APFI Meat and Poultry Supplement 2010

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MICA (P) 179/12/2009

meat poultry and

supplement

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| 2010

Enquiry Number

1107

Progress through innovation

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CONTENTS

ASIA PACIFIC FOOD INDUSTRY 2010

2

MEAT & POULTRY

SUPPLEMENT

PROCESSING

•

PACKAGING

•

FLAVOURS & ADDITIVES

•

12

STORAGE & HANDLING

www.apfoodonline.com

34

24

3

Advertiser’s List

4

Editor’s Note

6

or on-site preparation. By Paul Heness, Heat And Control

16

Automation and documentation in industrial processes described using the example of a production line for canned paté. By Dr Andrea Freese, Kilia

10

Meat & Poultry: Cut To The Chase A uniform cut will reduce waste and products can be fried, dried, chilled or frozen evenly. By Andrew Neo, Urschel Asia Pacific

12

A Fry Up Of Convenience Much of the foodservice industry need fully-cooked products for fast in-store

20

Almond: Meat For The Long Haul Two recent studies demonstrate that almond skins could be used to extend the shelf life of ground beef and poultry.

By C Broughton, Parker Broughton & Associates, and S Cunningham, Nut-trition

ASIA PACIFIC FOOD INDUSTRY’S special supplements are published by Eastern Trade Media Pte Ltd twice a year. The Publisher reserves the right to accept or reject all editorial or advertising material, and assumes no responsibility for the return of unsolicited artwork or manuscripts.

All rights reserved. Reproduction of the magazine, in whole or in part, is prohibited without the prior written consent, not unreasonably withheld, of the publisher. Reprints of articles appearing in previous issues of the magazine can be had on request, subject to a minimum quantity.

The views expressed in this journal are not necessarily those of the publisher and while every attempt will be made to ensure the accuracy and authenticity of information appearing in the magazine, the publisher accepts no liability for damages caused by misinterpretation of information, expressed or implied, within the pages of the magazine. All correspondence regarding editorial, editorial contributions or editorial contents should be directed to the Editor.

Cover Picture Courtesy Of © Eugeneel | Dreamstime.com • Printed by GP Cyberprint

Meat Opportunities: Value-Add For Premium Quality Manufacturers and markets are adding value to less expensive cuts and meats, therefore raising budget cuts to a more premium product. By Kayleen Ternes, Kerry Australia

All In Good Taste The flexibility of using flavourings and the opportunity they bring to innovate and experiment, mean poultry manufacturers, are well placed to offer products which deliver a healthy profile and satisfy many different consumers around the world. By Geoff Allen, Synergy

Paté: Put A Lid On It

24

28

Eye On Asia Messe Frankfurt shares more on the latest trends for the Asian market at an exclusive interview with Asia Pacific Food Industry. By Tjut Rostina

34

Case Study: Data Management For Slaughter House With a share of close to 90 percent of the market for pig slaughterings in Denmark, Danish Crown looks to new technologies to further improve its bottom line. By Nich Barfoed for ABB

THE CIRCULATION OF THIS PUBLICATION IS AUDITED BY BPA INTERNATIONAL THE ADVERTISERS’ ASSOCIATIONS RECOMMEND THAT ADVERTISERS SHOULD PLACE THEIR ADVERTISEMENTS ONLY IN AUDITED PUBLICATIONS

MICA (P) 179/12/2009 • PPS 1566/8/2010 (028233) ISSN 0218-2734 • Co Reg No: 199908196C

ASIA PACIFIC FOOD INDUSTRY ADVERTISING INDEX ENQUIRY NO.

ADVERTISERS

PAGE

1115

ANGSANA FOOD INDUSTRIES SDN BHD

1110

BEMIS ASIA PACIFIC SDN BHD

27

3

1113

CAMA GROUP

31

1114

GOURMET FOOD SAFETY CONSULTANCY

36

1101

HEAT & CONTROL PTY LTD

1107

HONG KONG TRADE DEVELOPMENT COUNCIL

1111

JOHN BEAN TECHNOLOGY SINGAPORE PTE LTD

1102

KALSEC INC

1103

KERRY ASIA PACIFIC

15

1112

LAWSON SOFTWARE ASIA PACIFIC PTE LTD

23

1104

MULTIVAC PTE LTD

21

1105

PEI CHUAN MACHINERY

19

1106

SANDVIK SOUTH EAST ASIA PTE LTD

1108

SCHAEFER SYSTEMS INTERNATIONAL PTE LTD

1116

VIV Asia 2011

1 IFC OBC 5

9 IBC 3

This index is provided as an additional service.

The publisher does not assume any liability for errors or omissions.

HEAD OFFICE (Singapore) - Eastern TRADE MEDIA PTE LTD 1115

1100 Lower Delta Road #04-02 EPL Building Singapore 169206 Randy Teo / Peh Sue Ann | Tel: 65-6379 2888 | Fax: 65-6379 2805 / 6379 2806

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MEDIA REPRESENTATIVES

CHINA Wan Xin Xian | Tel: 86-20-3411 4806 | Fax: 86-20-3411 4805 JAPAN Ted Asoshina | Tel: 81-3-3263 5065 | Fax: 81-3-3234 2064 TAIWAN Tom Lin | Tel: 886-22619-2798 | Fax: 886-22619-2799

VIVAsia 2011 VIV Asia 2011 is the world’s most promising meeting point to boost your future business from Feed to Meat

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Bangkok

9-11 March, BITEC Bangkok, Thailand

1116

Don’t miss our special features!

adv viv asia 203x134 show catalogue2-V3.indd 1

Enquiry Number

Feedtech-Croptech Asia 2011 LAB@VIV Asia 2011 07-04-2010 14:35:26

EDITOR’S PAGE 4

MEAT & POULTRY

SUPPLEMENT

meaty opportunities

This special meat and poultry supplement marks the start of a series of genre-focused editions, in addition to the staple Asia Pacific Food Industry magazine.

Appearing at all major trade shows in the region, the supplement aims to provide an overall view of all things to do with the meat industry, from processing and packaging equipments, right up to ingredients.

In this edition, the organiser and exhibitors from IFFA 2010, the international meat-processing event, share their thoughts on the latest trends in the industry.

The event that took place during the month of May 2010, in Frankfurt, Germany, saw automation and healthier ingredients as some of the more dominant emerging trends. Energy efficiency in production processes, waste reduction and increase in shelf life are just some of the other trends that are apparent at this year’s event. (Page 28) Consumers have responded to the economic downturn, planning their purchases in advance, in line with household budgets. Even though some consumers are more budget conscious and trading down, some are looking for premium at-home alternatives to eating out. This has provided opportunities within the meat category with numerous value adding options and creative flavours being applied. (Page 24) The flexibility of using flavourings and the opportunity they bring to innovate and experiment, mean poultry manufacturers, are well placed to offer products which deliver a healthy profile and satisfy many different consumers around the world. (Page 16) With meat consumption in Asia on the rise, food manufacturers can look forward to even more opportunities in the market.

managing director

Kenneth Tan editor

Tjut Rostina

tjutrostina@epl.com.sg editorial assistant

Audrey Ang

audreyang@epl.com.sg senior art director/studio manager

Lawrence Lee

lawrencelee@epl.com.sg assistant art director

Libby Goh

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

randyteo@epl.com.sg advertising sales manager Peh Sue Ann

sueannpeh@epl.com.sg senior circulation executive

Brenda Tan

brenda@epl.com.sg contributors

Andrew Neo

C Broughton

Dr Andrea Freese

Geoff Allen

Kayleen Ternes

Nich Barfoed

Paul Heness

S Cunningham

board of industry consultants Dr Aaron Brody Managing Director Packaging/Brody, Inc Dr Alastair Hicks Agroindustries and Postharvest Specialist UN Food & Agriculture Organisation 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 financial controller

Robbin Lim

Tjut Rostina

etm

Eastern

TradeanMedia Pte Ltd Eastern Holdings Ltd company

Head Office & Mailing Address Eastern Trade Media Pte Ltd 1100 Lower Delta Road, EPL Building #04-02, Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2805 Email: apfood@epl.com.sg

Kalsec Asian Liquid Spice Blends ®

Authentic Flavor and Efficient Application

Curries, Tom Yam, Satay, Rendang, Adobo, Pho, Otak-Otak, Sambal and Kimchi Advantages from Kalsec Natural Asian Blends.

