December 2010 | Food & Beverage International by FoodBev Media Ltd

BEVERAGE

INTERNATIONAL

FOOD &

DIGITAL SAMPLE COPY

Sustainability: challenge and opportunity

Novel preservation technologies Pulsed electric field & tomato juice Vitamins & minerals Technology update: Packaging Processing Ingredients

Shelf-life analysis & challenge testing Hi Europe review

FoodBev com A world of food and drink

www.foodbev.com/food

ÂŠ F&BI 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.

December 2010

DECEMBER 2010 CONTENTS

Click here to subscribe

Features 4 Editorial Sustainability is here to stay on the food & beverage industry agenda: now is the time to act

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

10 CIAA report Innovation is central to meeting the economic, social and environmental concerns as revealed at the CIAA Congress 2010 in Brussels in November

11 Industry news Consumer trends for 2011 put sugar and high fructose corn syrup reduction under the spotlight

Innovation Awards The finalists and winners in the 2010 Water Innovation Awards were announced at a special gala during the 7th Global Bottled Water Congress in the Ballroom at Gleneagles, Scotland, on 2 November

14 Innovations The latest convenience foods, soups and sauces to have been seen on supermarket shelves around the world

Technology updates 26 Ingredients Dairy ingredients including proteins, hydrolysates and whey; and ingredients for dairy products provide a wealth of opportunities for today’s new product development teams

preview

The prevailing trends of health, nutrition and natural set the scene for activities at this year’s Hi Europe exhibition

foodbev com

16 Novel Processing Systems The need to improve food safety and quality, fulfil on the demands of a tough economy and increasingly environmental concerns have motivated processors and researchers alike to improve existing preservation technologies

20 Pulsed Electric Field Technology Pulsed Electric Field technology could provide advantages for the processing of tomato juices to retain their nutritional value

22 Vitamins & Minerals Formulating with vitamins and minerals continues to offer opportunities for new product development and there are many interesting solutions available for innovation

42 Sustainability: challenge & opportunity The first in a regular Sustainability section in Food & Beverage International covering the news & developments taking place in the area of sustainability including energy & water saving and ingredient sourcing and the impact on food & beverage companies’ strategies and performance

38 Packaging Bottle cans used for a Hibiscus infusion in Japan, eco-friendly cartons, and sports caps for sports water and syrups are just some of the developments taking place in the packaging arena

30 Hi Europe

12 Water

34 Processing Blending, batching, dosing and pumping operations require robust solutions. A look at some recent technological advances

Special reports, this issue, from John Fawell, DSM and Archer Daniels Midland Company

Food safety and analysis Your practical guide to food safety, hygiene and analysis

40 Safety & analysis Any alteration to a formulation or production process will affect the shelf life of a product and it is essential that procedures are adopted for evaluating the effects of the changes and any subsequent hazards to safety

December 2010 www.foodbev.com

EDITORIAL

Click here to subscribe

Sustainable strategies: here for the long term

he current global food system is on an unsustainable track, which poses a threat to long term global food security, according to the latest Rabobank study, ‘Sustainability & security of the global supply chain’, which resonates with other reports and headlines appearing everywhere. The study concludes that large investments are required to improve current agriculture both up- and down-stream in order to secure the sustainability of the global food supply, but points out that the fundamental changes required will bring new markets and business opportunities. Paul Polman, CEO of Unilever has also commented (p43 Sustainability News): “We are already finding that tackling sustainability challenges provides new opportunities for sustainable growth: it creates preference for our brands, builds business with our retail customers, drives our innovation, grows our markets and in many cases, generates cost savings.” However, Bob Meek, CEO of Wada Farms, one of the keynote speakers at the Sustainable Agriculture Partnerships Summit in London this month, said that making a conscientious choice towards farming in a sustainable manner can raise costs by as much as 20% vis-à-vis growing practices. And, he stressed that it was important to educate consumers about the value of sustainable produce. The opportunities for this are growing, and already the impetus for change has resulted in valuable collaborations between industry

urges companies to seize the opportunity. ‘The key message is that new business opportunities will arise as part of the buildup to the internationalisation of the new costs of resources.”

We are already finding that tackling sustainability challenges provides new opportunities for sustainable growth. and organisations such as the Sustainable Agriculture Initiative, WWF, and the Union for Ethical Biotrade, bringing certification as well as greater knowledge, and the chance to communicate the tangible benefits of sustainable strategies to consumers. Ultimately, the industry will have to embrace these activities, address the cost implications and discover methods of stimulating consumers to vote with their own purses for a brighter future. ‘The valuation of social and environmental issues will, sooner or later, be factored into costing and companies’ balance sheets, predicts the Rabobank study, which

To support manufacturers with this aim, Food & Beverage International has been publishing Sustainability Supplements since it was first launched in 2002. We will now include a regular Sustainability section within every issue of the magazine, which will include news of legal and voluntary frameworks, certification, research, training and industry initiatives that are shaping the landscape. It will bring case studies that highlight and acknowledge the activities of the major industry players as well as news of the latest sustainable solutions from ingredient, packaging, technology and service suppliers. There will be regular contributions from some of the foremost authorities in the area of sustainability who will share their expertise on what food & beverage manufacturers should consider when looking at their environmental and sustainability plans. Sustainability is here to stay on the food & beverage industry agenda, and FBI plans to bring you the information you need to make it possible.

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

EDITORIAL ADVISORY BOARD Dr Paul Berryman

Dr Michael Knowles

Dr Philip Richardson

Chief executive, Leatherhead Food Research

Vice president, Global Scientific &

Head of Food Manufacturing Technologies,

Regulatory Affairs, The Coca-Cola Company

Campden BRI

Huub L.M. Lelieveld

Mrs Helen Sisson

President, Global Harmonization Initiative

Group technical director, Greencore Group

Director, Food Safety Programmes,

Karin Östergren

Dr J André de Barros Teixeira

(CIES - The Food Business Forum)

PhD, Scientific Co-ordinator of the section

President, Founding Partner,

The Consumer Goods Forum

Sustainable Food Production, SIK - The Swedish

eemPOK, Experiential Innovation

Institute for Food and Biotechnology

Management

Dr Gerda Feunekes Global nutrition director, savoury, Unilever Catherine François

Mella Frewen

Director General, Confederation of

Dr Sebastiano Poretta

the Food and Drink Industries of the EU (CIAA)

President, Italian Association of Food Technology

Food & Beverage International December 2010

FoodBev com

FoodBev Media’s Beverage Innovation magazine and Zenith International’s functionaldrinks newsletter announce...

Launches October 2010 | 6 categories | 24 awards Launched InnoBev Beverages Summit – Washington DC, March 2011 visit www.foodbev.com for more information

Click here to subscribe www.foodbev.com/food EDITORIAL 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

ADVERTISING Paul Tschornow Sales executive Tel: +44 (0)1225 327863 paul.tschornow@foodbev.com Carolyn Eychenne - France, Benelux Tel: +33 1 30 21 15 62 • Fax: +33 1 30 21 12 09 eychenne.carolyn@wanadoo.fr Colm Barry - Denmark Tel/Fax: +46 40 41 41 78 colm.barry@telia.com Michelle White - UK, US, Canada Tel: +44 (0)1883 734 793 whitemm@btopenworld.com

PRODUCTION Production manager Jane Harris jane.harris@foodbev.com Please send advertising materials to: FoodBev Media Ltd, 7 Kingsmead Square, Bath, BA1 2AB, UK Electronic files should be sent to jane.harris@foodbev.com Printed in the UK by Holbrooks Printers Ltd ISSN 1479-0823

December 2010. Volume 9, Issue 6 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,

including electronic format, without the prior consent of the Publisher. NB: While every effort has been made to ensure that the information contained in Food & Beverage International is correct, the Publisher can accept no liability for any inaccuracies in any editorial, photographs or advertising, nor any loss or damage resulting from any material contained in the magazine.

All articles appearing in the magazine Food & Beverage International, or on the website www.foodbev.com are strictly covered by copyright.

foodbev com

December 2010 www.foodbev.com

EVENTS

2011 January

January 30-February 1 European Food Manufacturing and Safety Forum, Amsterdam, The Netherlands. Details from World Trade Group, 90 Union Street, London SE1 0NW, UK. Tel: +44 (0)20 7202 7500; Fax: +44 (0)20 7202 7600. www.foodmanufacturingevent.com January 30-February 2 ISM - the International Sweets and Biscuits trade fair covering end products for retail sale in chocolate, sugar confectionery, biscuits, snack products, ice cream and raw pastes categories, Cologne, Germany. Details from Ines Weber, product manager ISM, Koelnmesse, Messeplatz 1, 50679 Cologne, Germany. Tel: +49 221-821-2466. www.ism-cologne.com. i.weber@koelnmesse.de

February February 8-10 Food & Beverage Test Expo, exhibition for technologies, solutions and services specifically for food and beverage producers, manufacturing test technicians and personnel; and Forum & Workshop programme organised by Campden BRI, Cologne, Germany. Details from Mr David Stradling, Total World Media Ltd, 10 Dunley Hill Court, Ranmore, Dorking RH5 6SX, UK. Tel: +44 (0) 1306 803 032; Fax: +44 (0) 1306 803 034. www.foodtestexpo.com. d.stradling@hulst-expo.com February 16-18 Global Food Safety Conference - Creating a Global Food Safety Culture, London, UK. Details from Food Safety Secretariat, Aurélie Brochard, Tel: +33 1 43 18 60 19 or Daphné Bernard, Tel: +33 1 43 18 61 81. Fax: + 33 1 43 18 60 58; and The Consumer Goods Forum, 7 rue de Madrid, 75008 Paris, France. www.tcgffodsafety.com. tcgffoodsafety@ theconsumergoodsforum.com

