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New food products from around the world

Technology update: Packaging Processing Ingredients

Packaging for convenience Optimising line efficiency Health trends IFFA preview

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April 2010

APRIL 2010 CONTENTS

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Features 5 Editorial

14 New food

Investment in robotics and automation is increasing and can bring significant improvements in production efficiency

The Economy & Consumer Demand is Top of Mind for manufacturers and retailers this year

10 CIAA report The CIAA is convinced that nutrition labelling based on GDAs is a powerful tool to help improve the food literacy of European consumers

New developments in enzyme technology open doors to a wide range of new products and help optimise existing formulations

Mintel looks at the latest new food and product to have appeared on supermarket shelves around the world and assesses the trends taking place

19 Special

Technology updates 32 Ingredients

Cover image: © Monkey Business Images | Dreamstime.com

A record of conferences, exhibitions and other events of interest to industry professionals

11 Industry news

44 Processing Extrusion technology opens up the possibility of new product concepts and boosts productivity

39 IFFA Preview

8 Events

products from around the world

focus: Health trends Leatherhead Food Research highlights how producing successful healthy products in today’s competitive markets requires a full understanding of the prevailing trends and legislative environment

25 Packaging

for Convenience Convenience remains a key driver for new product development and no more so than in the area of packaging where the design has to be convenient not just for the consumer, but also for the supply chain, the manufacturer and the retailer

IFFA, Europe’s foremost trade fair or the meat processing sector opens its doors again from May 8 to 13 in Frankfurt, Germany

46 Vitafoods

Preview

Vitafoods will showcase the latest developments for the global nutraceutical market in Geneva, May 18 to 20

42 Packaging Nanotechnology could soon be used to stop the escape of air from plastic bottles and help produce packs with inherent antimicrobial properties

49 Total Preview Total Processing & Packaging is set to open its doors to thousands of visitors at the NEC, Birmingham, UK from May 25 to 27

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28 Line efficiency:

The role of pumps, valves & drives

In any manufacturing process, optimising operational efficiency is a key driver of business competitiveness. This is especially so in food production where any downtime can mean that ingredients perish and product lost, according to Brammer UK

April 2010 www.foodbev.com

EDITORIAL

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Robots and automation bring benefits

ith the IFFA exhibition in Frankfurt and Total in Birmingham in May both featuring dedicated Robotics pavilions this year, it is interesting to note the growth in interest in this area. At Total, a dedicated Vision & Robotics Pavilion will bring together members of the UK Industrial Vision Association and the British Automation & Robotics Association to showcase innovations; while at IFFA, the Robotik-Pack-Line is a fully operating, automated production line that demonstrates the latest robotic solutions for sorting, portioning, verification, packaging, sealing and labelling systems. In Quakenbrück in Germany in March, the DLG (the German Agricultural Society) joined forces with DIL (the German Institute of Food Technologists) for the first Robots in Food Production seminar, which concluded that for the successful and sustainable application of robotics in food production long term planning and the involvement of all employees was vital. In the UK, CenFRA (the Centre for Food Robotics & Automation) has been set up to provide advice on automation solutions. “Almost any function on a biscuit production line (for example) can be automated. The key is to pick the right functions that deliver the greatest benefits,” said Richard Charlesworth, director of CenFRA in the UK and Batley site general manager at Fox’s Biscuits,

problems with the integration of this equipment into our existing processing methods. CenFRA evaluated the robotic needs and set out a project plan to resolve the issues concerned. It has been able to re-design and reconfigure the robot and successfully supported its assimilation into the bakery.” It is this assessment of the optimum investment opportunity that is the secret to successful automation projects. There are so many solutions on offer – see the June issue of Food & Beverage International to read about some of the latest – that obtaining the right advice and ensuring that the solution will bring true payback to the business is crucial.

It is this assessment of the optimum investment opportunity that is the secret to successful automation projects. part of Northern Foods, which has benefited from a technology audit by CenFRA that identified opportunities for automation. Fosters Bakery in the UK has also benefited from CenFRA consultancy. “We designed and installed a fully bespoke baking robot to load and unload an oven,” said Michael Taylor, operations director of Fosters Bakery and chairman of CenFRA. “Unfortunately, while the design concept was great, there were

Living Salads worked with CenFRA to do just this and achieved a 50% increase in production units with a matched decrease in labour costs within twelve months of its consultation. Critically, by installing automated packing equipment, Living Salads not only improved production, but also increased volume, thereby creating more jobs rather than losing them as a result of automation – which, is a win, win result in today’s tough environment.

Claire Rowan, Managing editor claire.rowan@foodbev.com

EDITORIAL ADVISORY BOARD

Dr Philip Richardson

Dr Yasmine Motarjemi

Huub L.M. Lelieveld

Campden BRI

Assistant vice president,

President, Global Harmonisation Initiative

Head of Food Manufacturing Technologies,

Dr Harmen Hofstra

Food Safety manager, Nestec Ltd Karin Östergren

Secretary general, The EU Association for Food

Dr Michael Knowles

PhD, Project Leader & Scientifically responsible

Safety; and Head of New Business Development,

Vice president, Global Scientific &

within the Sustainable Food Production section,

Food Safety, TNO Nutrition & Food Research

Regulatory Affairs, The Coca-Cola Company

Swedish Institute for Food Research, SIK

Dr J André de Barros Teixeira

Dr Sebastiano Poretta

Director, Food Safety Programmes, (CIES - The

Vice president, International R&D,

President, Italian Association of Food Technology

Food Business Forum) The Consumer Goods Forum

Catherine François

The Campbell Soup Company Dr Paul Berryman

Mella Frewen

Mrs Helen Sisson

Chief executive,

Director General, Confederation of the

Group technical director, Greencore Group

Leatherhead Food Research

Food and Drink Industries of the EU (CIAA)

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www.foodbev.com/food EDITORIAL

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Managing editor Claire Rowan claire.rowan@foodbev.com FoodBev Media Ltd 7 Kingsmead Square, Bath, BA1 2AB, UK Tel: +44 (0)1473 311 531 • Fax: +44 (0)1225 327891 Group editorial director Bill Bruce bill.bruce@foodbev.com

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April 2010. Volume 9, Issue 2 Food & Beverage International is published six times a year by FoodBev Media Ltd, 7 Kingsmead Square, Bath BA1 2AB, UK. It is circulated to food and beverage manufacturers in Europe. For companies/organisations that are not manufacturers of food or beverage products, or located outside Europe, the subscription charge is €109 (US$179) for one year, or €218 (US$358) for two years. Cheques should be made payable to FoodBev Media Ltd, and sent to FoodBev Media Ltd, 7 Kingsmead Square, Bath BA1 2AB, UK. No items may be reproduced, copied or stored in any form,

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EVENTS

2010 May

May 8-13 IFFA - International trade fair for processing, packaging and trade for the meat industry, Frankfurt, Germany. Details from Messe Frankfurt GmbH, Ludwig-Erhard-Anlage 1, 60327 Frankfurt aM, Germany. Tel: +49 69 75 75 0; Fax: +49 69 75 75 64 33. May 10-13 Cibus, the finished food and beverage exhibition, held alongside Dolce Italia, the confectionery exhibition; and Planet Nutrition, Parma, Italy. Details from Fiere di Parma, Viale delle Esposizioni 393a, 43126 Parma, Italy. Tel: +39 339 666 8750. www.cibus.it May 11-12 Conference on Sustainable Agriculture - The Art of Farming, Brussels, Belgium. Details from Conference Secretariat, WG Plein 475, 1054 SH Amsterdam, The Netherlands. Tel: +31 20 589 32 32. www.sustainable-ag.org May 13 UK Soft Drinks conference Refreshing the Nation, London, UK. Details from Ms L Gascoigne, Zenith International, 7 Kingsmead Square, Bath BA12AB, UK. Tel: +44 (0) 1225 327 900; Fax: +44 (0) 1225 327 901. www.zenithinternational.com May 18-20 Vitafoods, international nutraceutical ingredients exhibition, Geneva, Switzerland. Details from Laura Plumbly, Exhibitions Administrator, IIR Exhibitions, 5th Floor, 29 Bressenden Place, London, SW1E 5EW, UK. Tel: +44 (0)20 7017 7019; Fax: +44 (0)20 7017 7818. www.vitafoods.eu.com May 18-20 Food Ingredients Central & Eastern Europe, Warsaw, Poland.

Food & Beverage International April 2010

Click here to subscribe Details from CMP Information, PO Box 200, 3600 AE Maarssen, The Netherlands. Tel: +31 346 559 430. www.fi-events.com May 19-20 Central European Congress on Food, Bratislava, Slovakia. Details from Food Research Institute, Priemyselná 4, PO Box 25, 82100 Bratislava, Slovakia. Tel: +421 255 574 622. www.vup.sk www.cefood2010.eu May 25-27 Total Processing & Packaging exhibition, integrated processing & packaging exhibition, showcasing production line solutions from beginning to end, Birmingham, UK. Details from Mr Graham Earl, Reed Exhibitions, Gateway House, 28 The Quadrant, Richmond, Surrey, TW9 1DN, UK. Tel: +44 (0)20 8910 7890. www.totalexhibition.com May 25-27 Snackex Asia, international snack production exhibition, Beijing, China. Details from the European Snacks Association, 6 Catherine Street, London WC2B 5JJ, UK. Tel: +44 (0)20 7420 7220; Fax: +44 (0) 20 7420 7221. www.snackex.com May 25-28 European Congress on Obesity being held by the European Association for the Study of Obesity (EASO) and the Turkish Association for the Study of Obesity (TASO), Istanbul, Turkey. Details from Professor Volkan Yumuk, EASO, 113-119 High Street, Hampton Hill, Middlesex TW12 1NJ, UK. Tel: +44 (0) 20 8783 2256; Fax: +44 (0) 20 8979 6700. www.eco2011.org

June June 10 Campden BRI Open Day, Chipping Campden, UK. Details from Daphne Llewellyn Davies, Campden BRI, Station Road, Chipping Campden, Gloucestershire GL55 6LD, UK. Tel: +44 (0) 1386 842 040;

Fax: +44 (0) 1386 842 100. www.campden.co.uk June 10-11 Sustainable Foods Summit, Amsterdam, The Netherlands. Details from Organic Monitor, 20B The Mall, London W5 2PJ, UK. Tel: +44 (0) 208 567 0788; Fax: +44 (0) 208 567 7164. www.sustainablefoodssummit.com/ contactus.htm June 8-11 Fispal Tecnologia, exhibition of food processing technology for the Latin America food processing industry, Sao Paulo, Brazil. Details from Messe Dusseldorf GmbH, Stockumer Kirchstr 61, 40474 Dusseldorf, Germany. Tel: +49 211 4560 242; Fax: +49 211 4560 87 242. www.messe-duesseldorf.com June 8-11 Packology, the Italian manufacturers’ packaging trade show organised by the Italian Packaging Machinery Manufacturers Association (UCIMA) and Rimini Fiera Spa, Rimini, Italy. Details from Packology, Communications - Nuova Comunicazione, Via Clodia, 19 - 47900 Rimini, Italy. Tel: +39 02 24 97 97 11; Fax: +39 02 24 97 97 31. www.ucima.it June 10-11 International Fresenius Food Allergens conference, Frankfurt, Germany. Details from Ms Mummenbrauer, conference manager, Die Akademi Fresenius, Alter Hellweg 46, 44379 Dortmund, Germany. Tel: +49 231 758 96 81; Fax: +49 231 758 96 53. www.akademie-fresenius.com June 15-17 Probiotics & Prebiotics, international probiotic conference, Kosice, Slovakia. Details from the organising secretariat, PAMIDA International spol. Sro, Komenského 2656, 02401 Kysucké Nové Mesto, Slovak Republic. Tel: +421 918 707 371; Fax: +421 41 4000 123. www.probiotic-conference.net