• Natural, non-GMO, and Halal Suitable • Flavor consistency and intensity • Lower micro count • Improved color stability and versatility ®

• •

Consistent clean and fresh flavor Easily incorporated

Malaysia GULF CHEMICALS SDN. BHD. An Operating Unit of Connell Bros.

603-5192 6868

Philippines CONNELL BROS. CO. PILIPINAS, INC. +63 (0) 2 533 9688

Singapore CONNELL BROS. CO. (SINGAPORE) PTE. LTD. 65-6862 1772

Thailand CONNELL BROS. CO. (THAILAND), LTD. 66-2-259-8500

Vietnam CONNELL BROS. CO. (VIETNAM), LTD. 84-8-3899-0596

kalsec Products, Service and Science you can trust…naturally.™

Kalsec ®, Inc. Kalamazoo, MI USA 49006 +1 2 6 9 3 4 9 9 7 1 1 w w w.kalsec.com

Enquiry Number

Indonesia PT. CONNELL BERSAUDARA CHEMINDO (62-21) 5794 1900

1102

Let our experienced team help you find the natural solution to your next liquid Asian Blend need.

MEAT & POULTRY 6

Paté:

ASIA PACIFIC FOOD INDUSTRY 2010

Put A Lid On It

MSEN, Turkey / Natalie Maynor, Jackson, Mississipi / Fdecomite

肉浆: 成品包装上市

In modern industrial food processing industry, automation and documentation are becoming more and more important. The effect of lowering personnel costs, though still given, is no longer the only type of effect.

More important are factors like securing a standardised quality, an efficient process control and, most important of all, a nonmanipulated documentation of the production. The latter grants the possibility to prove an impeccable product process. This will be shown using the example of a production line for canned paté, which has recently been implemented by Kilia Fleischereiund Spezial- Maschinen Fabrik GmbH from Neumünster in Germany.

The Big Break Up Primary material of the line is frozen meat (approx: –15 to –25 deg C) delivered in more or less standardised blocks, as it

Automation and documentation in industrial processes described using the example of a production line for canned paté. By Dr Andrea Freese, marketing & sales manager, Kilia

is today frequently used in the industry.

As a first step, a prior size reduction of the blocks is necessary, which was achieved in a conveyor belt loaded with frozen meat breaker.

The breaking up of blocks is preferred over the alternative process of cutting, especially since the fibrous structure of the meat is best preserved this way. Ideally, the breaker unit is situated on top of the further processing machine,

an automatic angle meat mincer.

The resulting approximately double-fist sized pieces of frozen meat fall into the hopper. Then, the

MEAT & POULTRY

2010 ASIA PACIFIC FOOD INDUSTRY

7

It avoids unnecessary squeezing of meat fibres and grants a homogenous production capacity.

High capacity systems allow the processing of the frozen meat blocks (down to –25 deg C) in one single step, to 3 mm minced material. The result is an optimal preprocessed product quality for all further processing. conveyor worm transports them to the main worm and cutting system, which are positioned at a 90 degree angle.

This angular system has a higher capacity and a more gentle treatment of frozen meat as compared to one-worm systems.

The Right Mix Different transportation systems, depending on product type and viscosity, are centrally steered and connected with weighing systems. This is to compose the individual batches for each of the following mixers, into which

Mixing times, temperatures as well as vacuum conditions can be programmed according to the required result with a vacuum mixer.

The breaker unit is situated on top of the further processing machine, an automatic angle meat mincer.

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ASIA PACIFIC FOOD INDUSTRY 2010

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additional automated dosing systems pour further additives, like spices, oil, and water.

The following mixing process is carried out under vacuum and continuous product warming/ heating. Here, it is especially important, that the heating process is carried out in a gentle and steady way. Therefore, mixers, which are equipped with a double-walled hopper using either steam or special heating liquids are usually preferred.

An optimal and speedy mixing process is always given, when the machines provide horizontal as well as vertical mixing (eg: with s p e c i a l l y developed paddle mixing arms as wells as a transportation and mixing worm).

Mixing times, temperatures as well as vacuum conditions can be programmed according to the required result. A constant vacuum secures minimised air inclusions and grants a maximum of economical efficiency.

The Emulsifier Hopper Whenever more than one mixer is used at the same time, it is suggested to connect them with the emulsifier through a valve-steered high capacity pump system.

After the end of the mixing cycle, each batch of mixed product, can then be unloaded and further processed separately.

When selecting a suitable emulsifier, attention should be paid not only to a sufficient

Whenever more than one mixer is used at the same time, it is suggested to connect them with the emulsifier through a Jean Scheijen, Maastricht, Netherlands

valve-steered high capacity pump system.

With the optionally available ‘order management module’, complete production cycles can be planned from the office PC and the relevant batch numbers are sent directly to the machines.

throughput capacity, but also to the degree of fineness, that can be reached under the least temperature increase.

Especially good results in this direction have been reached with a contact free cutting system, which has the additional advantage of little maintenance requirements and so, minimal costs.

To be able to work and document completely batch-wise, the emulsifier hopper should be able to handle a complete mixer batch. A level measuring

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2010 ASIA PACIFIC FOOD INDUSTRY

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Sandvik steel belt meat cutting tables

Sandvik stainless steel belts provide the best conveying option for meat cutting tables.Their inherent strength and flatness help to prevent scratches and resist corrosion from blood and/or fatty acids.The cleaning process is automatic and designed to minimise water consumption.

They also provide the lowest levels of bacteria growth of any belt type on the market, a key reason why our technology has been adopted by the world’s largest meat exporters.

Our scope of supply extends from simple work tables to complete production lines for meat products, including slaughter, de-boning and packaging. We can provide expertise in all areas of production through extensive experience of working with clients throughout the world.

Sandvik South East Asia Pte Ltd E-mail: sea.sps@sandvik.com www.processsystems.sandvik.com

SANDVIK SOUTH EAST ASIA PTE LTD 50, ALPS Ave, #04-00 Sandvik Building, Singapore 498782 Tel: +65-64773736 | Fax: +65-64773785 Email: sea.sps@sandvik.com | www.processsystems.sandvik.com

1106

VisUAlisATioN oF proCesses In connection with visualisation and documentation software and recipe manager, it is possible to steer the whole installation and to coordinate production cycle times, even under frequent change of recipes.

A complete process control is possible anytime. Mistakes, that might occur, are instantly repor ted and visualised, respectively rectified. In the ideal case, the process steering software also offers a batchwise documentation feature (ie: all production conditions are documented manipulationfree).

That would be an essential component for the batch traceability as required by European law (regulation 178/2002). For each batch, its number, operator code, time, production time, temperature development, vacuum conditions and mixing, as well as cutting speed are transferred to a standard office PC of the production manager, via an USB interface.

Analysis and documentation of data can then be carried out with the help of a pre-programmed mask. Alongside a clear text manager, which allows the storage of detailed text modules, the connection with eventually already available ERP systems is possible.

With the optionally available ‘order management module’,

complete production cycles production, which guarantees can be planned from the office standardised, high quality PC and the relevant batch products under consistent numbers are sent directly to the documentation, which fulfill machines. Also recommended is consumers expectations and the assignment of a camera, which interests. allows a continuous overview of 111x183 14.07.2008 10:25 Uhr Seite 1 For more information, production processes.

ENTER No: 0xxx The result is an automated

Enquiry Number

is obligatory for steering the whole installation centrally.