Food & Beverage International December 2010

Click here to subscribe

March March 1-2 Annual World Food Technology & Innovation Forum, focusing on the most effective innovation and new product development strategies to maximise competitiveness and profitability, Brussels, Belgium. Details from World Trade Group, 90 Union Street, London SE1 0NW, UK. Tel: +44 (0)20 7202 7500; Fax: +44 (0)20 7202 7600. www.foodinnovate.com March 2 Enhancing the Health & Nutritional Benefits of Food Products through Nanotechnology, conference, Leatherhead, UK. Details from Leatherhead Food International Ltd, Randalls Road, Leatherhead, Surrey KT22 7RY UK. Tel: +44 (0)1372 376 761. www.leatherheadfood.com/ conferences March 3-4 Global Summit on Nutrition, Health and Human Behaviour - LC-Omega-3 for a Better World, conference, Bruges, Belgium. Details from VVZRL Nutrition & Health Claims Europe, Haverhuisstraat 28, D 8870 Izegem, Belgium. Tel: +32 51 31 12 74; Fax: +32 51 31 56 75. www.omega3summit.org March 8 Microbiological safety of UK raw milk cheeses, seminar, Chipping Campden, UK. Details from Campden BRI, Chipping Campden, Gloucestershire, GL55 6LD, UK. Tel: +44 (0) 1386 842 104. www.campden.co.uk/cheesesafety-seminar.htm March 13-16 International Food Exhibition, held alongside Pro2Pac, the processing & packaging solutions exhibition, London, UK. Details from Christopher McCuin, event director, Fresh RM, 9 Manchester Square, London, W1U 3PL, UK. Tel: +44 (0) 20 7886 3016. www.ife.co.uk. chris.mccuin@freshrm.co.uk

March 16 European Consumer trend conference, Zurich, Switzerland. Details from Ms Brigitte Fischer, the Gottlieb Duttweiler Institute, Langhaldenstrasse 21, P.O. Box 531, CH-8803 Rüschlikon/Zurich, Switzerland. Tel: +41 44 724 62 66; Fax: +41 44 724 62 62. www.gdi.ch/en. brigitte.fischer@gdi.ch March 22-23 Food & Beverage Green Tech Asia conference, Shanghai, China. Details from Commercial Director Organizing Committee of Food & Beverage Green Tech Asia 2011. Tel: +86 21 52 120 927 112; Fax: +86 21 52 120 818. www.greenwisdomindustry.org

organic industries, London, UK. Details from Diversified Business Communications Ltd, 120 Church Street, Brighton, BN1 1UD, UK. Tel: + 44 (0) 1273 645 110; Fax: + 44 (0) 1273 645 169. www.naturalproducts.co.uk April 5-6 ECR Europe conference and marketplace - Meeting the Future Together, Brussels, Belgium. Details from ECR Europe, 9 Avenue des Gaulois, B1040 Brussels, Belgium. Tel: 32 2 736 03 05; Fax: 32 2 734 67 02. http://conference.ecrnet.org. ecr@ecreurope.com

May

March 24-25 ILSI Europe Annual Symposium 2011 – Science for Health, conference, Brussels, Belgium. Details from ILSI Europe (International Life Sciences Institute, Avenue E Mounier 83, Box 6, B1200 Brussels. Belgium. Tel: +32 2 771 00 14; Fax: +32 2 762 00 44. www.ilsi.org

May 10-12 Vitafoods, the global nutraceutical event, Geneva, Switzerland. Details from Mr Chris Lee, event director, IIR EXHIBITIONS, 5th Floor, 29 Bressenden Place, London SW1E 5EW, UK. Tel: +44 (0)207 017 7036; Fax: +44 (0)207 017 7818. www.vitafoods.eu.com. vitafoods@iirx.co.uk

March 27-30 TecnoAlimentaria held alongside Alimentaria & Horexpo Lisboa, trade shows for the food & drinks industry, distribution, the hospitality channel and food technology, Lisbon, Portugal. Details from Alimentaria Exhibition, Diputació 119, 08015 Barcelona, Spain. Tel: +34 93 452 1800. www.alimentariahorexpo-lisboa.

May 12-18 Interpack, international processing & packaging exhibition, Düsseldorf, Germany. Details from Messe-Düsseldorf, Postfach 101006, 40001 Düsseldorf, Germany. Tel: +49 211 4560 01; Fax: +49 211 4560 668. www.messe-duesseldorf.de

March 29-31 InnoBev Global Beverages Summit, Washington, USA. Details from Zenith International, 7 Kingsmead Square, Bath BA1 2AB, UK. Tel: +44 (0) 1225 327 900; Fax: +44 (0) 1225 327 901. www.zenithinternational.com/events

May 17-18 5th Annual Food Technology, Innovation & Safety Forum, Chicago, USA. Details from World Trade Group, 90 Union Street, London SE1 0NW, UK. Tel: +44 (0)20 7202 7500; Fax: +44 (0)20 7202 7600. www.thefoodsummit.com

April April 3-4 Natural & Organic Products Europe, trade show for the natural products, health food and

Your event: If you have

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

foodbev com

CIAA REPORT

Click here to subscribe

CIAA Congress calls for innovation, innovation, innovation

n 18-19 November, the CIAA Congress 2010 in Brussels brought together a host of internationally renowned high-level speakers and moderators to discuss Europe’s food and drink industry’s vision for 2020 around the theme ‘People, Planet, Partnership’. There were four sessions over the two days discussing the challenges and opportunities for a more competitive industry, through which it became clear that innovation is central to meeting the economic, social and environmental concerns of our time, making the industry more competitive today and tomorrow. The first session, food for the future, asked how the industry can innovate to meet the growing demand for food, producing more from less. Speakers stressed how we live in a changing world, with new challenges which require new responses and new technologies. Science and science-based regulation have an important role to play in meeting these challenges. In particular, panellists called for a fresh look at biotechnology and GMOs, as well as ensuring emerging technologies, such as engineered nanoparticles, are given the support needed to realise them - it is clear that these technologies are part of the toolkit for meeting the increasing demand for food in the future. Finally, speakers underlined the need for partnership; we live in an interdependent world and we need to work together to build acceptance around innovation and emerging technologies. The second session, health and wellbeing, looked at how the industry is playing a leading role in addressing complex diet and lifestyle challenges whilst empowering consumers to make informed choices. Again, innovation (for example, reformulation) was considered central to ensure consumers have a balanced diet and lead a healthy lifestyle, with science-based regulation needed to encourage this further (for example, health claims should be scientifically substantiated). Industry was commended for its collaboration with its partners, for example through its work on the European Platform for Action on Diet, Physical Activity and Health and the European Technology Platform Food for Life,

Food & Beverage International December 2010

and industry representatives reiterated the fact that meeting its commitments is not a constraint but a catalyst for continued action. Finally, industry and consumer organisations engaged in a lively debate over information to consumers, with panellists agreeing with Commissioner Dalli that ‘I don’t want to tell people what to eat; I want to tell people what they are eating’. Consumer education is important in bringing about behavioural change. The third session, planet and environmental sustainability, explored how Europe’s food and drink industry is delivering continuous environmental improvements to its products and processes by working with its partners in the food chain, particularly through the European Food Sustainable Consumption and Production Round Table. Panellists agreed on the need to green the economy, with industry representatives detailing how they are doing more for the planet - sustainability makes good business sense. Again, it was clear that innovation can unlock new opportunities for more sustainable products and processes, with knowledge-based growth central to all companies’ competitiveness. The fourth session, trust and partnership, stressed the importance of industry in working with its partners in the food chain to tackle the challenges of both people and the planet.

Industry recognised the trust placed in its products and the need to continue to build confidence through its relations with key stakeholders. Panellists also stressed the need to maintain trust and transparency when it comes to scientific research, with regulation having a role to play in fostering this trust. The Congress was complemented by an exciting exhibition space, demonstrating how industry is innovating to meet its commitments to ‘People, Planet, Partnership’. Over the two days, the 500 delegates were able to approach the exhibitors, informing themselves about how all manufacturers, whatever their size, are working to meet social and environmental challenges while competing for sustainable growth - and how the industry’s partners are involved in this. Closing the 2010 Congress, CIAA President, Mr Jesús Serafín Pérez, commented: “I am delighted that CIAA’s 2010 Congress has brought together such distinguished guests in a spirit of partnership. Innovation is invaluable as we work with Commissioner GeogheganQuinn and other stakeholders under the Europe 2020 Flagship Initiative ‘An Innovation Union’ to realise our vision for smart, sustainable and inclusive growth for Europe’s industry in the next decade and beyond.” For more information visit, www.ciaacongress2010.eu

foodbev com

INDUSTRY UPDATE

Click here to subscribe

Consumer Trends for 2011 A quiet reduction in sodium sugar and high fructose corn syrup (HFCS); a positive, clear, natural approach; quality offerings; and sustainability will be the top trends in consumer packaged goods in 2011, according to Mintel, the global market and consumer intelligence provider. While sodium reduction has long been the focus of covert reductions in formulations, sugar and HFCS are now following suit as consumer awareness

Environmental initiatives launched The end to deforestation and use of older generation refrigerant gases are to be two main areas of activity for the industry, following agreement by members of The Consumer Goods Forum (CGF), which announced the two major initiatives on climate change at the Cancun Climate Summit in November. “We are in Cancun to lend our support to this monumental but essential task of creating solutions that lead to a lowcarbon world,” said Muhtar Kent, CEO, The Coca-Cola Company on behalf of the CGF. “The initiatives that our industry announced today are good examples of the kind of bold and positive action that will be needed to move the needle in combating climate change.” The CGF pledged to help end deforestation by 2020; and to begin to phase-out hydrofluorocarbon (HFC) refrigerants as of 2015 and replace them with non-HFC refrigerants.

gains momentum. The expected approval of Stevia could help with this trend, with new products, communicated as ‘naturally sweetened’ or ‘reduced sugar’, likely to appear on shelves in Europe during the year. However, the word ‘natural’ with all its connotations of goodness is also likely to come under scrutiny in 2011 as it is as yet illdefined. A focus on accentuating the positives of a product (rather than what is not in it) will grow,

yet, terms that are vague or not well understood will come under fire and regulatory bodies may well become increasingly involved, according to Mintel. A quest for knowledge and experience will fuel consumer demand for quality products such as chef-endorsed, restaurant-style meals; and Sustainability will continue to give rise to packaging reduction and will extend further into water conservation.

