APFI October 2013 by Eastern Trade Media

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CONTENTS

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

PROCESSING

•

PACKAGING

•

FLAVOURS & ADDITIVES

www.apfoodonline.com

•

Staying Fit With Whey Protein Isolate

STORAGE & HANDLING

volume 25 no.7

24 Goodwill Hunting

52 PACKAGING & PROCESSING 24

Goodwill Hunting

INGREDIENTS & ADDITIVES 38

With the scandals that continue to plague China, consumers are looking towards established food producers who make product packaging and processing a serious business. By Didier Lacroix, Cognex

HEALTH & NUTRITION 46

Technical obstacles have limited the use of fruit-based ingredients in products with long shelf life. Ultra rapid concentration fruit ingredients can mitigate moisture transfer by controlling water activity in baked goods, cereals and snacks, while delivering exceptional taste. By Grant Taylor, Taura Natural Ingredients

Counting Down To Zero In one of the biggest-ever investment projects in the company’s history, CocaCola Amatil is currently changing all of its plants to in-house PET-container production, rendering itself independent of converters. The company will be installing over 30 blow-moulder/filler monoblocs from 2007 to 2015, bringing concomitant benefits for both the company’s cost structure and the natural environment. By Peter Buchhauser, Krones

Extending Shelf Life With Fruit Concentrates

Lecithin: Nature’s Versatile Emulsifier As nature’s principal emulsifying agent, soy lecithin can greatly enhance the dispersion of the fatty and aqueous components in many types of food production. By Andrea Wolters, Lecico

The Sweet Smell Of Flavour

Staying Fit With Whey Protein Isolate

The population of older adults around the world is on a steady rise, leading to a new focus on health span rather than life span. Protein intake can be critical in ensuring that the elderly stay healthy and fit. By Phanin Leksrisompong, Davisco Foods

BEVERAGE 52

The Sweet Smell Of Flavour With smell playing a large role in sensory perception, aroma delivery systems provide a glimpse into the future of tasty, low sugar beverages. By Sherlyne Yong

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OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

PROCESSING

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FLAVOURS & ADDITIVES

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FEATURES 56

Time To Go Lean Going lean can help increase productivity of food and beverage production and processing plants. However, there are many considerations to think about before jumping on board. By Chew Ee Lin, Brady Corp

The Forefront Of Food Allergen Management Many people around the world are affected by food allergies, which are incurable conditions. In order to help manufacturers adhere to safety guidelines and labelling requirements, a guidance has been developed to increase knowledge. By Fintan Hastings, FoodDrinkEurope

•

STORAGE & HANDLING

volume 25 no7

for Advertisers’ Enquiry Numbers

Halal: The Label Of Trust In order to enter the lucrative Halal markets, manufacturers first have to understand the requirements and expectations of the modern day Muslim, the most fundamental of which is proof that the product is Halal. By Sherlyne Yong

EXHIBITION WATCH

Exhibition Review 72 Food & Hotel Thailand 74 Asia Fruit Logistica Exhibition Preview 76 AllPack Indonesia 77 Bio Fermentation China

Beyond The Future Of Lab-Grown Hamburgers Besides reducing land and labour needs, impacts on environment and the risk of animal-borne diseases, cultured beef can also help improve food security. There is a long way to go before it makes it way to restaurant menus, but this technology may well change the future. By Henk W Hoogenkamp and Henk R Hoogenkamp

Refer to Advertising Index on Pg

Beyond The Future Of Lab-Grown Hamburgers

DEPARTMENTS 08 10 12 20 79 80A 80B

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

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EDITOR’S NOTE 8 managing director Kenneth Tan

Economic IntegratIon FlipsidE At Fi AsiA, the spotlight was once again on the formation of the ASEAN Economic Community (AEC) by 31 December 2015. The total population of the ASEAN is approximately 600 million and the combined nominal GDP of member countries was over US$2 trillion in 2011. The creation of a single economy entity, free of trade tariffs, will bring a lot of opportunities and challenges to companies. It will be anyone’s guess whether the small and medium enterprises are ready to step forward and compete against their foreign counterparts, especially for those in more developed countries, where labour and material costs are naturally higher. Then, there is the issue of harmonisation of the standards and regulations. While representatives from the respective countries are making efforts to reach a consensus, there are still many things to be discussed before a homogenous system can be achieved. For example, given the diversity in culture, it is difficult to identify key benchmark levels for food labels. As a moderator of a panel discussion has aptly commented, we cannot expect everything to change overnight from the date the AEC is formed. Comparing the situation to the formation of the European Union, she said that the establishment of AEC is just the start of a process. While by then, most of the guidelines shall be in place, there will be a lot of adjustments and refinements as the communities begin to adapt to it. The benefits of the AEC are that manufacturers will have more markets to sell their products, while consumers will enjoy more options to choose from. However, at the other side of the coin, that means that competition will be more intense and with just two years before everything is finalised, now is a good time for companies to prepare their strategies going forward.

editor Wong Tsz Hin wongtszhin@epl.com.sg assistant editor Sherlyne Yong sherlyneyong@epl.com.sg editorial assistant Audrey Ang audreyang@epl.com.sg assistant art director Ahmad Halik

ahmadhalik@epl.com.sg

business development manager Randy Teo randyteo@epl.com.sg publication manager Peh Sue Ann sueannpeh@epl.com.sg senior circulation executive Brenda Tan brenda@epl.com.sg contributors Andrea Wolters Chew Ee Lin Didier Lacroix Fintan Hastings Grant Taylor Henk W Hoogenkamp Henk R Hoogenkamp Peter Buchhauser Phanin Leksrisompong 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

Wong Tsz Hin

executive director Lum Kum Kuen

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Enquiry Number

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ASIA PACIFIC FOOD INDUSTRY ADVERTISING INDEX ENQ NO

ADVERTISERS

PAGE

ENQ NO

ADVERTISERS

PAGE

3495

ANDRITZ SINGAPORE PTE LTD

3474

KH ROBERTS PTE LTD

3479

BASF

OBC

3482

KHS ASIA PTE LTD

3330

BRADY CORPORATION ASIA PTE LTD

3497

BERICAP ASIA PTE LTD

3484

3488

KRONES AG

28-30

3344

MENSHEN PACKAGING SINGAPORE PTE LTD

CAMA GROUP

3490

NATUREX

3493

CENTRAL FILTER MFG CO LTD

3460

OISHII JAPAN 2013

3494

CLEARPACK SINGAPORE PTE LTD

3480

PALSGAARD

3478

EVERGREEN PACKAGING

3481

PAUL LEIBINGER GMBH & CO KG

3477

EXXON MOBIL INDUSTRIAL LUBRICANTS

3471

POM WONDERFUL

IFC

3470

FLEXICON CORPORATION (AUSTRALIA) PTY LTD

6059

SICK PTE LTD

3483

FOOD & HOTEL ASIA 2014

3434

SIDEL GROUP

3491

FOOD INGREDIENTS CHINA 2014

3485

SYSTEM LOGISTICS SPA

3487

FORTITECH ASIA PACIFIC SDN BHD

6&7

6053

TCP PIONEER INCORPORATED

3496

GEA PROCOMAC SPA

3492

THAIFEX - WORLD OF FOOD ASIA 2014

3428

GLANBIA NUTRITIONALS SINGAPORE PTE LTD

3489

WACKER CHEMIE AG

3475

HEAT AND CONTROL PTY LTD

3486

WATERS CORPORATION

3476

HEAT AND CONTROL PTY LTD

3011

WOLF VERPACKUNGMACHINEN GMBH

3473

IGUS SINGAPORE PTE LTD

3472

YAMATO SCALE CO LTD

3440

KAOHSIUNG FOODSHOW 2013

IBC

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

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BUSINESS QuickBites

Asia Pacific’s Top News at a glance

Royal FrieslandCampina Opens Development Centre The development centre, located in Singapore, will focus on dairy-based beverages and baby nutrition.

DSM Reveals Trends For Natural Tasting Food Survey results from 5,000 urban consumers show that more than half prefer ‘fresh and natural’ flavour. Kellogg Makes Singapore Regional HQ Singapore will now be the company’s regional headquarters and home to its new R&D centre. Palsgaard Inaugurates Emulsifier Factory The facility in Malaysia can produce single emulsifiers and has a capacity of 20,000 MT per year. BASF Launches Live Newtrition Initiative Launched at Fi Asia, the initiative showcased consumer-driven prototypes based on the hottest trends. Brenntag Expands Distribution In India With the acquisition of a distribution division, the company expects to accelerate growth in the area. Tetra Pak Unveils Vietnam Dairy Plant Known as the Vietnam Milk Factory, the US$110 investment has an annual capacity of 400 million litres of milk in the first phase. Omega Engineering Opens Singapore Office The Singapore office is part of a multi-phase plan to expand the company’s global presence. GEA Heat Exchanges Launches China Website In addition to the China country site, the company is also preparing other local sites.

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Royal FrieslandCampina Establishes Singapore Development Centre AMERSFOORT, THE NETHERLANDS: The newly established FrieslandCampina Development Centre in Singapore houses the company’s nutritional expertise and product development for its Consumer Products International business group in Asia. The location emphasises the importance of the Asian markets to the company. The company’s aim is to offer people essential nutrients with natural dairy products. The development centre, located in the Singapore Science Park, will focus on the development of dairy-based beverages and infant and toddler nutrition, tailored specifically for Asian consumers. The centre will operate as an extension of the company’s innovation centre that will be launched in Wageningen in the Netherlands. Thien Kwee Eng, assistant MD of the Singapore Economic Development Board (EDB), congratulated the company on the opening of its development centre. “The company will be able to tap on Singapore’s integrated ecosystem of capabilities spanning market research, branding and marketing, and food & nutrition research expertise to develop products that cater to the nutritional needs of Asia’s diverse consumers. The company established a regional office in Singapore in 2011. The office is strategically located close to local operations in China, Hong Kong, Indonesia, Malaysia, Philippines, Thailand and Vietnam. ________________________________________ Enquiry No: 0700

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Cargill Invests In Thai Poultry Facility Expected to be completed by July 2014, the US$10 million upgrade will increase the company’s efficiency.

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saraBuri, tHailand: Cargill is investing US$10 million to upgrade its integrated poultry processing facility in Saraburi, Thailand, which produces a range of cooked poultry products for food service chains, convenience stores, food manufacturers, retailers and distributors across Asia, Europe and North America. The planned upgrades, which are expected to be completed by July 2014, include investing in the plantâ&#x20AC;&#x2122;s food safety system, installing more efficient equipment and expanding the facilityâ&#x20AC;&#x2122;s cold storage capabilities. The company also recently completed a US$110 million expansion of its other poultry processing facility in Thailand, located in Korat. Together, the facilities have an annual production capacity of 80,000 metric tonnes. They are part of a fully integrated poultry supply chain that includes breeder facilities, hatcheries, feed mills, pullet and g ro w o u t f a r m s , processing plants and a product development facility. Each step of the supply chain meets global biosecurity and food safety standards. The company has been operating in Thailand since 1968 and currently employs about 12,000 people across 10 locations. In addition to its poultry processing operations, the company sources, processes and markets a wide range of products including agricultural commodities, animal feed and food and beverage ingredients.

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BUSINESS NEWS

QuickBites OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

INDUSTRY & MARKET

Did you know?

“A study has shown that using red containers for food would discourage consumption.”

DSM Survey Reveals Trend For Natural, HomeMade Tasting Food Heerlen, tHe netHerlands: Global life sciences company DSM has published results of a consumer s u r v e y re v e a l i n g t h a t u r b a n consumers buying pre-prepared foods are seeking fresh, natural flavours and dishes that taste as though they could be home cooked. The survey results from 5,000 urban consumers in countries as diverse as the US, Brazil, China, Poland and Nigeria are included in the second of a series of global i n s i g h t re p o r t s p u b l i s h e d b y the company to explore people’s perceptions of savoury tastes. Revealing urban consumers’ taste preferences, attitudes and behaviours, the survey data shows that more than half (55 percent) believe a ‘fresh or natural’ flavour is what makes the food they buy taste delicious. This was felt most strongly by urban consumers living in China (72 percent). Closely following, was ‘taste as if it were made at home’ with respondents in Brazil saying this was the most important driver for delicious food (67 percent). These cravings for fresh-tasting, natural or homemade tastes present something of a challenge for food producers in the face of consumer behaviour,

as nearly two-thirds (64 percent) of urban consumers report they are using the same or more processed food at home than they were three years ago. Fur thermore, the sur vey demonstrates how discerning consumers are when it comes to choosing foods. They will actively seek out food that meets their taste and health requirements, with nearly

half of those who check labels before buying foods globally and 76 percent in China habitually checking labels for additives. Those who check labels are more likely to believe that a fresh and natural flavour is what makes food delicious when compared to those who do not check labels (60 percent versus 44 percent). _________________ Enquiry No: 0702

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2013

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DO YOU WANT TO REPL ACE CASEINATE IN COCONUT POWDER?

Kellogg Makes Singapore Asia Pacific HQ & Research Centre

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singapore: Kellogg, a manufacturer of ready-to-eat breakfast cereals and producer of savory snacks, cookies and crackers, has relocated its Asia Pacific headquarters to Singapore. The company’s regional president, as well as supply chain, human resource, research and development (R&D), marketing and finance leaders will all be based in the new office. Singapore will also be home to the company’s new R&D regional centre for savoury snacks, including foods marketed under the Pringles brand. The R&D centre will focus on food, flavour and packaging developments, as well as nutrition and sensory science. The company’s Asia-Pacific headquarters and R&D centre currently employs about 50 professionals in Singapore. This number is expected to grow as the company’s savoury snacks business expands in the region. According to Amit Banati, the company’s Asia Pacific president, the new regional headquarters in Singapore represents an important step in realising the company’s ambitions for long-term growth throughout Asia Pacific.

04.09.13 09:49

BUSINESS NEWS

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

INDUSTRY & MARKET

Did you know?

“People deprived of sleep are found to purchase more food items the next day.”

Palsgaard Inaugurates Emulsifier Factory In Malaysia Juelsminde, denmark: Danish emulsifier specialist Palsgaard has announced that the company’s new factory is open and ready for business. The facility is able to produce various single emulsifiers, as well as a variety of emulsifiers and stabilisers blends, and has a capacity of 20,000 MT per year. The official opening ceremony was attended by the Danish Ambassador to Malaysia, Nicolai Ruge, and the Deputy Minister of Malaysia International Trade and Industry, Datuk Haji Ir Hamim Samuri, in addition to the staff from the company and its Asian agents and distributors, as well as the architects, contractors and vendors who had contributed to the construction of the factory. The factory is located in Nusajaya, Johor, in the southern part of Malaysia

and has cost approximately US$36 million to build. The location for the company’s new facility has been chosen specifically for its proximity to the source of raw materials, such as palm oil and its derivatives. Additionally, the infrastructure is very developed and the easy access to the harbour as well as the company’s Singapore innovation centre for dairy, ice cream, soya, bakery, and confectionery applications, makes the location ideal. The new factor y covers an area of approximately 7,300 sq m, comprising a high tech manufacturing plant and research and development facility, laboratory, warehouse and administration centre. It is a highly automated plant with integrated energy saving functionalities. _____________________ Enquiry No: 0704

BASF Launches Live Newtrition Initiative Bangkok, tHailand: BASF Human Nutrition has launched its Live Newtrition initiative in the ASEAN region with consumerdriven prototypes based on the hottest trends at this year’s Fi Asia trade show. The market-oriented solutions displayed at the booth are tailored to meet both the diverse nutritional needs of consumers while meeting the value and versatility required by the industry. The ASEAN region commands a fast-growing beverage market due to consumer demand for convenient, delicious and healthy drinks. The €23 billion (US$31.11 billion) ASEAN soft drink market is projected to grow at eight percent annually through 2017, and the sub-segment of ready-to-drink tea is projected to grow at 11 percent per year. The €3.7 billion ASEAN vitamin and dietary supplement market is projected to grow at 11 percent annually, fuelled in part by rising concern for health issues like metabolic syndrome, a condition which predisposes individuals to cardiovascular disease. Growing waistlines, high tri-glycerides and cholesterol levels, and high blood pressure are hallmarks of the syndrome. Asian consumers influenced by Western culture are choosing baked goods over traditional food options. The €6.7 billion ASEAN bakery market is poised for seven percent annual growth through 2017. Both packaged and artisanal bakers are capitalising on this growth. ____________________ Enquiry No: 0705

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2013

BUSINESS NEWS 17

INDUSTRY & MARKET

Brenntag Expands Distribution In India mülHeim an der ruHr, germany: Brenntag has signed an agreement to acquire the chemical distribution division of the Zytex Group, a biotechnology food formulation and manufacturing company in India, by means of an asset deal. The acquired food ingredients distribution business will become part of Brenntag India, headquartered in Mumbai. The acquired business has its focus on enzymes and yeast for a broad application range in the food and beverage industries in India. With this acquisition, the company is further strengthening its nutrition and health business in India by adding new customer segments and products to its portfolio as well as further expanding its strategic relationships with key global suppliers. Henri Néjade, President and CEO of Brenntag Asia Pacific, says: “India is already one of the largest chemical distribution markets in Asia and offers substantial growth opportunities. This acquisition further underlines our commitment to India and our Indian partners. Our Indian business has rapidly grown over the past few years partly through organic growth as well as strategic acquisitions. This new business will improve our economies of scale, broaden our product offerings to our Indian customers,

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BUSINESS NEWS

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

INDUSTRY & MARKET

Omega Engineering Opens Singapore Office

Tetra Pak Unveils Vietnam Dairy Plant lausanne, switzerland: Tetra Pak has inaugurated an advanced liquid dairy plant in automation and integration in Vietnam with Vinamilk, one of the country’s top dairy manufacturers. Known as the Vietnam Milk Factory, this new facility, which covers 20 hectares in Binh Duong Province with an investment of US$110 million and has an annual capacity of 400

million litres of milk in the first phase. “The Vietnam Milk Factory is by far the most advanced plant in automation and integration that Tetra Pak has ever built,” said Bert Jan Post, MD or of Tetra Pak Vietnam. Commenting on the announcement, Madam Mai Kiều Liên, Vinamilk’s chairwoman and general director said, “This new plant has laid solid foundation for us to achieve our goals to become one of the world’s top 50 dairies with over US$3 billion revenues by 2017”. _____________________ Enquiry No: 0707

Did you know?