From the emulsifier, the product is pumped to a can filling station. Core of the whole installation is the steering software, which connects all individual machines (each of them equipped with PLC steering) and coordinates the automated process.

MEAT & POULTRY

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All operation costs were up when fuel prices hit a high about 12 months back; however, even after fuel prices returned to the price range of US$50 – 60 per barrel, the costs remained high.

The financial crisis also provided another blow to the Asian food industry as export to America and Europe was greatly affected. Surviving this economic

due to older technology and possibly worst, losing customers who are unsatisfied?

Regardless of whether food products have been fried, dried, chilled or frozen before cooking or eating, they would have been washed and cut prior to these processes. Many food processors know that a uniform cut will reduce their waste, and products

is that bigger sizes take longer to process, mainly because the temperature difference between the core and surface could be more and heat transfer between them is slow.

M a n y p ro c e s s o r s h a v e difficulty in producing good product quality due to inconsistency in the fr ying, drying, chilling or freezing time

Meat & Poultry:

Chase To The

肉类和家禽:完美的切割技术 A uniform cut will reduce waste and products can be fried, dried, chilled or frozen evenly.

By Andrew Neo, regional sales manager, Urschel Asia Pacific crisis is crucial, and almost all food processors have been looking at cost control without compromising the quality.

Get Even One of the ways that some food processors think of is in acquiring cheaper equipment to minimise cost. This is a tangible cost, but what about intangible losses like less yield in production, poor product cut quality, shorter shelf life, higher energy consumption

can also be fried, dried, chilled or frozen evenly. As such, this gives better control of quality as well as energy savings.

Some of the parameters affecting these processes are product size, heating or cooling rate, and moisture content; just to name a few.

Size Matters The product size of meat and poultr y affects the process significantly. The reason for this

for each individual product. As an illustration, dehydrated meat slice, frozen meat/poultry dice and cooked chicken strip cut will be used as examples.

• Drying In drying a product, inconsistent sizes or thickness of the meat will affect the drying process, making quality control a difficult task.

Unnecessary amount of energy may be used to process the oversized product or processors

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will face the issue of product deterioration due to incomplete drying. A poor cut slice surface will create a tearing effect. This will produce more fines/wastage after the drying process, resulting in loss in yield.

• Frozen Meat/Poultry Next, frozen meat/poultry dice pack; if the meat dices are produced with irregular shape, by crushing instead of cutting, it creates more wastage.

The freezing process will be greatly affected and the shelf life will be shortened. Irregular cut leads to packaging problems as getting the correct weight per pack will be a challenge.

• Cooked Poultry For cooked poultr y applications, the cutting process is very important because poultry meat fibre is very delicate after cooking. The meat can easily break up if the cutting action is not swift and sharp. Poor quality equipment will crush and tear the fibre instead of cutting. This creates more fines and breakage in the final product.

A low quality slicer or dicer may come cheap. but it will add more to operating costs. Here are the reasons: • Poor cutting quality creates more fines and wastage. More raw materials will be needed.

• Poor cutting quality crushes products and damages the products’ cell structure. Part of the product turns into juices, where it is a wastage and shelf life of the dices is greatly reduced.

• It creates an irregular cut

product shape and there would be difficulty in uniform packaging or chill/freeze. Like frying, uneven sizes or thickness will cause some portions of the product to be overfrozen, while certain parts would be insufficiently chilled.

PreCiSiOn QUaLitY Getting a high quality precision

cutting machine gives you the following advantages: • Uniform Cut Size It produces uniform cut size for either strip cut or dices, as such, minimising the undesired cut and fines. If the cut product needs to be cooked, a consistent cut size will ensure all products are well cooked without being burnt or leaving an uncooked centre.

• Consistency High quality machines supplied with cutting par ts are assembled and pre-determined within tolerances of +/- 0.0001 inches to ensure proper fit and interchangeability. Human adjust-

ment and potential human error are minimised, and inconsistency in cut setting is diminished.

Good quality equipment are capable of producing consistent quality product at high capacity.

As such, one machine can replace a few small-scale machines or a low quality machine, which is possibly producing inconsistent product quality. Good equipment also come with a small footprint and save on production area.

FreSH LOOKS The cut produced is clean and neat, without crushing the product cells. This gives the product a better appearance and it can stay fresh longer. The various knife options should also be designed t o m e e t d i f f e re n t product textures and processing conditions.

As mentioned earlier, washing and cutting is the first stage in most of the food processing line. If control is not carried out on a good quality cut at this initial stage, more will be spent at the rest of the process line in terms of product yield, energy efficiency, packing problems and poor product appearance and shelf life.

For more information, ENTER No: 1602

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could easily expand the cooking side of the existing processing line.

From here, increased the need to improve product integrity, quality and hygiene standards in order to guarantee consumer satisfaction, as well as developing systems that offer flexibility for alternating different types of products.

Rob Owen-Wahl, UK

COnVenienCe FOOdS The growth of meat based convenient foods has grown in both the retail and the food service sector. To service this growth processing improvements, machinery

A Fry Up Of

CONVENIENCE 简易的烤炸烹饪技术

much of the foodservice industry need fully-cooked products for fast in-store or on-site preparation. by Paul Heness, food technologist, Heat And Control IN response to consumer meat demand and the ever-growing regulation surrounding responsibility of processors to provide high quality products, the meat processing industry has changed dramatically over the last 20 years.

The convenience and readyto-eat markets, including the growing fast food and foodservice industries, have opened up opportunity for meat processors to expand into further processing of meat products.

developers are still required to provide some of the following:

This time-saving market for consumers, was an ideal expansion for meat processors, where further processing such as coating, par-cooking and full cooking seemed like a natural progression as operations

• Inline Fat Analysis Some systems have utilised the Near Infrared (NIR) technology to deliver systems that can measure fat, moisture and protein levels during the mixing and grinding phase. This has dramatically reduced the leadtime for results from days to nearly real time with obvious production and quality enhancements.

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• Multi-Stage Continuous Fryers These fr yers are two semiindependent frying systems, working in tandem to deliver high volume, high quality fried product, while at the same time maintaining high levels of oil integrity.

Both systems can typically utilise various oil filtering systems to remove the smallest of powder breading from the oil. However, for oil level control, both systems work as one unit.

More processors are cooking products fully today, with the growth of the ready-to-eat meals market. It is expected that processors must be able to provide a wide range of fully cooked products to a diverse consumer in order to be competitive in the marketplace.

In addition, these systems can come with internal by-pass conveyor systems to cater for products that require baking, and no frying. This minimises the duty and required cleaning of the fryer systems • Heatwave Fryers The special frying systems differ radically from the traditional immersion style of fr ying.

Rather, it enrobes the product in a series of oil curtains.

The basic principle of this system is to remove the issue of thermal transfer problems due to the vapour barrier surrounding frying foods. Being an indirectly heated fryer, the oil is continually filtered as it passes over the food product.

Twin Drum Spiral Ovens These units optimise the yield return to the processor at the same time delivering product of a very high standard. Each drum can be customised to perform

at different cooking parameters.

For example, the first drum is set to a relatively high wet dry bulb setting to cook the product, while the second oven has a much drier, hotter environment which delivers the required external colour and crust development.

Some twin drum systems can have the oven walls lifted for ease of maintenance and cleaning.

• Continuous Nugget Formers Meat nuggets (portions of meat) destined for pizza toppings have and continue to, increase in demand. Continuous nugget forming systems were developed to deliver product at around 1,000 kg/hr.

Instead of the previous form of reciprocating motion to form nuggets, this system undertakes this duty via a form of extrusion, thereby improving product quality, volume and integrity.

• Ready-To-Eat Foods More processors are cooking

products fully today, with the growth of the ready-to-eat meals market. It is expected that processors must be able to provide a wide range of fully cooked products to a diverse c o n s u m e r i n o rd e r t o b e competitive in the marketplace.

Much of the foodser vice industry needs such products for fast in-store or on-site preparation. Fully cooking the product before it leaves the plant also helps maintain good foodsafety protocols.