US overhauls safety legislation The first major overhaul of food safety law in the USA for 70 years was passed by the Senate in November. Representing over 10 years of research, the Food & Drug Administration (FDA) Food Safety Modernisation Act requires every food processing facility to implement a food safety plan and for the FDA to conduct more frequent inspections of farms and factories. Under

the current legislation, many peanut butter factories, spinach fields and egg farms can go five or 10 years without a visit from an FDA inspector. This will change as the new Act requires high-risk producers to be inspected more frequently, and gives the FDA mandatory recall authority rather than the current authority to request recalls on a voluntary basis.

Third series of Health Claims EFSA has adopted opinions on 808 ‘general function’ health claims, with favourable opinions being given mainly for claims around vitamins & minerals; dietary fibres related to blood glucose control, bowel function or weight management; fatty acid claims associated with brain function, vision or heart health; or claims related to live yoghurt cultures and lactose digestion. This is the third series of assessments to date and brings the total number of

assessments made to 1,745 out of a total of 4,637 that have been submitted. According to EFSA, the Panel on Dietetic Products, Nutrition & Allergies issued unfavourable opinions on many of the claims in this series due to the ‘poor quality’ of information provided. It is holding a series of consultations on specific topics, beginning in December (and focusing on claims related to gut and immune functions), to provide additional guidance to applicants.

In Brief Nestlé and Fonterra have entered into a joint venture in Chile to produce, retail and distribute liquid milks, yoghurts, desserts, fruit juices, cheese, cream, butter and margarine. The agreement excludes powdered milk, condensed milk and dairy ingredients, products for export and nondairy products. Orkla has put a for sale notice outside its Bakers bakery company in Norway, which produces branded breads such as Bakers Naturlig Sunt, Bakern’s Ferske, Birkebeinerbrød and Ingres SuperRug, with a view to divesting the company by the end of the first half of 2011. Greencore and Northern Foods, two of the leading food manufacturers in the UK and Ireland, have agreed to a ‘merger of equals’ to create Essenta Foods, with a presence in the private label convenience foods category as well as significant branded positions in Biscuits (Fox’s) and Frozen Pizzas (Goodfella’s). Danone and Unimilk have finalised the merger of their Fresh Dairy Product businesses in Russia and other CIS member countries. The new entity sees Danone control 58% of the enterprise, and Russia become Danone’s largest market. Kraft Foods and Barry Callebaut have signed a ‘longterm global agreement’ that will see Barry Callebaut supply the majority of Kraft Foods’ cocoa products and industrial chocolate requirements; as well as some of the Cadbury liquid chocolate deliveries under the

For additional news and developments in the food and beverage industry click on www.foodbev.com

foodbev com

current outsourcing agreement.

December 2010 www.foodbev.com

INDUSTRY UPDATE

Click here to subscribe

Packaged water industry celebrates success at the Water Innovation Awards Best new bottle in PET

At a special gala during the 7th Global Bottled Water Congress in the Ballroom at Gleneagles, Scotland, on 2 November 2010, the finalists and winners in the 2010 Water Innovation Awards were announced.

Winner: Mineral Technologies Ltd - Seryab Finalists: The Narang Group - Qua Coca-Cola Japan Co Ltd - I Lohas Highly commended: Isklar - Isklar sparkling

Organised by FoodBev Media’s Water Innovation magazine, this year’s awards attracted over 150 entries from 31 entries in 12 categories. To read more about all the innovations entered into the awards, see the 2010 Water Innovation Awards Showcase magazine, which features every single entry, as well as issue 63 of Water Innovation magazine which highlights the finalists and winners. For news, videos and updates, visit www.foodbev.com

Best environmental sustainability initiative Sponsored by Highland Spring Winner: Echo Beverages - Echo Finalists: Nestlé Waters North America - re-source World’s Fresh Waters - VLBs Highly commended: The Coca-Cola Company - PlantBottle The Green Drinks Co Ltd - Pouchlink

Best new bottle in glass Winner: Patagonia Mineral S.A. - Aonni Finalists: Hassia Mineralquellen GmbH & Co KG - Liz Canadian Mineral Water Developments - Gize

Best new label or decorative finish Sponsored by StoraEnso Winner: Danone - Paul Smith Evian bottle Finalists: San Pellegrino Spa - 50 Best Restaurants Awards Exclusive Collection - S.Pellegrino/Acqua Panna Iskilde - Iskilde Highly commended: Echo Beverages - Echo

Best new still or sparkling water Winner: Patagonia Mineral S.A. - Aonni Finalists: Deep Origin Water - Deep Origin The Narang Group - Qua

Best new flavoured water Winner: Kofola Holding - Rajec Summer Storm Finalists: Canadian Mineral Water Developments - Gize intense: Pear-Vinegar Kofola Holding - Rajec mystery of trees Chestnut Radenska dd Radenci - Oaza Elderberry with White Tea

Best new packaging or manufacturing innovation Winner: Hassia Mineralquellen GmbH & Co KG - Liz Finalists: Danone - Jug Aqua closure system Niagara Bottling LLC - Complete plant monitoring system

Best ethical or humanitarian initiative Winner: Global Ethics - One Water Finalists: Britvic Ireland - Ballygowan Pink Vlaskinka (Coca-Cola Hellenic Serbia) - Serbia’s first human milk bank

Best new functional water Winner: Borba Inc - Borba Skin Balance Water Finalists: Willow Water - Willow Water Eclipse Concepts - Blackwater Highly commended: Spritzer - Spritzer + Fibre Ustronianka Ltd Co - Ustronianka with Iodine

Best newcomer brand or business Winner: Mineral Technologies Ltd - Seryab Finalists: Nourish Inc - Nourish Patagonia Mineral S.A. - Aonni Highly commended: Nika Water Company - Nika Water Eclipse Concepts - Blackwater

Food & Beverage International December 2010

PLUS Coca-Cola Hellenic received a Special Commendation for ‘Outstanding and sustainable contribution to international water stewardship’, and from their entries a second winner in the category was awarded: Winner: Coca-Cola Hellenic Greece - Some Forests have their own Aura

foodbev com

INNOVATIONS

Click here to subscribe

Eating out but in In the current economic climate many consumers are spending less in restaurants and eating out less often, which is true for more than half of UK consumers, according to recent Mintel research. Although not good news for foodservice markets, this trend presents significant opportunities for retail brands that can capitalise on consumers staying in, and showing greater interest in food. In the USA, General Mills launched the Good Earth Restaurant Favorites line of shelf-stable meal kits. These are positioned as something ‘more special’ than standard products and are described as ‘delicious, restaurant quality meals at home’, and come in varieties such as Herb Crusted Chicken, and Spicy Citrus Glazed Shrimp with Angel Hair Pasta. All the recipes are

made with ‘premium ingredients’, and no artificial flavours or preservatives, and packs feature chef-inspired tips to customise the meal a little further. The range is marketed using the tag line ‘Stay in and go all out’. The Tuscan Chicken variety comprises pasta, sauce and seasoning and advises ‘just add chicken preparation time 20 minutes’. It retails at US$4.79 per 229g box.

Hides vegetables for adults The idea of ‘hiding’ vegetables in processed convenience foods is not a new one. However, it has mainly been restricted to children’s foods, such as the Heinz Hidden Veg line, launched in the UK in 2007, which is designed to help parents in their struggle to encourage children to eat vegetables. The new Prego Veggie Smart line of Italian pasta sauces, from Campbell’s in the USA, is a bit different in that it is positioned as an adult product. The sauces are described as ‘100% natural’ and a ‘hearty blend of five vegetables, delivering 50% of the daily vegetable recommendation’. A 24oz (680g) jar of sauce, labelled as containing more than two full servings of ‘veggies’, retails at US$1.99.

Oil with less frying odour New in Portugal from Sovena is a vegetable oil for cooking that contains essential oils derived from aromatic herbs. What makes this oil particularly interesting is the fact that the essential oils are there not for taste, but for functionality - they are designed to reduce unpleasant frying aromas in the kitchen. Sold under the Fula brand, the oil is labelled as 100% vegetable oil with natural flavours, and comes in a 1 litre bottle priced at €1.49. On its website the company claims that nine out of 10 consumers thought the product reduced frying odour, an important factor in a country where frying is commonplace and a great many consumers live in apartment blocks.

Spray salt Sodium has become a major health concern in recent years, resulting in on-going sodium reduction programmes from many manufacturers and consumers looking to cut down on their consumption of salt as a seasoning. A product launched in Spain this year could make a useful contribution. The Vaporized Liquid Salt can, it is claimed, helps reduce sodium consumption by around 90%. It works in much the same way as spray oils that have helped consumers reduce their fat and calorie intake. Two to four sprays can be used instead of a pinch of salt. The product contains just three ingredients: water, sodium chloride (10%) and potassium chloride (5%), giving it a strong ‘natural’ as well as ‘healthy’ image. The pack comprises a clear plastic bottle with a pump spray top and retails at a relatively high €2.79 - however, given the quantity used in each application, the pack should last a long time.

Mintel International Group Ltd, gnpd (Global New Products Database) is a web-based database capturing information on new packaged consumer goods products, including ingredients, nutritional information, pricing and packaging. The fully searchable database also includes colour photos of products, and editorial features on product trends and innovations. For further details on how the service can help you gain the competitive edge, call Mintel on Tel: +44 (0)20 7606 4533. www.gnpd.com

Food & Beverage International December 2010

foodbev com

INNOVATIONS

Click here to subscribe

Beauty soup The concept of beauty foods continues to push into new territory in parts of Asia. Although beverages, dairy products and confectionery account for a large proportion of products carrying beauty claims in Japan, there are now also options in dehydrated soup. Asahi Food & Healthcare has extended its Slim Up Slim Precious line of weight management products with a new corn soup variety, which is low in calories (166 kcal per 45g serving), formulated with multivitamins and minerals, collagen, hyaluronic acid and Co-enzyme Q10. The product also contains soy protein in order to deliver a feeling of fullness and help control weight - and its total protein content is 16.3g per 45g serving. A one pack serving of eight portions retails at the equivalent of around US$20.