“A Harvard study has revealed that Americans throw billions of pounds of food away due to confusion over ‘sell-by’ and ‘best-before’ labels on product packaging.”

C o n n e C t i C u t, u s : O m e g a Engineering has opened a new office in Singapore to coordinate its business throughout the Southeast Asia region. This is part of a multi-phase plan to expand its global presence and footprint across Asia. This follows the company’s opening of a China office last year, with additional investments to be made in other countries in the Asia Pacific region. The company appointed Michael Lopez as the GM of Southeast Asia. The Southeast Asian business unit will have more than a dozen employees, including applications and technical support engineers, offering quality customer service in this region. “Our move into Singapore helps us to better service our clients in Southeast Asia,” The company’s Asia Pacific VP and MD, Patricia Liu, commented, “We have a significant installed base of business here where customers in multiple industries continue to expand their operations. Locating our newest office near our customers allows us to serve their needs more efficiently. It also presents us with an opportunity to grow our activities and expand our impact while more effectively reaching new customers in this emerging economic region.” __________________ Enquiry No: 0708

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2013

BUSINESS NEWS 19

INDUSTRY & MARKET

3485

BoCHum, germany: GEA Heat Exchangers, has launched a new website for China to offer users product information in Chinese and English. The company has recognised China to be the most important industrial country in Asia and a locomotive for global growth. The company has presence in six locations of the country. The site is tailored made for Chinese customers with pictures and information on products and news that are only marketed in the country. Christoph Michel, segment president for the company, says: â&#x20AC;&#x153;With our new country-oriented website and its content oriented to this market, we are supporting our business in one of the strongest growth regions of the world, which means we can react to regional requirements. We want to assure closeness to our customer as well as top local service quality. Corporate presentation effectively adapted to market conditions is an essential part of our customer support efforts and contributes to futureoriented further development of our business.â&#x20AC;? The website has been online since early 2013. In addition to the new China country site, further local sites are already in preparation. By the end of 2013, there will also be a Russian and a French Web offering. Ten years ago, many heat exchangers for the Asian market were still being imported from Europe. Today, imported products are effective only for small niches

west of Shanghai, has undergone on the Asian scene. enormous development over the For years now, the company has past years. During 2011 and 2012, invested in its Chinese locations. the shop floor there doubled in Its plant in Wuhu, which is one size, now at over 40,000 sq m. of its largest production locations and is situated around 360 km _______________ Enquiry 0709 AD_System_Asia_Pacific_APPS_111x183_TR.pdf 1 08/09/13 No: 09.55

Enquiry Number

GEA Heat Exchangers Launches China Website

PRODUCT HIGHLIGHTS

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

Tetra Pak: Whey Filtration System Tetra Pak has launched the Tetra Alcross RO Lite, a filtration system that helps small and medium sized dairies extract value out of whey. A common by-product of cheese production, whey is often dumped as waste. The system is a standardised filtration solution, which is available in five different sizes, easy to install and costs about 30 percent less than the customised alternatives. It uses a process of continuous reverse osmosis filtration to remove excess water from the whey, tripling its concentration while retaining all of the dissolved salts, lactose, acids, proteins, fats and bacteria. The concentrated whey can then be sold on to food processors as an ingredient in a growing variety of products, bringing a valuable income stream to the dairy, while also significantly reducing or eliminating unnecessary transportation and waste handling costs. ___________________________________ Enquiry No: P710

Compunic: Metal Detector The MD6210 Slide-Down Channel Metal Detector by Compunic can surpass traditional conveyor belt platforms in testing products with sticky and oily properties. Its design helps to reduce maintenance costs, saving time and money. The detector features use-friendly functionality and is easier to clean compared to conventional belt systems. It is also easy to assemble and disassemble accessories if necessary. The rejection device can be turned down fast and can precisely filter out contaminated products. The highly sensitive machine can detect fragments of metal and non-metal objects and can be used in different areas of food production, from raw materials handling to packaging of final products. __________________________________ Enquiry No: P712

Key Technology: Digital Laser Sorter The Taur ys by Key Technology is a nextgeneration digital laser sorter that can achieve faster and more precise sort decisions. With its Enygma sort engine, new architecture, a reengineered and patented Chycane infeed chute, new ejection manifold, and effective and reliable lasers, the system handles higher incoming defect loads, increases detection resolution, and improves the accuracy of defect and foreign material (FM) removal. Faster data processing enabled the sorter’s architecture to be changed to reduce the distance from the inspection zone to the ejection zone, resulting in superior product control and improved sorting efficiency. The powerful new sort engine enables the fusion of multiple sensor characteristics into a single sort decision. This ‘fusion sorting’ capability differs from traditional food sorting that makes sort decisions based on the product attributes collected by each sensor separately. ___________________________________ Enquiry No: P711

Bosch: Product Distribution System

Bosch Packaging Technology has introduced the Transver SDP product distribution system together with Rotzinger. The product distribution system features a modular depositing pullnose station designed for fully automated format changeovers and simple adjustment to product-specific characteristics. The modular design of the station supports easy maintenance and cleaning. The non-contact belt system operates without side guides ensuring high product quality—even for sticky, fragile food products and irregularly-shaped baked goods. Hygienic elements include an easy-to-clean stainless steel frame designed to withstand cleaning solvents and processes, as well as hybrid signal and power cables to minimise wiring and speed up equipment installation. ___________________________________ Enquiry No: P713

Profitability is easier than you may think

Discover water the Proven Possibilities In a price-conscious, competitive market where a majority of your expenses relate to the water bottle itself, it is ever important to cut costs. Thatâ&#x20AC;&#x2122;s why we challenge all your budget restraints and maximise your earning potential with proven possibilities. We combine production efficiency, reduced consumption, line flexibility and product integrity, all to give you a lower total cost of ownership. Discover all the proven possibilities at sidel.com

PRODUCT HIGHLIGHTS

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

Bosch: Product Distribution System

The NAT color® range from Naturex offers endless possibilities in color through its E-Color™ and VegeBrite™ lines. E-Color™ is a complete range of high performing color additives that is extracted and isolated from natural origins to ensure exact color targets are achieved. VegeBrite™ gives a comprehensive, vibrant palette of brilliant shades made exclusively from concentrates of fruits and vegetables, edible flowers and algae. Obtained without selective extraction or isolation, these ingredients perform superbly in a wide range of applications. For the best natural colors, contact our team of experts today.

www.natcolor.com FOR MORE INFORMATION CALL Naturex: +66 2726 9540 E-mail: naturex.th@naturex.com

PACKAGING & PROCESSING

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

THE authorities in China have started to take active steps in the fight against fake and tainted meat products, according to news website AsiaOne in May 2013. This occurred after a series of food scandals that have shaken public confidence. In the same month, MSN News reported that a crime syndicate was busted along with 63 arrests being made. The crime ring was responsible for processing rat, fox and mink meats before selling them as mutton in Shanghai for US$1.6 million. Not surprisingly, a survey conducted by market research firm Ipsos indicated that over 75 percent of respondents had concerns about the quality of food products, based on a report from China Economic Review in July. Because of this, demand for imports have increased due to better safety controls during packaging and processing, and the stringent product testing. standing out For domestic food manufacturers who want to continue to stay in the game, ensuring that their food processing and packaging facilities are well equipped to maintain food safety standards is important. The existing landscape is also an excellent opportunity for them to build their own reputations in a sea of scandals and fraud. In a bottling facility that produces soft drinks, it is important to have quality control (QC) mechanisms that pick out production errors. An example of the latter would be bottles that have missing caps. Clearly, delivering an uncapped bottle to retailers could end up with the contents spilling out and creating a mess along the way. Similarly, bottles whose caps are crooked or improperly screwed on could have the same undesired results.

Besides, bottles that have not been completely sealed could also allow pathogens or contaminants to enter, resulting in the likely spoilage of the product. Accidental consumption of the beverage would present a health threat to an unsuspecting consumer. Another scenario that could arise is the capping of bottles with the wrong caps. This could be due to a number of reasons, such as negligence. For example, the operator on duty may have loaded on the incorrect caps, or the supplier of the caps could have delivered caps that bore the wrong brand or product name. While this might not necessarily pose a serious health issue, the embarrassment from the mistake could negatively affect the reputation of the brand name and the manufacturer. The problem would be further exacerbated in a situation where a contract manufacturer manufactures products for different brands. Delivering a batch of Brand A product sealed with Brand B caps could make a major laughingstock of the two brand names involvedâ&#x20AC;&#x201D;especially given the speed and accessibility of online social media today. This would naturally raise doubts in the consumer market over the credibility and integrity of the companies. It could also end in expensive lawsuits against the contract manufacturer and the potential loss of business and reputation.

GOODWILL HUNTING WITH THE SCANDALS THAT CONTINUE TO PLAGUE CHINA, CONSUMERS ARE LOOKING TOWARDS ESTABLISHED FOOD PRODUCERS WHO MAKE PRODUCT PACKAGING AND PROCESSING A SERIOUS BUSINESS. BY didier lacroiX, SENIOR VP, INTERNATIONAL SALES & SERVICES, COGNEX

Sean Gregor, Vancouver, Canada

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2013

Take a Fresh Approach with The Shelf Life People.

In vision applications, the wavelength of the light that is used may be an important variable in the inspection process. When light of a certain colour is used for illumination, contrasting colours can be differentiated more easily. For example, this method can be used to enhance the date codes found on jar lids. Infrared light can be applied to highlight bruises on produce, while ultraviolet (UV) light will cause ink or glue to fluoresce. Filters need to be used on the camera if infrared or UV lights are used. This allows the fluorescence of the object to be viewed, but not the light itself. Collimated light is created when light rays are aligned parallel, and is suitable for applications that require sharp images. Diffused light is produced by directing collimated light through frosted glass. This results in a softer, more even

illumination which avoids glare or shadows, but with the downside of lowering the intensity of the light. Another consideration when inspecting par ts is the speed of motion of the par t (eg: when bottles are moving along a conveyor belt) as they are photographed, as well as the exposure time of the camera. The choice of light source therefore depends on a number of production variables. By defining the goals and focusing on what is important for the inspection, the application can be simplified. Once these goals have been understood, choosing the light source is the next step, depending on whether the requirement is to highlight features/defects or to cancel out the unwanted elements of the image.

• Preserve freshness: Environmental control features and carton treatment maintain product quality • Maximize production: Servo-driven features simplify operation • Gain flexibility: Quick and easy changes to fill volume, carton heights • Reduce downtime: Easy to operate and maintain Want to apply our fresh approach to your next product? Call us today . . . because we’re The Shelf Life People.

Visit Booth 520 at Cedar Rapids, Iowa, USA +1 319-399-3200 www.evergreenpackaging.com Optional SPOUT-PAK® closure system available. ©2013 Evergreen Packaging Inc. All Rights Reserved. ELL is a registered trademark of Evergreen Packaging Inc. SPOUT-PAK is a registered trademark of Evergreen Packaging International BV.

3478

For Sight

Developed specifically for midsize volume markets, the EQ-70 is designed with our exclusive ELL® features to maximize the shelf life of milk, specialty milk products, liquid egg products and still beverages.

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LIGHT

Take shelf life to the next level with our new EQ-70 gable top filling machine.

PACKAGING & PROCESSING

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

The machine vision system is able to generate reports on the number of errors that are detected during each shift. imPortant dates Manufacturing and expiry dates are also typically printed directly on bottles. This is to help the supply chain and end users to identify products that have passed their useful shelf lives. In this manner, it can help prevent expired food and beverage products from being mistakenly consumed. And if this does happen and an adverse reaction occurs, it is easier to prove that the onus of responsibility does not lie with the manufacturer. The manufacturer, however, has to ensure that the printed dates are correct, legibly printed and accurate. For example, an expiry date of February 30, 2105 could draw

inspection process was not thorough and not every bottle could be checked for defects. Also, while it was possible to check the presence of the dates, it was very difficult to ensure that the dates were correct. After the vision system implementation however, every bottle is now thoroughly inspected, even at current production speeds. Any bottle that does not meet the grade is diverted to a rejection bin for collection by the operator at the end of the shift. The system is also able to overcome another problemâ&#x20AC;&#x201D;verifying that the printed dates are correct. It achieves this by comparing the predefined dates that have been stored in the system. With the previous manual checking process, operators were not able to record down any errors, leaving

the machine system saves images of each bottle that for future retrieval if required. the data can serve as ridicule and ire (since there are only either 28 or 29 days in that month) from the public, putting the reputation of the manufacturer at stake. Yet, all of the above-mentioned problems can be easily resolved with the help of machine vision. A particular manufacturer of beer initially depended on four human operators to perform QC operations on beer bottles travelling along the conveyor belt. The operators had to manually inspect the bottles to ensure that all the bottles were capped and that the expiry and manufacturing dates had been printed. This method seemed to work initially when the facilityâ&#x20AC;&#x2122;s output was still low. However, when orders increased and production speed was ramped up, problems began to surface that questioned the suitability of having human operators on this job. At a production line speed of 50,000 bottles an hour, the human eye could hardly keep up. This meant that the

the management team unaware of production problems. Furthermore, problematic bottles that may have slipped through the earlier human QC system would have gone unreported, until and unless consumers submitted complaints. Presentation of information The machine vision system on the other hand, is able to generate reports on the number of errors that are detected during each shift, thereby providing managers with the necessary information to fine-tune and improve their manufacturing processes. For example, if there had been a large number of errors with a particular batch, it could mean that there was a problem with a shipment of caps; or perhaps issues with the bottling equipment. The machine vision system saves images of each bottle that has been checked and stores this data for future

The system also has the intelligence to ensure that the labels are not crooked or out of position.