June 22-23 ProFood, food technology & equipment exhibition, Nantes, France. Details from ABE proFood, 35/37 rue des Abondances, 92513 Boulogen Billancourt Cedex, France. Tel: +33 1 41 86 41 76; Fax: +33 1 46 03 86 26. www.profoodmeetings.com June 23-24 Thermal Processing international conference, Chipping Campden, UK. Details from Daphne Llewellyn Davies, Campden BRI, Station Road, Chipping Campden, Gloucestershire GL55 6LD, UK. Tel: +44 (0) 1386 842 040; Fax: +44 (0) 1386 842 100. www.campden.co.uk June 30-July 2 Food Factory of the Future, conference bringing together industry and academia and emphasising important challenges that the food sector will meet in the future to satisfy consumer preference, acceptance and needs and to accomplish a sustainable development. Topics: Sustainable Food Production; Smart Process Control & Automation; Processing for Tailored Quality; and Controlling Micro-organisms, Gothenburg, Sweden. Details from Ms K Ostergren, SIK – the Swedish Institute for Food & Biotechnology/ Sustainable Food Production, Ideon, SE 223 70 Lund, Sweden. Tel: +46 10 516 66 00. www.sik.se. www.food-factory.se

July July 1 Food Enzyme Developments, seminar, Chipping Campden, UK. Details from Daphne Llewellyn Davies, Campden BRI, Station Road, Chipping Campden, Gloucestershire GL55 6LD, UK. Tel: +44 (0) 1386 842 040; Fax: +44 (0) 1386 842 100. www.campden.co.uk

Your event:

If you have a diary event you wish to publicise, send details to the editor at: claire.rowan@foodbev.com

CIAA REPORT

GDAs: Information at your fingertips A

sk any nutritionist about healthy eating and they will tell you that there is no such thing as good and bad or ‘healthy’ and ‘unhealthy’ foods - they will tell you that it is the balance of what you eat throughout the course of the day that’s important. It hasn’t always been easy to work out how an individual food fits into an overall balanced diet, but that has changed.

Guideline Daily Amounts GDAs (Guideline Daily Amounts) on food and drink labels help consumers to see ‘at a glance’ what their food contains. GDA labels provide a guide to how much energy and nutrients (sugars, fat, saturated fat, and sodium/salt) are present in a portion of a food or drink product and what each amount represents as a percentage of a person’s daily dietary needs. GDAs can be used to take the guesswork out of what and how much a consumer is eating in order to stay healthy. GDAs are based on a daily intake of 2000 calories - the average needed by a moderately active adult woman1.

Consumer literacy The GDA scheme was established as a CIAA commitment to the EU Platform for Action on Diet, Physical Activity and Health2 in 2006, with a view to improving nutrition labelling in Europe. At CIAA, we believe nutrition labelling based on GDAs is a powerful tool to help improve the food literacy of consumers enabling them to make choices in line with their individual dietary needs. And the evidence proves it. Peer-reviewed research by influential organisations such as the European Food Information Council (EUFIC) shows that:

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� GDAs allow consumers to understand their food choices. � GDAs ensure consumers can evaluate a product’s place in the daily diet. � GDAs empower consumers to compose a balanced diet adapted to their individual needs and lifestyle. Labelling to Advance Better Education for Life) was set up, one of the objectives of which is to better understand the prevalence and type of food labelling across Europe (WP1)7 and how nutrition information on food labels affects dietary choices and consumer habits.

‘In a survey of consumers from the UK,

In the first stage of this research project, more

France and Germany, more than 80% were

than 37,000 products across 28 countries

able to determine the healthier product by

were evaluated over a period of 6 months.

using GDAs.’4

The first set of results found that GDAs are

Successful Europe-wide application

one of the most prevalent forms of front-ofpack nutrition information for consumers.

GDA labelling is being rolled out on a

Case study: Poland

voluntary basis in all 27 EU Member States,

In Poland, nearly 500 food and drink

and over the past three to four years,

manufacturers representing almost the

thousands of manufacturers and many major

entire food industry are using GDA labelling.

retailers have implemented the scheme. The

An influential and wide-reaching education

success of this voluntary approach largely

campaign, ‘Choose with GDA’ involved the

stems from the ease with which it can be

support of all key stakeholders. As a result,

applied across Europe’s extraordinarily varied

today, over 77% of Poles are aware of GDAs

food and drink industry, including many

and use the scheme to make choices in line

SMEs, which account for over 99% of the

with their dietary needs.8

industry and which are increasingly rolling out the scheme5. In August 2008, a three-year EU-funded research consortium, FLABEL6 (Food

For more detailed information on GDAs and how they can help you to eat a more balanced diet, please visit the CIAA GDA website: www.gda.ciaa.eu

European food and drink manufacturers support mandatory nutrition labelling in the context of the current food labelling debate2. In addition, the GDA scheme provides nutritional information on how much a portion of a food or drink product contributes to the overall daily intake in terms of key nutrients.

Food & Beverage International April 2010

Eurodiet recommendations: www.eurodiet.com http://www.ciaa.eu/asp/documents/detailed_doc.asp?doc_id=881 3 http://ec.europa.eu/health/ph_determinants/life_style/nutrition/platform/platform_en.htm 4 EUFIC 2008 pan-European consumer research www.eufic.org 5 CIAA Monitoring Survey: www.ciaa.eu/asp/documents/brochures_form.asp?doc_id=70 6 FLABEL: www.flabel.org/en/ 7 FLABEL 1st Work Package research, April 2009: www.focusbiz.co.uk/webinars/flabel/wp1 8 Nutritional Labelling Research 2009: GDA Business Case Study Poland, March 2009: http://gda.ciaa.eu/asp2/links.asp 2

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INDUSTRY UPDATE

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Top of Mind for industry leaders The Economy & Consumer Demand remained in the top position among those issues concerning both retailers and manufacturers, in this year’s Top of Mind survey conducted by the Consumer Goods Forum. Although the grocery sector benefited from the fact that purchases of food cannot be postponed due to a recession, it has however suffered from the credit crunch and a shift in consumer purchasing patterns towards more economy products. At the same time, industry has for years trained consumers to shop smarter and more frugally, and participated actively in price deflation, a situation that may have a long lasting effect now, according to the Consumer Goods Forum.

‘While the financial crisis touched a minority of consumers in real terms, the recessionary mentality has been more pervasive’, highlights the report. ‘Media messages can take part of the blame for this, but recovery in consumer spending will depend on the industry’s ability to reignite itself and inspire consumers to think positively and enjoy spending again. Despite some efforts in this direction (Carrefour’s campaign: ‘le positif est de retour’ ‘the positive spirit is returning’, for example), there are few indications of this attitude gaining immediate traction. Consumers now expect high quality to come at a low price and delivering this will require fundamental shifts in

business models. As long as retailer pricing policies remain focussed on a race to the bottom, consumer spending is likely to remain subdued, even as confidence in the economy returns’. In second place this year for manufacturers was concern over Retailer-Supplier Relations; followed by The Competitive Landscape - a concern that was up from sixth place last year; with Corporate Responsibility dropping from second place to fourth place this year. Food & Product Safety and Consumer Health & Nutrition, which were in equal fourth position last year, are the fifth and sixth concern of manufacturers in 2010. www.theconsumergoods forum.com

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In Brief CIAA, the Confederation of the food and drink industries of the EU celebrated the fifth anniversary of the European Technology Platform (ETP) Food for Life in March. It proposed three more topics be added to the list of research priorities for EC funding as part of Framework Programme 7 - Food & Consumers; Food Chain Management and Food Quality & Manufacturing. Nano research might feature as part of Framework Programme 8, which starts in 2013. http://etp.ciaa.be

April 2010 www.foodbev.com

NEW FOOD PRODUCTS

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New food products from around the world Making claims on pack, whether for the healthy, free-from, natural or ‘green’ credentials of a product are helping companies to stand-out from the crowd and attract attention in a competitive market By David Jago, editorial director, Mintel*

ompetition for shelf space is always fierce and differentiating products from others is as always a challenging goal for new

Food & Beverage International April 2010

product formulators. To this end, many manufacturers are using the ‘Claims’ route to differentiation. Many factors influence on-pack claims: legislation is a key issue,

particularly in recent months, and especially in the area of health- and nutrition-related claims. Cultural factors play an important role, which is why we see products targeting seniors in some countries but not in others, for example; and of course trends dictate what claims marketers and manufacturers will use on pack to best draw the consumer’s attention. In 2009 food and drink categories saw some subtle, and one or two slightly less subtle, shifts in leading product claims

© Food & Beverage International 2010. Reproduced with the kind permission of FoodBev Media - www.foodbev.com. For details about syndication and licensing please contact the marketing team on 01225 327890.

Click here to subscribe as recorded on the thousands of new products monitored by Mintel’s Global New Products Database.

Specialist positioning goes mainstream The most significant shift in 2009 was that a new claim category took over as the most commonly seen on new food products globally. The family of claims classified as ‘suitable for’ includes products that are kosher, halal, suitable for diabetics, gluten-free, low allergen, vegetarian and vegan, and was seen on 24% of all new food products introduced last year. This represents an increase of three percentage points on 2008. Foods flagged as gluten-free or low/no allergen saw a significant increase, especially in Europe and Latin America, but to a large extent this reflects changes in labelling rather than changes to formulation, with many items now labelled as gluten-free, for example, that would not naturally contain gluten. The increase nevertheless reflects companies’ willingness to modify labelling in the face of consumer concerns and heightened awareness of food allergies. The bakery category unsurprisingly saw the bulk of launch activity, with a wide variety of new gluten-free lines from Nutrition & Santé under the Sans Gluten or Senza Glutine brand names in France and Italy respectively, and expansion of the gluten-free range from Tyrolean company Dr Schär. In Argentina, the Cero Glut brand from Susana A Jurich saw the launch of several sweet and savoury biscuit products, all gluten-free and formulated with corn and rice flour. New mainstream players also entered the allergen-free segment, with the launch, for example, of the Bewusst Geniessen line of baked goods, glutenfree and lactose-free, from German company Coppenrath Feingebäck.

Coppenrath Feingebäck has entered the allergen-free segment in Germany

Products labelled as vegetarian or vegan revealed similar patterns and were focused mainly on Asian and European markets, while halal food products saw significant growth in 2009 in South East Asia as well as South Africa and Australia.

All things natural The leading claim group in 2008 was ‘natural’, encompassing organic, all natural, additive-free, and wholegrain (naturally rich in…) products. The trend to ‘natural’ was seen on 23% of all new food products launched globally in 2008, and reached the same level in 2009, putting it in a close second position and providing further evidence that ‘natural’ values are here to stay.