Soups for women Japanese company Nagatanien has just recently reformulated and relaunched its Hieshirazu San line of dry soups, which are designed specifically to appeal to working women who feel the cold - for example if they work long hours in an air-conditioned office. The dry soups feature ginger, recognised for its bodywarming properties, and various other ingredients according to variety - for example cabbage, tofu, chili, shiitake mushrooms, etc. They are packaged as single-serve cups to which

consumers just add water, with a dry weight of 16-20g, and are priced at the equivalent of around US$2.

Big beans for the fridge Xylitol Natural Ketchup Canned baked beans are something of a staple foodstuff in the UK - the market was worth £365m (€427m) in 2009 and continues to see growth as a result of their ‘value for money’ and potential health positioning (a good source of fibre, virtually fat-free). Companies have also been innovating around recipes (ie with different flavours, reduced salt) and package formats to drive more growth. The latest development from Heinz is the Fridge Pack - a 1kg polypropylene jar with a resealable screw cap. The pack is claimed to keep the product fresh for five days once opened, and has a visistrip panel on the side with measures to indicate 200g portions, as well as recipe suggestions to encourage wider consumption. The pack is also good value for money, at £1.79 (€2.09).

foodbev com

It is not often that we see xylitol featured on the front of a food package, at least not in western markets. And, although, it is seen on some candies and gums, labelling it on a ketchup is unusual. Xylitol 100% Natural Ketchup has the name of the ingredient in large letters, arguably using it as a brand. The ketchup is positioned as natural, sugar-free and tooth-friendly - the latter being a claim now commonly linked to the use of xylitol. It is said to have a uniquely sophisticated, lightly spicy flavour and luscious tomato tang, and comes in a stylish, minimalist pack design that helps support the 100% natural positioning. Its retail price is on the premium side at £3.79 (€4.43) for a 280g bottle.

December 2010 www.foodbev.com

PROCESSING TECHNOLOGY

Click here to subscribe

Processing

the latest developments The need to improve food safety and quality, fulfil on the demands of a tough economy and increasingly environmental concerns have motivated processors and researchers alike to improve existing preservation technologies and look at other novel processing systems By Morales-de la Peña, M; Salvia-Trujillo, L; and Martín-Belloso, O.*

evelopments in novel processing technologies, packaging materials to preserve foods and natural antimicrobial compounds have become important areas for study as consumers increasingly demand foods that are convenient and easy to prepare, without compromising their nutritional, sensory and fresh-like characteristics and avoiding the use of synthetic preservatives.

Novel processing technologies The success of a new preservation technology depends greatly on its efficacy in countering pathogenic micro-organisms and several studies have focused on emerging thermal (TT) and non-thermal (NTT) technologies with encouraging results. Some novel TT such as ohmic and dielectric heating have been optimised to give the maximum effect against microorganisms and minimum deterioration of food quality. Ohmic heating applies an alternating electrical current throughout a food resulting in the internal generation of heat due to the food’s electrical resistance; while dielectric heating is the interaction of an electromagnetic alternating field and dipoles with the ionic charges contained within a food, which causes a heating effect. Due to the extremely rapid heating rates, both techniques allow improvements in terms of heating efficiency and a reduction in cooking times, resulting in less deterioration of the food’s natural compounds. Nowadays, industrial applications of ohmic and dielectric heating are numerous and

Food & Beverage International December 2010

include blanching, drying, evaporation, dehydration, fermentation, sterilisation and pasteurisation. Although there are many commercial ohmic systems available from a number of suppliers such as Invesys APV in the UK, Raztex Corporation in the USA and Emmpiemme SRL in Italy; full commercialisation of dielectric heating as an efficient preservation technology is still thwarted by potential problems such as dielectric arching and ‘thermal runaway’ heating. Non thermal technologies are thought to be more energy efficient and to preserve better quality attributes in food products than thermal technologies. At present, there are a number of non thermal technologies under development including highpressure, pulsed electric fields, pulsed light (PL), ultrasound (US), irradiation, oscillating magnetic fields (OMF) and low temperature-cold plasma (LTCP).While some of them are still at the early stages of research, others, such as high pressure and pulsed electric fields, are undergoing continuous development. In general, these technologies achieve the inactivation of pathogenic/spoilage micro-organisms using Pulsed Electric Field technology can be used in continuous systems

Non thermal technologies such as low temperature cold-plasma are at the early stages of research

different mechanisms, applied at low or moderate processing temperatures. Usually, the heat generated during processing is not substantial. Some of the techniques are inherently batch processes, while others are applicable in continuous mode; and as they are generally easy to clean processes, they appear to be more environmently-friendly than some existing technologies. High pressure processing subjects solid or liquid products, packaged or not, to pressures of between 100 and 700 MPa at 0-110ºC, for short periods of time up to periods of 20 minutes, depending on the product being treated. Researchers report that loss of cell viability begins at approximately 180 MPa, and that the rate of inactivation rises when pressure increases. High pressure processing technology (from companies such as NC Hyperbaric) has already been commercially implemented, spreading from its origins in Japan, followed by the USA and Europe, with worldwide take-up increasing almost exponentially since 2000. At present, over 145 industrial high pressure facilities exist throughout the world, for products such as meats, seafood, vegetable and fruit juices, jams, jellies and sauces, among others, and an important number of research groups are working on further scientific understanding of this emerging technology. Another non thermal technology gaining commercial interest is pulsed electric field (PEF - see article on p20). This process applies high voltage pulses (20-80 kV/cm) for short periods of time (microseconds) to a product confined or flowing between two electrodes. It has been demonstrated that

foodbev com

PROCESSING TECHNOLOGY

Click here to subscribe PEF’s microbial inactivation mechanism is based on electroporation, which affects micro-organism functioning and leads to cell death. PEF is applied in continuous systems for pasteurisation of fluid or semi-fluid foods, such as milk, fruit and vegetable juices, liquid eggs, beer, wine, mixed beverages and other products that can withstand high electric fields, have low electrical conductivity and do not contain or form bubbles. During the process, microbial and enzyme inactivation is achieved in different degrees, without detrimental changes to the sensory and physicochemical properties of the product. Different researchers have reported that PEF is a promising technology for increasing the shelf-life of liquid foods with high quality attributes, however, some drawbacks that must be overcome before its commercialisation include (a) proper scale-up of the system to industrial levels, (b) the presence of bubbles or solid particles in the product, which may lead to non-uniform treatment and (c) the availability of commercial units. Pulsed light (PL) is a novel non thermal technology used for the rapid inactivation of micro-organisms on the surface of food substances, equipment, and packaging materials. It involves the application of short duration, high-peak pulses of broad spectrum white light:

Power ultrasound Research is currently underway at Campden BRI into nonpreservation based applications for power ultrasound in food processing. Although pasteurisation using ultrasound is possible, it is likely to require a relatively high energy input, therefore Campden BRI is focusing on the other applications for power ultrasound, such as for viscosity modification of liquids; foam breaking; assisting emulsification and de-gassing, which all require comparatively low energy input. “We are working closely with an ultrasonic solutions supplier called Cavitus that claims that ultrasound can reversibly modify viscosity,” said Craig Leadley, of Campden BRI’s Food Manufacturing Technologies Department, which monitors and evaluates developments in new food processing technologies and NPD trends. The ability to alter the viscosity of a product would open up the potential to temporarily thin liquids prior to heat processing in order to make the thermal process as efficient as possible. During storage, it is claimed that the viscosity of the product recovers to its initial starting point, and the work just starting at Campden BRI is designed to provide an independent assessment of these claims. The power ultrasound system itself consists of a high powered ultrasonic probe mounted into a flow cell. The product is pumped through the flow-cell and is therefore brought into close proximity to the probe and ultrasound is therefore propagated throughout the food. The system is scalable and best suited to pumpable products. “New technologies can drive product development and in some cases can even result in unique products that were not previously achievable,” said Mr Leadley.

foodbev com

PROCESSING TECHNOLOGY

Click here to subscribe ranging from UV to the nearly infrared spectrum, which can cause the inactivation of bacteria, mold spores and viruses. Research has demonstrated that microbial inactivation by PL is mainly caused by the structural changes in DNA. Microorganism inactivation levels achieved by PL range from 2 to 6 log reductions; nevertheless, the efficacy of the process is mainly dependent on the transparency of the product in which it is applied. PL seems not to affect protein or lipid components and can be effective in limiting

Implementation of irradiation has been slow due to adverse consumer reactions

oxidative reactions because of the short pulse duration used. Minimally processed vegetables such as spinach, celery, green paprika, soybean sprouts, carrot, iceberg lettuce and white cabbage have been subjected to PL with promising results. However, use of the technology is currently limited by its generation of heat, the failure of light to penetrate opaque products and the presence of irregular surfaces. Ultrasound technology is one of great interest for liquid food processing. It causes microorganism and enzyme inactivation as a result of the energy produced from sound waves applied at a rate of 20,000 or more vibrations per second. Ultrasoundâ&#x20AC;&#x2122;s lethal effect is attributed to the cavitation phenomenon (micro-mechanical shocks that disrupt cellular structure and functional components up to the point of lysis), which causes the formation of bubbles or cavities in liquids. Current studies indicate that ultrasound could have a significant impact on microorganisms such as E. coli and L. monocytogenes. Nonetheless, its industrial

application has been hampered by the need to design and develop sufficiently powerful ultrasonic systems (generators and reactors) that can be specifically adapted to individual applications and capable of large scale operation. Meanwhile, irradiation has been shown to be the most suitable non thermal technology for application in solid foods, such as fruits, raw meat, seafood, spices, grains, legumes, vegetables and tubers. However, its application in milk and other foods with a high protein content has been found to cause off-flavours or discolouration; and some irradiated fruits may exhibit softening and discolouration, especially at high dose levels. Food irradiation usually reduces or eliminates pathogenic/spoilage microorganisms by generating highly active chemical species within the food, which react with the DNA of the micro-organism and cause its disintegration. A high dose (10-74 kGy) is required for food sterilisation, which can cause damage to the food, while a lower dose (0.1 kGy) can be