ADVERTORIAL The technology eliminates the need for expensive investments to be made to mechanically rotate the parts for the inspection of such containers. In this manner, it is possible to reduce the complexity of the production line, lowering costs and increasing production rate. The credibility of a brand name is an important consideration in the eyes of the consumer. The media has shown that reputations of companies that took many painstaking years to build, can be swiftly brought down by a single act of negligence. In order to safeguard themselves, manufacturing facilities would do well to invest in automated QC systems that can prevent such events from occurring. This can help prevent negative publicity, ensure product quality, while building up the reputation of a company. DoubleSeal SuperShorty® Family

experience also for the development of light weight BERICAP For more information, ENTER No: 0720 DoubleSeal® SuperShorty® CSD closures for the light weight neck PCO 1881. The design of the BERICAP DoubleSeal® SuperShorty® not only ensures safe sealing, but also safe venting for bottles

no drying of ink high print speed highest reliability unique nozzle seal suitable for all surfaces

About 10 years ago, BERICAP introduced a one-piec 38mm closure, based on its DoubleSeal® technology to gether with an adequate neck for hot fill application, whic became a standard mainly in Asia, but also in Europe an replaced two-pieces closures requiring a separate liner. Based on the multi-billion unit experience with hot fill cl sures, but also with the DoubleSeal® technology, BERICA developed a new light weight 38mm hot fill closure fitting a neck with 1,5mm e-wall only; closure and neck achieve resin weight saving of ~21% versus the previous variant. For further cost reduction compared to a 38mm solutio BERICAP developed also a 33mm hot fill closure, again fittin WW W.LE I B I N allows G E R - Gthe R Ocustomers U P . C O M once more to a 1,5mm e-wall, which solid weight saving of another ~23% compared to the ligh weighted 38mm variant. As Asia is a big market for 28mm hot fill packages, BER CAP can offer a very economic, but solid alternative: base 3481

has been checked and stores them imPortant evidence in the future.

Lot numbers, best-before dates, pro production dates... the LEIBINGER inkjet printer is the perfect solution for all marking & coding requirements on any kind of packaging in the production process. Perfect print quality at high production speeds guaranteed on all materials such as glass, plastic, cans or any kind of paper.

Enquiry Number

retrieval if required. These images are important in determining which bottles have the right caps on and which do not. In the event of any investigations or allegations of production error, this data can serve as important evidence. Besides inspecting caps and dates, machine vision can also be applied to ensure that the labels on bottles are correct. Again, this serves as a safeguard against human error, whereby an operator may have loaded the wrong set of labels for a particular job. Furthermore, the system also has the intelligence to ensure that the labels are not crooked or out of position. Machine vision can also determine if ‘double-pasting’ has occurred, ie: where a second label has mistakenly been pasted over the first. Although the surface of a bottle is rounded, the system is able to leverage on the three-dimensional reconstruction feature provided by OmniView technology—to generate one-dimensional images of the bottles. This allows label checks to be made as if the product was ﬂat. An example of a setup for this purpose, is the deployment of four cameras that can see the entire surface of a cylindrical bottle. This is regardless of the position that the bottle is in. The software processes the four images and displays them as a single image. At the same time, it compensates for any variations in position during the bottle’s movement along the line.

Kesselring_OmniView

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2013

ADVERTORIAL

CAPPING CHALLENGES – DELIVERING HIGH VOLUME, HIGH EFFICIENCY & LOWEST COSTS TODAY’S challenge in capping is not just to have a good closure and a good bottle or container to achieve good capping results. But to be able to do this consistently in a fast moving and high volume environment and consistently achieving good results with the lowest yield losses and downtime. Added to this is the additional challenge of the consumer’s ever changing expectation of a good design with nice packaging, multi-functional usage (from normal screw cap, to hinge cap to thumbs up and push-pull caps), low carbon foot-print resulting in lighter weight caps and bottles. tecHnicAl suPPOrt Bottlers need to run their lines at highest efficiency to control their costs. Any stoppage of a line generates costs. BERICAP’s Technical Service Team, based on its long standing international experience, supports customers around the world, if capping problems occur or if new products shall be introduced.The BERICAP Technical Service is a key element for a successful closure business and a satisfied customer. If a customer introduces a new closure, it is necessary to have a full check of the capper to avoid capping issues from the beginning. Beside that assistance, the BERICAP team also offers training to the operators of his customers to secure an efficient and safe capping of the product. The exchange of experience, knowledge and the cooperation with the main capping machine suppliers complete the service package and contribution, which BERICAP can offer to its customers. BERICAP also develops capping heads which meet the expectation of the consumer - low opening torques. Not every capping head can guarantee constant opening torques, as a variation of the capper speed leads to torque variations. The liquid tight BNX capping head, developed by BERICAP, provides a constant capping torque, even if the line speed at the bottler changes drastically in speed. The machine operator can adjust the application torque simply by hand to achieve the desired customer friendly opening torque. cOMMitted tO custOMers’ success BERICAP supports its customers as a globally acting manufacturer

of plastic closures with 21 factories in 19 countries across the world. Strategic partners support customers with the same quality product and service in some countries. As a privately owned company, BERICAP will extend its production footprint also in future, having a strong focus on Asia. BERICAP is an experienced major closure supplier for various markets and can offer a wide range of closure solutions for the beverages, food (edible oil, sauces & dressings) and non-food industries, including automotive, agro-chemical, blow molded containers or metal packaging. Some of the developments for the food and beverage segments are the DoubleSeal® system for CSD, PushPull sports closures, ring pull membranes for edible oil or ring line closures for hot fill sauces in glass bottles. Based on its experience and market knowledge� BERICAP continuously develops new or improved closure solutions for the different markets. Four major R&D centers in Germany, France, Spain and Turkey, each one specialized in certain fields of closure technology, drive new developments. They are supported by satellite R&D departments in individual plants in order to provide proximity to the market and the customers. BERICAP runs its own manufacturing site for injection molds in Hungary. This service provides shorter lead times for production of injection moulds and consistency of mould design for each product and fast delivery of spare parts.

In Singapore BERICAP opened a new production site end of 2010 to spear head and develop new business, followed by new production locations in other countries in South East Asia. WeiGHt sAVinGs WitH innOVAtiVe clOsure sOlutiOns BERICAP successfully introduced various light weight closures A major driver for all market participants is cost saving. Having understood the necessity at a very early stage, BERICAP developed light weight closure solutions for the different markets, which included new light weight necks as well. A positive side effect is the reduced resin usage and consequently an improved carbon footprint for the customers due to the reduction of CO2 (greenhouse gas effect), based on the saving of non-renewable resources. The light weight closure introduction by BERICAP, combined with lower costs for the customers, leads to a resin saving, which represents significant annual CO2 reduction. liGHtWeiGHt clOsure sOlutiOns FOr still WAter In the bottled water market in the past, the necks 30/25 or 26,7 and adequate closures are mostly used for consumer packages. Both variants appeared too heavy and bottlers needed to have alternatives. To develop new closures for that market, it is necessary to understand the necessity for the bottler, who may just look for the cheapest package solution, and requirements of the consumer, who needs an easy to open / re-close closure with a certain orifice size for good pouring or drinking. Based on such knowledge BERICAP introduced the HexaLite® product lines 29/11 and 26/10 and forced the adequate bottleneck development such as PET 29/25 and PET 26/22 for still water / beverages, which are meanwhile established as European standards by CETIE. Both new closures fulfil the requested requirement: the weight reduction achieved versus the previous systems is ~41% using the HexaLite® 26/10 and ~35% using the HexaLite® 29/11, whereas that variant still offers the wide orifice like its predecessor, the 30/25 closure and neck. As another weight reduced novelty, BERICAP has introduced an Ultra Light Weight HexaLite® 29/11 version, which offers a consumer friendly big orifice and a lowest possible weight for a 29mm closure. That closure is also of high interest in Asia. Due to the boreseal design, HexaLite® closures guarantee the exceptional leak proof of the container. Even N2 (nitrogen) dosing is possible, which is necessary when bottlers use very light weight bottles, a trend upcoming more and more. The consequence is that water closures become a kind of pressure holding closure. All BERICAP closures therefore are tested in a Secure Seal Test.

The cut and folded slit band guarantees high levels of product security as it breaks easily when first opened, thus the integrity of the product is clearly visible to the consumer. The BERICAP HexaLite® 29/11 is introduced in Europe, India and China mainly, but is available for countries in South East Asia as well, where the PET 29/25 neck is available. The HexaLite® 26/10 achieves high levels of acceptance in North America and China, but has also been able to celebrate its significant successes in Europe. The consumer requirement for a good grip of the closure and the customer’s wish for a high value looking closure in mind, BERICAP developed a high HexaLite® 29/13 version, fitting on the PET 29/25 neck. That version will be introduced by the end of 2013 liGHt WeiGHt clOsures FOr cArBOnAted BeVerAGes In the past, only 2-pieces closures have been used for carbonated beverages, having several disadvantages such as high opening torque, breaking of the product integrity already after a few degrees opening turn or loss of CO2 in hot climate areas, which disqualifies the product quality. Already in 1998, BERICAP introduced 1-piece closures with DoubleSeal® technology to the beverage market, which offered consumer friendly low opening torques, a product integrity breaking only after ~ 120 degree turn, and last but not least, the CO2 content in the bottle was maintained at the highest level and supported the quality of the product also in high temperature areas. That performance was achieved thanks to the technical closure design with an inner and outer seal. Since then BERICAP has become the world leader in designing, manufacturing and supplying 1-piece beverage closures worldwide and has used that

ADVERTORIAL

DoubleSeal SuperShorty® Family experience also for the development of light weight BERICAP DoubleSeal® SuperShorty® CSD closures for the light weight neck PCO 1881. The design of the BERICAP DoubleSeal® SuperShorty® not only ensures safe sealing, but also safe venting for bottles of up to 3 ltr in size. Some of the many outstanding characteristics of the BERICAP DoubleSeal® SuperShorty® include easy application, consumer friendly removal torque and safe breaking of the tamper band. BERICAP only chooses highquality resins to manufacture all of its beverage closures to preclude any negative impact on the taste or odour of the customer’s product.The closure is designed to ensure the best application performance and highest capper efficiency. •

•

• •

Latest BERICAP DoubleSeal® SuperShorty® products for carbonated soft drinks, containing up to 8g CO2 / ltr, comprises a 1-piece closure weighing less than 2g and a high-performance version weighing slightly over. Beyond carbonated beverages, Bericap’s DoubleSeal® technology can be designed to incorporate Advanced Tamper Evidence - the tamper evident band breaks before the seal releases. This technology is used for still water only. Major brand owners recognize the performance of BERICAP’s DoubleSeal® closures and accept BERICAP as closure supplier in many parts of the world – a success story that started 15 years ago. Following market or customer requests, BERICAP also offers customized designs. Bericap’s 1-piece technology has been successfully transferred to other application such as aseptic filling or hot filling

One-Piece clOsures FOr HOt Fill APPlicAtiOns The global market for juices, juice drinks or teas uses mostly either aseptic filling or hot filling to stabilize the filled product for a certain shelf life. The European market is mainly using aseptic filling, the North American market uses mainly hot filling and Asia uses both filling methods, but hot fill seems still to be the majority, mostly using a heavy 28mm closure and a heavy neck as well.

About 10 years ago, BERICAP introduced a one-piece 38mm closure, based on its DoubleSeal® technology together with an adequate neck for hot fill application, which became a standard mainly in Asia, but also in Europe and replaced two-pieces closures requiring a separate liner. Based on the multi-billion unit experience with hot fill closures, but also with the DoubleSeal® technology, BERICAP developed a new light weight 38mm hot fill closure fitting to a neck with 1,5mm e-wall only; closure and neck achieve a resin weight saving of ~21% versus the previous variant. For further cost reduction compared to a 38mm solution, BERICAP developed also a 33mm hot fill closure, again fitting to a 1,5mm e-wall, which allows the customers once more a solid weight saving of another ~23% compared to the light weighted 38mm variant. As Asia is a big market for 28mm hot fill packages, BERICAP can offer a very economic, but solid alternative: based on its DoubleSeal® design, the standard DoubleSeal® Supershorty® as usually used for CSD product was tested successfully for hot fill application up to 88°C (higher temperature feasible) using a standard PCO 1881 neck shape. The weight saving can be as high as 32 % versus current solutions. The hot fill closure technology has been applied to BERICAP Sport closures. PushPull sports closures for 28mm, 33mm and 38mm necks are feasible for hot fill applications without an aluminium foil. All BERICAP hot fill closures can sustain filling temperatures of up to 88°C. clOsure sOlutiOns FOr tHe FOOd MArket The Asian market is well known for its speciality sauces, very often hot filled in glass. Bericap has a wide range of closures for that market. One of the latest developments is a closure for a 36mm glass neck finish, which has achieved superior tightness thanks to its inserted liner. The two pieces CTC H IP 36/22 closure, offers double tamper evidence with tear-off band and a tear-off membrane, an active hinge and a marguerite flow control. Dispensing valves are en vogue for squeezable products such as sauces or ketchup. An inserted valve allows a controlled dosing of the filled product, even if it contains small pieces, and after squeezing the orifice area remains clean and nearly free of product, which gives a clean and esthetic look. BERICAP offers such TPE made valve solution for various closures, also as customized solution if required. Closures with dispensing valves are also used for body care products and even more important today for so-called water enhancer - a concentrate, which allows the consumer to get different tastes in a glass of water by adding little shots. Specially in North America, this product category is very successful - also a Bericap valve is involved. For more information, ENTER No: 3497

Always perfectly packed

You want to pack powdered, pourable or lumpy goods efficiently and safely? You set a high value on individual design options for promotional product presentation? Wolf packaging machines are in use all over the world.

Wolf Verpackungsmaschinen GmbH Bettenh盲user Strasse 3 35423 Lich-Birklar 路 Germany Phone +49 6404 9182-0 路 Fax +49 6404 9182-83 www.wolf-pack.de 路 contact@wolf-pack.de Enquiry Number

3011

Taylor-made applications of highest flexibility For food, non-food and pharmaceuticals Machines for vertical and horizontal applications Modular solutions for operational availability Quick pre- and after-sales service wordwide

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PACKAGING & PROCESSING

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

Counting Down to

Zero v

Tim Sackton, Miami, US

In one of the bIggest-ever Investment projects In the company’s hIstory, cocacola amatIl Is currently changIng all Its plants to In-house pet-contaIner productIon, renderIng Itself Independent of converters.the company wIll be InstallIng over 30 blow-moulder/ fIller monoblocs from 2007 to 2015, brIngIng concomItant benefIts for both the company’s cost structure and the natural envIronment. by Peter Buchhauser, Krones

CoCa-Cola Amatil is one of the biggest soft-drink producers in the Asia Pacific region, and ranks among the world’s five largest Coca-Cola bottlers. The company has a payroll of around 15,000 people and access to a potential of more than 265 million consumers in Australia, New Zealand, the Fiji Islands, Indonesia and Papua New Guinea In addition to Coca-Cola’s entire portfolio, the company also produces a series of in-house brands, including the Mount Franklin spring water. Furthermore, the company operates in the foods and spirits sectors, and in the beer market as well. In 2012, its turnover came to around AU$5 billion (approximately US$4.63 billion). In Australia, the company operates plants in almost every state. Each of these facilities produces the whole CCA range, a fact primarily due to the huge distances encountered in Australia, which would otherwise entail high distribution costs. “Australia is like five islands,” says Bill Mossati, national manager procurement & capital project at the company. “The vast majority of the market is concentrated in the five big cities on the Australian shoreline.” 14 of the company’s production facilities are located in Australia, with the blow-moulder/ filler monoblocs installed in the six largest of these, all of which are operationally self-sufficient. The re-

maining plants fill spring water in large containers. The company has five facilities in New Zealand.

harnessing relevant exPertise PET containers arrived in Australia’s beverage market a long time ago, even though—in stark contrast to Europe—the can has continued to play the leading role in the soft-drinks market there. It accounts for about half of all carbonated soft drinks (CSDs), with around 40 percent filled in PET and 10 percent in glass bottles. In 1997, the company was already involved with a subsidiary serving as an external producer of PET containers for the filling plants. Some years ago, the company had to come to terms with the fact that many of its PET lines were showing their age, which were between 18 and 20 years old. The time was ripe for some major investment and innovation. Coinciding with this insight, the Australian government was offering support for investment projects in a predefined time window with tax incentives. It was the perfect opportunity for Project Zero. “What we wanted was to find investments helping us to reduce our cost basis,” says Mr Mossati. “What we opted for was to make group-wide use of blow-moulder/filler monoblocs.”