Häagan-Dazs five is pursuing the natural trend

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New products with a ‘more natural’ positioning have been seen in every country and in every category, and have included processed foods from major suppliers. In the USA, for example, Häagen-Dazs extended

NEW FOOD PRODUCTS

Click here to subscribe its superpremium ice cream range with Häagen-Dazs Five, a line of products that uses just five ingredients. The ingredients - milk, cream, sugar, eggs plus the ‘flavour’ component, e.g. passionfruit or chocolate - are listed front of pack to underline the brand’s simple, natural positioning. Additive-free claims are most entrenched in children’s foods, where parental concerns over ‘unknown’ or unfamiliar food additives drive consumers to opt for more natural formulations. The trend has appeared to be towards the negative in recent years, with the proliferation of emotionally-charged ‘junk-free’ and ‘no nasties’ labelling, but the emphasis now seems to be shifting in favour of accentuating the positive. The new Planet Lunch line of kid’s foods from PepsiCo in the UK, for example, features the prominent claim ‘100% natural ingredients’. Labelling also promotes the ‘natural goodness’ of the formulations, communicating that the squeezable fruit pouch pack contains one of a kid’s five recommended daily portions of fruit and vegetables, or that the stick and dip is made with wholegrain and real vegetables. In many markets ‘natural’ has become accepted as part of the consumer’s health & wellness vocabulary, and is faring better than some of the more established areas of claims. The ‘minus’ group of claims, including products low in fat, calories, sugar, sodium, etc, was seen on just 16% of all new food products launched in 2009, down from 18% in 2008. In drinks markets, where low calorie and low sugar are very well established claims, the percentage of new products carrying a

minus claim fell from 19% of the total to 18%. Whether or not that reflects a long-term shift in health positioning remains to be seen, but many categories in many countries have seen a steady decline in ‘low in’ claims over the past two to three years.

Weight management Of course ‘low in’ claims have not gone away, and many consumers choose low fat and low calorie options as a simple solution to a healthier lifestyle. But another route to weight management focuses on satiety, with several recent introductions designed to keep consumers feeling full for longer, and/or help prevent snacking between meals. Among the more interesting is a line of prepared meals and sandwiches from UK retailer Marks & Spencer. Sold under the name Simply Fuller Longer, the meals are high in protein, have balanced levels of carbohydrates, and controlled calories. They were developed with expert advice from scientists at the University of Aberdeen, based on research showing that protein is more filling than carbohydrates or fats, and therefore helps the consumer feel fuller for longer, thus helping weight loss or maintenance without the feeling of hunger. Recipes tend towards the sophisticated, for example Chargrilled Chicken, Edame Soya Bean, Pak Choi & Noodles with a Miso Dressing. Another key area of health-oriented targeting is represented by the ‘plus’ claims group, which includes products with added vitamins or minerals. Despite high numbers of introductions of fortified beverages in diverse categories, this group accounted for just 8% of all drinks launches in 2009 and has been declining slowly but steadily over the past three years.

Health + indulgence

Marks & Spencer’s Fuller Longer meals target those watching their weight

Food & Beverage International April 2010

Marrying health benefits with indulgence is of course not a new trend, and can offer a route to success if the balance is achieved: two companies have

Maramor has launched Sweetlife Premium Chocolate with probiotics for digestive health and immune support launched ‘healthy’ probiotic products with an ‘indulgence’ difference in recent months. In the UK, Mars extended its Galaxy chocolate brand with a thick and creamy, probiotic milk drink. Made with real Galaxy chocolate, it nevertheless has only 2% fat and contains bifidobacterium BB12, claimed to help support the body’s natural defences. As is now fairly typical for the sector, it is sold in a 90g bottle. In the USA, Maramor launched Sweetlife Premium Chocolate with Probiotics, claimed to provide digestive balance and immune support. The probiotics in this line (microencapsulated Lactobacillus Helveticus and Bifidobacterium Longum) are said to be more effective than those found in yoghurt, as they have a survival rate up to three times higher. On-pack claims are supported by official studies and research conducted by Barry Callebaut in co-operation with the University of Ghent in Belgium - they show that while only 20% of milk or yoghurt probiotics survived after passage through the stomach and small intestines, at least 80% of those in chocolate passed through into the intestinal tract. As the company claims: ‘a delicious way to add probiotics to a healthy lifestyle’.

Home cooking, conveniently When it comes to home cooking, convenience is key but experimentation and participation are the watchwords. However, although consumers are interested in food preparation from scratch, they often lack the knowledge or the time (or both) and need a helping hand. This is where products like McCormick’s Recipe Inspirations come into play.

NEW FOOD PRODUCTS

Click here to subscribe Launched late last year in the USA, they comprise pre-measured spices with a recipe card, all priced at an affordable US$1.50. Six varieties are available, such as Rosemary Roasted Chicken with Potatoes, which includes paprika, crushed rosemary leaves, minced garlic and coarse ground black pepper. Instructions clearly indicate all of the ingredients that need to be bought, and the pre-measured seasoning ensures that everything is to hand for convenient recipe creation, without any fuss or waste. For the more adventurous home cook, French company Monin introduced Les Jus Cuisinés, a line of gourmet culinary additives based on vinegar, fruits, vegetables and spices. Monin is best known as a traditional supplier of concentrates (including fruit syrups) for making drinks, so this launch marks new ground for the brand. The new line is oil-free, and can thus be positioned as a relatively healthy option for seasoning creative and tasty Monin’s Les Jus Cuisinés is a line of gourmet culinary additives for adventurous cooks

meals. Exotic recipes include Carrot, Pink Grapefruit & Ginger, and Raspberry, Rose & Lychee, all created in conjunction

with Michélin starred chef Thierry Finet. Targeted towards the more confident consumer, the products retail at a premium of nearly €7 for a 25cl bottle.

Ethics and the environment still on the agenda One other notable shift over the past year relates to the ‘ethical & environmental’ category of claims, which cover products or packaging labelled as ‘environmentally friendly’, as well as ethical claims

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including Fairtrade, Rainforest Alliance,

The big news in ethical marketing comes

animal welfare issues and charity tie-

from outside the beverages market,

ups. Recorded on just 2% of new food

however, with the adoption of Fairtrade

products in 2007, this category grew to

certification by two major chocolate

5% in 2008 and reached 8% in 2009. And

brands - Cadbury Dairy Milk in the

in drinks markets, thanks largely to the

UK, Canada, Australia and New Zealand,

importance of Fairtrade and Rainforest

and Nestlé’s Kit Kat in the UK and

Alliance labelling in coffee and tea, ethical

Ireland. Ice cream brand Ben & Jerry’s has also announced that it will switch all ingredients to Fairtrade where possible by 2013.

and environmental claims have appeared on 13% of all new products during the past year.

NEW FOOD PRODUCTS

Click here to subscribe Menos é Mais claims concentrated iced tea is more environmentally-friendly than unconcentrated options

Economic conditions may not be favourable to premium ‘green’ products in many countries, but ethics and the environment are firmly on the agenda and are not going away. Successful introductions are likely to be those that offer an affordable step for the consumer, or those that combine an economic and environmental benefit.

on the road and, therefore, a reduced environmental impact.

In the USA, Kellogg’s introduced on trial a ‘space saving’ box for its most popular cereals - using different package dimensions to provide the same quantity of product. The immediate consumer benefit, evident from the front of pack labelling, is one of convenience (easier to handle and store). But the back of the pack describes how the new box uses 8% less packaging material, resulting in an environmental benefit, as well as cost savings throughout the distribution chain a win, win, win situation, apparently, for the consumer, the retailer, and Kellogg’s. In Portugal, Coca-Cola recently entered a new market segment, beverage concentrates, with the launch of Menos é Mais (‘less is more’) iced tea concentrate. Sold in a 1 litre carton, this makes 7 litres of product - but the positioning is more interesting than that of a standard dilutable. The front of the pack features a drop of concentrate falling into a glass of iced tea; the back of the pack has an illustration of a coin dropping into a piggy bank, promoting the product’s cost-efficiency without resorting to language such as ‘economy’. The package further details the efficiencies of shipping and storing a concentrate, rather than a diluted product, which includes fewer trucks

Die Faire Milch claims to be both environmentallyand animal-friendly

Food & Beverage International April 2010

Staying with Coca-Cola, one of the biggest news stories currently is the US launch of the PlantBottle, for its flagship cola brand and for Dasani water. The bottle is made with 30% plantbased materials from sugar cane and molasses, giving a 25% reduction in carbon emissions versus regular PET.

Local sourcing, and what next?

Finally on the subject of the environment, a big issue to watch out for in the future… is water footprint. Finnish cereals brand Elovena introduced what Mintel believes is the world’s first water footprint label, for a line of oat flakes. A small blue logo, positioned directly below the product’s carbon footprint on the front of the pack, indicates that 1kg of cereal uses 101 litres of water - this is claimed to be low as the oats do not require irrigation and they are processed using steam, so little waste water is generated. This type of communication might not be widespread yet but it is building especially in markets such as Australia where water usage is key - and it has the potential to become a major challenge for the food and beverage processing industry in future.

www.gnpd.com

Often allied to ethical and environmental issues, local sourcing continues to move up the agenda for product developers and marketers. Many moves towards local sourcing are restricted to less processed products, such as milk. In France, for example, Orlait has a UHT milk branded J’Aime le Lait d’Ici, or ‘I love the milk from here’. It is described as coming from regional farms, collected and packaged in France. MVS in Germany has a similar concept, Die Faire Milch, which is claimed to be environmentally- and animal-friendly, and supports local farmers. Local is a far more complex issue for major suppliers, but Frito-Lay (PepsiCo) took a move in this direction in 2009, when it introduced the chiptracker concept on bags of its bestselling Lay’s potato chips.

Elovena has opted for water footprint labelling on its oat flakes brand

The consumer can go to the chiptracker website and enter the production code from their bag of chips, together

Mintel International Group

with their zip code, to find

*David Jago is editorial director

out where the potatoes were

of the Mintel International Group,

grown and where the chips

which produces the Global New

were packed.

Products Database (gnpd), a

Although not promising to be

web-based database capturing

local, it uses information that

information on new packaged

food producers do not usually

consumer goods products including

give on-pack to provide a degree of transparency in communication.

ingredients, nutritional information, pricing and packaging.

HEALTH TRENDS Click here to subscribe

All trends point to health

Chris Brockman and Mary Gilsenan, Leatherhead Food Research

Couple this with the negative publicity that artificial colours, flavours and preservatives have received and you have the perfect powder keg for what is turning out to be a natural ingredients

Producing successful healthy products in today’s competitive markets requires a full understanding of the prevailing trends and legislative environment By Chris Brockman, market intelligence manager and Mary Gilsenan, head of regulatory services, Leatherhead Food Research*

ealth has never been as high on the agenda of the food industry as it is today and it seems that all influencing factors that shape the trends in food and drink are pointing toward an increased focus on healthy eating. Firstly, consider the global downturn. This had led to consumers going ‘back to basics’ and in many cases cooking from scratch which has focussed attention on what ingredients really go into food products and whether they are contributing positively to health. What’s more, for the increasing number of consumers who look for healthier food it is a lifestyle choice which does not diminish when times are hard. A sense of nostalgia has also prevailed with a yearning for simpler

explosion. All natural or clean label foods are becoming the minimum standard in many categories, especially for children’s foods but also in categories such as soft drinks where purity is a more visible part of the product offering. Witness the likes of Pepsi Raw, Zico natural coconut water, and Hansen’s Natural Soda in the USA

times and simpler food products and in many cases a focus on the intrinsic health benefits of foods.

(shown below).

Witness the continued interest in superfruits as naturally healthy ingredients and the never-ending list of new varieties such as the Boabab fruit, Cupuaçu and Maqui berry that are coming onto the market ‘out-superfruiting’ the now ubiquitous pomegranate, açai and goji berries.

globally. There were around 750 million

Secondly, the ageing of the population is the biggest demographic shift occurring

people aged 60 or over in the world in 2008 (11% of the total population) according to United Nations estimates. By 2050, the over-60 population is predicted to be just over 2 billion (22% of the total population).