ÂŠ F&BI 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 December 2010

foodbev com

PROCESSING TECHNOLOGY

Click here to subscribe used for pasteurisation. At slightly higher doses (1-3 kGy), the number of spoilage micro-organisms present in the food is well reduced. However, although the World Health Organisation has declared that irradiation of any food, up to 10 kGy, poses no toxicological hazard and more than 40 countries have approved its use in over 100 food items, at present commercial implementation of irradiation has been slow due to adverse consumer reactions to it, particularly in Europe.

system must be designed with specific functions and characteristics. Modified atmosphere packaging (MAP), edible films and coatings, active packaging and smart packaging are some of the most studied and appear to be very promising for novel processed food preservation. In MAP, the levels of CO2, O2 or other gases are increased or reduced within the package, providing a shelf-life markedly greater than that of traditional packaging. Edible films and coatings are natural substances used in direct contact with More than 40 countries have approved the use of irradiation

foods to protect them from microbial deterioration and oxidative reactions among other things. Active packaging involves the addition of absorbing

Interesting research work is currently being carried out on the efficacy of other non thermal technologies such as oscillating magnetic fields (OMF) and low temperature-cold plasma (LTCP), however, data about these processes is still scarce. During OMF processing, food receives 1-100 pulses at a frequency of 5-500 kHz during a short period of time (25-100 microseconds) at 0-50 ºC; and this has been shown to inactivate micro-organisms in bread roll dough, fruit juices, milk and yoghurt. LTCP, which is created by the excitation of gaseous atoms, ions and free radicals, has recently attracted attention as a means of effectively inactivating micro-organisms on the surface of heat sensitive materials. Factors that influence micro-organism inactivation by both OMF and LTCP have yet to be completely understood and further research is needed to extend the present knowledge.

food preservation purposes, adaptation of pathogens to environmental and processing stresses still constitute a

or emitting agents that limit product

serious challenge; and combinations of two or more technologies with the addition of antimicrobial compounds may be the most effective means to achieve high levels of microbial inactivation. There is a clear trend for substituting synthetic preservatives by natural products with multifunctional properties, such as essential oils, lacoperoxidase, lyzosyme and bacteriocins. Their antimicrobial activity is strongly dependent on their specific characteristics and the food composition; but in general, their use has been shown to be effective for microbial inactivation in several products. However, these compounds may cause changes to the organoleptical properties of the food, which is the major disadvantage for their commercial implementation.

and chemical functions that enhance the

Natural antimicrobials

New packaging systems

Although emerging physical thermal and non thermal technologies have achieved positive results for

All emerging technologies involve different packaging considerations and depending on the treatment applied, the packaging

All emerging technologies involve close consideration of the different packaging options

foodbev com

degradation or microbial growth; and smart packaging deals with the mechanical characteristics of the food.

Conclusions and future trends Recent scientific evidence indicates that there are many positive opportunities for the application of innovative technologies. However, although significant research has been completed and published, the successful commercialisation of these technologies requires further work to guarantee food safety and quality and collaboration among funding agencies, research institutions, equipment suppliers, food industries and regulatory agencies is crucial to achieving this.

Acknowledgments Morales-de la Peña, M. and SalviaTrujillo, L. thank the Consejo Nacional de Ciencia y Tecnologia (CONACYT) (Mexico) and the Agència de Gestiò d’Ajuts universitaris i de Reserca (AGAUR) (Spain) for the pre-doctoral grant. ICREA Academia Award is also acknowledged by Olga Martín-Belloso. *For further information, please contact the authors at: The Department of Food Technology, University of Lleida, Rovira Roure 191, 25198 Lleida, Spain. Tel: +34 973 702 593; Fax: + 34 973 702 596. E-mail: omartin@tecal.udl.es

December 2010 www.foodbev.com

PROCESSING TECHNOLOGY

Click here to subscribe

Pulsed electric field:

opportunities for healthier tomato juice Although frequently consumed fresh, over 80% of tomatoes are consumed in processed products such as tomato juices. Pulsed electric field technology could provide advantages for the processing of tomato juices to retain their nutritional value By Isabel Odriozola-Serrano, Pedro Elez-Martínez, Robert Soliva-Fortuny and Olga Martín-Belloso*

hermal processing is the most

preservation technologies that can replace

commonly applied method for extending the shelf-life of tomato juice, by inactivating micro-organisms and enzymes. However, heat treatments can dramatically affect the sensory and nutritional quality of juices (see panel opposite). Therefore, consumer demands for healthy and nutritious food products with a fresh-like appearance are motivating the industry’s pursuit of milder

PEF processing consists of the application of short pulses (1 to 10 μs) of high electric field strength (typically 20 to 80 kV/cm) to a homogeneous liquid at low or moderate temperatures. A PEF system is typically composed of a pulse generator, one or more treatment chambers, a fluid handling system and a monitoring device. Its nonthermal character and the fact that it can be applied to homogeneous liquids in continuous flow are among the principal advantages of this emerging processing technology. PEF processing has been shown to inactivate the naturally occurring microbial population in tomato juice, thus leading to microbial inactivation levels similar to those achieved with pasteurising heat treatments. It is also feasible to be applied in a hurdle approach. For instance, the application of PEF treatments in combination with the addition of natural antimicrobials to tomato juice has been shown to substantially increase the effects on pathogenic micro-organisms.

the conventional pasteurisation methods; and high-intensity pulsed electric field (PEF) processing of liquid foods is being investigated to avoid the negative effects of thermal pasteurisation.

Food & Beverage International December 2010

Studies on the evolution of quality parameters in tomato juice after PEF processing have led to promising results, with PEF-treated tomato juices being shown to have a better colour than heat-processed products. Brown compounds produced through nonenzymatic pathways are practically absent in fresh and untreated juices. However, their concentration levels tend to rise as a result of heating processes or long-term storage. Some studies have demonstrated that PEF-processed tomato juice had significantly lower amounts of resulting brown products than thermally processed juices. There also seems to be a relationship between residual peroxidase (POD) activity and the changes in colour of processed fruits and vegetables. PEF pasteurising treatments have been shown to achieve higher POD inactivation than thermal treatments, resulting in stable behaviour during refrigerated storage.

Sensory studies indicate that tomato juice treated by PEF has a greater flavour intensity and overall acceptability than thermally treated tomato juice. In a similar way, PEF processing is more effective than heat treatments in obtaining tomato juice with high viscosity. The ability of tomato juice to hold its solid fraction in suspension over the shelf-life of the product is mainly dependent upon the total amount and quality of pectin material present in the system. Pectin methylesterase (PME) is involved in the breakdown of these pectins, causing cloud and viscosity losses, in addition to gelification of commercial juices. The PME inactivation by PEF is similar to that reached by thermal treatment at 90ºC for 1 minute, and remains constant throughout storage. Sensory studies indicate that tomato juice treated by PEF has a greater flavour

foodbev com

PROCESSING TECHNOLOGY

Click here to subscribe intensity and overall acceptability than thermally treated tomato juice. Some volatile compounds that are typically associated with tomato flavour (hexanal, trans-2-hexanal and cis-3-hexenol) have been analysed as well as the activity of enzymes involved in the synthesis of these compounds, namely hydroperoxide lyase (HPL). PEF-treated juices exhibit higher amounts of hexanal and trans-2-hexanal compared to the thermally-treated juices (the concentration of cis-3-hexanol is not affected by any of the treatments). HPL is almost completely inactivated when the juice is subjected to the heat treatment, whereas only ~50% of the initial activity is depleted after PEF-processing. These results suggest that PEF processing may help to improve the flavour quality and stability of tomato juice.

Nutritional value PEF processing can lead to tomato juice with a higher nutritional value than conventional thermal processing. Different studies have proved the effectiveness of PEF in achieving juices with higher vitamin C retention in comparison to heat treatments. Some results have demonstrated that PEF-treated tomato juice exhibits higher vitamin C content just after the treatment and during refrigerated storage than thermally treated juice. The lower processing temperatures reached through PEF-processing (T < 40 ºC) would explain the higher retention of vitamin C in PEF-treated tomato juice compared to heat-processed juice. Although the recommended daily intake (RDI) of vitamin C is currently being revised, it should never fall below 60mg, according to the Food & Drug Administration in the USA. A 250ml serving tomato juice must have 20mg vitamin C in order to contribute a third of the dietary RDI, and it has been demonstrated that PEF-treated tomato juice retains its vitamin C content above 33% of the RDI for twice as long as a heat-pasteurised juice. Tomato juice pasteurised by PEF also exhibits greater levels of quercetin compared to heat-treated juices. However, changes in other phenolic compounds (chlorogenic acid, ferulic acid, ρ-coumaric acid, caffeic acid and kaempferol) in tomato juice processed by PEF are similar to those occurring in heat-treated juices. In addition, some studies have

foodbev com

Tomatoes contain high amounts of vitamin C. Experimental studies show that vitamin C plays an important role in human heath, including protection of the immune system and the reduction in the risk of Alzheimer's disease. suggested that PEF processing may enhance the antioxidant properties of juices compared to untreated juice. For example, fresh tomato juice has a lycopene content ranging from 50 to 112 mg/l. PEF processing enhanced the level of lycopene content significantly (from 3.8% to 37.7%), resulting in an increase in the antioxidant properties of the juice. The increase in lycopene just after PEF processing coincided with a depletion in other individual carotenoid contents (phytoene and neurosporene). Thus, PEF might stimulate the transformation of some carotenoids into lycopene. In addition, PEF pasteurisation treatments lead to tomato juices with higher amounts of carotenoids, β-carotene, phytofluene and vitamin A compared to fresh and conventionally processed juices.