PACKAGING & PROCESSING

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2013

Pete Taylor

Ever since the machines were commissioned, the bottle has been lightweighted by 56 percent.

the weight of the Bottle was reduced By 33 Percent from 2000 to 2012, Becoming the lightest 600 ml cola-cola Bottle in the world. “With this project, we’ve harnessed the relevant expertise and brought it inside our company”, explains Gigy Philip, national manufacturing & packaging ser vices manager at the company. “We want to get the exclusive benefits from the advantages this vertical integration gives us.” The company’s supply chain director Bruce Herbert adds: “Project Zero has given our company a vision for the future, has enabled us to organically grow on a continuous basis, and was the key to the success we’ve achieved over recent years, acting as a catalyst for a surge in growth which has propelled us ahead of our competitors.”

lightweighting “Thanks to this project, CCA has

launched 43 new products on the market during the past three years alone, a trend that’s set to continue. Above all, the project enables us to design our PET bottles in-house,” says Mr Herbert. That was what the company did—in abundance—especially in regard to lightweighting. While in 2000, the standard 600 ml water bottle for Mount Franklin, one of Australia’s leading water brands, weighed 29 g, it has been slimmed down to 21.5 g by 2004. In 2010, another reduction thrust was launched by the company, resulting in a weight of 16.6 g. Ever since the first blow-moulder/ filler monoblocs from Krones were commissioned in 2011, the so-called ‘Easy-Crush bottle’ is weighing a mere 12.8 g (without closure). This corresponds to total lightweighting of 56

percent since 2000. For this achievement, the Mount Franklin bottle won the Global Packaging Award ‘World Star’. As Mr Herbert sees it, this is not the end of the story for the company, not by a long, long way: “We’re convinced there’s still scope left for further lightweighting. Everything is getting lighter, smaller, handier. Just look at smartphones.” The company adopted a similar approach for the Coca-Cola bottle. Its weight was reduced by 33 percent from 2000 to 2012 to what is now 20 g. Australia has, together with Mexico, the world’s lightest 600 ml Coca-Cola bottle.

sustainaBility Quite generally speaking, key targets for sustainability can be achieved by

PACKAGING & PROCESSING

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

monobloc-synchronising the blowmoulder and the filler, both in terms of reducing raw material input, water and energy consumption, and of utilising a higher percentage of recycled PET material. “Another option remains open to us, that of building our own recycling plant, but there are no plans for this at present,” explains Mr Mossati. In addition to that, weight reductions can also be achieved for end-of-theline packaging in cases or shrink film, as they can be for labels and closures. A study commissioned by the company in 2011 on the utilisation of the new technology in the Northmead plant (where so far three Contiform Bloc systems are up and running) revealed that

be possible to save a total of more than 9,000 tonnes of PET raw material a year as soon as all production lines have been equipped with blowmoulding/filling technology. The CO2 footprint was reduced further after the company commissioned its own preform and closure factory, worth AU$57 million, in 2012 because this obviates the need for transporting these components from the vendors to the company. The ‘Eastern Creek’ Preform Plant boasts of the latest plastic injection moulding machines and possesses an annual capacity of more than three billion units. At present, the plant produces 1.4 billion preforms and 1.4 billion

ture Works Team in-house, and is the lowest-weight 1881-type Coca-Cola closure in the world.

imPressive results Once all of the lines have been commissioned in 2013, the company will be working with a total of 18 blow-moulder/filler monoblocs from Krones in Australia, with 13 in Indonesia, three in New Zealand and one in Papua New Guinea. “In our plants, the monoblocs really have to show what they can do”, adds Mr Mossati. “Each of them fills 50 to 70 stock-keeping units (SKUs).” The company channelled AU$100 million into its production capacities, so as to cope with main-season peaks,

Key targets for sustainaBility can Be achieved Both in terms of reducing raw material inPut, water and energy consumPtion, and of utilising a higher Percentage of recycled Pet material. closures for Australia, New Zealand and the Fiji Islands. It is here, too, that the ‘Sylon’ closure is made, which was developed by the company’s Fu-

to increase the number of different SKUs and to offer more consumerspecific packages. The kit installed by the company for these purposes

The company estimates that it will be possible to save a total of more than 9,000 tonnes of PET raw material a year as soon as all production lines have been equipped with blow-moulding/filling technology.

Beverley Goodwin, Liverpool, UK

this alone had by the end of 2011 caused water consumption in the plant as a whole to fall by eight percent. The water saved there was essentially what had previously been needed for rinsing the containers prior to filling them. The new technology provided its user with an average reduction in CO2 footprint for each individual container of 22 percent as compared to a converter solution. The most significant carbon dioxide savings achieved there stem from 15 to 23 percent less PET raw material being needed for container production, 33 percent less PET being used for the closures, 30 percent less energy required for blow-moulding the bottles from preforms, and the option for doing so without the prewarmer, since the blow-moulding/filling technology permits the bottles to be filled at ambient temperature. In addition to that, around 65,000 km of truck transport can be dispensed with each year. All in all, the company estimates that it will

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Løjt Kirkeby

AustrAliAn Premium Beer mArket Project Zero may be coming to an end, but the company will continue to channel capital expenditure into new markets. In future, the company will again be engaging more proactively in business involving alcoholic beverages. For more than seven years now, there has been a distribution agreement in force with the American premium spirits producer Beam Global Spirits & Wines. In addition, the company also markets beer brands from the Grupo Modelo, Carlsberg and Molson Coors beer groups on the Pacific islands and in New Zealand. In 2012, the company took over the Fiji Brewery & Distillery, with plants on Fiji and Samoa. On December 16, 2013, a contractual provision dating from the termination of a former joint venture with an international brewing conglomerate and stipulating that the company must not enter the Australian beer market, will expire. Also in 2012, the company had lent the Australian Beer Company, as part of the Casella Group, AU$46 million for building a new brewery, a

CCA aims to save costs amounting to an annual AU$3040 million over the upcoming three years.

nikagnew, Nova Scotia, Canada

purposes includes three flexible canning lines, plus two hotfill lines for the Powerade sports drink, juices, vitamin-fortified water, and tea, in which two Sleevematic wrap-around labellers have also been integrated in 2013 for special dress. The spectrum of variants offered for the can, Australia’s all-important container for drinks, has been upsized from two to eight formats, while the figure for delivery incapacity during the peak season fell from twelve in 2006 to two percent in 2011. “Project Zero has enabled CCA to expand its product portfolio while also cutting its costs and improving its service support and delivery capabilities for its customers,” explains Mr Herbert. “In the period from 2001 to 2012, we increased the number of different SKUs from 194 to 1,100, we upped our proportion of delivered in full on time accurately invoiced (DIFOTAI) consignments from 83 percent to 97 percent, and our return on invested capital (ROIC) from seven to 24 percent. Our target is to use the measures initiated so as to save costs amounting to an annual AU$30-40 million over the upcoming three years, starting in 2013.”

loan that after 16 December 2013 is to be channelled into a joint venture. The company will then re-enter the Australian premium market, through the Casella Brewery at Griffith in New South Wales, which possesses a Steinecker CombiCube B brewhouse rated at 160,000 hectolitres. “Not only will CCA in the future be utilising further options for automation and goods logistics, it will also aim to deploy new technologies for filling and packaging,” explains Mr Herbert. “For us, innovative packaging is just as important as the product it contains.” For more information, ENTER No: 0722

3484 Enquiry Number

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INGREDIENTS & ADDITIVES

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

ExtEnding shelf life wiTh fruiT concenTraTes

Technical obsTacles have limiTed The use of fruiT-based ingredienTs in producTs wiTh long shelf life. ulTra rapid concenTraTion fruiT ingredienTs can miTigaTe moisTure Transfer by conTrolling waTer acTiviTy in baked goods, cereals and snacks, while delivering excepTional TasTe. by Grant taylor, sales manager-asia pacific, Taura naTural ingredienTs HealtH and wellness has been the biggest megatrend in the food industry in recent years and consumer appetite for healthy eating shows no sign of diminishing. In particular, products featuring real fruit appeal strongly to today’s health-conscious consumers. Fruit ingredients provide a colourful, tasty and attractive way to tap into this trend and create a ‘health halo’ around products. However, significant technical obstacles have previously limited the use of fruit-based ingredients in many products with a long shelf life. Applications such as biscuits, baked goods, cereals and snacks have been especially problematic. Incorporating fruit into dry products like these has presented a challenge because introducing any additional moisture poses a threat to the texture and shelf life of the finished product. Solutions based on ultra rapid concentration (URC) fruit ingredients can sweep away these technical barriers and pave the way for a wide range of new products featuring fruit pieces, flakes and pastes. These can be designed to deliver all the taste, colour and nutritional benefits of fruit inclusions in products requiring an ambient shelf life of up to 12 months or more. Moisture reMoval The fruit solutions mitigate moisture transfer in a range of long shelf life dry foods, enabling

manufacturers to include fruit in products where it would otherwise be impossible without seriously compromising shelf life. The proprietar y URC technology concentrates fruit purées and blends them to below 10 percent moisture in less than 60 seconds. However, it is not the absolute moisture content that decides whether ingredients can be used successfully in tricky applications. The crucial parameter is water activity (Aw), which is a measure of the ability of water to migrate from a given ingredient into the surrounding food matrix. It is the technology’s ability to tailor the water activity of its ingredients to each application that opens up new product development opportunities. The ingredients are designed to deliver technical, marketing and ultimately consumer benefits in applications such as: 1. 2. 3. 4. 5. 6.

Baked goods Biscuits Cereals Chocolate and other confectionery Snack bars Fruit snacks

INGREDIENTS & ADDITIVES

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2013

Water activity Water is typically bound inside a material by a combination of hydrogen bonds, ionic bonds, dipoledipole interactions and Van de Waals forces. With such complex forces at work, the absolute amount of water in the system may not relate to the ability of water within a food to escape. As a result, manufacturers require another means to measure the tendency of water to migrate into the surrounding food matrix. Water activity provides this means. It measures the energy status of the water in a given system. Highenergy water is better able to escape than low energy water. At room temperature, water molecules move from the surface of a food to the atmosphere and back again until they reach equilibrium. The definition of water activity effectively compares the pressure generated by the vapour escaping from the surface of the food (p) with the vapour pressure of pure water under the same conditions (po):

will not grow if the water activity is below 0.70. Moulds will not grow if the water activity is below 0.60. Physical properties: Water activity can have a major impact on colour, taste, texture and aroma. Controlling moisture migration: Water activity is an important tool for controlling water migration in multi-component foods. In

Aw=p/po

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The reason why water activity is such a critical parameter for food manufacturers varies depending on the application. In cereals, for example, fruit pieces need to exhibit the same water activity as the other components in order to prevent the cereal flakes from going soggy and the fruit pieces turning hard. In baked fruit filled bars, cakes or cookies, the fruit paste must have the same water activity as the surrounding product to prevent moisture and colour leaching into the rest of the bar. More generally, ensuring that fruit ingredients have the correct water activity can prevent shelf life problems that might otherwise arise in one or more of the following areas:

INGREDIENTS & ADDITIVES

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

tHe Urc tecHNOLOGy USeS PHySicaL aND MecHaNicaL FOrceS tO reMOve Water FrOM FrUitS. other words, achieving the correct level of water activity can help to prevent unwanted softness or moistness in biscuits and cereals. Chemical/biochemical reactivity: Water activity can play a significant role in determining the activity of enzymes and vitamin stability in foods.

Water may influence chemical reactivity in different ways. It may act as a solvent or reactant, for instance, or it may change the mobility of a reactant by affecting the viscosity of the system. Water activity therefore influences a range of common chemical processes in foods, including non-enzymatic browning, lipid oxidation, degradation of vitamins and enzymatic reactions, which can all impact on shelf life. taiLOreD SOLUtiONS The URC technology uses physical and mechanical forces to remove water from fruit purées and blends. This process is suitable for heat-sensitive fruits, so the resulting concentrate retains the flavour, colour and nutritional characteristics of the raw materials. Most importantly, the process can be used effectively to control the water activity of the resulting ingredients. The ingredients exhibit a water activity of between 0.35 and 0.65, in contrast to conventional ‘dried’ fruit, which has a water activity of about 0.6. In practice, this means that finished foods with URC inclusions enjoy a shelf life of at least 12 months and that crunchy and crispy foods will maintain their texture—even when they feature soft fruit pieces, layers or ﬁllings. The ingredients can be formulated to maximise the water binding characteristics for a range of product types and formats. These include ultra-dry pastes that create soft, real fruit ﬁllings with a water activity of just 0.35. MarKet OPPOrtUNitieS The ability to include meaningful amounts of real fruit creates excellent opportunities for new product development. The URC process

can utilise flavour blends, natural extracts and a range of fortification options. In other words, it enables manufacturers to respond quickly to emerging trends in healthy eating. The portfolio of ingredients ranges from 100 percent fruit-derived material with no added sugar to indulgent flavour concepts. With no artificial preservatives, colours or flavours, manufacturers can explore these opportunities w i t h o u t c o m p ro m i s i n g t h e c l e a n - l a b e l credentials of their products. URC ingredients also offer a range of technical benefits. They are highly bake-stable, and URC fruit pieces and pastes feature a pectin gel structure that will not burn or boil-out, so the texture can be controlled through the cooking process. The ingredients also stand up extremely well to physical processing, including pumping, extrusion and filling. They are also very easy to use. They can be stored at ambient temperature, they require no messy preparation and they are free-flowing for straightforward incorporation into the manufacturing process. The fruit ingredients effectively tear down the technical barriers that have prevented manufacturers from developing delicious, long shelf life products with the powerful consumer appeal of real fruit. These solutions offer the flavour, texture and goodness of fruit with less wastage and mess. They are also easy to use in a wide range of commercial applications, where they offer long shelf life and significant taste and texture benefits over dried or candied fruit. For more information, ENTER No: 0730