April 2010 www.foodbev.com

HEALTH TRENDS Click here to subscribe

A doubling in the population that

Heart Benefit Foods Market Development , 2009-2014 (US$ million)

experience the most health issues is going to focus the minds of food and drink

2009

2014

% Growth

Cereal products

3,780

4,575

+21

Fats & oils

1,531

2,250

+47

Fish & eggs

1,528

2,500

+64

an ageing population, conditions such as

Bakery product

1,307

1,675

+28

dementia and Alzheimer’s will affect more

Soya products

1,094

1,345

+23

Dairy products

802

1,500

+87

Soft drinks

794

1,275

+61

Total

10,836

15,120

+40

manufacturers that have so far largely shied away from directly targeting the rather unfashionable ‘grey’ market. Enhancing and prolonging cognitive ability is thus an area of ongoing interest. With

and more people. To date, there has been a lot of activity in mental performance in products aimed at children but comparatively little for the over 60s, a situation which is likely to change. Thirdly, one of the biggest health issues the world faces is the continued rise in obesity levels. The World Health Organisation expects the number of overweight adults to grow from 1.6 billion in 2005 to 2.3 billion in 2015, and the number of obese adults to grow from at least 400 million to 700 million. The problem is potentially more devastating among children, with 10% of the global child population already either overweight or obese a figure which rises to as high as 32% in the USA. Once more of a problem only in high-income countries, ‘overweight’ and obesity are now dramatically on the rise in fast developing economies such as India and China. Given the focus on weight issues, it is no surprise that weight management is one of the key growth areas within the functional food sector and within this category, most development recently has focused on foods that suppress appetite or induce satiety. High fibre, high protein ingredients, such as oats and whey protein, have been used. For example, Kellogg’s Special K Actief weight control breakfast cereal was launched in The Netherlands in 2008. It contains a special combination of protein and fibres to promote a longer period of satiety. Within this category, and in other successful functional food areas such as digestive health and energy products in particular, consumers being able to quickly feel the benefit is the key to ensuring ‘buy-in’.

Includes data for the market in the USA, Japan, UK, France, Germany, Italy, Spain, Australia

Data for Japan includes FOSHU (Foods for Special Health Uses) foods with cholesterol-reducing and blood-pressure-lowering claims only Source: The Market for Heart Benefit Foods: 3rd Edition (Leatherhead Food Research)

Another area of continued interest will be in general immunity boosting products, which will continue to prove popular especially if conditions such as swine flu rear their head again, as well as high fibre ingredients. Most consumers still do not meet their recommended intakes of dietary fibre. So, pre- and probiotics, antioxidants and vitamins, and wholegrain and highfibre ingredients will continue to permeate across more and more food categories. So, what impact will the changing regulatory landscape have on these global health trends? It is now apparent that the European health claims approval process may allow some categories to flourish more than others. Some of the winners of the European Food Safety Authority (EFSA) review process to date are in the heart health benefit foods sector such as cholesterol lowering products (plant stanols and sterols) and oat products (beta glucans for healthy blood cholesterol). Heart health is already a relatively well developed health category but one which can be expected to continue to advance.

the repositioning of certain products away from cardiovascular health, particularly in the USA, overall sales in the sector look set to rise by at least 40% between 2009 and 2014 (see table above). However, not all health sectors will pass through the regulatory hurdles as smoothly as the heart health sector. Take immune health, for example. The blanket rejection last October of a series of probiotic health claims by EFSA caused a lot of unrest in the probiotic sector. A similar blow hit the antioxidant sector with the release of a second batch of health claim scientific opinions from EFSA at the end of February this year; all but a few antioxidant claims relating to vitamins and minerals received negative opinions. Several health claims relating to cognitive function in the elderly are currently undergoing review. These relate to ingredients such as phosphatidylserine, creatine and DHA (Docosahexaenoic acid). We await with anticipation the outcome of the review process and what impact

Leatherhead Food Research expects the market for heart benefit foods to grow strongly over the next five years, although overall growth rates will depend on various factors, not least legislative.

this may have on the food and beverage

Assuming that the claims situation does not undergo radical change resulting in

what a food contains (nutrition claims)

market for the elderly. High fibre and high protein claims are generally subject to a less stringent regulatory hurdle because they relate to rather than its effect on health. There

April 2010 www.foodbev.com

Click here to subscribe

are minimum threshold levels of these nutrients which products must contain in order to bear these nutrient content claims. For a high fibre claim, there must be at least 6g/100g of fibre in the product; for a high protein claim, a product must contain at least 20% of its calories from

counterparts. Apart from its use in relation to flavouring substances, the term ‘natural’ is not currently regulated at European level. The same applies to the use of superfoods, although national bodies, such as the UK’s Food Standards Agency (FSA) have developed guidance for use in

protein.

this regard.

Although claims relating to satiety did not get the thumbs up from EFSA, the criteria for substantiating satiety claims is now a lot clearer; robust satiety studies which record subsequent calorie intakes (ie all food eaten following consumption of any satiety ingredient or product) are required

Whilst global health food trends are affected by several factors, Leatherhead Food Research expects that legislative factors will play a much bigger role than

for the continued success of satiety claims in Europe at least. Superfoods and natural trends are not subject to regulatory restrictions to the same extent as their health claim

Food & Beverage International April 2010

ever before. *Leatherhead Food Research is an independent organisation delivering innovative research, scientific consultancy and regulatory guidance and interpretation. Leatherhead’s unique portfolio of products has attracted over 1,000 companies worldwide, representing a who’s who

of the global food and beverage industry ranging from large multi-nationals to small and medium-sized companies. Services are built around five key platforms; Regulatory; Food Innovation; Food Safety; Nutrition Research; Knowledge Transfer, each representing a core area of expertise. www.leatherheadfood.com

Reader offer Readers of Food & Beverage International are entitled to a 20% discount off the price of Leatherhead’s The Market for Heart Benefit Foods Report www.leatherheadfood.com/ heart-benefit-foods

HEALTH TRENDS

CONVENIENCE

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Convenient packaging: Solutions for the supply chain Convenience remains a key driver for new product development and no more so than in the area of packaging where the design has to be convenient not just for the consumer, but also for the supply chain, the manufacturer and the retailer By Claire Rowan, managing editor

any convenient options are

available for companies launching new products or looking to repack their existing product offerings. And convenience is not just about an easy to open pack; convenient packaging is relevant throughout the supply chain. “We continuously strive for innovative and more sustainable packaging solutions,” said Birgitta Farago, marketing manager of Ospelt in Switzerland, which has recently relaunched its Malbuner sliced meat range in recloseable packaging from Amcor Flexibles Europe. “By using Amcor ReClose we help to reduce food waste as our product stays

fresher for longer. The reduced thickness of the lidding film results in packaging weight reduction and therefore has a positive impact on CO2 emissions. Furthermore, Amcor ReClose ensures brand recognition of our Malbuner range throughout the products’ lifecycle, as the meat does not need to be repacked in plastic boxes or foil.” The Amcor ReClose top web is highly transparent, which provides good product visibility for consumers, and is puncture and tamper resistant, which provides added security for both retailers and consumers. Developed in conjunction with Amcor, the ReClose packaging for Ospelt’s Malbuner range can be peeled off and easily stuck back down after use. Easy opening coupled with the benefits of added communication opportunities were behind United Biscuits’ choice of tear tape from Payne, which specialises in tear tape technology. The larger tear tape solution now provides easy opening in combination with cost-effective communication for United Biscuits’ Jacob’s Cheddars cheese biscuit packaging.

Amcor Flexibles Europe’s resealable packaging for sliced meat brings brand recognition to Malbuner’s sliced meat range throughout its lifecycle

By cutting a larger, U-shaped horseshoe tab into the film during the application of the tear tape, it is possible to create a tab, which protrudes beyond the seal area to deliver a prominent opening feature that is easily visible to the consumer and which can also carry a message, according to Payne. The tab tear tape can be used on both roll wrap and flow wrap packaging for biscuits. “Roll wrap is already one of the simplest and most efficient forms of packaging,

United Biscuits has opted for a tab tear tape from Payne to provide easy opening and communication benefits to its Jacob’s Cheddars cheese biscuit packaging

and we believe that with the addition of Payne’s communication tab system, we have managed to improve and enhance the overall product for the consumer,” said Paul Cheeseman, United Biscuits’ packaging systems manager. In seeking an easy opening and resealing solution for its nut assortment range, The Dutch Nut Group was concerned that the solution would be easy and convenient for consumers but a challenge in production. However, the company worked closely with Faerch Plast, as well as the machinery producer, Sealpack, and the sealing film supplier, Maag, and the result was a clear APET dispenser container with resealable lid that provided maximum stability and display on shelf. It comprises a tray sealed with a perforated sealing film, together with a perforated re-closeable lid that bends at a

April 2010 www.foodbev.com

CONVENIENCE

Click here to subscribe The resulting easy open/reclose packs are now thermoformed at Faerch Plast in Denmark and transported to The Dutch Nut Group’s manufacturing plant at Bergschenhoek for filling, and are said to meet the production convenience also required. “We import nuts directly from producers all around the world,” said Perry Van Otterloo. “Quality and uniformity are key for us. The dispenser tray and the lid combination is just what we were searching for.” The Dutch Nut Group worked with Faerch Plast, Sealpack and Maag to perfect a convenient APET solution for nuts that would work on its production line 90 degree angle and stays open while the contents are poured out. “The biggest difficulty was to make the lid easy to open while, at the same time, ensuring that it remained tightly closed during distribution and display. It also had to be easy to handle during production,” said Bastiaan Bekkers, director of Faerch Plast sales on continental Europe. “Perry Van Otterloo, CEO at the Dutch Nut Group proposed the initial idea, which entailed making a cut and perforation of the lid along the flat part of the pack, which is normal, and also along the side of the lid, which is not.”

Microwave convenience Microwaveable meals remain a key area of development for convenience and Sirane has recently entered this arena with a range of bags, pouches and films for packaging foods that can be cooked in the microwave or conventional ovens. Sira-Cook M for microwaves, and Siro-Cook R for ovens can be heated to 160°C and 230°C respectively and are available in pure film or a natural-look, ‘old-fashioned’ papery style film. Each is supplied on a reel and has excellent barrier properties. “The food typically cooks inside the bags in its own juices, but where there is any excess fat generated, we can add an absorbent skillet, tailor-made for each application,”

said Jeremy Haydn-Davies, sales director, Sirane, who explained that the Sira range of films can be printed, are very low in weight and can be produced through form, fill & seal machines as well as run as reels on flowwrappers. “Any size is available.” For convenience in the production of its new convenient-for-the-consumer, range of microwaveable meals, Marie Surgelés in France has recently installed an Ishida line for weighing and packing the product. The company awarded the contract for the new tray line at its Airvault plant to Ishida due to Ishida’s project capability and its new QX-1100 Traysealer technology, which was installed for the first time at Marie Surgelés. The new line includes two tray denesters, a multihead weigher with distribution system, the Ishida QX-1100 Traysealer, a volumetric dosing system for rice and pasta, a 20m chain-and-peg conveyor, a converger and a central control point for all the equipment. Two existing sauce-dosing systems were also integrated into the line. The QX-1100 operates at speeds of up to 200 trays per minute, with rapid, easy changeovers, and exceptional control both of the sealing process and of the atmosphere within the tray. It also accommodates most types of sealing materials. The 350g meals, such as Marie Surgelés pasta & prawns in a

Oxygen scavengers keep snacks fresh In Australia, HJ Heinz Co Australia Ltd has launched an innovative microwaveable, lunch bite range under the brand name Greenseas using a packaging solution with oxygen scavenging technology from RPC Bebo Nederland.

