkexpo.ae

❑ To Exhibit ❑ To Visit ❑ General Enquiry

❑ To Exhibit ❑ To Visit ❑ General Enquiry

Find us on Facebook www.facebook.com/ AsiaPacificFoodIndustry

*All details subject to change without notice. Please check with organisers for updates.

7 – 9: SHANGHAI INTERNATIONAL FISHERIES & SEAFOOD EXPO Shanghai Everbright Convention & Exhibition Center Shanghai Gehua Exhibition Service E-mail: kim.yang@gehuaexpo.com Web: www.sifse.com/en ❑ To Exhibit ❑ To Visit ❑ General Enquiry

7 – 10: PACKPLUS India Expo Centre New Delhi, India Print-Packaging.com E-mail: info@packplus.in Web: www.packplus.in ❑ To Exhibit ❑ To Visit ❑ General Enquiry

11 – 12: ASEPTIPAK ASIA FORUM Westin Grande Sukhumvit Bangkok, Thailand Schotland Business Research Web: aseptipakasia.com ❑ To Exhibit ❑ To Visit ❑ General Enquiry

23 – 26: HONG KONG FOOD FESTIVAL HKCEC Hong Kong Hongkong-Asia Exhibition Web: www.hka.com.hk ❑ To Exhibit ❑ To Visit ❑ General Enquiry

January 10 – 12: FOOD HOSPITALITY WORLD MMRDA Grounds Mumbai, India Global Fairs & Media E-mail: soumodip@fieramilano.in Web: www.fhwexpo.com ❑ To Exhibit ❑ To Visit ❑ General Enquiry

NOTE To be considered for a listing in the Calendar of Events, send details of event including: name of event, date, venue and organiser’s contact details to the address given below.

Editorial Dept Asia Pacific Food Industry Eastern Trade Media Pte Ltd 1100 Lower Delta Road #02-05 EPL Building Singapore 169206 Tel: 65 6379 2888 Fax: 65 6379 2805 E-mail: apfood@epl.com.sg

Enquiry Number

3210

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