www.apfoodonline.com

M BASF Beneo Clearpack Gebo Cermex Krones KHS Schaefer Waters Bericap Flexicon Tecsia Fortitech Sidel Heat and Control Hosokawa Ev ng Andritz Brady Ishida Kluber Matcon Multivac Nagase Palsgaard Leibinger PIAB Sollich TNA Viscotec Wacker Chemie Yamato LycoRed JBT B xon Mobil Glanbia Hughson Nut Almond Board of California Ingredion KH Roberts System Logistics Unitech Urschel Wenger Wolf Leiber TUV S K Fiberstar Gericke Kalsec Naturex Sandvik Cognex Vitablend Zebra CP Kelco Cargill Statec Binder Hydrosol Stern Ingredients Intertek SATS Ca tyne GEA Tate & Lyle DSM BASF Beneo Clearpack Gebo Cermex Krones KHS Schaefer Waters Bericap Flexicon Tecsia Fortitech Sidel Heat a okawa Evergreen Packaging Andritz Brady Ishida Kluber Matcon Multivac Nagase Palsgaard Leibinger PIAB Sollich TNA Viscotec Wacker Chem ed JBT Buhler Connell Bros Exxon Mobil Glanbia Hughson Nut Almond Board of California Ingredion KH Roberts System Logistics Unitech Ursc eiber TUV SUD Brenntag AAK Fiberstar Gericke Kalsec Naturex Sandvik Cognex Vitablend Zebra CP Kelco Cargill Statec Binder Hydrosol Stern SATS Cama Purac Ballantyne GEA Tate & Lyle DSM BASF Beneo Clearpack Gebo Cermex Krones KHS Schaefer Waters Bericap Flexicon Te el Heat and Control Hosokawa Evergreen Packaging Andritz Brady Ishida Kluber Matcon Multivac Nagase Palsgaard Leibinger PIAB Sollich TNA r Chemie Yamato LycoRed JBT Buhler Connell Bros Exxon Mobil Glanbia Hughson Nut Almond Board of California Ingredion KH Roberts Syste ch Urschel Wenger Wolf Leiber TUV SUD Brenntag AAK Fiberstar Gericke Kalsec Naturex Sandvik Cognex Vitablend Zebra CP Kelco Cargill Sta ASF Beneo Clearpack Gebo Cermex Krones KHS Schaefer Waters Bericap Flexicon Tecsia Fortitech Sidel Heat and Control Hosokawa Everg ndritz Brady Ishida Kluber Matcon Multivac Nagase Palsgaard Leibinger PIAB Sollich TNA Viscotec Wacker Chemie Yamato LycoRed JBT Buhle Mobil Glanbia Hughson Nut Almond Board of California Ingredion KH Roberts System Logistics Unitech Urschel Wenger Wolf Leiber TUV SUD erstar Gericke Kalsec Naturex Sandvik Cognex Vitablend Zebra CP Kelco Cargill Statec Binder Hydrosol Stern Ingredients Intertek SATS Cama P GEA Tate & Lyle DSM BASF Beneo Clearpack Gebo Cermex Krones KHS Schaefer Waters Bericap Flexicon Tecsia Fortitech Sidel Heat and wa Evergreen Packaging Andritz Brady Ishida Kluber Matcon Multivac Nagase Palsgaard Leibinger PIAB Sollich TNA Viscotec Wacker Chemie Ya BT Buhler Connell Bros Exxon Mobil Glanbia Hughson Nut Almond Board of California Ingredion KH Roberts System Logistics Unitech Urschel eiber TUV SUD Brenntag AAK Fiberstar Gericke Kalsec Naturex ablend Zebra CP Kelco Cargill THE MARKET LEADERS ARE WITH US, ARE YOU? Statec Binder Hydrosol Stern Ing S Cama Purac Ballantyne GEA Tate & Lyle DSM BASF Beneo Clearpack Gebo Cermex Krones KHS Schaefer Waters Bericap Flexicon Tecsia at and Control Hosokawa Evergreen Packaging Andritz Brady Ishida Kluber Matcon Multivac Nagase Palsgaard Leibinger PIAB Sollich TNA Visc emie Yamato LycoRed JBT Buhler Connell Bros Exxon Mobil Glanbia Hughson Nut Almond Board of California Ingredion KH Roberts System L rschel Wenger Wolf Leiber TUV SUD Brenntag AAK Fiberstar Gericke Kalsec Naturex Sandvik Cognex Vitablend Zebra CP Kelco Cargill Statec Stern Ingredients Intertek SATS Cama Purac Ballantyne GEA Tate & Lyle DSM BASF Beneo Clearpack Gebo Cermex Krones KHS Schaefer W xicon Tecsia Fortitech Sidel Heat and Control Hosokawa Evergreen Packaging Andritz Brady Ishida Kluber Matcon Multivac Nagase Palsgaard L ch TNA Viscotec Wacker Chemie Yamato LycoRed JBT Buhler Connell Bros Exxon Mobil Glanbia Hughson Nut Almond Board of California Ing rts System Logistics Unitech Urschel Wenger Wolf Leiber TUV SUD Brenntag AAK Fiberstar Gericke Kalsec Naturex Sandvik Cognex Vitablend o Cargill Statec Binder Hydrosol Stern Ingredients Intertek SATS Cama Purac Ballantyne GEA Tate M BASF Beneo Clearpack Gebo Cermex Krones KHS Schaefer Waters Bericap Flexic rtitech Sidel Heat and Control Hosokawa Evergreen Packaging Andritz Brady Ishida ultivac Nagase Palsgaard Leibinger PIAB Sollich TNA Viscotec Wacker Chemie Yam d JBT Buhler Connell Bros Exxon Mobil Glanbia Hughson Nut Almond Board of C KH Roberts System Logistics Unitech Urschel Wenger Wolf Leiber TUV SUD B star Gericke Kalsec Naturex Sandvik Cognex Vitablend Zebra CP Kelco Carg Hydrosol Stern Ingredients Intertek SATS Cama Purac Ballantyne GEA Tate M BASF Beneo Clearpack Gebo Cermex Krones KHS Schaefer Water n Tecsia Fortitech Sidel Heat and Control Hosokawa Evergreen Packag dy Ishida Kluber Matcon Multivac Nagase Palsgaard Leibinger PIAB So otec Wacker Chemie Yamato LycoRed JBT Buhler Connell Bros Exxon Mobil Glanbia Hughson Nut Almond Board of California Ingredion KH Ro gistics Unitech Urschel Wenger Wolf Leiber TUV SUD Brenntag AAK Fiberstar Gericke Kalsec Naturex Sandvik Cognex Vitablend Zebra CP Kelc er Hydrosol Stern Ingredients Intertek SATS Cama Purac Ballantyne GEA Tate & Lyle DSM BASF Beneo Clearpack Gebo Cermex Krones KHS

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LECITHIN:

nature’s Versatile eMulsiFier

AS an emulsifier, soy lecithin is used in food

Windell Oskay, California, US

applications as an aerating agent, viscosity modifier, dispersant and lubricant. Typically, an emulsion is a suspension of small droplets of one liquid in another liquid with which it is incapable of mixing. Oil-in-water (O/W) and water-in-oil (W/O) are the two primary types of emulsions. Lecithin’s molecular structure makes it an effective emulsifier for the interaction of water and oil. Phospholipids, the major component of lecithin, are partly hydrophilic (attracted to water) and partly hydrophobic (repelled from water). It is lecithin’s ability to simultaneously interact with both oil and water that makes it such an effective and stable emulsifier. When introduced into a system, an emulsifier such as lecithin acts to help maintain a stable emulsion between two unmixable liquids. The emulsifier decreases the surface tension between the two liquids and allows them to mix and form a stable, heterogeneous dispersion.

Amelia Crook

AS NATURE’S PRINCIPAL EMULSIFYING AGENT, SOY LECITHIN CAN GREATLY ENHANCE THE DISPERSION OF THE FATTY AND AQUEOUS COMPONENTS IN MANY TYPES OF FOOD PRODUCTION. BY andrea Wolters, MARKETING MANAGER, LECICO eMulsiFier ClassiFiCation The classification of emulsifiers is often expressed as the relation between hydrophilic and lipophilic groups = HLB-System (hydrophiliclipophilic balance). Numbers of a scale from one to 20 are allotted to the emulsifiers. Lipophilic emulsifiers have a lower HLBNumber, whereas emulsifiers of a hydrophilic character have a higher number. The turning point between lipophilic and hydrophilic emulsifiers lies at number 10 of the scale. This HLB-System can very well be applied to non-ionic synthetic emulsifiers. By means of the HLB-Value, conclusions can be drawn regarding the behaviour as an emulsifier. It is a general rule that when preparing an emulsion, the phase, in which an emulsifier has better dispersing properties, becomes the outer phase. Therefore, a lipophilic emulsifier with an HLB-Value of six is likely to facilitate the preparation of a w/o emulsion and vice versa, ie: a hydrophilic emulsifier will support the creation of an O/W emulsion. In practical applications, often a mixture and/ or combinations of different emulsifiers are used. Experience has shown that by this procedure, very stable emulsions can be prepared. The HLBValue helps in the calculation of the optimum mix for a certain types of emulsifiers. As the HLB-System is traditionally a good aid for characterising emulsifiers, the effort has been made to also apply this system to lecithins. The HLB-Value (the determination of

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the HLB-value was only possible by comparing waterdispersibility of the lecithins with reference standards of synthetic nonionics) when applied to lecithins, however, it provides only little information about their functionality as emulsifiers, ie: whether a certain lecithin quality is suitable as a W/O or as O/W emulsifier. It appears as if other mechanisms play a more important role for the preparation of a stable emulsion besides the hydrophilic and lipophilic balance, eg: tendency of lecithins in an aqueous dispersion to form extended lamellar structures and networks. For lecithins, the HLB-Value can just only be used as an indicator for water dispersibility, ie: the higher the number, the better the water dispersibility of a certain lecithin. Versatile natural ingredient Lecithin is nature’s principal emulsifying agent. It greatly speeds up the dispersion of the fatty and aqueous components in many types of food production, for example, in the manufacture of bread, biscuits, sweet pastries, convenience foods, ice cream, chocolate and margarine.

C C

M M

Y Y

CM CM

The following examples show the manifold application possibilities.

MY MY

CY CY

CMY CMY

MARGARINE/OIL Due to its specific properties, soy lecithin is widely used in margarine applications. In frying margarines, it is used for its anti-spattering characteristics. Lecithin also promotes browning due to its interaction with proteins. It improves the aroma, avoids sediment sticking to the pan, keeping particles dispersed, and limits foam formation. Spattering during frying is caused by the explosion of water droplets. During frying, water comes free. When frying in oil, water droplets will not be emulsified and will coalescence and become bigger. The bigger droplets will sink to the bottom of the frying pan and come in contact with the hot pan bottom. This will heat up the water droplet in such a degree that it explodes, producing fat spattering. The lecithin in a frying margarine will emulsify the water droplets, avoiding coalescence, keeping the droplets small, facilitating fast evaporation before reaching the hot pan bottom and avoiding explosion of water droplets. In margarine for baking applications, lecithin improves the elasticity of the margarine and its baking properties

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OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

extruded from the dough mass on the belt, eg: biscuits. The lecithin systems are also used for a better cleaning and rinsing of the belt. Examples of applications are: fried, baked, pre-cooked or marinated products, like meat products, breaded products, pizza, biscuits, snack and dehydrated or frozen products like fruits and vegetables (potatoes, and fries).

bob

Food release/seParation agent Cheese and meat products have var ying moisture levels and are stored under different conditions of temperature and humidity. These conditions provoke sticking of slices of cheese or meat to each other or to the cutting knives, wires, grinders and extruders. Low viscous lecithin can be used as a nonsticking aid and forms a barrier between the sliced and shredded products.

mould. It forms an interaction barrier between the food product and the metal surface. Lecithin is used in different formulations like: â&#x20AC;˘ Pure low viscous lecithin compounds: oil/lecithin mixtures â&#x20AC;˘ Pump and aerosol sprays: oil, lecithin, propellant Next to these formulations, it can also be an emulsion of water and oil. Improved heat-resistant lecithin provides a reduction in the darkening process during heating. The release agents can directly be applied on the cooking surfaces or used in the food grinders, extruders, cutters. Lecithin can also be incorporated in the food formula to encourage mould release. Different lecithin is used for iron release of waffles and wafers, and also provides improvements in break-resistance, even browning and uniform surface.

Continuous Cooking/Freezing Belt release Oily and aqueous formulas with lecithin are developed for better release and non-sticking of the food from the belt. This layer will also control the formation of the final shape and dimensions of the end product, when food products are

Lecithin improves the elasticity of margarine and its baking properties.

Bakery ProduCts Lecithin improves the extensibility of the gluten, which has an impact on various aspects of the baking process. It improves the machinability of the dough, stabilises the fermentation process as the dough becomes less porous and improves gas retention which results in an increased loaf volume and a more uniform crumb structure. Additionally, lecithin interacts with the wheat starch, delaying retrogradation of the amylose, and improves water binding which results in a longer shelf life. In deep frozen doughs, lecithin improves the freezing and thawing stability. The growth of large ice crystals is inhibited. This reduces mechanical damage of the dough gluten network and protects yeast cells.

SG-933-iglidur EU-Buchse li+re 54x240_SG-933-ig ASIA PACIFIC FOOD INDUSTRY OCTOBER 2013

Don't lubricate The quality of biscuits, wafers and other pastry products is improved by adding lecithin as it assures: a better homogenisation of the different ingredients; a better emulsification of the fat; improved water binding. This results in better cohesion and a more uniform browning of the product. It will also reduce breakage. Wafers can be more easily removed from the waffle irons. The nutritional quality of the biscuit and wafer is also improved due to the reduction of fat and oil. Because of the emulsifying properties, fat is more evenly distributed which results in a more efficient use of the fat or oil.

For more information, ENTER No: 0731

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other ConFeCtionery Caramel and toffees demand a very homogeneous texture for good mouthfeel because of the slow melting process in the mouth. Lecithin will improve the distribution of the emulsified fats and particles. This will also increase the shelf life of the products as lecithin reduces the probability of fat bleeding. In the recrystallisation of sugar, lecithin acts as a mild anti-oxidant.

... for better taste

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ChoColate & ConFeCtionery Lecithin is a traditional additive in chocolate production. Chocolate is a dispersion of sugar, milk powder and cacao particles in a fat phase, the cacao butter. The chocolate production process requires significant energy as the chocolate mass is kneaded during the conching process over a period of several hours. This processing is necessary for the homogenisation of the different ingredients and the aroma development. The conching process is highly energy consuming due to the high viscosity of the chocolate mass and the increase in viscosity during the conching process. Chocolate mass viscosity is a complex processing variable and is influenced by several parameters: particle size distribution (the finer it is, the more particle surface to coat, the less available ‘free’ cacao butter there is, the higher the viscosity), and the relative proportion of cacao butter in comparison to the solid particles (the more ‘free’ cacao butter there is, the lower the viscosity). In order to reduce the viscosity during processing, chocolate producers add lecithin as it improves the dispersability of the particles in the cacao butter, and therefore, reduces viscosity and increases the yield value of the chocolate significantly. Lecithin disperses solids in a much more efficient way in comparison to a chocolate without lecithin due to its amphiphilic characteristics. A dosage of 0.35 percent lecithin results in a comparable viscosity reduction realised with a dosage of eight percent of cacao butter. This viscosity reduction results in significant cost savings for the chocolate producer by allowing savings on energy and cacao butter, the most expensive ingredient in chocolate. The optimal dosage varies between 0.4 to 0.6 percent in chocolate. The addition of lecithin also impacts the crystallisation of the chocolate and improves the gloss of the chocolate.

HEALTH & NUTRITION

Staying Fit With Whey Protein isolaTe The populaTion of older adulTs around The world is on a sTeady rise, leading To a new focus on healTh span raTher Than life span. proTein inTake can be criTical in ensuring ThaT The elderly sTay healThy and fiT. by Phanin LeksrisomPong, direcTor of business developmenT, davisco foods

Championship Catering, Bloomington, US

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

The world’s total population of older adults has experienced a steady increase on an annual basis. A continued decline in birth rates combined with increased life expectancy has resulted in an increase in the total number and proportion of adults aged 60 and over. According to the World Health Organization (WHO), the world population of adults in this age group has doubled since 1980 and is projected to reach two billion by 2050. Approximately 400 million adults will be aged 80 or older.

The world’s ageing population can be seen in nearly every country and older populations are beginning to outnumber younger populations. The MIT Age Lab reports nearly 77 million American baby boomers are well into their sixties, while China’s total population over the age of 60 already exceeds that of the entire population of Russia. Wheelchairs and walkers outnumber baby strollers in parts of Europe. The number of adults in Japan over the age of 65 is expected to comprise nearly one-third of the

country’s total population by 2050. Ageing populations can be a strain for individual economies, as they require more health and other services, and produce less wealth than younger populations. As the total population of older adults continues to increase and life expectancy is extended, it is imperative that the specific wellness and nutrition needs of older adults are addressed. heaLth sPan over Life sPan Life span is how long we live, and health span is how long we live with the best possible health. Improvements in sanitation, use of antibiotics, and improved medical care have all significantly contributed to increasing life span, but the quality of health tends to decline with increasing age. Understanding how to address the health challenges of our ageing population is essential for maintaining optimal health and improving overall quality of life. Common health challenges of older adults include:

HEALTH & NUTRITION

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2013

Ian Ransley, San Francisco, US

Dennis Hamilton, Washington, US

Recent research strongly indicates that most adults would benefit from replacing some dietary carbohydrates with protein. •

• •

•

Loss of bone mass (osteopenia, a precursor of osteoporosis) Loss of muscle mass (sarcopenia) Frailty (a state of high vulnerability for adverse health outcomes, including falls, hospitalisation, disability, and death) Metabolic syndrome (having a combination of three or more metabolism-related disorders at the same time, increasing risk of heart disease, stroke, and diabetes. Disorders include: obesity, high blood sugar, high blood pressure, high cholesterol) Heart disease

The above are all age-related diseases with direct links to nutrition that have raised new questions about optimal dietary ratios of carbohydrates, fats and protein for long-term health. Recent nutritional

research strongly indicates that most adults would benefit from replacing some dietary carbohydrates with protein. Potential benefits include help in maintaining body composition and mobility, improved blood lipid and lipoprotein profiles, and increased satiety. With optimal nutrition, health span can be extended. Dietary Protein & Musculoskeletal HealtH Conventional dietary guidelines for protein recommend 0.8 g/kg body weight as adequate for adult health. However, a growing body of research suggests high dietary protein intakes of 1.5 g/kg body weight are more beneficial for maintaining muscle function, mobility, and for preventing and treating sarcopenia. Dietar y protein intake is not only vital for muscle health, but it is also a very important component of maintaining optimal bone health. This is because osteopenia and sarcopenia are closely related phenomena of ageing: they go hand in hand over an individual’s life span. Factors that affect muscle synthesis, including protein intake, also affect bone mass. Stimulating muscle synthesis is one approach to balancing muscle loss that occurs with ageing. There are three factors that play an important role in muscle protein synthesis: hormones, exercise, and diet.

aMino aciD leucine & WHey Protein isolate Nutritionally, not all proteins are created equal. Proteins are made from building blocks called amino acids

and different proteins have different amino acid profiles. There are 20 different amino acids consumed from food, nine of which are considered essential (must be obtained through dietary means) because they are not synthesised by the human body, though they are necessary for human health. One of these essential amino acids (EAA), leucine, is a branchedchain amino acid which plays an important role in muscle protein synthesis (MPS). Leucine is exceptional because it is the critical metabolic trigger required to initiate MPS. The richest sources of dietary leucine are animal proteins. In general, animal proteins (dairy, eggs and meat) contain more leucine and have a more complete balance of EAAs than plant proteins, such as wheat, oats, and soy. Whey proteins are known to be a good source of leucine. Whey protein isolate (WPI) is exceptionally high in leucine, containing approximately 11-13 percent leucine, which makes it an ideal protein source for use in supplements for individuals seeking to preserve or grow lean muscle mass. Different isolation methods result in protein with different leucine concentration. WPI made from ionexchange process contains higher leucine than membrane filtration process. The leucine content of individual proteins ultimately determines the optimal amount of total protein per meal. Research has shown that 2.53 g of leucine per meal is needed to maximise muscle protein synthesis (MPS). This leucine threshold is of critical importance because a meal containing less than 2 g of leucine fails to initiate MPS. A meal containing leucine content of 2.5 g corresponds to approximately 20-40 g of total protein, depending on the particular source of protein.