The oxygen scavenging technology helps to extend the shelf life of the ambient snacks. For further convenience, an integral spoon has been included together with a printed cardboard outer pack that doubles as a practical stand for microwaving and a tray

to avoid handling the heated pot. The sides of the cardboard are perforated - when ready to use, the consumer simply tears off the top part of the cardboard leaving only the base. www.rpc-bebo.nl

The ambient snack range combines tuna with a variety of flavours such as green curry with rice, and sweet chilli noodles, and can be enjoyed straight from the pot or easily heated in a microwave. The packaging selected by Heinz Australia is a robust plastic pot, thermoformed at RPC Bebo Nederland in a layered construction combining polypropylene (PP) and ethylene vinyl alcohol (EVOH) polymers, and incorporating an oxygen scavenger, which is used to capture oxygen within the barrier layer of the sealed pack before it reaches the food.

Food & Beverage International April 2010

Heinz Australia has selected a convenient microwaveable pot with an integral spoon, and additional oxygen scavenging properties for its Greenseas lunch bite range of tuna snacks

CONVENIENCE

Click here to subscribe sauce, with diced courgettes, emerge from the traysealer at a rate of over 90 packs per minute. They are converged into a single line for sleeving and secondary packing.

“The line is very user-friendly, and offers simple changeovers, as well as being very easy to clean,” said Julien Le Garrec, sector manager at Marie Surgelés, which also benefits from the single control point of the Ishida line as an additional point of convenience for production.

performs two key functions. Firstly, the Edge Tape guides the tear as the box is opened, ensuring a clean finish and preventing damage to on-pack graphics or branding. Secondly, its printability provides additional communication opportunities for brand reinforcement or promotional messages.

Retailer convenience

The Payne solution gives retailers a shelfready packaging system that can be opened safely, quickly and easily without damage to on-pack graphics or branding. Both tapes are easily separated from the board during the disposal ensuring that the recyclability of the pack is not compromised. And, throughout the design, both convenience and functionality are key.

For retailer convenience, a new tape-based solution for Shelf-Ready Packaging has also been developed by Payne. It provides the benefit of easy opening while also maintaining the integrity and appearance of the transit packaging.

For retailer convenience, Payne has developed a new tear tape solution for shelf ready packaging

A purpose-built applicator applies two tapes to the corrugated board during production. The first tape, a Rippatape is applied to the inner liner of the board and acts as the opening mechanism providing quick and easy access to the box contents without the need for knives. The second tape, an Edge Tape, is applied to the outer liner of the board, just below the point where the box is opened by the Rippatape and

As with all trends, convenience takes many forms and taking a holistic approach to it can make a significant difference not just to the product and consumer, but also bring benefits in production and on the retail shelf. www.amcor.com; www.sirane.com; www.payne-worldwide.com; www.faerchplast.co.uk; www.ishidaeurope.com

April 2010 www.foodbev.com

LINE EFFICIENCY

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Operational efficiency: the role of pumps, valves & drives In any manufacturing process, optimising operational efficiency is a key driver of business competitiveness. This is especially so in food production where any downtime can mean that ingredients perish or product is lost *By Jeremy Salisbury, Brammer UK

he availability, performance and output of an individual machine

further increased through the specification of a variable speed drive (VSD), which can

or production line are key factors affecting operational efficiency, but these variables can be heavily impacted by breakdown or process issues.

reduce energy consumption by up to 50%.

The key to maximising operational efficiency, therefore, is to ensure that production plant performance is optimised. A key enabler to the achievement of this goal is the adoption of an appropriate maintenance and asset management strategy that will extend product life and reduce plant downtime.

of manufacturing applications. VSDs can

The energy saving and process improvement benefits of variable speed drives (VSDs) are well proven across a range

In particular, the optimal selection and maintenance of drive systems for process equipment such as pumps and valves, impacts positively on both operational efficiency and reduced energy consumption - both of which are key to maintaining competitiveness.

Drives and motors The importance of selecting the right drive or motor is brought home clearly by figures showing that in the UK, electric motors and drives account for more than two thirds of power consumption in industry. Yet many motors are unnecessarily oversized for the machines they drive. The annual energy consumption cost of running a motor can be up to ten times its purchase cost. A 10kW motor operating at 87% efficiency could cost £1,500 (€1,678) more over its lifetime than one that is just 5% more efficient. Meanwhile, in any application where the pump is not required to work constantly at full speed, energy efficiency can be

Food & Beverage International April 2010

also help to increase the life of mechanical drive train components, which benefit from a smoother start-up. As well as driving pumps, in the food industry, VSDs are commonly used in applications such as on extraction fans to control oven temperatures. One typical pump application in the sector saw a pump being driven by a 21kW motor operating at 90% demand and costing £12,532 (€14,032) per year to run. The introduction of a VSD reduced the annual energy consumption by more than £3,000 (€3,356).

Funding Given the many sources of funding available for new, energy-efficient equipment such as high efficiency motors and VSDs, as well as the rapid payback achievable, there is often a strong business case for replacing inefficient or failing motors and drive systems. In the UK, the Carbon Trust’s Enhanced Capital Allowance (ECA) Scheme is a form of accelerated tax relief which encourages businesses to invest in energy efficient plant and machinery from its highly extensive Energy Technology List (ETL). Companies purchasing products from this list can claim 100% first year capital allowance on their

Electric motors and drives account for more than two thirds of power consumption in industry in the UK

LINE EFFICIENCY

Click here to subscribe The annual energy consumption cost of running a motor can be up to ten times its purchase cost

acquisitions - effectively writing off the entire cost against taxable profits during that financial year. In the above example, based on a VSD costing £2,000 (€2,237), payback can be achieved within eight months. Meanwhile, as a further incentive for Small to Medium Enterprise (SME) manufacturers to commit to more energy efficient manufacturing processes, the Trust has doubled the maximum size of its interest-free Energy Efficiency loans from £100,000 to £200,000 (€111,890 to €223,780) and increased the overall annual amount available for loans by 45% to £31 million (€34.7 million). The loans are unsecured and repayable over a four year period - and with reduced availability of alternative sources of finance, may even be available for the total cost of projects that deliver the required reduction in carbon emissions. Other initiatives are available in countries throughout Europe as governments become increasingly conscious of the benefit of improved energy efficiency. (for other examples see: www.techno-science.net/?onglet=glossaire&definition=10394 and www.actu-environnement.com/idx_ae.php4)

How Cadbury is benefiting One major manufacturer where investment in energy-efficient products has delivered significant and measurable cost savings is Cadbury. Through its ‘Purple Goes Green’ campaign, the company has pledged to reduce its absolute carbon emissions by 50% by 2020. In one of several projects completed with Cadbury during 2009, Brammer reduced carbon emissions by 300 tonnes while delivering a cost saving of nearly £60,000 (€67,141). Brammer was called in to assess the manufacturing process at the Trebor Basset factory in Sheffield. The gum stoves, part of the jelly baby process, were identified as an area where the specification of more energy efficient components would significantly reduce carbon emissions and deliver reduced energy consumption and tangible cost savings. Brammer developed a revised, more energy efficient specification and, after the new equipment was successfully trialled on four of the stoves, all 13 gum stoves were upgraded. Brammer replaced the two 11kw motors in each stove with more efficient and equally effective 4kw motors. Meanwhile, the standard V belts were replaced with Gates Polychain synchronous drive belts and the motors improved their energy efficiency with the installation of a variable speed drive to each stove. This increased process speed control, and improved the effectiveness of the production process.

Condition monitoring and maintenance Once the correct products have been selected and commissioned, an appropriate condition monitoring programme and a proactive maintenance schedule are required to ensure they are operating at maximum efficiency. Techniques such as thermography and vibration analysis will identify any problem areas and allow early remedial action to be taken to minimise energy usage and prevent breakdown. Precision alignment of components, for example, is proven to create energy savings of up to 5%, while properly aligned machinery is also more reliable. A variety of laser alignment tools are available for this task from several different suppliers including SKF, which produces laser alignment tools for both shafts and belts, and other companies that make pulley alignment tools as well as geometric systems. The importance of a rigorous lubrication and sealing regime cannot be overestimated and the actual product specified is often as important as when, and how well, it is applied. All lubricants have a specified effective temperature range outside which they cannot be guaranteed to perform to the required standard. Using the wrong product will almost certainly impact negatively on machine performance. Similarly, incorrect application or the use of insufficient quantities of lubricant, will increase friction and rolling resistance, reducing energy efficiency while increasing the risk of premature component failure. Optimising this element of the maintenance programme can reduce energy usage by up to 2%.

April 2010 www.foodbev.com

LINE EFFICIENCY

Click here to subscribe Another project at the Sheffield factory has seen Brammer deliver significant carbon emission reductions and a further £16,000 (€17,900) energy cost saving. A revised, more energy efficient drive specification was developed, which consisted of an EFF1 motor, linked to a VSD. The standard V belts were replaced with Gates Polychain synchronous drive belts.

Brammer distributes industrial, maintenance, repair and overhaul products and services

in new, more energy efficient, equipment and correct management of those assets will help to reduce costs, increase production uptime and productivity and enhance business competitiveness. www.brammer.co.uk

Brammer *Jeremy Salisbury is head of

By replacing standard V belts with Gates Polychain belts, Brammer was able to achieve an energy saving of between 5% and 6%. This instant payback, combined with the improved results from the variable speed drive and EFF1 motor gave Cadbury immediate, quantifiable energy savings amounting to 185,000kwh or 79 tonnes of CO2 each year - a further example of how reviewing processes and optimising product specification can enhance both operations and energy efficiency.

marketing for Brammer, a division of

Whether a company’s focus is on short term cost savings or on positioning the company for the long term, investment

range of tools, maintenance and

the European distributor of industrial, maintenance, repair and overhaul products and services. The company can supply and provide advice on over one million individual products including bearings, mechanical power transmission products (gearboxes and motors), pneumatics, hydraulics, seals and industrial automation, as well as a complete health and safety products.