One area that has shown significant growth is pre-packaged, fully cooked product primals, or large meat cuts. Examples are bone-in beef products that have been marinated, slow cooked, packaged and frozen, so the customer only needs to heat the product for serving.

HACCP It could be said that HACCP and its scientific approach has driven a major shift in the food industry

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ASIA PACIFIC FOOD INDUSTRY 2010

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especially in the meat sector.

As this approach saw industry wide adoption, a fundamental shift within the meat industry resulted in moving away from the imposed regulatory controlled functions to systems where substantial responsibility was transferred and managed by the processors.

H A C C P, w h e n p ro p e r l y developed and implemented, covers nearly all areas of the meat industry, enhancing and improving methods, operations, and ultimately helping the bottom line. Furthermore, the system has also changed some of the customs and habits within the meat processing area, some of which have been in use for

many years. All this is for the betterment of the process, product and consumer.

Product Integrity In-line continuous checking/ inspection equipment has been developed to ensure the integrity of the raw and finished product.

Metal detection systems continue to be a major element in product integrity, and processors are now using real time X-ray equipment more extensively.

These X-ray systems work in both the raw and finished areas, thereby minimising any product contamination, or system downtime due to damage from foreign materials. These elements not only help maintain the quality standard of the product, but also help satisfy due diligence of safety systems.

Flexibility Of Systems Processors now require their processing systems to have the

capability to fully and efficiently cook a wide range of products.

They are always trying to maximise their yields and product quality. They also have to be flexible in what they are capable of producing.

It is becoming rare to have a single line dedicated to a product as the majority of new lines designed have the ability to be as flexible as possible, and allow for the widest range of products types.

This line includes batter and breading capabilities, frying (both full and par-fry) and oven capabilities. The equipment also needs to be portable or easily by-passed when not needed.

For more information, ENTER No: 1603

Enquiry Number

1103

MEAT & POULTRY 16

ASIA PACIFIC FOOD INDUSTRY 2010

All

Jill Chen

Good Taste 集美味之大成

the flexibility of using flavourings and the opportunity they bring to innovate and experiment, mean poultry manufacturers, are well placed to offer products which deliver a healthy profile and satisfy many different consumers around the world. By Geoff allen, director of export, Synergy THE food industry is inundated with competing trends. Clean label, low salt, healthful and fortified are just some of the buzz words consumers react to today.

There is however, a consensus that inevitably taste ranks top of the purchasing processes: 77.9 percent of respondents from 15 countries stated that ‘taste or flavour’ has a high or very high influence on their choice of food and beverages, according to Datamonitor.

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Flavour Fix Taste preferences are dependent on a multitude of factors: culture, upbringing, current trends, and cost are to name, but a few.

For this reason, identifying key market trends in each region and proposing an offer that taps into these is essential.

Cultural traditions and ingredient availability traditionally drive taste trends. This means preferences can vary greatly from country to country, and even regionally.

In Europe, for example, the top flavours in the poultr y industry over the past five years have been garlic, spice, tomato, cheese, onion and chilli. In Asia Pacific this differs: spicy, hot, barbecue, cheese and butter take the top spots.

Flavour preferences are also beginning to expand beyond traditional favourites. Today’s consumers tend to be better travelled, meaning they are open to trying new flavours. This has not waivered despite the global recession, with Europeans and Asia Pacific consumers still intrigued by the prospect of experimenting with flavour.

Regional variation in taste preferences and the latest trends offers huge scope for innovation.

Poultry manufacturers must map each target sector and remain sensitive to regional requirements.

Traditional flavours will work well as a basic offering, but in Europe in particular, more exotic flavours will ensure products

Traditional flavours will work well as a basic offering, but in Europe in particular, more exotic flavours will ensure products stand out and attract attention.

Massimo Zunino, Milan, Italy

Bearing this in mind, manufacturers in Asia Pacific must juggle market trends to offer the best tasting products, and this is by no means an easy feat.

The coated meat industry has a tough job on its hands.

Questions over fat, salt and MSG content, coupled with an upswing in vegetarianism have meant manufacturers must up their game to offer premium quality and healthy products.

Poultry manufacturers already benefit from offering leaner meats, but must be careful to ensure coatings do not compromise a healthy profile.

To maximise flavour impact, manufacturers must monitor taste trends in the quick service restaurant (QSR) channels, and identify overarching food industry trends such as the move towards healthier products.

Here, we look at flavour trends in Europe and Asia Pacific, and how poultry manufacturers can boost the taste and appeal of their offering.

Poultry manufacturers can innovate with coatings to reflect demand for the bolder, more striking flavour expectations of consumers.

Supermarket shelves are stocked with more adventurous flavour combinations such as chilli and lime, which differentiate products, giving them additional appeal.

stand out and attract attention.

Asian cuisine, for example, is enjoying huge success in the European market and works well in meats such as chicken and turkey. In the UK, a flavour for Asian cuisine sees menus once dominated by Indian and Chinese dishes, now including Thai, Malaysian and Japanese offerings.

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A Healthy Outlook Health remains a major preoccupation for consumers around the world today. Government initiatives in Europe targeting health, such as the ‘five-a-day’ campaign in the UK, are raising the importance of a balanced and varied diet to maintaining a healthy lifestyle. Other initiatives promoting salt and fat reduction

levels in meat have taken their toll on the industry. Poultry manufacturers, however, are well positioned in the sector with lean, white meats such as turkey and chicken, which are perceived as healthier and more environmentally friendly, compared to red meats like beef and lamb.

Products in both Europe and

factor by developing bold flavours for coated meats, while also reducing fat and salt contents.

Re-Evaluate & Reformulate Ultimately, consumers are looking for great tasting, nutritious foods which do not break the bank. This translates to three challenges for poultry manufacturers: imparting impactful taste, increasing the health profile, and keeping production costs low.

In order to maximise cost efficiencies, while also boosting the flavour and healthy profile of coated poultry products, manufacturers must analyse the

Flavours do not only offer the opportunity to reduce un-desirable ingredients, they can also be used to mirror the flavour of less

Isaac Wedin, Washington DC, US

healthy cooking methods. Ovenbaked and grilled meats are preferable to fried, due to less oil absorption.

and the removal of MSG from products are also contributing to the trend for ‘better for you’ products.

This trend has repercussions for manufacturers in Asia Pacific wishing to gain market share in Europe by positioning their products as healthier.

One of the main ways to infuse meat with flavour is by using a coating or batter. However, many consumers avoid fatty and salty batters and coatings. As such, manufacturers need to combine taste with healthier labels to ensure success.

Questions over saturated fat

Asia Pacific are increasingly including ‘low fat’ and ‘low salt’ claims to counter the pressure being felt.

Flavour delivery is known to encourage repeat purchases, and consumer expectations about taste are high – if a product lacks flavour we feel cheated.

More intense flavours will increase overall consumer satisfaction. Also, health-conscious consumers increasingly expect the same taste satisfaction from reduced fat and salt products, as they do from less healthy options.

Poultry manufacturers can capitalise on this satisfaction-

whole production line. To create superior taste, flavourings must be chosen according to specific needs, for example: oil soluble, spray-dried, heat stable, freeze stable, healthy profile.

Flavour Solutions There are four main ways flavour can be applied to coated meats.

Flavour can be added directly to the meat, used in a pre-dust, added to the wet batter or be used in a second optional predust. Some manufacturers will use all of these methods.

This type of process allows manufacturers to add depth to flavour profiles, layering notes at different stages. For example, adding flavouring to the pre-dust can enhance a roast chicken flavour profile, and a different

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manufacturers are well placed t o o f f e r p re m i u m t a s t i n g coated products that deliver a healthy profile, maximise cost efficiencies, and satisfy many dif ferent consumers around the world.

For more information, ENTER No: 1604

1105

In Short‌ The poultry industries in Europe and Asia Pacific share many characteristics: consumers in both regions are increasingly expecting healthy products that also offer premium taste.