Therefore, PEF technology has good prospects for use in the food industry as a preservation technology - as an alternative to or in complementary combination with traditional thermal treatments. PEF technology could help not only to obtain safe and stable tomato juices, but also to produce juices with high antioxidant properties. However, further research is required to assess the mechanism of enzyme inactivation by PEF in fruit and vegetable products and the mechanisms influencing the degradation/ formation of health-related compounds, in order to provide a greater understanding of the impact of PEF processing on the nutritional value of food products. (For further commercial news of PEF, see p39).

*The authors of this article participate in the EC funded Integrated Project ‘NovelQ’ that aims to remove hurdles to the application of novel food processing methods. Department of Food Technology, TPV-XaRTA, University of Lleida, Rovira Roure 191, 25198, Lleida. omartin@tecal.udl.es; www.etsea.udl.es/dept/tecal

Tomatoes and health Regular intake of tomatoes and tomato based products has been associated with a lower incidence of various forms of cancer, in particular prostate cancer, and heart disease. This beneficial effect is believed to be due, at least partially, to the action of antioxidant compounds, which reduce oxidative damage in the body.

Tomatoes also contain high amounts of vitamin C. Experimental studies have shown that vitamin C plays an important role in human health, including protection of the immune system and the reduction in the risk of Alzheimer’s disease. Other antioxidant compounds contained, such as phenolics, confer health-promoting effects to tomato products.

Tomato and tomato products are the predominant dietary source of lycopene, which exhibits a high radical scavenging capacity, and β-carotene, which is the main carotenoid possessing provitamin A activity. Both are highly unsaturated compounds and therefore they are susceptible to oxidation, isomerisation and other chemical changes during processing and storage.

December 2010 www.foodbev.com

FORTIFICATION

Click here to subscribe

BASF supplies high quality vitamin D3 in oil-based formulations and powders

Vitamins & minerals Despite the fact that vitamin and mineral fortification is generally in decline - 5% of all new food & drink products launched globally in 2007 were vitamin or mineral fortified, this figure fell to just 3.4% of all new products in 2010, according to Mintel International - there is still plenty of formulation activity taking place By Claire Rowan - managing editor

here is no clear leader in the field of vitamins, but fortification with folic acid, vitamin B12 and E have shown a slight increase during the past three years, according to Mintel, which also highlighted that calcium and iron maintain a strong first and second position in the mineral fortification stakes. “Solutions to health conditions are what people are looking for and it is an evolving knowledge,” said Ram Chaudhari, chief scientific officer, Fortitech, which produces premixes for the food & beverage industry globally and also runs its GAIN project for health & nutrition, which involves developing

Food & Beverage International December 2010

affordable fortified products and distribution systems for developing nations. “Vitamin D3 is increasingly popular for immunity and bone health, but needs a fat soluble delivery system such as dairy products, ice creams, drinkable yoghurts etc. Vitamin D3 and calcium fortification, perhaps with a probiotic, might be niche now but this is the way that things become mainstream.” Fortitech’s expertise is widespread: from ensuring the performance of the fortified product during processing and the supply chain to assessing the bioavailability of the finished vitamin, mineral or antioxidant at point of consumption.

“Some vitamins might bind with other components in the finished product, so the overall matrix of a product is vitally important,” explained Mr Chaudhari. “You need some fats or lipids in order to achieve a homogeneous product - without syneresis, sedimentation or separation - and, which is acceptable to the consumer. Vitamins A, D, E and K are all fat soluble so you need at least 1% fat in the matrix or you can’t deliver and they can’t be absorbed in the intestine.” Through its GAIN project, which has worked with governments, NGOs and companies throughout the world, Fortitech has identified many highly effective and widely available product solutions for delivering essential vitamin and mineral fortification. One of its latest innovations was being tasted on its stand at Hi Europe. A crunchy textured snack food medley for cognitive health was coated with a pizza-flavoured seasoning containing vitamins A, C & E, sodium, niacin, magnesium, L-Glutamic acid, and choline. Although a cost-effective and readily available product option for developing nations, the savoury snack

foodbev com

FORTIFICATION

Click here to subscribe concept also provides a novel delivery method for the West. It was shown alongside a bone & joint health ice cream fortified with calcium, vitamin K1, D3, magnesium, manganese and soy isoflavones; and a weight management blood orange beverage fortified with niacin, pantothenic acid, chromium and L-carnitine. Beverages continue to hold the greatest potential as a vehicle for fortification and many of the key ingredient developments have focused on clarity and solubility in order to provide solutions to beverage manufacturers. “The global beverages market is still the biggest innovator in terms of energy drinks, beauty, wellness or health drinks etc. In 2010, we perfected our own vitamin E using a highly technical process, which makes the powder easy to handle. Among others, SternVit E 50% SD offers a good flowability and very good dispersibility in water, which is key for the beverage sector. It is also highly stable in ‘extreme’ conditions,” said Nicole Schulze, marketing, Stern Vitamin, part of the Stern Wywiol Group, which Stern Vitamin has perfected its SternVit E 50% SD to give a good flowability and very good dispersibility in water

has also seen demand rise for premixes containing vitamins and minerals plus other ingredients in the areas of anti-stress, 50+, sports, healthy eyes, bones and joints.

“The B vitamins, either individually or as vitamin B complex are found in practically all our mixes. They are very interesting because they have so many different possible uses in consumer products and perform such a wide range of functions in the body.”

Clear beverage solutions Winner in the Nutrition for Young & Old category at Hi Europe for its VersaCAL Clear was Innophos. A highly soluble calcium phosphate for clear beverages, VersaCAL Clear opens up the possibility for fortification of beverages with both calcium and phosphorus in order to promote healthy teeth and bones without compromising on the taste or stability of the finished beverage. VersaCAL Clear from Innophos “Traditionally, calcium fortification is a highly soluble calcium phosphate for clear beverages in clear beverages has involved other calcium sources such as lactates, gluconates and citrates, which can have an impact on flavour and stability in some formulations,” said Joseph W Golowski, vice president - specialty phosphates, Innophos. “Using our technical expertise, we were able to developed VersaCAL Clear, which overcomes

foodbev com

FORTIFICATION

Click here to subscribe these problems and provides manufacturers with a soluble source of both calcium and phosphorus.” VersaCAL Clear - a blend of monocalcium phosphate anhydrous and monocalcium phosphate monohydrate - is the result of three years’ of research to create a clear solution that does not cause cloudiness or sedimentation over time. It has a pH of 3 at 1% concentration and can therefore be used in fortified juices without affecting their pH; and, as it contains 14.5% to 15% calcium, VersaCAL Clear allows for health claims. It joins Innophos’ other beverage developments including VersaCAL MP for neutral beverages such as soy and rice milk, and VersaCAL DA for low-carbohydrate, high-calcium citrus beverages. At Hi Europe in Madrid this November, Jungbunzlauer was highlighting its development work to fortify with potassium citrate in products such as its Heart’n’Healthy cocktail, which with its potassium, fibre and vitamin C content, was proving popular on the stand. Jungbunzlauer’s potassium citrate is said to help provide the perfect acid-base balance, promote bone health, keep blood pressure healthy and maintain the body’s water and electrolyte balance. Magnesium was the focus of conversations on the ActivInside booth, which was part of the French Pavilion at Hi Europe. Natural Mg’Inside is extracted from Melissa officinalis (Lemon Balm) using natural mineral waters as the extraction solvent. Once the water is removed after extraction, it leaves the naturally present minerals such as magnesium, which can be used for health claims such as contributes to ‘normal cell division’; ‘normal energyyielding metabolism’; ‘normal muscle function including the heart muscle’; ‘normal nerve function’; ‘normal protein synthesis’;

Novel Food approval in July 2010. Natto is traditionally made by fermentation of soy beans and has been consumed in the Far East as a food or food ingredient for centuries, stressed Frutarom, which claims that during the fermentation process, vitamin K2 increases making Natto one of the richest natural sources of the vitamin. UniK2 is produced using Bacillus natto - a bacteria naturally occurring in Natto - by J-Oil Mills of Japan. In Norway, Kappa Bioscience has perfected its vitamin K2 MK-7, MKVITAL, based on proprietary technology. Frutarom has introduced its UniK2, vitamin K2, produced using Bacillus natto - a bacteria naturally occurring in Natto 'maintenance of normal bone’; ‘electrolyte balance’; and ‘maintenance of normal teeth’, according to ActivInside, which says that 1g of Natural Mg’Inside contains 800mg, or 6 to 8%, of magnesium.

Vitamins Following numerous conversations along the aisles at Hi Europe, it appears that vitamin K2, which is well-established in the East and increasingly known for its bone and cardiovascular benefits in the West, is the new ‘buzz’ vitamin. To reflect this trend and to help consumers meet the recommended daily intake of 45μg, Danisco, Frutarom and Kappa Bioscience among others have recently introduced new vitamin K2 offerings. Danisco’s new ActivK MK-7 brand of long chained menaquinone vitamin K2 is said to provide a high bioavailability and bioactivity, which ensures a greater utilisation for both bone and cardiovascular functions. A fermented and purified vitamin K2 derived from Natto, ActivK MK-7 has novel food status in Europe and is stable under most processing conditions. It can be used in beverages, as well as dairy, fats & oils, bakery, and cereal applications. “This launch shows Danisco’s long-term interest in this new and highly functional vitamin and will open doors for the future,” said Peter Wisler, global business development director, Danisco Health & Nutrition.