Motor and drive safety in dusty environments Electric motors and low voltage AC drives being operated in areas with combustible dust are now regulated by the ATEX directives, which came into force in 2006. Many companies, however, still seem unaware of their obligations under the ATEX directives and of the dangers posed by combustible dust, which can be caused by substances such as sugar or flour that burn rapidly potentially causing high energy explosions, according to ABB. Within the ATEX directives, hazardous areas are classified in Zones based on the frequency and the duration of occurrence of an explosive atmosphere. The Zone dictates which Category of equipment needs to be used, and it is the end-user’s duty to select the right product for the right Zone - ie equipment of Category 1 for Zone 0 or 20; equipment of Category 1 or 2 for Zone 1 or 21; and equipment of Category 1, 2 or 3 for Zone 2 or 22. Motors used in atmospheres where explosive dust surrounds the motor, or where dust settles under its own weight on the motor are known as Ex tD motors. Dust is measured either as a ‘cloud’ or

Food & Beverage International April 2010

a ‘layer’ - the ignition temperature for a cloud of dust must be at least 50% above the motor’s marking temperature and at least 75°C above the marking temperature of the motor for a 5mm layer of dust. In any case, it is the responsibility of the user to ensure that the dust layer does not exceed 5 mm. Motors with low voltage AC drives can be installed in hazardous areas, offering safe, economical power combined with effective control. However, the drive must always be installed in a safe area and it is important to recognize the effects the drive has on the motor, mainly to prevent motor surface over-temperature. The motor temperature can be controlled by using a temperature measurement signal from the motor and this signal used to initiate shut-down if necessary. Alternatively, it is possible to monitor the amount of energy transferred to the motor and control the temperature this way; the energy flow can be easily monitored using an ABB industrial low voltage AC drive with motor control platform DTC (direct torque control), according to ABB. Otherwise, a combined test with the motor and low voltage AC drive is necessary to ensure

Because of the addition of dust within the ATEX directives, they now cover processes such as food manufacturing, which were not regulated under previous explosive atmospheres legislation. Picture courtesy of ABB, which supplies a wide range of solutions for all processing applications that the motor’s surface temperature does not exceed the limits. The ATEX regulations require users to draw up an Explosion Protection Document to decide whether hazardous area motors are needed, assessing each area of the plant for hazardous gas or dust and dividing the plant into zones. An area can be declared safe only as the result of a risk assessment. ww.abb.com

INGREDIENTS

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Enzymes target beer and juice types from many different

Ondea Pro allows the production

modified malts. Novozymes

of great tasting, 100% barley

estimates that typical raw

beer, with an 8% reduction in

material savings per hectolitre

CO2 emissions. Using barley as

of beer made from 100% barley

its only raw material, Ondea Pro

are in the region of 40 to 50%

is said to optimise raw material

- or up to 3kg of barley per

usage, improve productivity

hectolitre of beer.

and therefore sustainability, and facilitate the creation of new beverages. A carefully balanced enzyme blend, Ondea Pro works in synergy with the barley enzymes in an infusion mashing programme and can be used in all standard brewhouse equipment. According to Novozymes, the robust nature of Ondea Pro means it is effective with a wide variety of barley

geographical regions. The extract yield from the infusion mashing programme is said to be better than when using a typical barley with malt combination, and the wort and beer filtration is comparable or better than the performance achieved when using well

The barley and Ondea Pro beer offers excellent foam and foam stability, and can be used as a platform for developing beverages with new flavours or stand alone as a sustainable, environmentally responsible product. For fruit juices from berries or grapes, Novozymes has developed its Pectinex Ultra

Color, which extracts more of the vibrant and stable colour of the raw materials. A new generation of mashing enzyme, Pectinex Ultra Color is specific to the production of berry and grape juice and improves their pressability while also offering smoother downstream processing. It is the result of combining two fermentation technologies, which creates a blended pectinase that is suitable for organic production. By precisely targeting pectin degradation to give an almost pectin-free mash, Pectinex Ultra Color helps to release the colour from the raw material and ensures stability over time, according to Novozymes. It also gives faster mashing and throughput, which boosts productivity. Pectinex Ultra Mash is the new generation of apple mashing enzymes from Novozymes. It is designed to improve juice yield and give smoother clarification

and filtration. Again produced using a combination of two fermentation technologies, this blended pectinase product targets both acidic and sweet fruits, without dissolving the structure of the fruit. It offers rapid mashing, reduced viscosity and faster throughput, according to Novozymes, which claims that it also gives increased production capacity. It operates in all existing mashing equipment and at either low or high temperatures. www.novozymes.com

Novozymes has recently perfected several new developments in enzyme technology including Novozymes Ondea Pro for brewing, Pectinex Ultra Color mashing enzyme for the production of berry and grape juice, and Pectinex Ultra Mash for improving apple juice yield

Novozymes has developed several new enzymes for optimising production of 100% barley beer, apple juices, and juice from berries or grapes

Naturally sweet yoghurt and better bread solutions DSM Food Specialties has developed a solution that combines enzymes and cultures to create healthy, natural and sweet tasting

yoghurts that do not require additional sweeteners; and launched a new addition to its Panamore range of enzymes for bread manufacture. By combining the performance of Maxilact LX5000 purified lactase enzyme to convert lactose to glucose and galactose with the smooth and creamy viscosity contributed by Delvo-Yog Flow Velvet CY-346 cultures, DSM has produced a system that enhances the sweetness of yoghurts without the addition of sugar.

DSM Food Specialties has developed enzyme solutions that can give naturally sweet yoghurt and provide cost savings for bakers

Food & Beverage International April 2010

DSM produced a range of stirred yoghurts with differing enzyme/culture combinations to identify the blend that delivered

the optimum level of sweetness, creaminess and viscosity and the options were then evaluated by an independent tasting panel, which found that Maxilact LX5000 with Delvo-Yog Flow Velvet CY-346 cultures worked synergistically to enhance the natural sweetness of the yoghurt while delivering a product with a clean, mild taste. It was also shown to improve the yoghurt’s creamy mouthfeel, increase its viscosity and boost smoothness and sheen. For bread manufacturers, DSM Food Specialties has also introduced a new enzyme technology, which offers a cost-effective and sustainable

alternative to calcium and sodium stearoyl lactylate. Panamore Spring contains several enzyme solutions, which have a combined action on the lipids naturally present in wheat flour, producing compounds that have emulsification properties. The result is a more stable, tolerant and shock-resistant dough and an end product with fine and soft crumb structure as well as good volume and extended shelf life. Used at lower dosage levels than sodium stearoyl lactylate, Panamore Spring also delivers cost savings for bread manufacturers. www.dsm-foodspecialties.com

INGREDIENTS

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Brewing enzymes help reduce costs Highly efficient brewing enzymes that can optimise beer production and reduce costs have been developed by Danisco. The new concentrated enzyme complex, Laminex Super 3G is based on traditional technology, but can relieve bottlenecks, save time and cut brewing costs, according to Danisco. In small doses, Laminex Super 3G is designed to speed up wort separation and give higher consistency in beer filtration. It is said to improve brewhouse capacity and allow for longer beer filtration cycles, making the brewing process more cost-efficient.

In conjunction with the Danish Council for Strategic Research, Danisco is also currently investigating the potential of powerful enzymes derived from snakes, spiders and carnivorous plants, which it say could hold significant potential for food applications. www.danisco.com

Other Danisco brewing enzymes have been developed to offset variations in raw material quality and maximise yield when using a high level of cereals, such as barley, maize, wheat and rice.

“In this way, brewers gain the freedom to choose cheaper raw material options without compromising the quality of the final beer,” said Ulf Brøcher Sørensen, global product manager, Danisco, who added that the company also has enzymes that will help with the production of speciality beers. “Speciality beers have enjoyed growing popularity in recent years and, for some consumers, represent an affordable occasional indulgence during the recession. This is an area of development we can help customers with.”

Danisco has perfected several enzyme solutions for beer and speciality beer production, and is researching the potential of enzymes from snakes & spiders

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April 2010 www.foodbev.com

INGREDIENTS

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Galactofructose boosts digestive health For improved digestive health, Solvay has introduced a new prebiotic ingredient that is designed to improve intestinal regularity as well as improve intestinal microflora. Solactis galactofructose is a disaccharide naturally occurring in heat-treated milk and obtained by isomerisation of lactose to create an indigestible carbohydrate that both balances the intestinal flora and regulates transit. Although it is not recognised as a fibre in Europe due to its low degree of polymerisation, galactofructose has some of the intrinsic properties of fibre such as the non digestibility in the small intestine and beneficial physiological effects. The claim ‘Galactofructose is a prebiotic, which helps the development of the intestinal flora and contributes to a better transit at 2.5g/day’ has been validated by the Belgian authorities and the Italian Ministry of Health; and the ingredient’s ‘prebiotic’ and ‘transit’ effects are currently under evaluation by EFSA.

Solvay’s new Solactis galactofructose can be formulated in a wide range of food and beverage products to improve both gut flora and intestinal regularity Solactis galactofructose is commercially available in liquid form as a yellow, odourless clear syrup, or in solid form as an amorphous white powder, which is highly soluble in water. It has a soft, sweet taste - with a sweetness equivalent to 0.6 the sweetness of sucrose. Stable at both high temperatures and low pH, it can be easily integrated into a wide range of foods including yoghurts and fermented milk products, biscuits, beverages and baby foods. www.solvay.com

Alternative to dairy ingredients Symrise has perfected a range of cost-effective, enzyme-modified and cultured, natural dairy flavours for replacing expensive dairy ingredients in baked goods, cream fillings, toppings, sauces, cereals and cereal bars. Designed to enhance flavours that might have been affected by harsh processing conditions, the Enzyme Modified & Cultured Dairy Flavours range are said to balance the variances that are sometimes found in natural raw materials and to deliver

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authentic dairy tastes. They are compatible with other dairy ingredients, so can be used to synergistic effect and to deliver added mouthfeel, particularly in reduced fat or sugar formulations, according to Symrise. Natural Cultured Cream varieties, Natural Cream, Natural Butter, Natural Buttermilk Type Flavour and Natural Cream Cheese Type Flavour are available in the range. www.symrise.com

April 2010 www.foodbev.com

INGREDIENTS

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Natural colours for extruded confectionery Following collaborative work

able to withstand the shear

with the highest stability that give

with the Dutch extrusion

forces applied at the beginning

an efficient naturally-sourced

specialist Extrufood, Wild

of the extrusion process; and

colour in the end product.

has introduced a new range

the different parameters of heat,

of natural colours specifically

light, oxygen and pH value.

designed to be used in extruded confectionery.

www.wild.de

Wild worked with Extrufood to perfect a range of naturallysourced colours and colouring foodstuffs for extruded confectionery applications

Available in a colour spectrum from green to yellow, orange, red

Extrusion technology is a

and brown, the new extruder-

challenging process for

stable colours are suitable for

ingredients with the compound

use in liquorices, chewing gums

being pushed or drawn

or chewy candies and can be

through a die under high

combined with each other to give

pressure and extremely high

variegated finished products.

temperature. Therefore, Wild’s

The colours have been tested

new natural colours have been

and products simulated under

developed to be bakestable

industrial extrusion conditions on

and withstand temperatures up

Extrufood’s Kiemix and Dieswitch

to 80 or even 135°c depending

extrusion technology. The results

on the colour. They are also

are brilliant confectionery colours © Food & Beverage International 2010. Reproduced with the kind permission of FoodBev Media - www.foodbev.com For details about syndication and licensing please contact the marketing team on 01225 327890.

Food & Beverage International April 2010

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IFFA Preview

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Making the most of

Meat & Poultry IFFA, Europe’s foremost trade fair for the meat processing sector opens its doors again from May 8 to 13 in Frankfurt. Over 60,000 trade visitors are expected from more than 100 countries and they will take the opportunity to discover the latest developments from around 900 companies providing solutions to meat and poultry processors By Claire Rowan - managing editor

he great and the good of the meat & poultry industry will gather in Frankfurt in May for the first time in three years as IFFA again opens its doors to the latest developments for the market. “Despite the difficult economic situation, we anticipate roughly the same number of exhibitors and visitors as at the last event (three years ago),” said Detlef Braun, member of the board of management of Messe Frankfurt, which organises the show, which includes exhibitors demonstrating products for the entire supply chain: from slaughtering, via processing and packaging, to cooling, storing and selling of meat. Exhibitors will come from around 50 different countries and approximately 48% of the visitors will come from outside Germany. Among those exhibiting this year are equipment and packaging specialists such as Multivac, Multipond and CFS; ingredients specialists such as Danisco and Hydrosol; and specialists in at line analysis, such as NDC.