However, to successfully cater for consumers across different regions, poultry manufacturers

should provide varied taste profiles. By examining QSR channels, popular taste trends can be identified and translated into a product offer.

The flexibility of using flavourings and the opportunity they bring to innovate and experiment, mean poultr y

Enquiry Number

flavouring, such as garlic can be added to a batter.

Herbs and spices can then be incorporated into a crumb. By layering flavours, the depth and intensity of taste is increased. It also means only one component needs modifying in order to meet new consumer preferences.

Reformulating to increase the health profile is a more complex, and often costly task. Often salt, fat and MSG are integral to maximising flavour intensity and mouthfeel. When removed, they can decrease the product’s sensory appeal. Manufacturers must therefore use effective flavour solutions, which perform well in low fat coatings or flavour enhancers, to recreate desirable fatty and salty notes and textures.

Flavours do not only offer the opportunity to reduce undesirable ingredients, they can also be used to mirror the flavour of less healthy cooking methods.

Oven-baked and grilled meats are preferable to fried, due to less oil absorption.

The taste, however, of fried meat is popular. Manufacturers wishing to communicate on a healthy platform, but maintain desirable tastes, can add fried notes to the pre-dust or batter flavourings. This flexibility of combining flavours to maximise eating enjoyment means poultry manufacturers can develop products to meet multiple taste preferences.

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Satoru Kikuchi, Tochigi, Japan

Chapman University in California.

The first study evaluated the effect of almond skin powder on colour and lipid oxidation of ground beef.

In the study, ground beef was blended with 0.5 percent almond skin powder. The almond skin was effective in lowering hexanal content and thiobarbituraic acid

Antioxidant Effects I n t h e s e c o n d s t u d y, t h e antioxidant effects of almond skin powder in ground chicken

meat Almond:

Almond bran may provide multiple solutions for food processors looking for functional ingredients. It is the brown outer skin that is removed from the almond during the blanching process. The skins are dried, and then ground into a powder or meal consistency.

The skins contain phenolic acids and flavonoids that function to protect the kernel from oxidation, insects and spoilage.

Shelf Life Extension Two recent studies demonstrate that almond skins could be used to extend the shelf life of ground beef and poultry. The studies were conducted in 2008 at

Ernesto Andrade, San Diego, US

showed a higher red colour value after 11 days compared to ground beef samples, including those with added butylhydroxytoluene (BHT).

for the long haul 杏仁：为货架上的肉类延长寿命 Two recent studies demonstrate that almond skins could be used to extend the shelf life of ground beef and poultry. By C Broughton, Parker Broughton & Associates, and S Cunningham, VP, R&D Nut-trition.

reactive substances, which are indicators of lipid oxidation in ground beef.

Reduced lipid oxidation means longer shelf life. In addition, the colour of the ground beef containing almond skin powder

breasts under cooked refrigerated storage, and uncooked frozen storage conditions, were studied.

All samples containing almond skin powder had decreased oxidation as compared to the negative control.

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In general, according to the authors: “Almond skin powder incorporated in both cooked refrigerated and uncooked frozen ground chicken breasts had significantly lower primary and secondary oxidation products as compared to the negative control as shown by CD, TBARS and hexanal content. Results indicate that almond skin powder has the ability to enhance the shelf-life of ground chicken breast during refrigerated and frozen storage.�

The potential for a nutritious whole food ingredient to provide meat and poultry processors with an alternative, in part or whole, to chemical antioxidants is an exciting concept for natural food advocates. Additional research and product development, as well as future consumer attitude

and taste studies will show how well the addition of the mild nutty flavour, reduction of chemical additives and improvement to the nutritional profile of ground beef and poultry, will be embraced by consumers worldwide.

Based on recent studies by the Almond Board of California, 78 percent of European and 85 percent of North American consumers surveyed, report nutrition is a major consideration in buying and/or preparing food, and rate almonds as good or excellent for being nutritious.

Health Benefits Over the past decade, a substantial body of scientific literature has been generated on the antioxidants in almonds and almond skins, revealing

that most of the antioxidants including flavonoids and phenols are found predominately in the skin of almonds.

Flavonoids include flavanols, dihydroflavonols and flavanones.

Many of the flavonoids exist both conjugated to sugars, and in aglycone forms. The most abundant flavonoids in almond skin are catechin, epicatechin, kaempferol and isorhamnetin, and typically they are conjugated to sugars such as glucose or rhamnose.

Almond skins also contain both A-type and B-type proanthocyandians. Flavonols and Flavan-3-ols have numerous beneficial effects on the gastrointestinal tract as well as antiviral, anti-inflammatory, antiallergenic, antimutagenic,

T 200 and T 250 tray sealers: Semi-automatic and fully profitable for packing small and medium-sized batches.

Enquiry Number

1104

Everything possible. The application range.

T 200 and T 250 pack everything that fits into trays: fish and meat, sausage and cheese, and also convenience products. But also fresh fruit, vegetables, salad or dried fruit. Along with foodstuffs, they are also ideally suited to medical sterilised goods and industrial and consumer products. The type of packing is up to you: vacuum or skin packing, air packing, or protective atmosphere packing. This versatility makes both tray sealers ideal solutions. For example, as an entry-level machine for protective atmosphere packing in small businesses, or as a capacity standby or laboratory machine for industrial firms. Anywhere it is not economical to have a fully-automatic system, you will profit from the semi-automatic tray sealers from Multivac.

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such as stigmasterols and campesterol are thought to have beneficial effects on blood lipids.

Almonds are among the nuts granted a health claim by the United States Food and Drug Administration (FDA). In July 2003, FDA approved a health claim stating: “Scientific evidence suggests but does not prove that eating 1.5 ounces per day of most nuts, such as almonds, as part of a diet low in saturated fat and cholesterol may reduce the risk of heart disease.�

Safety and Nutritional Value Even though humans have been consuming almond skins for many centuries, research has confirmed its safety for use as a food ingredient and dietary supplement.

Research published in Food a n d C h e m i c a l To x i c o l o g y, demonstrated that almond bran is safe. A sub chronic oral toxicity study demonstrated that it had no genotoxicity and did not lead to organ or systemic toxicity when consumed.

Almond bran is a concentrated source of nutrition. It is a source of vitamin E, dietary fibre, and essential minerals such as magnesium, calcium, phosphorus, and potassium.

Mike McCune, Portland, US

anticarcinogenic, and anticholesterolemic activities.

Non-flavonoid compounds include protocatechuic aldehyde, and protocatechuic, vanillic, parahydroxybenzoic, coumaric and chlorogenic acids.

Studies have determined that the antioxidants in almond bran are both bioactive and bioavailable. Researchers at the University of Barcelona have conducted clinical research in vivo to better study the bioavailability of almond skin antioxidants in human subjects.

Dr Urpi-Sarda showed that almond skin antioxidants are absorbed in human subjects. Both animal and human trials have been conducted with extracts of almond skin, showing rapid bioavailability of monomers of various flavanols directly in the small intestines, but oligimers and polymers are absorbed after being metabolized by microorganisms in the colon.

In vitro studies at Tufts University revealed that almond skin polyphenols act in synergy with vitamins C and E to protect low-density lipoprotein (LDL) from oxidation. Polyphenols are among the most abundant bioactive compounds in a healthy diet and may also play a key role in healthy circulation and prevention of heart disease, neuro-degenerative diseases and cancer.

Almond skins show excellent free radical scavenging activity and compares well with commonly used as benchmarks trolox and quercetin. The skins are similar to grape seeds and skins in ORAC values, and have more than 10 times the phytosterol content compared to whole almonds. Phytosterols have been shown to reduce absorption of dietary cholesterol and have anticancer properties. Phytosterols

Two recent studies demonstrate that almond skins could be used to extend the shelf life of ground beef and poultry.