Danisco’s new ActivK MK-7 brand of vitamin K2 is said to provide a high bioavailability and bioactivity

Food & Beverage International December 2010

Frutarom has also made moves into the vitamin K arena with the introduction of its Natto-derived uniK2, which received

“We are very excited to move from research to application, bringing this new, soy-free and highly purified vitamin K product to market,” said Dr Egil Greve, CEO of Kappa Bioscience, which has conducted three years of research to produce the best quality vitamin K from pure and highly concentrated and active MK-7 – without fermentation. The patent-pending process creates a ‘natural man-made’ and highly pure vitamin K2 in both powder and oil forms, which can be used in multivitamin mixes and various food matrices. BASF and Lallemand Health Ingredients’ vitamin D products are also providing opportunities for formulators. The beneficial effects of vitamin D3 have been shown to be more than its regulation of the body’s calcium intake, according to BASF, which supplies high quality vitamin D3 in oil-based formulations and powders. It has now been recognised as being important for lowering the risk of health problems as diverse as cardiovascular illness, various forms of cancer, diabetes and inflammatory diseases such as asthma - and health authorities are now studying whether the recommended minimum daily intake of Vitamin D3 should be raised. At Hi Europe, Lallemand Health Ingredients unveiled its new Lalmin VitaD vitamin D, an inactivated dried whole cell yeast (Saccharomyces cerevisiae) containing elevated levels of vitamin D. The active yeast is subjected to ultraviolet light under controlled conditions to catalyse the conversion of the naturally occurring endogenous ergosterol in yeast to ergocalciferol (vitamin D). The yeast cream is then inactivated through pasteurisation and roller dried, to leave the natural, instant dried yeast ingredient, Lalmin VitaD.

foodbev com

INGREDIENTS

Click here to subscribe

Clean tasting whey protein hydrolysates Carbery has developed its Optipep hydrolysed whey protein range to include a new clean tasting offer for sports nutrition and beverage applications. Offering high levels of di- and tri-peptides that are suitable for rapid recovery and strength building in sports nutrition products, Optipep’s new clean tasting profile is the result of sensory studies into the flavour profiles of hydrolysed whey proteins conducted by Carbery with the North Carolina State University (NCSU) in the USA. It allows manufacturers to make

a hydrolysed whey protein claim on the label, results in an increased inulin response, and delivers high levels of essential branched chain amino acids, which reduce the breakdown of protein to protect muscle tissue, according to Carbery. “The research into hydrolysed whey protein flavour profiles with NCSU included benchmark work comparing a range of leading products in the market place and is the first in-depth study of its kind,” said Bridget Holmes, innovation project manager, Carbery. “The study allowed

Designed for milk drinks with clean labels Ulrick & Short has developed its Synergie range of functional clean label starches and Delyte range of fat replacers specifically for use in dairy applications, such as processed and fortified milks, to provide alternatives to modified starches and fats.

Produced from different crops and available as cook-up or pre-cook powders, the new clean label solutions have a low pH and high process tolerance. They are able to withstand the pasteurisation process - from standardising and heat treating to homogenisation - and also offer ‘incomparable binding qualities’. They are easy to use, according to Ulrick & Short, and provide a silky mouthfeel, which helps make the dairy beverages enjoyable to drink. The Synergie dairy thickening agents can be used instead of cream or starches to thicken flavoured milks without other additives and without affecting the flavour of the finished product. Delyte 6 is designed as an easy to use fat replacer in a wide range of dairy products including instant and probiotic yoghurt drinks. Ulrick & Short’s new clean label solutions can be used in processed and fortified dairy beverages

Food & Beverage International December 2010

The clean flavour profile of Optipep hydrolysed whey proteins from Carbery has been sensory tested at the North Carolina State University us to evolve Optipep’s taste profile, and has given us the

toolkit to produce consistently, clean tasting hydrolysates.”

Stabilisers for protein beverages TIC Gums has developed three new stabilisers for protein beverages including pasteurised milk products, chocolate and alternative protein beverages. TIC’s Pretested Colloid 760 MB Powder, Dairyblend MB2 and Ticaloid 875 stabilising ingredients help to improve the thickness and provide thick, mouth coating sensations in the end products and help to overcome the challenges of formulating healthy beverages, according to TIC Gums. Dairyblend MB2 is based on proprietary technology and can be used to stabilise chocolate dairy and milk beverages, and particularly those that require challenging UHT processes. It contributes to viscosity while ensuring that the cocoa is suspended well in UHT processed beverages. For pasteurised chocolate milk and other dairy products, TIC Pretested Colloid 760 MB

Powder is a process-stable ingredient that provides good cocoa and flavour suspension in the pasteurised products and can also increase the body and creamy texture in syrups, eggnog and buttermilk. Ticaloid 875 gum system has been developed for protein fortified products and interacts well with milk and soy protein ingredients to impart viscosity and body. It has synergistic properties with starch, which also makes it suitable for use in puddings and protein beverages where thick and creamy characteristics are desired.

TIC Gums’ three new stabiliser solutions have been developed for protein beverages

foodbev com

INGREDIENTS

Click here to subscribe

Coating suits low fat ice creams ADM Cocoa has introduced a range of low saturated fat ice cream coatings in its deZaan chocolate range. Developed in collaboration with ADM Oils & Fats, and specifically the company’s oils & fats division, Noblee & Thorn in Hamburg, the new vegetable fat system provides an alternative to coconut oil, which is higher in saturated fats and is therefore suitable for optimising low fat ice cream applications. The new fat system has 43% less saturated fat than coconut oil and yet offers the same characteristics of clean snap, smooth texture, fast melting at body temperature, quick flavour release and rapid solidification on frozen foods, when used in a chocolate flavour ice cream coating, according to ADM. It produces a coating with 40% less saturated fat than a standard coating recipe containing 50% fat. “With a 40% reduction in saturated fat compared to standard ice cream coatings, we can provide a high quality alternative for ice cream manufacturers looking to meet consumer demand and industry guidelines for reduced saturated fat products that look, feel and

taste great,” said Simon Gogen, new product development manager, ADM Cocoa in Liverpool. ADM Cocoa has also extended its cocoa butter equivalents (CBEs) range with the introduction of Chocovit Extra - custom-formulated blends of deZaan cocoa butters & Chocovit Plus CBEs. Designed to perform in a range of chocolate formulations, ADM’s Chocovit Plus CBEs can be used to substitute cocoa butter in fillings, coatings and shells in quantities up to the EU permitted 5% level. “CBEs offer clear cost benefits, but the complexity of blending the correct ratios of CBEs and cocoa butter can discourage some manufacturers,” said Rinus Heemskerk, technical director of ADM Cocoa. “We have developed Chocovit Extra using the technical expertise of our cocoa, chocolate and speciality oils & Fats teams to produce custom blends that save our customers time and money.”

ADM Cocoa has teamed up with ADM Oils & Fats to create a new fat system, which has 43% less fat than coconut oil, for coating low saturated fat ice creams

foodbev com

INGREDIENTS

Click here to subscribe

Milk proteins & hydrolysates launched At Hi Europe in Madrid in November, Ingredia Nutritional launched a series of 100% milk proteins and hydrolysates with enhanced formulation properties. They were demonstrated alongside the company’s Bio-Actives range, which includes Lactium, StarchLite, CarbLite, and CranMax. Created from natural milk using membrane separation with low heat for the drying process, so that the proteins are not denatured, the new specialty protein and hydrolysates contain 85% or more of protein on a dry weight basis. The proteins are 100% soluble, rich in caseins, low fat, either low in lactose or lactose-free, organic and highly dispersible. They have improved fluidity, a high microbiological profile and no bitterness. “Our new hydrolysates offer a high bioavailability of amino acids without the allergens usually associated with the protein, which makes them suitable for infant formula, weight management, clinical nutrition and sports products,” said Harmony Villemin, marketing, Ingredia Nutritional, which was tasting its finished Refuel & Repair product concept at the show. “They allow manufacturers to formulate high protein beverages without increasing the viscosity as other proteins do.” Refuel & Repair is a high protein beverage packed in a 250ml bottle, which contains 30g of protein in each bottle without impairing the fluidity and drinkability of the beverage. It contains Ingredia Nutritional’s Prodiet 87 B Fluid protein for faster recuperation & repair after exercise and Prodiet Hydrolysate, which helps reduce the recovery time required after exercise through the quick assimilation of amino acids such

Food & Beverage International December 2010

as BCAA (branched-chain amino acids). According to Ingredia, BCAA are impacted during work out causing micro muscle damage, and if consumed directly after exercise, they can promote muscle reconstruction. In order to open up the opportunities for companies to fortify with proteins, Ingredia Nutritional has developed some of the range with enhanced solubility, including Prodiet 85 Dispersible and Prodiet 95 S, which also offers a very high protein content of 95%. Prodiet 87 B Fluid has been designed to give high protein levels without the increase in viscosity associated with high protein beverages. Other applications include high protein foods and drinks, powdered and ready meals, creams, bars, biscuits, instant powders and other beverages. As the soluble proteins are translucent and pH-stable, they suit a wide range of beverage applications, and as proteins rich in caseins resist thermal treatments, they can also be used in ready meals that will undergo pasteurisation, or UHT beverages.

Herza Schokolade is targeting yoghurt and dairy products with new sterile chocolate chip pieces, which will result from an investment of over €1.1 million over the next two years

Chocolate pieces for dairy applications Herza Schokolade will invest €1.1 million over the next two years to develop sterile chocolate pieces that can be mixed with yoghurt and other dairy products during the production process. The use of chocolate pieces in dairy products such as yoghurts, quark and desserts causes problems as they contain a very high water content - over 80% - which causes the sugar crystals in the chocolate pieces to dissolve and the chocolate pieces to lose their stability and consistency over the shelf-life. In addition, yoghurt is an ideal breeding ground for adhering bacteria and as the chocolate chips have a low bacterial count but are nevertheless not sterile they can cause dairy products to deteriorate quickly. “Our aim is to develop a technical process and suitable

Ingredia Nutritional’s new 100% milk proteins and hydrolysates with enhanced formulation properties can be used to enhance the protein content of beverages without influencing the fluidity of the drink

plant for producing sterile chocolate in different shapes and sizes, which will help to enhance the sensory quality of the end products,” said Torsten Wywiol, managing

director of Herza Schokolade. “The constituents of cocoa are very sensitive. Excessively high temperatures and incorrect cleaning, roasting, grinding or conching impair the quality of the finished chocolate pieces. All that has to be taken into account when you are developing new sterilisation techniques.” Herza Schokolade is looking at degerming the cocoa beans or cocoa mass, then sterilising the chocolate paste made from them, before producing and packing the chocolate pieces under sterile conditions. It will develop these sterilisation techniques, and look at cutting town the sugar content of the chocolate so that individual sugar crystals are covered with a thicker layer of fat as a protection against the water in the yoghurt. It will also investigate the possibility of coating the sugar crystals with emulsifiers or other barrier layers to prevent the interaction between the sugar and the water and so extend the shelf-life of the product.