Exhibiting alongside each other this year are Multivac and its subsidiary MR Etikettiertechnik, which will be showing a fully automatic packaging line for primal meat cuts. The packaging line will feature the latest developments in handling, labelling and quality inspection, which are all operated via a graphical user interface. At the centre of the line is Multivac’s R275 CD thermoformer for producing Darfresh packs. At IFFA, Multivac will be demonstrating the Darfresh Bloom vacuum skin process, triple-film packaging that combines the visual and technological advantages of vacuum skin packaging with MAP technology. This ensures that the meat permanently retains its red colour under vacuum. In addition to the Darfresh Bloom packaging, Multivac will also show how LipFORM packaging is produced on the R275 CD thermoformer. This pack shape combines the efficiency of thermoforming with the visual advantages of prefabricated trays, according to Multivac, which will also demonstrate the fully automatic packing of steaks, including its

Multivac will be demonstrating a wide range of solutions on its stand (above) new under-grip gripper, which places ‘floppy’ objects such as steaks, fish or pizza into trays without distorting the shape of the product. Multipond’s two highlights on its stand are the multihead weigher SAL 10-3100/2500-H for weighing of large meat portions; and the fully-automatic weighing system for sticky products such as fresh or marinated meat, poultry and fish. The SAL 10-3100/2500-H has 10 linear weighing systems and is suited to delicate product that is not normally suitable for automatic feeding. Prefeed hoppers are fed with meat portions, such as turkey or chicken breasts, chicken leg or pork chops, which are transferred to the weighing hoppers for weighing. The best combination of meat pieces is deposited onto two integrated conveyor belts, which transfer the product into a timing hopper. If short weights are detected the conveyor belts reverse and reject

April 2010 www.foodbev.com

IFFA Preview

Click here to subscribe the product into a reject container. The timing hopper deposits product onto a conveyor belt for transfer to final packing. For very sticky and delicate products, such as marinated meat, poultry and fish, Multipond has also introduced a fully-automatic weighing solution. The patented innovation is based on a special surface profile on the feed trays and a central distribution cone, as well as improved product feeding characteristics on the weigher. The stepped profile of the weigher minimises the contact surface between the product and the cone and/or the feed tray surface, which leads to lower product adhesion. The simple design of the Multipond solution does not require additional equipment, such as a screw conveyor, traditionally needed to control the feeding of these sticky products. CFS will display a wide range of equipment for preparation, marinating, processing, slicing and packaging on its stand. It is introducing machines for on-weight slicing; fully automated robot loading; high performance grinding; yield enhancing multizone cooking; fast defrosting and an entrylevel model of its PowerPak thermoformer. The entry-level CFS PowerPak ST now provides a thermoforming solution for businesses working with smaller volumes and batches. At just 3.8m long, it is ideal for where space is limited, yet still delivers fully automated deep-draw packaging capabilities. Integrated into the CFS PowerPak NT thermoformer is the new CFS RobotLoader, which features one robot station and enables full automation when handling products such as sliced portions, fresh meat or product pieces such as sausages, schnitzels and nuggets. The new CFS MegaSlicer generation will be shown for the first time with the CFS OptiScan, an x-ray based system that Hydrosol’s stabilising systems for meat products will be the focus of activity on its stand

Food & Beverage International April 2010

Multipond’s two highlights this year include a multihead weigher for weighing large meat portions, and a fully automatic weighing solution for sticky products increases yield when slicing products like hams and bacon that have an irregular shape and varying product density. According to CFS, the data provided by the OptiScan reduces costly giveaway and gives a high proportion of on-weight portions.

Checking the quality of the meat being processed is vital to any production line and NDC Infrared Engineering will be taking the opportunity to demonstrate its simple-touse InfraLab at-line Near Infrared (NIR) Meat Analyser at the show.

In Hall 4.1 the latest innovations in ingredients for the meat industry will be demonstrated. Among the exhibitors, Hydrosol will highlight new additions to its portfolio including, for scalded sausages, its HydroTop and Plusmulson series of stabilisers, which ensure good, uniform quality in the end product even when inexpensive raw materials are used. Even scalded sausages with an ice content of 40% are possible using the HydroTop Firm-Tec complex, which consists of special proteins combined with hydrocolloids and enzymes. Using this system, sausages have a characteristic ‘snap’ bite when eaten hot. Other new products on show will include emulsifiers for boiled sausage; stabilising systems for restructured meat and bacon products; stabilising systems for marinating fresh meat; structure improvers for mechanically recovered meat; stabilising systems for low fat sausages; anti-staling agents and preservatives; and stabilising systems for fat emulsions.

NDC’s technology provides the rapid and accurate measurement of moisture, fat or protein in meat, without the need to send samples off for time-consuming laboratory analysis. It can be calibrated to standard laboratory methods such as Gravimetric Oven or Karl Fischer for moisture; Soxhlet, for crude fat; Werner-Schmidt or Weibull Stoldt for total fat; NMR for fat; and Kjeldahl for protein. Said to be easy to use, and with automated sample detection, the InfraLab requires no special user skills. According to NDC, the grab samples used by the InfraLab are much larger than those used by many laboratory techniques making them more representative of the actual manufacturing process.

Danisco will be demonstrating new cultures, stabilisers and natural antioxidants among its range of solutions designed to give meat products the right taste, colour, texture, shelf life, safety and nutritional profiles. For cured products, Danisco will show its Texel NatuRed meat culture capable of giving an effective curing process and colour development in combination with nitrite salts or natural nitrate alternatives. For reformed meat, the Grindsted MeatBinder Stabiliser Systems can be used to turn waste into value, according to Danisco. Now available in a phosphate-free version, the MeatBinders transform odd-shaped meat trimmings into medallions and nuggets with defined shapes and sizes, excellent cooking and freeze-thaw stability.

In addition to the range of products and services on show, a complementary programme of events will give visitors the chance to gather further information about the sector and discuss developments with experts. The Meat Vision conference being held on 10 and 11 May is aimed primarily at the international industry and will cover the current situation in international markets; new manufacturing processes for meat and sausage products; and legislation.

For more information www.iffa.com www.multivac.com www.multipond.com www.cfs.com www.hydrosol.de www.danisco.com www.ndcinfrared.com

PACKAGING

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Oxygen scavengers helps boost shelf life M&H Plastics has developed a new oxygen-scavenging system for PET containers that limits exposure to oxygen and retains a food or beverage product’s quality during its shelf life. The packaging material is manufactured from a mix of PET blended with oxygen-scavenging concentrate, which together create an active barrier against the ingress of oxygen through the walls of the containers. Fire Foods in the UK is now using the technology to pack its range of homemade chilli-based foods such as Chilli Sauces and Hot Chilli Chutney.

VTT Technical Research Centre of Finland has developed an environmentally-friendly coating that can be used for producing fully recyclable, light, air-tight packaging materials. Fire Foods is now using M&H Plastics’ PET blended with an oxygen scavenging concentrate to pack its chilli-based products “M&H worked with us to develop the PET packaging for our products, which are all about taste,” said Nick Woods of Fire Foods. www.mhplastics.com

New pack competes with glass containers

A twist-off screw cap allows reclosure and re-use of the pack and helps the pack compete further with glass. The plastic is said to offer complete clarity, and allow for in-mould labelling

Food & Beverage International April 2010

Developed using a special atomic layer deposition (ALD) method, which has been used on microelectronics up until now, the coating has excellent gas permeation resistance and as such it is suitable for use with foods and sensitive food products to help extend their shelf life.

The ALD solution allows the packaging of materials, which are thinner, lighter and better sealed than traditional barrier materials. With the new coating, barrier properties are possible without using aluminium film, which traditionally causes a hurdle to a pack’s recyclability. The ALD coatings are thin and pinhole-free and closely follow the contours of the coated packaging material, which therefore creates a very thin protective layer - around 25 nanometres in thickness, which is both bendable and flexible. www.vtt.fi

Nano solutions for plastics Researchers at Nottingham Trent University of Science & Technology have used nanotechnology to perfect a solution to leaching from bottled beverages.

A plastic packaging that is said to double or even triple the shelf life of vegetables such as beetroot or red cabbage, and provides an alternative to traditional glass jars, has been developed by Superfos. The 400ml SuperLock is a thin walled container with a new oxygen barrier, which allows a shelf life of up to 24 months. Following development work in its Research & Development Lab, Superfos has perfected a technology that allows the barrier protection to be used on all surfaces of the pack. In combination with a membrane seal, the barrier ensures almost zero oxygen transmission.

Barrier coating creates recyclable packaging

Superfos’ new SuperLock allows for barrier protection to be used on all surfaces and gives a shelf life of up to 24 months and ‘razor sharp’ printing for decoration. According to Superfos, additional benefits are that the new plastic packs stack well, are low in weight - therefore reducing transport & warehousing costs - and quiet on the filling line. www.superfos.com

Awarded the title of Food & Drink iNet Innovation Champion and winner of the CenFRA Award for Most Innovative Research Project, the research drew on existing manufacturing techniques to overcome the problem of the leaching, or escaping, of gases from within bottled beverages. By using nanofillers to enhance the plastic packaging materials by no more than a few nanometers (one millionth of a millimetre), the scientists ensured that the solution has no affect on the appearance of the plastic packaging. The research has also led to the development of materials with antimicrobial properties, which kill or inhibit the growth of micro-

Nottingham Trent University has perfect a nano-based solution to the problem of leaching of gases from bottled beverages organisms. Unlike conventional methods to combat microbial contamination, the Nottingham Trent solution can be used in direct contact with food and can be incorporated into plastic packaging. It uses a special antimicrobial nanocomposite that can be used within the plastic packaging and is also expected to help extend the shelf-life of the food. www.ntu.ac.uk

PACKAGING

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Full-body shrink film labels suit shaped packs Eastman’s full-body shrink film labels incorporating the company’s Embrace LV copolyester are now available in Europe and allow packaging with 360° graphics. Capable of being used on one-off contoured and shaped bottles and jars, the film is durable and tough and can enhance the visual impact of the finished product. Eastman’s Embrace copolyester can be printed with thermochromatic, metallic and glow-in-the-dark inks and used with spot varnishing and organic photovoltaic finish. Its ability to be decorated and embossed provides interesting options for

shrink labelling; and as the film is consistently stretched from the top to the bottom of the bottle, Embrace eliminates the ‘smiley faces’ often found on square or oblong containers, according to Eastman. Embrace does not contain halogens, sulphur, nitrogen, lead, mercury, cadmium or hexavalent chromium and is designed to be compatible with today’s recycling infrastructure. The shrink film does not require glue and allows for thinner packaging walls, which reduces the overall material consumption of the pack. www.eastman.com

Eastman’s full-body shrink film labels with Embrace LV copolyester are now available in Europe

For more information on packaging innovations see www.foodbev.com

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April 2010 www.foodbev.com

PROCESSING

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Extrusion expansion Baker Perkins has introduced a new twin-screw cooker extruder and a new range of wafer thin, ‘credit card’ snack concepts produced using twin screw extruders. The company specialises in twin screw extruders that can be used in the snack and breakfast cereal industries as standalone machines, or as part of a full production line that can be expanded with different modules to produce different novel products. In the snacks arena, for example, direct expanded products such as corn curls, chipsticks, and maize rings can be produced on a standard line, which can be extended in stages to produce a full range of high specification snacks including whole grain/multigrain and co-

extruded filled pillows and bars with novel shapes, textures and surface patterns. For cereals, standard products such as corn balls, multigrain rings, alphabet shapes and cocoa balls can be made or, with the addition of different modules, high added value flakes, multigrain flakes and filled pillows can be created. Baker Perkins’ new SBX Master twin-screw cooker extruder has been introduced for both snacks and cereals. It is a solid-barrel unit that has outputs, dependent on the barrel diameter selected, of 225 to 2,000kg per hour. The SBX Master twin-screw cooker extruder produces direct expanded snacks as well as more innovative end products such as pillows, tubes and filled products with the addition of

Co-extruder for filled dumplings

Food & Beverage International April 2010

cutters, crimpers and coextrusion equipment.

filled snacks dipped into cheese, for example.