The strong body of almond research was a factor in the approval of the nut health claim petition. A meta-analysis of seven almond studies showed a 5.3 percent to 7.2 percent decrease in total cholesterol and 6.8 percent to 10 percent reduction in LDL cholesterol for subjects with high cholesterol levels. The results of this study show that almonds do have a convincing impact on total and LDL cholesterol levels with as high as a 10 percent reduction.

Applications Almond bran adds insoluble fibre, natural colour and a mild nutty flavour to all types of wholegrain breads, rolls, crackers and other products. It binds with fruit concentrates, nuts, grains and other ingredients commonly used in nutrition bars. It can be added to meat emulsions and sausage, or used as a bulking agent.

Incorporate the ingredient into flaked, puffed or granulated cereals for improved fibre and nutrition. It can also be easily formed into a nut-like bit that is useful in reducing both cost and fat calories associated with other almond forms.

The ingredient is suitable for inclusion in cereals, bakery items and with other products where nuts and whole grains are used.

With demonstrated prebiotic effect, almond bran extends the shelf life of meat, poultry, and probiotic organisms in yogurt and probiotic supplements. It is natural and contains no other ingredients.

For more information, ENTER No: 1605

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Enquiry Number

1112

Contact us at +65 6788 8769 or infoASIA@lawson.com to learn how Lawson Food & Beverage software can help set your food business up for success.

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Meat Opportunities:

Value-Add For Premium Quality

© klikk / Fotolia

肉类增值机会：高品质的提升 Manufacturers and markets are adding value to less expensive cuts and meats, therefore raising budget cuts to a more premium product. By Kayleen Ternes, product development manager, Kerry Asia Pacific Food consumers all over the world are striving to know more about the food they consume, incorporating health benefits, clean labelling and convenience. In more recent times, sustainability and provenance are having a huge influence on purchase decisions.

Consumers have responded to the economic downturn, planning their purchases in advance, in line with household budgets. There has been a return to cooking at home and cooking from scratch.

They are tending to eat out less, and spending more time choosing the products they purchase.

Even though some consumers are more budget conscious and trading down, expectations remain high in terms of flavour and quality. Some are looking for premium at-home alternatives to eating out. This has provided opportunities within the meat category with numerous value

adding options and creative flavours being applied.

Many manufacturers and markets have positively taken advantage of this by value adding to less expensive cuts and meats, therefore raising budget cuts to a more premium product. Such products include sausages and burgers. Other products include meats which are pre-marinated or injected and sometimes sold with a sachet of sauce. Another example is lamb shanks and ribs, often sold in a tray.

Food To Go Convenience continues to be an important driver with food development. People are leading busy lifestyles, with smaller households and less time to cook.

The UK & Europe, in particular, have provided the grocery market with premium value added and ready meal choices for many

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options emerged and continue to do so, however, we are seeing an increase in techniques such as marinades, injectants, rubs and seasonings applications being used by ingredient & flavour companies. These companies i n t u r n p ro d u c e p re m i u m quality products with authentic flavours with the added benefit of convenience.

To add value to meat is to improve the sensory properties such as: appearance, taste, aroma and quality in order to make the product more desirable to the consumer, through the delivery of, monetary value and convenience. Product value can be created by the addition of customised ingredient systems to meat, in order to generate a desired end product.

© Liv Friis-larsen / Fotolia

© klikk / Fotolia

years. The economic downturn has seen some interesting changes in this region as well, including a transition from complete ‘ready to heat’ take home ready meals, to more ‘ready-to-cook’ styles.

Either in the form of a ‘meal kit’ or ‘tray’ - containing pre-marinated, flavoured or coated meat products. Often incorporating meal component make-up, it therefore needs only partial meal preparation, but still offering the added convenience of having the ingredients at hand.

Value adding through ready meals and meal kits has seen

some interesting alternatives to eating out. Flavour development has become somewhat regionalised with authentic flavours incorporating health benefits and fortification.

Meat product development in Asia has seen some interesting developments over the last five years. Consumers’ are seeking a higher standard of meat and often fully cooked options.

Therefore, this generated many opportunities with value added processed meat. Premium coated

Meat Rubs & Seasonings This can be a combination of fine and/or coarse herbs, spices and vegetables, along with salt, sugar, and other ingredients which define the style of the seasoning.

For instance, Tandoori rub will often contain a high propor tion of yoghur t solids. Honey, soy, fruits,

To add value to meat is to improve the sensory properties such as: appearance, taste, aroma and quality in order to make the product more desirable to the consumer, through the delivery of, monetary value and convenience.

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nuts and grains can also be used to define the products character.

They can be applied either topically or internally, if the intention is to flavour an emulsified/reformed product, typically sausages, meatballs and burgers. Quality seasoning not only delivers authentic flavours to the meat, but they also enhance the visual appeal, encouraging t h e c o n s u m e r ’s d e c i s i o n to make an initial purchase.

FunCTionAl BindeR sYsTeMs Binder systems are commonly used in applications such as traditional European small goods,

and sausages such as Frankfurts, Cabana, Kransky, Continental Hot Dogs, Chorizo, Chicken Loaf, 4 x 4 Hams. Additionally burgers, meatballs and reformed meat & vegetable products, all use functional binding systems.

These functional systems are designed to give products flavour, texture and visual attributes as well as assisting in the overall processing of the products. These systems may contain ingredients such as flours, crumbs/rusk, starch, egg, phosphates, salt, sugar, herbs & spices, proteins, and fibre, along with various functional ingredients. There are

Quality seasoning not only delivers authentic flavours to the meat, but they also enhance the visual appeal,

© Eugeneel | Dreamstime.com

encouraging the consumer’s decision to make an initial purchase.

also specialty ingredients, which may be added such as Omega 3 to improve nutritional quality and specialised natural shelf-life extenders and curing agents. inJeCTABle/TuMBle MARinAdes Specialist functional systems are mainly used in value adding for whole muscle or larger portions of meat, such as bone in and boneless hams, traditional style bacon, fresh whole meat muscle, corned beef, whole bone-in poultry, meat fillets and moisture infused roasting portions.

They can offer many benefits to the overall eating quality of the meat, by improving the texture, succulence, flavour, colour and sliceability. This has proven advantageous in the transformation of lower grade meats, to more premium products.

They also assist in maintaining the quality of meat products that undergo many processing steps prior to consumption.

Finally, they can extend the weight of the meat by retaining increased amounts of water, as such, increasing its overall monetary value. When selecting an injectable/tumble marinade, it is important to consider the ingredients and functionality, as it will have a significant contribution to the desired end product.

CoATinG sYsTeMs There are many products on offer to consumers with many points of difference. Some of these include, fat reduced, vitamin fortified, low E number or E number free coatings, tempura coatings containing particulates, low salt, gluten free, and coated products designed specifically for children.

Coating systems contain a complex array of ingredients with varying attributes, that when combined, perform a specific

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Clean Label Demands Consumer’s wants and expectations are also changing the way meat products are developed.

There is an increasing demand for reduced additives (E numbers), allergens, removal of artificial

colours and flavours, vitamin fortification, reducing sodium, sugar and preservative levels in products sold on the market.

This has been a challenge for ingredient suppliers to develop products that meet the demand of processors and retailers, while providing products of equivalent quality and remain commercially viable.

There are ingredients available such as salt and sugar replacements offering processors sodium and sugar reduction without compromising flavour, MSG alternatives, natural preservative systems, gluten free products and an expanding range of natural colours and flavours.

For more information, ENTER No: 1606

1110

texture (dense and hard, or light and crispy), levels of fat & moisture absorption and flavour.

An emerging trend in crumb applications is a crust coating.

This is a mixture of crumbs blended with a combination of herbs, spices, fruit, vegetables and oil/butter/margarine. It is applied on top of a roast meat portion, and baked in the oven.

The end result is a flavoursome crunchy crust, which adds an interesting twist to an everyday roast.

Enquiry Number

function. Each ingredient is carefully selected with the end use in mind. Batters are commonly made up of ingredients such as flour, starches, gums, sugars, proteins and leavening agents. Flavours and visuals may also be added in either one or all of the components (batter/ pre-dust/crumb), depending on the desired effect.