HEALTH & NUTRITION

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

Therefore, on average, 30 g of protein is recommended per meal to provide enough leucine to initiate protein synthesis; only 20 grams of total protein is necessary if the protein source is whey protein isolate. A study from a group led by Dr Douglas Paddon-Jones, professor at the University of Texas Medical Branch, demonstrated the importance of daily distribution of protein at individual meals. They showed that it is necessary to distinguish optimal protein content per meal, rather than per day, because MPS is a cycling process lasting only up to three hours after consuming a meal containing adequate protein. Eating protein only at a single meal limits overall daily stimulation of MPS, while eating protein in frequent small meals may fail to trigger the leucine response and produce an anabolic resistance. It is important to recognise that the total quantity of protein necessary for MPS can be reduced when high quality protein, such as whey protein isolate, is consumed. This reduction in the necessary total quantity has critical implications for senior adults, who commonly experience loss of appetite and cannot consume a large amount of food. This focus on quality over quantity also results in lower cost, improved palatability, and avoidance of unnecessary weight-gain due to over-consumption of calories from larger amounts of lower-quality protein.

amino aciD Leucine concentration Sarcopenia Sarcopenia is the loss of skeletal muscle mass and function as a natural part of the ageing process. This loss of muscle mass typically coincides with increased fat mass. Sarcopenia is a complex process, with a combination of factors responsible for its onset. Contributing

Micah Sittig, Shanghai, China

Eating protein only at a single meal limits the overall daily stimulation of MPS.

aDuLts Lose aPProximateLy eight Percent of Lean muscLe mass Per DecaDe after the age of 25-30 years oLD. factors include changes in anabolic hormones, sedentary lifestyle, insulin resistance, inadequate dietary protein or caloric intake, chronic disease and inflammation.

Since adults lose approximately eight percent of lean muscle mass per decade after the age of 25-30 years old, there is a wide opportunity for pre-emptive intervention and preservation of muscle health well before advanced ageing occurs. Ideally, adults should begin focusing on consumption of high quality proteins rich in leucine long before signs of sarcopenia are noticed. Protein turnover is the balance between protein synthesis and protein degradation. The primary purpose of protein synthesis is to repair and replace proteins in the body that have been degraded. Proteins are synthesised and degraded in the

Emulsifier solutions for margarine that make your business come together Palsgaard offers a wide range of specially designed emulsifiers for margarine and shortenings. These emulsifiers make it possible to create margarines and shortenings with the qualities requested by cake manufactures to secure volume and a soft crumb structure in cakes, a good, homogeneous cream that is easy to use in confectionery production and in fine bakery, as well as excellent lamination and expansion in puff pastry.

• Aeration • Crystallization • Fat reduction • Plastification

Asia Palsgaard Asia-Pacific Singapore Phone +65 6468 6905 pap@palsgaard.com.sg www.palsgaard.com

Enquiry Number

Headquarters Palsgaard A/S Denmark Phone +45 7682 7682 direct@palsgaard.dk www.palsgaard.com

3480

We have just opened a new emulsifier factory in Malaysia and will soon open margarine pilot plants in Singapore where we’ll be happy to share our expertise with you.

HEALTH & NUTRITION

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

University of the Fraser Valley

dietary protein is associated with increased intestinal absorption of calcium, as well as enhancing bone matrix turnover. Research also suggests that different protein sources may vary in their impact on bone metabolism. Animal protein sources have been associated with increased bone mineralisation and fewer fractures when compared with plant-based proteins.

body every day and this continuous cycling of proteins is a normal part of healthy ageing. According to Dr Donald Layman, professor at the University of Illinois, both growing adolescents and middle-aged adults have similar needs for daily repair and replacement of body protein. Adults break down and need to re-synthesise approximately 250 g of proteins every day. When the rate of protein synthesis does not keep up with protein degradation, sarcopenia arises. Additionally, ageing reduces the efficiency of amino acid use. Older adults need at least 30 percent more EAA to get the same protein turnover, increasing daily protein needs. OsteOpOrOsis Osteoporosis is characterised by a decrease in bone mass and density, causing bones to become fragile and more likely to fracture. Osteoporosis-related fractures most commonly occur in the hip, wrist or spine. Bone health is a multifactorial musculoskeletal issue. Although we often think of calcium as the main micronutrient needed to prevent os-

Older adults need 30 percent more EAA to get the same protein turnover. teoporosis, dietary protein interacts synergistically with calcium to affect bone health and is equally as important. Intake of both calcium and protein must be adequate to fully realise the benefit of each nutrient on bones. Approximately one-half of bone volume and one-third of its mass is comprised of protein. Bone is a living tissue, undergoing continuous turnover and remodelling. Osteoporosis occurs when the rate of bone removal exceeds that of new bone creation, similar to sarcopenia and muscle protein synthesis. Many factors are known to influence bone mass. The impact of dietary protein on bone health has been shown to depend upon a variety of factors, including total protein intake, protein source, calcium intake and weight loss. There has been a long-held belief that excessive dietary protein could cause bone loss, due to an observed association with increased urinary calcium. More recent studies have shown, however, that increased

Dietary Protein & Weight Loss In addition to musculoskeletal degeneration, ageing adults are often challenged with increased weight gain. Many ageing adults, particularly women, are concerned with both obesity and osteoporosis. Treating obesity often increases risk for osteoporosis because many people lose bone mass when they lose weight. A study from Dr Laymanâ&#x20AC;&#x2122;s group, however, showed that protein-rich weight-loss diets help preser ve muscle mass and improve body composition while lowering blood sugar. This illustrates that a diet rich in protein, emphasising a high quality protein like whey protein isolate, can effectively result in weight loss without bone loss. As the number of ageing adults in our world population continues to rise, it is more important than ever to address their specific health and nutrition needs. Many of the common health problems experienced by ageing adults can be dramatically influenced by dietary intake. Understanding the increased need for high quality proteins in ageing populations is crucial for optimising their health span. Incorporation of high-leucine containing proteins, like whey protein isolate, into each meal, in adequate quantities and at the right frequency, can positively and significantly impact musculoskeletal health and weight. For more information, ENTER No: 0740

Your Vision, Our Solution

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Please contact Yamato Subsidiaries or Distributors listed below for further information.

YAMATO SCALE CO., LTD. Yamato Subsidiaries/Distributors

Telephone: +(81) 78-918-5567 URL: http://www.yamato-scale.co.jp/

BEVERAGE

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

The SweeT Smell Of

flavOur been increasing in prevalence, even attaining newfound status as a disease in recent months. With this issue brought to the fore, many have developed greater health consciousness and a targeted focus on better nutrition, resulting in the demand for products with less sugar, salt, fat and calories, and preferably fortified with nutrients. This has had a direct impact on beverages, which is one of the top few categories blamed for providing empty calories or sugar laden products, especially in the case of juices and carbonated soft drinks. As a result, manufacturers have introduced formulations with reduced sugar and recipes that use non-nutritive sweeteners (sweeteners with few or no calories) as replacements. Adding sucrose to juices can decrease sourness and bitterness while enhancing fruit odours.

Nonetheless, there is only so much sugar that manufacturers can remove before taste is compromised. Most non-nutritive sweeteners (eg: aspartame, saccharin and stevia) come with an aftertaste that consumers find unpleasant. This proves as an impediment as taste is after all, the hallmark of commercialisation success. Fortunately, flavour is a multi-faceted component that mirrors the complexity of the human sensory system. Depths Of flavOur Contrary to what is believed, flavour is not confined solely to the five taste perceptions of sweet, sour, bitter, salty and umami. In fact, the different types of tastes are not segregated to specific areas of our tongue as commonly taught. Studies have shown that the human tongue has receptors for tastes that include fat, calcium, water, metallic, and even carbonation. In the

Stiftelsen Elektronikkbransjen

Obesity is a problem that has

D. Sharon Pruitt, Layton, US

With smell playing a large role in sensory perception, aroma delivery systems provide a glimpse into the future of tasty, loW sugar beverages. by sherlyne yOng same vein, overall flavour perception is much more than just what our taste buds detect; it is a multi-sensory experience that combines taste, smell and sensations like irritation, texture or mouth feel, and thermal levels. This makes smell as important as taste or sensation, which has often been overlooked in product development. In a time when developments in the two latter areas may be saturated, olfaction serves as a complementary solution to better formulate flavoured food products that fulfil specific nutritional recommendations and consumer expectations. For instance, some studies have highlighted the effect of aroma release on enhancing satiety and decreasing food intake. Foods contain volatile chemicals that activate our olfactory receptors, which happens when we actively sniff food (orthonasal olfaction), or are released when we chew our food, where the aroma then travels through the back of the throat (retronasal olfaction). Flavour perception, depending on the activation route, is influenced by the dynamic release patterns of volatile compounds during chewing, as well as the signals that tastebuds on our tongue are sending to the brain. Known as the taste capture of odour, the brain consolidates sensory information from multiple sources before transferring it to our mouth. It is through this unitary concept of flavour that abilities like masking an unpleasant flavour or making some-

BEVERAGE

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2013

RESULTS FORMULATED DAILY At Glanbia Nutritionals, we have a simple mission: make ever y project a success. With vast applications know-how and a far-reaching network of resources, weâ&#x20AC;&#x2122;re equipped to do just that. Our R&D teams are always finding better, smarter nutritional fortification solutions. No matter where you are, our team is ready to deliver the science that can give you the edge.

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encapsulating Benefits A huge impediment to aroma delivery is its susceptibility to diffusion and degradation, either through chemical reactions with other ingredients or

ness. In terms of fortified beverages, such systems also protect nutrients like vitamins, minerals and polyunsaturated fatty acids from degradation due to oxidation. Drawing inspiration from shelf life enhancement of beverages, coacervation techniques are promising

Micronutrient Premixes Amino Acids Vitamins Specialty Ingredients Functional Ingredient Systems Whey Proteins Whey Peptides Flaxseed Solutions

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smelling sweet In light of the recent studies suggesting that sweeteners may be exposing consumers to the very same risks they are trying to avoid (eg: type 2 diabetes, cardiovascular disease, weight gain), aromatics could possibly be the reprieve that the beverage industry is looking for. Volatiles could be used to enhance the taste and perception of sweetness while allowing manufacturers to ease up on added sugar or sweeteners. This works especially well in pairings that are appropriate and congruent in nature. Some tested models that successfully enhanced sweetness perception includes the addition of vanilla flavouring to milk, as well as the common pairing of the smell of strawberries to whipped cream. Apart from increasing sweetness, adding sucrose to juices can also decrease sourness and bitterness while enhancing fruit odours. Another potential method of prolonging aroma delivery is the inclusion of fruit bits, which not only increase exposure time but also modifies oral processing. However, odours can also be used to reduce taste intensity in cases where the pairings are incongruent. For instance, the smell of caramel has successfully decreased the intensity of sourness. Flavour technology can also be used to mask undesirable flavour notes like bitterness in sweeteners, a common issue today. More importantly, aromatics can be used to increase the efficiency of sweet taste receptors, which allows developers to enhance the impression of sweetness without having to increase the quantity of nutritive or non-nutritive sweeteners.

through oxidation after exposure to air. In certain cases, degradation could lead to off notes in the end product. Consequently, efforts have been focused on building sophisticated encapsulation systems, such as those that can deliver controlled releases of sweet smelling aromas to boost sweet-

GlanbiaNutritionals.com

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thing taste sweeter than it really is are possible.

BEVERAGE

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

Depending on the beverage, aroma delivery can be enhanced through encapsulation and effervescent agents. in controlling aroma releases as well. Coacervates are tiny lipid molecules (eg: fat, oil) that are held together by hydrophobic forces and surrounded by a tight skin of water molecules. This method is particularly useful with viscous, semi-solid products, where in one example, limonene was successfully encapsulated. However, flavour release is dependent on capsule sizes and the cross linkages across wall materials. Another way of incorporating flavour into beverages is through oil encapsulation in gel particles, which could be made out of gelatine, agar or starch. Depending on the medium, the flavours are then released through thermal triggers (gelatine), interactions with digestive enzymes (starch), or chewing (agar), resulting in a burst of aroma.

arOmatics increase the efficiency Of sweet taste receptOrs, naturally enhancing the impressiOn Of sweetness.

zuan_raz

SteFou!, Toronto, Canada

Vox Efx, Baltimore, US

David Pacey, Leeds, UK

Should encapsulation be insufficient, masking techniques can be used to account for undesired flavours that may occur along a productâ&#x20AC;&#x2122;s shelf life. Depending on the flavours inherent in the product, selected volatile compounds can be added to block access to an olfactory receptor that is responsible for a specific odour that is undesired. Because finding the right compounds to mask a specific set of odours are traditionally time consum-

ing, some researchers have devised an olfactoscan screening method that makes use of an olfactometer and a gas chromatography with odour port to speed things up. A novel way of using encapsulation for aroma delivery is incorporating it into packaging, which bypasses the challenges of chemical reactions or atmospheric degradations. US company ScentSational has developed packaging applications where specially engineered, FDA approved food grade flavours are added to the plastic packaging at the time of manufacturing. This results in a stable delivery of volatile compounds, which may be released at point of purchase, package opening, product preparation or consumption. Suitable for both flexible and rigid packaging, standard barrier layers are used to keep the flavours sealed within the package until it is opened.