In the snacks domain, Baker Perkins has developed flat, thin, rectangular co-extruded wafers

Due to their shape they allow a small amount of filling to occupy a large surface area,

that can incorporate a wide variety of fillings. They can be used as a snack in their own right or as ‘dipping’ products - such as peanut butter snacks dipped into savoury spread; or a tomato-

subsequently giving an intensely flavoured product. They can be based on any grains used for extrusion, such as corn, wheat or rice. www.bakerperkinsgroup.com

Large volume extrusion Coperion has opened a new Food Test Lab equipped with its state–of-the-art ZSK 43 MegaVolume Plus, which has been developed over the past two years.

Vemag’s 893 co-extruder can be used to create filled croquettes or dumplings with a wide variety of fillings such as meat balls with ketchup, poultry croquettes with cheese, fish fingers with tomato sauce, potato dumplings with spinach or fish croquettes with shrimp filling. The Co-extrusion device 893 is a special shaping module that is designed for use with two vacuum fillers, according to Vemag. It is connected to the fillers by pipes and the first machine portions the case, while the second portions the filling. Both mixtures are combined within the 893 shaping device, which has a patented shut-off valve that guarantees that the filling is positioned accurately in the portion case. The ends of the product also remain reliably sealed as processing continues.

Baker Perkins has introduced a new twin-screw cooker extruder, and new wafer thin credit card snack concepts

Vemag’s new co-extrusion device 893 can be used for accurately filling and sealing croquettes or dumplings If required the line can be extended with the addition of an integrated grinder with separation device that uses an automated separation valve to ensure that hard constituents such as gristle, sinews, scales or stalks are reliably separated off. www.vemag.de

Offering a high output, the ZSK 43 MegaVolume offers a large free volume in the extruder barrel and high screw speeds. With the same screw diameter, it offers ten times the output of its forerunner, Coperion’s Continua, without any loss of product quality. The ZSK 43 MegaVolume’s self-cleaning twin screw has a modular design, which permits easy adaptation of the screw configuration dependent on application. Besides the usual screw elements for conveying, mixing and kneading, the ZSK 43 MegaVolume offers numerous different types of element designed for different applications – including shoulder and strainer discs. Side feeders

Coperion has opened a new Food Test Lab to demonstrate its latest innovations in extrusion technology boost the throughput and the flexibility of the system still further as they facilitate the feeding of difficult bulk materials, such as fine powdered starch, into the extruder barrel. Typical areas of application for the ZSK 43 MegaVolume are direct expanded breakfast cereals and snacks; the manufacture of chocolate, chocolate mixtures; and caramel mixtures and sweets. www.coperion.com

PROCESSING

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Greencore Chilled Sauces & Soups controls the steam pressure of its cooking vessels with the new CV-COS electro-pneumatic pressure reducing valve from TLV

Valve optimises cooking process Greencore Chilled Sauces & Soups has invested heavily in cooking and filling equipment to increase the production capacity and output of its Bristol, UK site, which produces a range of ownbranded cooking sauces and fresh soups for UK retailers. Most recently the company has standardised its steam processing equipment to increase the efficiency of the ten cooking vessels. “When the vessels were first installed they were fitted with standard TLV Pilot Valves which, from a cold start provided 1.5 bar of steam pressure in the jacket for the initial stages of cook. However, we realised that in order to increase the productivity of the process we needed to increase the efficiency of the heat transfer, and TLV suggested fitting its new CV-COS electropneumatic pressure reducing valve, which combines a

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convenient control function with a pressure reducing valve, separator and steam trap in one compact unit,” said Spencer Wills, engineering manager at Greencore. The new TLV valve is designed for process applications that require automatic control of the pressure, temperature and the flow rate of steam. It maintains a constant pressure in the jacket from start-up. In addition to improving the heat transfer and therefore efficiency and productivity of the cooking vessel, the CV-COS also allows Greencore to change the pressure of the vessel easily in order to cook different sauces. An integral separator and steam trap ensure that the CV-COS provides consistently good steam quality at the point-of-use, which also contributes to the efficiency of the production process. www.tlv.com

April 2010 www.foodbev.com

VITAFOODS PREVIEW

Nutraceuticals on show

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Vitafoods will showcase the latest developments for the global nutraceutical market in Geneva, 18-20 May

ast year saw Vitafoods increase its stand space by 15%, which translated also into the visitor figures, according to the organiser, IIR Exhibitions. This year, the growth is expected to continue with around 9,000 visitors attending from throughout Europe, the Americas and Asia; and over 500 exhibitors taking the opportunity to demonstrate their latest innovations. A free to attend Vitafoods Discussion Forum will look at the EU Claims Regulation and examine the need for new marketing strategies in Europe. Held on Thursday, May 20 between 9 and 10.30am, the panel discussion will be led by Simon Pettman from EAS. Questions for the panellists can be sent in advance to: forum@eas.eu. In addition to the Discussion Forum, EAS will also be holding one-to-one free strategic advice sessions tailored to the specific needs of the company involved. Other free to attend events at the show will be held in the Supplier Seminar Theatre where exhibitors will be able to highlight their latest innovations and demonstrate them in action. Companies taking part this year include Fortitech Europe, Ocean Nutrition Canada, Epax, Danisco, Lonza and Lipid Nutrition among others. These companies will also be giving further details along with product concepts on their stands. Fortitech will highlight the fortification challenges of beverages aimed at children’s health concerns including custom nutrient premixes for aiding in maintaining overall health, preventing a specific health condition or targeting a certain demographic. On the stand, the work of its newest business unit, the World Initiative for Nutrition (WIN), will be discussed. WIN’s focus is to work with non-

Food & Beverage International April 2010

governmental organisations, governmental and international agencies with the aim of tackling malnutrition in the world. A highlight on the Ocean Nutrition stand will be its new dry application Omega-3 powder. The MEG-3 powder allows Omega-3 EPA/ DHA to be successfully incorporated into a variety of dry blend applications such as meal replacement powders, powdered juice mixes, protein powders, weight management powders and powdered sports drinks. Containing up to 105mg of EPA and DHA per gramme, the MEG-3 powder has an additional, patent-pending carbohydrate layer that provides extra protection in applications such as multi-serve products that might suffer oxidation issues from repeated opening and closing of the pack. Further information on the performance of this and other Ocean Nutrition solutions for fortifying with Omega-3 will be discussed on the stand. Fellow Omega-3 supplier, Epax, will focus on its control of the fish oil production process (from catch to finished product) for its concentrated marine Omega-3 ingredients. It will discuss its portfolio of EPA and DHA Omega-3 products and their impact on health. In the Seminar Theatre, Professor Holub will be presenting on the pre and post natal role, in particular. Novel probiotic delivery vehicles for its Howaru range of probiotic ingredients, such as yoghurt bears and the Howaru straw, will be under the spotlight on Danisco’s stand this year. Developed for products for gut and immune health, the flavoured yoghurt bears are a fun and tasty way for kids to be given their daily dose of probiotics; whilst the Howaru straw can be used to deliver probiotics to a range of beverages, but keeps them safe until the moment of consumption. Also being discussed will be MenaQ7, Danisco’s natural vitamin K2,

Novel probiotic delivery vehicles will be the subject of discussion on the Danisco stand

which has been approved by EFSA for bone health claims; and a VivaGrape, a natural grape extract with antioxidants for food and beverage applications. Lonza will be offering its wide range of branded health ingredients at the show. These include Carnipure, the high quality L-Carnitine; FiberAid, a premium prebiotic fibre consisting of arabinogalactan; ResistAid, an all-natural, multifunctional product made from the bark and wood of larch trees, which consists of soluble prebiotic fibre arabinogalactan and bioactive flavonoids; and DHAid, a pure vegetarian source of Omega-3 DHA. Lipid Nutrition will be discussing the best weight management ingredients at the Supplier Seminar and on its stand where new application samples using Pinnothin, Clarinol and Marinol can be tasted. In particular, visitors will be able to try the first yoghurt containing Clarinol CLA, which has just been launched by Old Home Foods in the USA. www.vitafoods.eu.com; www.fortitech.com; www.ocean-nutrition.com; www.danisco.com; www.lonzanutrition.com; www.lipidnutrition.com

TOTAL PREVIEW

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Total Processing & Packaging

show doors open Total Processing & Packaging is set to open its doors to thousands of visitors at the NEC, Birmingham, UK from 25-27 May

his is the third edition of Total, the integrated processing and packaging exhibition, which takes place every three years. Over 680 exhibitors from 30 countries took part in the last show in 2007 and 20% of the 11,000 plus visitors were from overseas. They came from companies such as Arla Foods, Coca-Cola Enterprises, Diageo and Masterfoods to discover the latest developments in the areas of processing and packaging. This year’s exhibition is no different and includes complete production line solutions, covering sectors such as raw materials, solids & fluids handling, control & instrumentation, FMCG (fast moving consumer goods) processing equipment, industrial plant & equipment, contract packing & manufacturing, and packaging machinery. In addition, the Packaging Innovation Hub, sponsored by Linx, will focus on packaging materials, containers, pack design and marketing, smart and intelligent packaging, and sustainable solutions. At the heart of the Packaging Innovation Hub will be the 2010 Design Challenge, first held at Total Processing & Packaging in 2007. The Challenge invites major pack and machinery manufacturers to share their latest material and technological developments with leading design houses in order to explore opportunities for the creation of new products, market applications and consumer experiences. “Although the brief is very open and offers the potential for some blue sky thinking, participants are being asked to consider

Over 11,000 visitors attended the last Total Processing & Packaging Exhibition in 2007 in particular some of the current major criteria and requirements for a new pack in today’s markets, balancing environmental needs, consumer demands (for example for convenience), cost-effective manufacture, and retailer requirements (such as ease of transport and display) with other essential ingredients - end user enjoyment and satisfaction,” said Ian Crawford, group exhibition director, Total. “The resulting developments will be visualised and modelled, and on display throughout the three days of the exhibition.” With the changing economic landscape, businesses are continuing to seek out efficiency savings whilst increasing productivity. Responding to these needs, the Robotics & Industrial Vision Pavilion in association with BARA and UKIVA is a brand new show feature that will provide the perfect opportunity for visitors to find out more about the benefits of incorporating this type of technology into their businesses, while at the same time allowing them to view the latest solutions. A further highlight throughout the three days of Total Processing & Packaging 2010 will be two wide-ranging seminar programmes, focusing on industry issues.

In order to help attendees plan their visit in advance, the show organiser’s have launched TotalTV at www.totalexhibition. com/totaltv. Some of the exhibitors who will be demonstrating their new technologies include: Multipond with its fullyautomatic weighing system for sticky products; Artenius PET Packaging Europe with its dual colour manufacturing process for PET bottles; PFM with its ultra-fast MAP bagging machines; Allen Coding Sytems with its range of high performance laser, thermal transfer and carton coding and marking equipment; Witt Gas Techniques with its latest leak detector and gas mixing/analysis products; ICE Interactive Coding Equipment with its latest innovations in thermal transfer coding; Endoline Machinery showcasing its fully automatic random case sealer; and Ilapak with its Vegatronic integrated weigher and bagging machine and Carrera flowrapper. Further details of the innovations will be covered in the next issue of Food & Beverage International. www.totalexhibition.com

April 2010 www.foodbev.com

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Food & Beverage International February 2010

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