When creating coated crumbed products, there are many crumb options for marketers and product developers to choose from.

These include purpose baked crumbs, Japanese style crumbs and extruded crumbs. Depending on the crumb of choice, they contribute to a multitude of organoleptic properties such as, visual appearance (coarse, medium or fine crumb), colour,

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Asia is becoming increasingly important, due to increased income, and in turn the consumption of meat. There is a demand for more processed food in Asian cities, and a need to supply safe and high quality meat, which impact areas such as packaging and logistics.

Dr Michael Sturm, director for marketing communications, s a i d t h a t t h e o rg a n i s e r ’s partner, VDMA, an association for machinery manufacturers in Germany, had shared with them that the automation degree is currently between 10 to 20 percent in the meat sector.

eye

a i on as 洲 亚 放眼

test n the la sive o e r o xclu es m rt shar arket at an edustry. u f k n a m In Fr Messe for the Asian Pacific Food a s i trend ew with As intervi t Rostina

By Tju

(L - R) Detlaf Braun, member of the management board, Dr Michael Sturm, director for marketing communications, and Iris Jeglitza-Moshage, director for technical fairs.

Upcoming Trends With regards to ingredients, companies are looking to create traditional flavours of Asian dishes, and are also exploring opportunities for additives enhance health, like vitamins and low sodium solutions.

Another area of interest is the emerging trend for automation

and software management in the meat industry. According to Iris Jeglitza-Moshage, Messe Frankfurt’s director for technical fairs, the key players in the market have machines with higher degrees of automation or improved automation systems for existing companies, other than a handful of new entrants.

Energy efficiency in prod u c t i o n p ro c e s s e s , w a s t e reduction and increase in shelf life are just some of the other trends that are apparent at this year’s IFFA. International Presence I F FA , w h i c h i s o rg a n i s e d once ever y three years by Messe Frankfurt, serves as an international platform for the meat industry.

“These days, it is especially important to have an international platform. Industries around the world went through tough times, as we all know. The years 2010 and 2011 would still be challenging for the industry.

In a crisis like this, when the going gets tough, exhibitors and visitors are focusing on the most efficient platform,” commented Detlaf Braun, member of the management board.

One criteria of quality is the level of international participation.

Most of the industries are made up of small and medium sized companies, and these companies make up about 90 percent.

“For them, it is very important that they meet new clients, and mainly international ones.

With our structure, which we have established, we have the opportunity and possibility to deliver the highest international level of any of these shows in the industry,” added Mr Braun.

Although times are tough, the company has not reduced their investments in the show.

The team’s preparation for the show stretches for the whole three years between the each installation of the shows. Efforts are spent on promoting the event at smaller shows worldwide, networking, and getting into contact with associations as well as the media. ______________________ Enquiry No: 1607

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reVIew: IFFa 2010 IFFa, which was held from may 8 – 13 in Frankfurt this year, saw a large increase in the number of international visitors, with 58,000 decision makers at the trade fair for the meatprocessing sector. the trade visitors came from 130 countries to see the range of products and services offered by 949 companies this year. the proportion of trade visitors from outside germany rose significantly compared to the last event three years ago, from 47 to 59 percent. this means full order books for manufacturers of meatprocessing and packaging machines, and a sector distinguished by a much greater willingness to invest following a very difficult year. the drop in attendance compared to 61,328 visitors in 2007, is due to a decline in the number of german visitors, the result of a process of concentration that has been taking place in both the butchers’ trade and the industry over the last three years. the role of the event as the meeting place for the international meatprocessing sector is also reflected by the top ten visitor nations, which were, apart from germany, russia, Italy, spain, Poland, the netherlands,

austria, switzerland, the Us, Belgium and australia. after the meatprocessing industry, butchers formed one of the most important groups of visitors, accounting for approximately 12 percent.

Important subjects at this year’s event were increased automation, safety, traceability and hygiene. the fields of additives, spices, aromas and packaging are growing in significance for meat and sausage production in the wake of increasing consumer expectations with regard to healthy food and convenience products. this trend is also reflected by the results of the visitor poll conducted by messe Frankfurt with regard to the most important product groups at the fair (multiple answers possible). In 2010, 32 percent of visitors said they came to the fair to see machines and equipment for processing and packaging meat products. this segment was followed by spices, additives and aromas for meat and sausage products (30 percent), products and services for butchers’ shops (26 percent), and slaughtering and dismembering equipment (22 percent). there was a noticeable increase in interest in automatic machinery and

handling equipment. almost a fifth of visitors said this was one of their main reasons for attending the fair.

For visitors, ‘trends in the Butcher’s shop’ and ‘specialities from the region’ special shows were a source of tips and ideas for new fields of business. the meat Vision conference, organised by the deutscher Fachverlag publishing company and the german Institute for Food technology (deutsches Institut für lebensmitteltechnik), offered information about the meat markets of the world and visions for meat processing in the coming decade. the next IFFa will be held in Frankfurt am main from may 4 – 9, 2013.

Frankfurt am Main Frankfurt, Germany May 8 – 13, 2010 ___________________ Enquiry No: 1608

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Meat Trends:

Chew On This!

Exhibitors at IFFA tell us what they think are the trends to look out for in the meat industry.

Anritsu Industrial Solutions Europe:

Safety First

Yoshiaki Lizuka Company Secretary/European Sales Manager Food manufacturers’ keen effort in keeping up the quality of their brands has kept the market demand for food safety equipment on the rise.

According to Yoshiaki Lizuka, Anritsu’s company secretary and European sales manager, in a bid to keep up with food safety regulations, the need for x-ray inspection systems has increased, as customers seek to not only detect metal, but also other foreign objects such as stone and glass.

In terms of future development plans, Mr Lizuka shares that India is a developing country, and that there is a possibility of setting up an office in the country within the next two to three years. ________________________________________ Enquiry No: 1609

Cretel:

CSB System:

Integration To Save Costs Terry McCorriston Director of business development Companies are under tremendous pressure to keep their costs down and running the plant efficiently. For this, CSB System is helping to overcome the pressure by providing technology and integration, to maximise profits in the food industries.

The company does this through the integration of shop floor equipment, so as to speed up processes and improve quality.

“By integrating, there will most definitely be improvements in yield of about two to five percent, and labour efficiency can go upwards by 15 percent,” said Terry McCorriston, CSB’s director for business development.

He added that the company would continue to integrate more equipment, and provide improved tools for production scheduling. ____________________________________________ Enquiry No: 1611

Automation For the Future Harold Demoen Managing director In view of an increase in the near future, the use of automated equipment would help to meet the level of increase.

Harold Demoen, the managing director of Cretel, said: “There will be more industrial equipment needed, instead of manual handling, because labour costs more. As such, manufacturers would go for fully automated equipment.”

An example is the dismembering and skinning process, where manual handling would raise the temperature of the product, and decrease its quality. In response to this demand, the company has developed fully automatic skinners for the industry, which includes PLC programming.

The company currently has business interactions in countries like Vietnam and China, and are increasing their works with Thailand. They will also be introducing more products to Malaysia and Indonesia. ____________________________________________ Enquiry No: 1610

Marelec:

The Right Cut Piet Rommelaere Managing director More consumers are looking for pre-packed solutions, which means that meat and chicken need to have a precise portion and weight, before packaging and sold in supermarkets.

Weighing, grading and portioning machines play directly into this trend, and can deliver a product with fixed weight. “We are expanding the features of our existing machines. Like, instead of just cutting for fresh products, we are also looking at cutting and portioning for frozen products,” said Piet Rommelaere, Marelec’s MD. The company has an agent in Vietnam, which currently cover its business for Asia Pacific. He adds that the company is looking to expand its business within Asia Pacific in about year’s time. __________________________________________ Enquiry No: 1612

Enquiry Number

1113

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Martsons Food Corporation:

Fresh appeal

Michael Ang Jr Vice President Martsons Food Corporation, which promotes its carrageenan from the Philippines is one of the newer players in the market with carageenan from the Philippines as its main product.