BEVERAGE

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2013

With its technical limitations, the use of volatiles is not a one-fit solution for all industries. However, its potential in helping beverage manufacturers achieve their fat and sugar reduction goals is simply too big to ignore. Not to mention, volatiles have an unimaginable impact on sensory evaluation and the overall development of health-ori-

ented products. Despite its challenges, continual developments technologies like encapsulation and effervescent methods are successfully bringing the volatile concept much closer to reality, and with it, the sweet dream of tasty, healthy, sugar-free drinks. For more information, ENTER No: 0750

DCF (Dynamic Cross-flow Filtration) Dynamic membrane filtration for high-efficiency clarification of beverages

Every drop counts. In times of rising customer demands on taste and increasing costs of raw materials, membrane filtration has been established as the best approach to achieve high-quality clarified beverages. The new ANDRITZ SEPARATION DCF retains every single drop of the beverage, while reducing costs and environmental impact at the same time: ■ Lowest mechanical stress on product due to minimized process volume

■

Top performance thanks to unique principle of overlapping and rotating membranes Best taste thanks to closed and self-venting design avoiding oxygen pick-up Highest quality product due to oval housing design ensuring minimum residence time Long service life thanks to the use of ceramic membranes Minimized operation cost due to reduced energy consumption

ANDRITZ Singapore Pte Ltd 25, Tuas Avenue 4, Singapore 639375 Phone: +65 (6512) 1800, Separation.sg@andritz.com

www.andritz.com

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instant Beverages Effervescent methods are extremely useful for instant drinks like coffee, which are heavily dependent on aroma delivery for the perception of product quality. Particularly for processed coffee, a lot of flavour is degraded during processing due to its delicate and unstable nature, leaving behind unpleasant notes that are unlike coffee. To prevent this from happening and to prolong the intensity and duration of aromas in headspace, researchers from the University of Nottingham have devised an alternative to using conventional agents like sodium hydrogen carbonate or citric acid to release volatile compounds. In their method, spray dried coffee powder is heated beyond its transition temperature and put under elevated pressure until it becomes plasticised and permeable, which allows internalised gas to be incorporated into the powder. Upon adding water to the instant powder, gas will be released either when it rises to the surface or when it forms the crema (the top layer of froth covering the coffee). Compared to using effervescent agents, this method of trapping pressurised gas has much faster and intense results. Meanwhile in beverages like beer, champagne and carbonated soft drinks, effervescent techniques are used to increase in-vivo aroma delivery. Carbonation in beer increases aroma delivery after consumption, while in champagne, the formation of gas bubbles significantly enhances the release of aromas. In other studies, it has been found that the content of carbohydrates and lipids in instant beverages has a direct impact of aroma delivery. Adding fructose increases the viscosity of the solution as well as its solubility, enhancing the delivery of volatiles. As a result, beverage manufacturers must be mindful that reformulations involving fat reduction or nutritional enhancement could affect not just functionality, but also attributes like aroma delivery.

Enquiry Number

Curt Smith, Bellevue, US

FEATURES

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

Time To Go

Lean

GoinG lean can help increase productivity of food and beveraGe production and processinG plants. however, there are many considerations to think about before jumpinG on board. by Chew ee Lin, product specialist, south asia, brady corp

Fruitnet

best location for the remaining items, and use equipment ID to clearly identify the flow of ingredients through the processing plant. Use location identifiers such as labels and tags to clearly identify the storage place for every piece of processing plant equipment, and ensure that labels are clearly displayed. Set inventory limits and re-order triggers using replenishment indicators and inventory labels to implement a just-intime (JIT) re-order system for your raw ingredients.

Lean is a set of techniques used to manage a work environment by eliminating waste, organising the workplace, streamlining procedures and establishing clear, visual standards. In a food and beverage processing plant, lean initiatives help to improve safety, eliminate wasted space and supplies, and reduce errors that will undermine your business profitability. In addition, the food and beverage industry is governed by strict health and safety regulations, and lean techniques can help you create better control of your processes to reduce or even eliminate the chances of flouting the regulations. The 5S ApproACh The 5S approach is designed to create a clean and clutter-free production area, and emphasises the importance of maintaining an or-

derly workplace and using visual cues to reduce the amount of wasted time that is spent searching, looking, waiting and asking, optimising productivity for your processing plant. Below are some simple ways you can apply the 5S principles to your processing plant: Sort: Reduce processing plant clutter by sorting through all of the items in a given location into essential equipment and unnecessary items. Mark all unnecessary items with a sticker, and move the tagged items into a temporary holding area where management can determine how to dispose of them. A visually neat workplace enhances efficiency by reducing the time and effort in locating equipment. Set in order: Determine the

Shine: Prevent massive wastage of ingredients via contaminated equipment. Clean your entire processing plant to eliminate the sources of contamination frequently, and use cleaning as a form of inspection to detect equipment abnormalities and impeding failures before they occur. Put in place operator control labels, maintenance and cleaning labels, and warning labels to ensure compliance to all food and safety health regulations. StandardiSe: Create guidelines and procedures for maintaining the first three S principles. Use visual controls like check sheets and schedules to provide daily, monthly or quarterly instructions on how to maintain order. Display operating procedures and maintenance instructions, using labels and tags at the point

FEATURES

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2013

of use, to ensure that your staff follow safe and efficient practices consistently. SuStain: Regularly communicate and train employees to maintain the processing plant’s adherence to the 5S standards. Scoreboards, slogan banners and improvement displays can inform staff of key initiatives, track performance and recognise their achievements. TrACk & TrACe Lean techniques go beyond the visual workplace, and include any systems that cut time wastage and improve energy and efficiency. Track and trace technology reduces the time and effort it takes to pinpoint and rectify errors in the food and beverage processing plant, helps maintain inventories at efficient levels and can trigger re-order statuses for the replenishment of raw ingredients for JIT management The barcode system was first commercialised in 1974 on a packet of chewing gum. Over the past four decades, the barcode became ubiquitous as a track and trace tool, from supermarket to F&B production lines. Barcodes offer simplicity, universality and low costs—unmatched by any other track and trace technology. The benefits of implementing a barcode system make a powerful argument for any food and beverage company wishing to:

• •

inCreASed produCTiviTy Track and trace barcode solutions help businesses track and trace the goods from production to sales and distribution. For food and beverage processing plants, barcode stickers on the products help to track and trace mistakes and faults along the production line quickly. This greatly

simplifies the process of identifying the problem and rectifying the error and problematic batches, and in turn increases productivity With today’s track and trace technology, you can monitor and track the sales and distribution of your products with unique unit level security codes and labels to gain a better understanding of your sales performance. The serialised codes also allow you to run promotions and marketing activities (such as reward and rebate programs) and connect directly to your customer base via the code verification process. An experienced track and trace solution vendor can even implement real-time analytics to help you locate and identify market activity using easy to access business portal interfaces with heat map dash boards, alerts and business reports that offer real-time details.

Lean techniques go beyond the visual workplace, and include any systems that can cut time wastage and improve energy and efficiency.

Improve production efficiencies Improve management and reporting Improve accuracies and reduce mistakes

Often, retail stores and supermarkets employ barcode for fast checkouts by scanning barcodes instead of the manual input of price tags, to improve customer experience by shortening checkout time.

Nick Saltmarsh, London, UK

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B y i n t e g r a t i n g t h e b a rc o d e checkout process with the backend inventory system, the store manager knows which stocks have been selling and require replenishment, greatly improving the logistics process and preventing loss of sales opportunities when inventories are not replenished on time. Retailers also depend on barcodes on their membership cards to identify consumers and create profiles for customised marketing efforts and to understand consumers’ shopping patterns.

FEATURES

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

trace solution, so it is critical that it is simple and efficient in order to be effective. Ask for case studies to ensure your vendor has a good track record in delivering such a system for your needs.

Nate Grigg, Salt Lake, US

3) A gOOD venDOR MUST PROvIDe The BeST hARDWARe AnD SOFTWARe A barcode track and trace solution comprises of the label, label printer and software. Your vendor should have a range of label printers that comes with user-friendly labelling software to customise labels if required, instead of pushing you offthe-shelf solutions. We cannot over emphasise the importance of the vendor having good supporting software systems and data collection tools to integrate barcode systems with backend logistic software for a seamless and complete track and trace solution!

It is easy to see the potential of how the barcode system will help your business, but you should understand that the barcode label represents only part of the track and trace process. It is critical to work with a vendor that can deliver a system that fits into your process instead of the other way around. here are four key considerations when selecting your vendor: 1) The venDOR ShOULD hAve LABeLS ThAT WORk On vARIOUS SUBSTRATeS Do you need labels that are freezeproof, heat-proof or greaseproof? Food and beverage processing will

Barcode label represents only part of the track and trace process. put special demands on labels and printers. Consult your vendor to ensure their labels can adhere securely and withstand your operating environment. You want a solution that does not limit future application, and this is especially critical if the labels are to be used in extreme environments, such as on frozen foodstuff. 2) LOOk FOR A TRACk AnD TRACe SOLUTIOn ThAT IS SIMPLe AnD eFFICIenT numerous staff in your organisation will use your barcode track and

4) The SOLUTIOn ShOULD SUIT YOUR WORkFLOW Your workflow probably records the batch numbers of your products, so use a vendor that can provide a solution that can create serialised labels using your supplied number sets or standard alphanumeric serialisation sequences. It also reduces implementation cost and makes the system more flexible, and makes it easy to integrate with your existing workflow. TAmper indiCATing TeChnoLogy Food and beverage products can adversely affect consumersâ&#x20AC;&#x2122; health, and consumer confidence will be increased tremendously when they are assured that the products they are purchasing have not been tampered with. Sabotage of your products at any stage, from production to delivery and sales, can bring your business to a halt with subsequent investigations and fines, and you can take

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ASIA PACIFIC FOOD INDUSTRY OCTOBER 2013

Ravenshoe Group

the proactive step to deter such attempts with tamper proof labels. The BeneFiTS oF impLemenTing A LeAn What is Elabels mizu Tamper evident and Killer？ tapes The value ofseals the sodium hypochlorite solution is adjusted from 5 to 6 (acidulous) by using carbon dioxide What is E mizu Killer？ are used aspH security to provide proCeSSing pLAnT iS weLL worTh The so,ofstrong sterilizable water that contains a large amount is manufactured. The pHand value the sodium hypochlorite solution is adjusted from 5 toof6HOCl (acidulous) by using carbon dioxide visible (CO2) evidence of label switching, eFForT. so, strong sterilizable water that contains a large amount of HOCl is manufactured. reuse or(CO2) illegaland entry into packaging, Feature of product E mizu Killer a science in itself, but many of the unauthorised service, dilutechniques are logical extensions of tion, or◎ alteration. Feature E mizu Killer Carbon of dioxide completely dissolves to water because of using the membrane. any food and beverage production Protect your brand with security ◎ Neither chlorine gas nordissolves the hydrogen gasbecause are generated. Carbon the dioxide completely to water of using the membrane. facilities. labels ◎ that show clear evidence of running cost is cheaper thanhydrogen electrolysis the medicine. ◎ The Neither the chlorine gas nor the gasand areusing generated. You should your first steps tampering and protect ◎ device ofcost a safe, cheap and handling can be chosen according to thestart usage. ◎ The The runningagainst isfraudcheaper thaneasy electrolysis and using the medicine. towards a lean processing plant by ulent remarking. Some labels are ◎ The device of a safe, cheap and easy handling can be chosen according to the usage. 〈Basic Flow〉a visible and ir〈Sterilization Effect inspecting Test Results〉 your current operations, designed to provide counts before 30 seconds Bacteria and using visual aids such as signs reversible pattern 〈Basic Flow〉〈SterilizationBacterial Effect Results〉 CO2on the label when NaClO treatment Test （pcs./ml） Bacterial counts before 30 seconds and labels to improve removal is attempted, while others Bacteria coli 4.3×10⁵ ＜10 your efficiency Escherichia CO2 NaClO treatment （pcs./ml） and cut waste in your processing break into pieces to show signs of Hollow 7.2×10⁵ ＜10 Salmonella 4.3×10⁵ ＜10 Escherichia coli plant. You should also consider improduct tampering or attempted reMixer Fiber Water 7.7×10⁵ ＜10 Staphylococcus Hollow 7.2×10⁵ ＜10 Salmonellaaureus plementing track and trace systems moval of the security seal. Membrane Mixer pH:5.48 Residual Temperature＜10 ：20℃ Fiber 7.7×10⁵ Water Staphylococcus aureuschlorine concentration:32ppm Sterilizable to improve chain of custody tracking can assist you in the implementation Implementing a lean processing Membrane Water pH:5.48 Residual chlorine concentration:32ppm Temperature ：20℃ Sterilizable Bacteria：Bacilluswith subtilis Before 1 of minute 3 minutes 5 minutes products. your food and beverage of lean operations, consultants plant for food and beverages manuWater 7.8×10⁵ 3.1×10⁵ ＜10 80ppm, pH 5.42subtilis recommend you cost-effifacture may seem like a daunting who canCl Bacteria：Bacillus Before 1 minute 31.3×10⁵ minutes 5 minutes CO 2 CO 2 ts are well worth cient solutions. task, but the benefi 7.8×10⁵ 3.1×10⁵ 1.3×10⁵ ＜10 80ppm, pH Cl 188ppm, pH5.42 9.20 7.4×10⁵ 6.6×10⁵ 4.3×10⁵ For more information, CO 2 Implementation of lean can be (Japan ENTER the effort. There CO 2 are vendors who Food Research Laboratories) No: 0760 Cl 188ppm, pH 9.20

CO 2

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E mizu Killer Dissolved CO2 E mizu Killer 5.0～6.0

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pH Cl concentration （ppm）

5.0～6.0 10～100

5.0～6.0 10～30（80）

8.0～ 80～

Water

Cl concentration Safety （ppm）

10～100 ◎

10～30（80） △

80～ △

Corrosivity Safety

No ◎

Yes △

Treatment of Chlorine gas Corrosivity and Hydrogen gas

Unnecessary No

Necessary Yes

Water Water CO 2

7.8×10⁵

〈Comparison of Manufacturing Method〉 (Japan Food Research Laboratories) Electrolusis 〈Comparison of Manufacturing Method〉 Dissolved CO2

CO 2

Electrolyzed Electrolusis Acidulous W ater Electrolyzed Acidulous 5.0～6.0 8.0～ W ater

CENTRAL FILTER MFG. CO., LTD.

CO2 CO Hollow Fiber 2

セントラルフィルター工業株式会社

Dissolved CO2 Hollow Fiber Dissolved CO2

Running cost gas ◎ △ ○ Unnecessary Necessary Necessary Central Filter MFG Co., LtdTreatment is aof Chlorine comprehensive filter manufacturer and Hydrogen gas ◎ △ △ Initial cost Running cost covering the full spectrum of the filtration business requirements ranging ◎ △ ○ 100 80 Cl from reverse osmosis (RO)Initial equipment to cost ◎large mesh △ strainers. △ 2 〈Specification〉 RateRate Rate ％％％

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1,000 500

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CCK5000 5,000

CCK10000 10,000

BIOPLORER 650×1,600 600×1,700 5,000 10,000 ×700 ×700 Rapid Microbe

650×1,600 600×1,700 Counting System ×700 ×700 Complete high-precision microbe counting easily, in only about 6 minutes 20～100 5.0～6.0

500×1,500 ×600 5.0～6.0

2 3 4 5 6 7 8 9 10 ※ The above specifications are subject to change without notice. Ｃｌ (ppm） 20～100 ○ We offer apH total system from design and manufacturing through maintenance contribute to the society. ※ The to above specifications and are subject to change without notice.

Shinjuku Estate Bldg. 1 -34-15, Shinjuku-ku, please Tokyo 160-0022 ForShinjuku, more information, contactJapan MF Nishi-Umeda Bldg. 5-1-26, Fukushima, Fukushima-ku, Osaka 553-0003 Japan Shinjuku Shinjuku Estate Estate Bldg. Bldg. 11-34-15, -34-15, Shinjuku, Shinjuku, Shinjuku-ku, Shinjuku-ku, Tokyo Tokyo 160-0022 160-0022 Japan Japan MF Nishi-Umeda Bldg. 5-1-26, Fukushima, Fukushima-ku, Osaka 553-0003 Japan 102E Pasir Panjang Rd#02-06 Ctilink W arehouse Compalex Singapore 118529 Shinjuku Estate Bldg. 1 -34-15, Shinjuku, Shinjuku-ku, Tokyo 160-0022 Japan info@central-filter.com.sg 102E Pasir Panjang Rd#02-06 Ctilink W arehouse Compalex Singapore 118529 http://WWW .central-filter.co.jp/english/index.html info@central-filter.com.sg http://WWW .central-filter.co.jp/english/index.html

SINGAPORE BRANCH

Tel 81-3-3350-0091 Fax 81-3-3350-0095 Tel 81-6-6345-3531 Fax 81-6-6345-3500 Tel Fax 81-3-3350-0091 81-3-3350-0095 Tel 81-3-3350-0091 81-3-3350-0091 Fax Tel 65-6272-1191 81-6-6345-3531 Fax Fax 65-6272-0170 81-6-6345-3500 Tel Tel 81-3-3350-0091 Fax 81-3-3350-0091 Tel 65-6272-1191 Fax 65-6272-0170

Enquiry Number

Tokyo Head Office Osaka Branch Tokyo Head Office Technical Center Osaka Branch Singapore Branch Technical Center E-mail Singapore W ebsite Branch E-mail W ebsite

Technical tei-up with DAICEL CORPORATION CENTRAL FILTER MFG. CO., LTD. CENTRAL FILTER MFG. CO., LTD. SINGAPORE BRANCH

3493

Please TECHNICAL CENTER about the test necessary the selection the filter elements. ○ We offer aconsult total system from design and manufacturing through to for maintenance andofcontribute to the society. Technical tei-up with DAICEL CORPORATION Please consult TECHNICAL CENTER about the test necessary for the selection of the filter elements.

FEATURES

The ForeFronT oF Food allergen ManageMent

Many people around the world are affected by food allergies, which are incurable conditions. in order to help Manufacturers adhere to safety guidelines and labelling requireMents, a guidance has been developed to increase knowledge. by Fintan Hastings, junior Manager, ep relations & coMMunications, fooddrinkeurope Our scientific understanding of the risks posed by food allergens has grown steadily over the last twenty years. Between two and four percent of Europeâ&#x20AC;&#x2122;s population (10-20 million) suffer from a food allergy and this number is higher among children (five to eight percent), many of whom tend to outgrow their allergy. In continental Europe, the most common food allergies among children are to eggs, cowâ&#x20AC;&#x2122;s milk and tree-nuts, while among adults, they are to fresh fruit, nuts and vegetables. The extent of an allergic

contact with trace amounts of allergen-causing ingredients via cross contamination of raw ingredients, manufacturing lines and also workers in the manufacturing facility. Certain methods of food processing may enhance, reduce, or eliminate the allergenic potential of a food product.

reaction depends largely on the individual concerned and at present, no cure exists for food allergies, so consumers must be aware of the ingredients in the foods they eat. In addition, due to an increasingly complex global food supply chain, it is important that food manufacturers have a thorough understanding of where to look to prevent any potential cross-contamination between ingredients which cause allergies and those which do not. During the manufacturing process, food products can come into

allergen ManageMent systeM Europe has a competent allergen management system and the European Union has published a list of allergens which may pose a risk, something which many other countries around the world have yet to do. Europeâ&#x20AC;&#x2122;s food industr y, recognising that food allergies and intolerances are a food safety issue for all those concerned, believes that allergen management should be an integrated part of overall food safety assurance strategies. As such, the industry has made significant efforts to reduce the unintended exposure of allergic consumers to major allergens. Food manufacturers, as required under EU law, have robust inventory and traceability systems to ensure the full implementation of EU legislation on allergens, including tracking changes in the formulation of manufactured foods products. mjtmail (tiggy)

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

guidance For ManuFacturers

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ASIA PACIFIC FOOD INDUSTRY OCTOBER 2013

the risk to allergic consumers and enabling them to make informed product choices. The guidance provides food manufacturers with a detailed stepby-step approach to managing allergens, from supplier management, to raw materials handling, all the way down to final product development and documentation. In addition, it features practical information for food manufacturers on cleaning, validation and verification, as well as technical and detailed reference information on food allergies, intolerances and gluten-free products.

Daniella Segura, California, US

FoodDrinkEurope, the trade body representing Europe’s food and drink industry, has taken concrete steps to aid its members in their efforts to provide safe nutritious food and drink products which meet the diverse dietary requirements of Europe’s 500 million consumers. A prime example of the organisation’s efforts in this area is the ‘Guidance on Food Allergen Management for Food Manufacturers’, developed over the past four years under the direction of its Allergen Expert Group. A number of guides on allergens have been published in the past by national agencies, industry and consumer groups. However, in developing the guidance, the organisation identified the need for a consolidated guidance document which would identify and share best practices and provide up-to-date information on risk assessment, good manufacturing practices and analytical protocols. The first of its kind, the guidance sets out, in a clear, user-friendly format, general principles to manage specific prepacked foods causing allergy or certain intolerances. It also provides sound, evidence-based and consistent information on good practice in risk management of allergenic foods for producers. Harmonising and disseminating good practice across Europe’s food industry at all levels, the guidance ensures a consistent understanding of, and approach to, managing allergens and certain food-causing intolerances among Europe’s food manufacturers, helping to minimise

iMpleMentation The guidance can be readily adapted to different production processes and production facility designs to provide relevant information about food allergens and to indicate their importance as food safety hazards. The guidance was developed for European food producers who, from December 2014, will be required under the EU’s Food Information to Consumers Regulation to mention on pack, allergens named in an EU approved list. The guidance could, however, be applied worldwide in any country whose regulatory regime requires allergen labelling on food products. The guidance can also serve as a type of hazard analysis of critical control points (HACCP) for allergen management. Europe’s food industry already has much experience in the application of HACCP and other such risk assessment techniques and tools. In developing the guidance, the organisation worked closely with many sectors across the entire food industry to develop multi-functional expertise covering a range of matters, including: • Risk assessment; • Good manufacturing practices; • Methods of analysis; and

•

Allergic consumer perspectives.

T h ro u g h t h e g u i d a n c e , t h e organisation aimed to create an equivalent to its Acrylamide Toolbox, designed to assist individual manufacturers (including SMEs with limited R&D resources) in reducing acrylamide formation in their specific manufacturing processes and products, in line with the latest developments in science. The toolbox was updated in 2011 with the latest scientific research and feedback from food operators and like the Guidance, is available to download for free online. It is ver y difficult to ensure that a food product is entirely allergen-free, therefore food allergen management must be an integral part of overall food safety management. While current practices to manage major allergens have increased the safety of food products for allergic consumers, the lack of an agreed approach to quantitative risk assessment has led to uncertainties for both food manufacturers and enforcement bodies. This has led to an increase in precautionary allergen labelling, which reduces the choice of products available to allergic consumers, in turn resulting in frustration and risk-taking behaviour, which negates its purpose. Precautionary labelling has an important role to play in protecting allergic consumers, but to fulfil that role, it must be applied consistently, in accordance with defined and agreed principles. The guidance, which has already been communicated broadly to food industry operators, risk assessors, regulators and consumer and patient groups, will play an important role in this respect.

For more information, ENTER No: 0761

FEATURES 62

OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

Beyond The Future of Lab-Grown Hamburgers Besides reducing land and laBour needs, impacts on environment and the risk of animal-Borne diseases, cultured Beef can also help improve food security. there is a long way to go Before it makes it way to restaurant menus, But this technology may well change the future. By Henk W Hoogenkamp and Henk R Hoogenkamp Stem cell technology is slowly ‘growing’ out of its role in the clinical armamentarium against disease and ultimately may make its way to our refrigerators and fast food menu boards. Lab-grown meat uses cells harvested from animal tissue that can be cultured, multiplied and turned into edible meat products. D r M a r k P o s t , p ro f e s s o r o f physiology at Maastricht University Netherlands, is the lead scientist for this futuristic technology. The idea and technology has been lingering around for a while now. However, the recent spike in media coverage seems like a well-orchestrated effort to raise awareness and funding. Coincidently (or not?), the cofounder of Google, Sergey Brin, has already invested substantial assets in order to push this stem cell technology to the next stage. Is cultured meat doomed to fail or here to stay? Stem Cell teCHnology The myosatellite cells—or adult stem cells that are only able to become muscle cells—are programed to form myofibrils in unison as they multiply

and as such are strikingly similar to skeletal muscle tissue in vivo. The result is tissue that is biologically similar to the meat from which it was harvested. The technology basically comes down to allow a small sample of muscle tissue to be separated into individual cells that are subsequently placed in a nutrient solution (medium). These cells are then nurtured to allow multiplication to create muscle tissue grown outside the animal. The cells naturally merge and rearrange into small myotubes. These myotubes are grown around gel hubs similar to a doughnut shape, contracting and creating bulk tissue. A single strand can actually multiply to trillions of new strands which—when layered together—replicates meat tissue. About 15,000 strands are needed to make a 100 g or four oz burger patty. For now, the most obvious reengineered tissue research is done to duplicate beef. The overriding reason is that beef has a very long outgrow cycle demanding extraordinary amounts of clean fresh water

and feed. Generally, about nine kg or 20 lbs of feed and 2,000 litres or 520 gallons of water are needed to generate one kg or 2.2 lbs of lean beef. In vitro meat production using stem cells, also dubbed cultured meat, is possibly an ecological and sustainable alternative to the economically inefficient livestock o u t g ro w c y c l e s . C u r re n t l y, 7 0 percent of all agricultural land, corresponding to 30 percent of the earth’s surface, is being used for livestock production in both grazing pastures and securing food stock. Cultured beef could, therefore, reduce the need for agricultural land and labour-intense feedlots dedicated to meat harvests and substantially freeing up space to grow crops to be eaten directly by humans without a transitory transformation. B e s i d e s i m p ro v i n g e t h i c a l standing and food security, cultured meat could also help to significantly reduce the risk of animal-borne diseases like salmonella and E coli, or even BSE, which causes mad cow disease. The ad-

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ASIA PACIFIC FOOD INDUSTRY OCTOBER 2013

vantages can even be extended onwards and have indirect implications on human health in general, possibly reducing the risk of cancer, cardiovascular disease and type 2 diabetes in particular. This futuristic option to grow meat could greatly reduce ecological and environmental stress factors such as clean water, energy use, emissions of methane and other forms of greenhouse gases that are some 20 times more potent than carbon dioxide. According the Food and Agr i c u l t u re O rg a n i z a t i o n o f t h e United Nations, about 18 percent of all greenhouse gas emissions are generated by livestock production, m o re t h a n a l l g l o b a l transportation sectors combined. The anticipated huge increases in world meat demand by the rapidly increasing population will surely further increase stress levels of greenhouse gases.

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Besides improving ethical standing and food security, cultured meat can reduce the risk of animal-borne diseases.

It is obvious that cultured beef should be considered as a serious alternative in the future. However, many hurdles stand in its way before it arrives onto the consumer’s plate. As previously explained, the technology currently uses myosatellite cells as a basis to grow the meat. However, currently, the size and shape to which the muscle pieces can be cultured is limited to 1.5 x 0.5 x 0.15 cm.

Enquiry Number

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Hurdles To overcome

Larger pieces of cultured muscle cannot receive enough nutrients in its core due to the lack of a vascular system for the transport. Moreover, the in vitro proliferative capacity of mysatellite cells is far inferior to embryonic stem cells and therefore, needs to be improved on in order to obtain a commercially interesting culture time. Embryonic stem cells (which can form all cell types in the body) are not used due to the difficulties encountered when trying to direct the cells for only muscle tissue generation. Another important issue is that cultured muscle cells by themselves have not yet resulted in a satisfactory product because of their inability to fully mature to functional muscle, which can contract. Biochemical signals can be provided via bioactive proteins called growth factors, in order to help the

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OCTOBER 2013 ASIA PACIFIC FOOD INDUSTRY

cultured meat products as natural food colouring. In the future, stem cell technology can be used to produce in vitro red blood cells, once again eliminating the need for animal blood. What might prove to be most important feature: flavour, taste and texture organoleptic parameters will be the fat present in the final product. Let’s face it, cultured beef flavour and texture will only be appreciated by consumers, if fat is part of the equation. After all, fat is the carrier of flavour and typically some 20 percent of fat is needed in a hamburger to provide for the highest degree of organoleptic satisfaction. Not surprisingly, the technology to use stem cells to grow fat is already known,

Stuart Heath, Rhymney, UK

muscle cells mature and differentiate into functional tissue. However, these growth factors are often isolated from animal sources like fetal calf serum or are made by recombinant DNA technology, subsequently limiting its use in cultured meat technology. So for now, myosatellite cells are the way to go, and luckily, there are some tricks up the researcher’s sleeves that might accelerate the growth rate and overall quality of the cultured beef. For example, it is important to mimic the in vivo conditions during the culturing to ensure that the formed muscle really resembles the real thing. These conditions may be partially simulated by providing biophysical stimuli in the form of mechanical and electrical contractile stimulation. These methods have proven to be successful in the maturation of the muscle pieces towards functional tissue with native properties. Moreover, the myosatellite cells can be cultured together with other cell types, which help the formation of the extracellular matrix to which the muscle cells can adhere. This so called ‘co-culturing’ of cells ensures that the composition of the cultured muscle is starting to resemble the in vivo situation.

It will be essential to combine cultured beef with other animal tissues such as fat.

peRCeptIon IS RealIty Consumer acceptance and perception is almost even more important than the technological hurdles that have to be taken. In order to gain consumer acceptance the sensory appreciation and quality of the products have to be spot-on. It will be essential to combine cultured beef with other animal tissues such as fat, connective tissue and blood. The red colour of meat is created by the proteins haemoglobin and myoglobin. Myoglobin can be found in muscles, and commercially available haemoglobin isolated from red blood cells can be added to the

and like cultured meat, still needs refining before actual mass production can be upscaled. For now, it is expected that science will need at least another 20 years before the first commercial production stem cell based tissues are economically and technically feasible.

Fat SImulatIon WItH pRoteIn An alternative and much cheaper method to incorporate the much needed fat into a cultured meat hamburger is the use of micro-stabilised

vegetable oil globules by using milk protein or plant protein sources that have microparticulation properties to simulate fat. Actually, it is even possible to prepare a double emulsion in which the inner-layer can contain nutraceuticals, vitamins and minerals such as iron. This fat-simulation technology is already widely used in many meat and food products. Besides improving texture and juiciness, it will significantly reduce the amount of saturated fat. High amounts of naturally occurring saturated fatty acids in meat fats are known to significantly increase the risks of heart disease. Since more than 50 percent of all beef is eaten as ground meat, it is obvious that hamburger versions will draw most attention and probably are the fastest way forward to bring this technology to market introduction. Here in the ground meat market, it is where other protein sources can, and will, excel and gain interest, just like the cultured meats. For example, using texturised vegetable proteins to mimic meat structure has recently been introduced and is now being used by the world’s leading fast food companies as well as organic whole foods companies. Subsequently, it has started to find its way into our everyday food and hybrid meat products. Structured and/or textured proteins mimicking chicken, ground beef and fish are used in meat-free or vegetarian products, as well as frequently blended with meats to form hybrid products.

InSeCtS anyone? Proteins from insects are of high quality and can also be structured to mimic animal tissues. Moreover, insect protein hydrolysates can be added to vegetable proteins to supplement the essential amino acids. Next to bacteria and fungi, insects are one of the most efficient organisms on this planet, which need little nourishment and energy to flourish.

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ASIA PACIFIC FOOD INDUSTRY OCTOBER 2013

It is still too early to know for sure, but it is estimated that one single bovine cell sample (taken from the cowâ&#x20AC;&#x2122;s shoulder) could produce 20,000 MT of cultured beef. Translated into McDonaldâ&#x20AC;&#x2122;s language, this would mean that more than 175 million quarter-pounder hamburgers could be served. Since cultured beef will not appear on the menu boards sooner than 2030, it is safe to assume that by that time, these cultured beef burgers would be infused with structured plant protein fibres that uniquely mimic organoleptic meat properties including texture, juiciness, flavour and colour. Combining premium sources such as soy protein, wheat, and rice bran protein makes these structured plant protein fibres an ideal solution to further stretch cultured meat. By going this pathway, truly sustainable and cost efficient hybrid meat products can be produced that will have a very satisfactory consumer appreciation level. As such, it can be assumed that for coarsely ground meat foods, the infusion or blend level will be about 50 percent cultured beef, and 50 percent of structured plant-based meat analogue fibres that completely match the characteristics of lean meat. Extrapolating the numbers in the previous paragraph, it would translate to about 350 million burgers or the equivalent of 800,000 cattle. Think about the huge amounts of savings that can be generated, including less intensive livestock farming and of course, a much high-

ceptance. After all, the highly intense GM-debates and confrontations with special interest groups such as Greenpeace have shown the food industry how to avoid the pitfalls of groundbreaking technology and its potential consumer impact. For more information, ENTER No: 0762

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