Michael Ang Jr, VP for Martsons Food Corporationg said: “Right now the world is into renewable resources, so as carageenan from the Philippines is renewable, it can be seen as a green product.”

He adds that the ingredient can be used for meat and dairy products. The ingredient gives meat products a fresh mouthfeel with ‘bounce’ when bitten into, as consumers associate this feel with freshness.

The company sells its products to the European, North America, and Asian markets. Mr Ang adds that most of the company’s new enquiries are from Eastern Europe.

Steriflow Thermal Processing:

Improve Processes For Healthier Foods Matthieu Cillard Export Manager Steriflow Thermal Processing is following on the path of improving processes to meet the demand for healthier foods. The company based in France, is responding to this trend by bringing in the recently developed Shaka technology, which is aimed at reducing sterilising cycle time on the products.

With regards to the impact of the current economy, Matthieu Cillard, Steriflow’s export manager said: “We confirm that some emerging countries are catching up with the economy, especially in Southeast Asia. I do agree that the future is still fragile, but there is a trend for this.”

The company is currently has agents in Asia Pacific, and plan to participate in more trade shows within the region. ____________________________________________ Enquiry No: 1615

______________________________________ Enquiry No: 1613

Treif:

Purac:

Sodium Reduction Edwin Bontenbal Innovation Director Food Sodium reduction is one of the trends that are geared towards healthier products. To meet this demand, Purac has developed a product that would enhance the salty taste, so that even if the salt level is reduced, the ingredient can compensate for its salty flavour and preservation.

Edwin Botenbal, Purac’s innovation director for food, shared that the company is looking towards developing products that have a specific flavour aspect, and for more natural preservatives.

The company has already launched some of these products in the North American and European markets.

For the Asian market, the company is looking at natural preservatives, however, it is noted that the need for inexpensive preservation is much more, as compared to the need for natural preservation.

“We will look for markets that have the highest need for natural preservation, and we will develop some products for the Asian market. However, I do not expect them to be in the market for the next three years,” Mr Botenbal added. ____________________________________________ Enquiry No: 1614

Small Companies, Big demands Iris Henrich, Public Relations Hartmut Dengel, Manager Treif has swooped in to make sure that they are in line with the demand for automation and industrial solutions, as well as machines for small businesses.

“We see two different trends, one for more automation, complete solutions. The other trend, which is more German specific, are small companies, who are interested in small machines,” according to Iris Henrich, the company’s public relations personnel.

An example is the company’s ‘Divider Orbital’, for small companies who need a slicer that is efficient and flexible, so as to allow them to slice a wide range of products without changing the equipment.

The company currently exports its machines to countries in Asia Pacific, like Japan, Korea, Taiwan, Philippines, Singapore and Australia. ________________________________________ Enquiry No: 1616

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MEAT & POULTRY

ASIA PACIFIC FOOD INDUSTRY 2010

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Data Management Case Study:

For Slaughterhouse 案例研究:屠宰场的数据管理 With a share of close to 90 percent of the market for pig slaughterings in Denmark, Danish Crown looks to new technologies to further improve its bottom line. By Nich Barfoed for ABB Apart from the sheer size and automation of the production, tracking production and the ability to trace products is the single most important feature to secure a dominant place in the increasingly competitive world market for the Danish slaughterhouse.

Production planning, follow-up, quality assurance, documentation and traceability all form an integral part of the so-called factor y database, developed and implemented by a project team with representatives from ABB Denmark and Danish Crown.

The Competitive Edge The Danish company was looking for a system that could handle the enormous amount of data generated in the slaughterhouse, and could help improve traceability, flexibility, raw materials usage, and other key competitive and financial factors.

“Apart from being a highly competitive sector, where customers, including the largest super and hypermarket chains in Europe constantly demand improved quality and lower prices, the players on the international pork market are also under great pressure, from both national

MEAT & POULTRY

2010 ASIA PACIFIC FOOD INDUSTRY

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and EU authorities to implement systems that improve the traceability of their production,” explains Per Laursen, the factory manager.

According to project manager, Arne Boye-Møller, the primary focus was to find a solution that would suit the needs of the new slaughterhouse with its structure and work processes, which are completely different from what the company was used to. At the same time, they had to maintain a broader focus to ensure that they did not create an ‘island’ within the company.

In other words, the platform had to fit all new installations, but at the same time be applicable elsewhere in the organisation. It had to be able to communicate seamlessly across the entire company. Finally, it was a firm requirement that the IT system should be open, so that they would not become dependent on one or a few suppliers.

Monika Henkel, Baia Mare, Romania

The Traceability Neccessity An important issue for Danish Crown was the ability to live up to the demands for traceability in their production – a requirement

on all food producers including s l a u g h t e rh o u s e s f ro m E U authorities.

However, due to the characteristics of the production, the implementation of traceability from each individual cut and up the chain to the breeder, who supplied the pig, is quite complicated. As such, this requires the generation of an enormous amount of data.

Add to this the practical issue of marking all the meat cuttings in order to allow a unique identification of the product all the way from breeder to supermarket.

The system generates more than one million data records every working day. The amount

unique relationship between the production planning, and what is actually being produced.

It was a prerequisite that the factory database should be able to communicate and link to all the existing administrative systems, not least SAP, which is used as their global planning and financial management system.

All information is stored in and distributed by the FDB. It is also possible to perform detailed production planning directly in the factory database, without the need to communicate with any of the global systems. This is important not only due to its flexibility, but more importantly, allowing the slaughterhouse to

All information is stored in and distributed by the FDB. It is also possible to perform detailed production planning directly in the factory database, without the need to communicate with any of the global systems. of data together with the complexity of the processes currently makes it virtually impossible to secure traceability all the way to each individual pig.

Therefore, the company opted for a solution, which traces in batches of 20 pigs from the same breeder, and as such lives up to the requirements from the authorities. This can be done without sacrificing the possibility in the future to increase the degree of detail, if at some point this becomes a requirement and/or whenever it becomes economically feasible.

Database For Traceability A so-called ‘Factory Data Base’ (FDB) was then designed and implemented, to allow the slaughterhouse to collect and save all the data required for traceability.

The database is the only place, where they can establish a

continue its production, even when communication links to the administrative systems may be broken.

The factory database is a standard MES system that does not have any rights to automatically initiate or execute production.

Satisfactory Delivery The whole process from the initial contact till the final implementation has been satisfactory.

Both parties participated and provided sparring, whenever things got complicated, or when the slaughterhouse company came up with new ideas and requirements that would impact the complete setup – something which happened quite frequently during the complicated development process.

For more information, ENTER No: 1617

Mr. Lawrence Low is the founder of Gourmet Food Safety Consultancy and has been serving in the food safety industry for more than 15 years. He is a MSc Food Technology (Specialized in QA ) graduate from The University of Reading (UK) under scholarship awarded by the SIFST (Singapore Institute Food Science & Technology) He is one of the few registered ISO22000:2005 approved auditor under International Register of Certificated Auditors (UK) & an officially registered HACCP Consultant under SIFST in Singapore. On top of that, Mr Lawrence Low is also a member of International Food Protection (IFP-US).

Specializing in : Customized food safety consultation Customized food safety & Hygiene training, audit services for food & beverage companies Implementing food safety management systems Implementing laboratory setup services Food Safety training on ISO22000:2005, HACCP, cGMP, BRC QC & Assurance for products exporting to International Markets:

Email:

Mr Lawrence Low Kai Fong lawrence@gourmetfoodsafety.com

Tel:

(+65) 9179 7675

Fax:

(+65) 6297 6048

Address:

Website:

195 Lavender Street #03-18 Eminent Plaza Singapore 338 758

www.gourmetfoodsafety.com

“BETTER BE SAFE THAN BE SAVED�

1114

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