foodbev com

INGREDIENTS

Click here to subscribe

Tate & Lyle focuses on speciality ingredients Hi Europe was the forum for Tate & Lyle to discuss the latest structural developments that have taken place within the company and to demonstrate the innovations being produced at its Health & Wellness Innovation Centre in Lille, France, which was opened last year. As part of its refocus on Speciality Food Ingredients and following the sale of its EU Sugar Refining operations to American Sugar Refining, for £211 million, earlier this year, Tate & Lyle has recently agreed the sale of its Molasses business to W&R Barnett. “Tate & Lyle’s clear priority is to grow its Speciality Food Ingredients business, supported by cash generated from Bulk Ingredients,” said Javed Ahmed, chief executive of Tate & Lyle. “This disposal represents another important step as we focus, fix and grow our business.” The company will now focus on its Create, Optimise, Rebalance

and Enrich solutions within its three main areas of activity: Sweeteners, Texturants and Health Ingredients. During FBI’s visit to the Health & Wellness Innovation Centre in Lille, Caroline Sanders, global marketing & communications director, Speciality Food Ingredients explained how Create stood for creating innovations in shape, structure, taste and texture in order to make products more exciting & distinctive; while Optimise stands for maximising the efficiency of processes and adding value by helping meet cost and margin targets. Rebalance is reformulating for less fat, sugar or salt, or fewer calories without compromising taste; and Enrich stands for enhancing the nutritional profile of products without compromising on taste. As part of it Optimise solution, Tate & Lyle has invested €4 million in its new Innovation Centre, which includes a

fully equipped pilot plant complete with a Tetra Pak KF80 continuous ice cream freezer; APV heat exchangers and homogenisers; Armfield CarboFill FT 102X carbonator; Lagarde RP 319 retorting steriliser; Ystral shear mixer X50, Hobart planetary mixer A200; Artek kneader and Rondostar 4000 sheeter for bakery and snacks, among numerous other pieces of equipment.

Tate & Lyle will be focusing fully on its Speciality Food Ingredients business following restructuring during 2010

Drawing on this equipment and the state-of-the-art laboratory on the premises, Tate & Lyle has developed several product concepts, which it demonstrated at Hi Europe, including a 30% calorie-reduced orange carbonated soft drink or Tea Drink, both containing Fructopure fructose in combination with rebaudioside A and sucrose.

& application engineer, Tate & Lyle, who explained that in taste tests fructose was found to be preferable thanks to a more rounded flavour. “We are also working with polydextrose in combination with fructose and stevia in order to reduce the calories and give a nice round flavour.”

“We have been working extensively with sugar and stevia, and fructose and stevia, to create product concepts without the bitter flavour associated with stevia,” said Els De Vos, sensory

At the show, Sta-Lite polydextrose was used to boost the fibre content as well as reduce the sugar in white bread, a yoghurt drink, and cereal clusters.

Coating stays crispy after microwaving A crumb coating technology that keeps frozen snacks crispy after microwaving and when kept warm for lengths of time has been developed by Crisp Sensation Holding of Switzerland.

nuggets, fish fingers and cheese or vegetable sticks with a significantly reduced fat content and which can be prepared in the microwave without using active packaging.

Following years of research by Crisp Sensation Holding, and tests at Wageningen UR Food & Biobased Research, the Crisp Sensation coating has been shown to protect the taste and texture of coated products for more than nine months.

Breaded frozen foods can be created that have a very crisp initial bite that is followed by a juicy succulent centre, and, as they do not need to be fried, contain up to 70% less fat in the final product.

It can be used to create snacks such as chicken

foodbev com

According to Crisp Sensation Holding, tests at Wageningen included sensory tests with a panel which compared

chicken nuggets with the new coating and a reference product from a Dutch market leader. The samples were prepared in microwaves with and without ‘crisp’ functions, as well as a standard convection oven. In all cases, the Crisp Sensation snacks were found to be significantly crispier than the standard product.

Crisp Sensation Holding has developed a frozen snack food coating, which keeps the product crispy after microwaving or when kept warm for periods of time

Ready meals made with Crisp Sensation are also said to retain their crispness and texture when kept warm for long periods before eating.

Crisp Sensation’s patented technology is now available for full-scale production of a wide range of frozen breadcrumbed products.

December 2010 www.foodbev.com

Hi Europe

Click here to subscribe

Healthy, nutritious and natural The prevailing trends of health, nutrition and natural set the scene for activities at this year’s Hi Europe exhibition in Madrid in November

ver 90 exhibitors took part in the nutraceutical and functional ingredients show, which took place for the first time in the beautiful city of Madrid, and most of the high-tech solutions being discussed were also being promoted for their natural credentials.

fruits, vegetables and plants. Created using physical processes without the use of organic solvents, the products do not require additive labelling, E numbers or warning notices, but can be identified as ‘concentrate’ and the name of the raw material (for example, tomato concentrate).

To this end, the benefits of natural plant extracts were explored by several exhibitors including GNT, Naturex, Plantextrakt and Cognis.

Naturex was promoting its increasing portfolio of fruit and vegetable powders; pectins; natural colours; colouring foodstuffs; its Talin (Thaumatin) ingredient, which can be used for flavour enhancement, sweetness and bitterness masking benefits; and inactive dried yeast.

Natural is the benchmark for GNT, which was tempting visitors to its ‘Garden of Colour’ stand with delicious gummy bears coloured and enhanced with its wide range of natural fruit and vegetable extracts.

Sustainability is not just a short term goal, so our approach is to go fully natural, said Paul Collins, managing director of GNT UK, who confirmed that the company’s Exberry colours and Nutrifood concentrates with phytonutrients are based only on natural concentrates derived from edible

It was demonstrating the performance of its natural colours range, which has been added to with the acquisition of Overseal Natural Ingredients, and its Cereboost ingredient, which has been demonstrated in a recent clinical study to have a positive effect on mental function. A patent-pending extract of American ginseng incorporating a specific profile of ginsenosides, Cereboost can be used in functional beverages and foods such as fruit bars, chocolates & candies for cognitive health.

On the Plantextrakt stand, PhytoTrade Africa was extolling the benefits of the baobab fruit On the Plantextrakt stand, PhytoTrade Africa, which represents baobab producers in eight Southern African countries, was extolling the benefits of the baobab fruit that it says has naturally three times the vitamin C of an orange, twice as much calcium as milk and twice as many antioxidants as goji berries. It is also a flavour enhancer and can be used in formulations to help reduce the sugar content. Its tangy taste is described as ‘caramel pear with subtle tones of grapefruit’.

Baobab is exceptionally adaptable and we are very excited about its wide range of uses as an ingredient, said Rosie Abdy-Collins of Phytotrade, who was on hand to highlight the new baobab powder and new clear baobab extract, which open up new application areas for the fruit. “Our new baobab extract means it can be incorporated into even more product ranges.” Baobab can be used in sweet and savoury applications, and the new extract is suitable for ready to drink ice tea, juice and juice beverages, near waters, energy drinks, dairy products such as yoghurt & yoghurt drinks, confectionery and instant powdered products. Its fibre content is standardised to 20%, calcium to 3% and magnesium to 1.5%. Novel Foods approval in 2008 opens it up for wide use in Europe. Highlighting the new natural superfruit ingredients within its Plantalin range of plant extracts as part of its ‘Newtrition

GNT’s Exberry colouring foods and its Nutrifood range are derived from fruits & vegetables and can be used in a wide range of product applications to impart a natural hue or to provide important phytonutrients, respectively

Food & Beverage International December 2010

- Eat, Feel,Live’ strategy, Cognis unveiled Plantalin Acerola and Plantalin Pomegranate.

foodbev com

Hi Europe

Click here to subscribe “Acerola is considered to be one of the richest sources of vitamin C, containing about 1% to 4.5% vitamin C compared, for example, to peeled oranges that contain about 0.05% of vitamin C,” said Maria Jose Guerrero, global product line manager, Cognis. “Pomegranate has had a meteoric rise in popularity in recent years and its status as a superfruit is more than justified because of its natural richness in unique antioxidants.”

water ‘so the actives provided are similar to those obtained when tea is brewed and consumed in the traditional way’.

Plantalin Acerola and Plantalin Pomegranate join Cognis’ existing aloe vera, ginseng, guarana and lemon balm extracts in the Plantalin range, which are all water soluble. Cognis is also quick to point out the natural credentials of the ingredients, which are extracted using

disappeared off the stand during the three

Protein & fibre Natural credentials were also prevalent for the protein and fibre solutions being unveiled and trialled at the show. Roquette’s VegBoost protein & fibre beverage alternative to dairy or soy milk days of the show as visitors seized the chance to try the vegetable-based drink concept. Formulated with Roquette’s enhanced pea protein, Nutralys, and its Nutriose prebiotic fibre, VegBoost boasted 4g of protein and 3g of fibre in a 100ml serving.

Cognis introduced two new ingredients, Plantalin Acerola and Plantalin Pomegranate, to its Plantalin range of plant extracts

Hi Europe Awards This year the Hi Europe Awards scheme invited companies to compete within five separate categories: Heart Health; Digestive Health, Nutrition for Young and Old; Sports Performance and Weight Management, with individual winners and an overall winner being selected. After winning in the Heart Health category, DSM Nutritional Products picked up the coveted, overall Hi Excellence Innovation of the Year Award for its Fruitflow ripe tomato extract for healthy blood flow, which was developed by Provexis. Supported by an approved EU health claim, Fruitflow helps maintain a healthy cardiovascular system, by keeping blood platelets smooth and reducing platelet aggregation. Published clinical studies have demonstrated that Fruitflow reduces platelet aggregation in 97% of individuals within 1.5 hours of consumption and its effect lasts up to 18 hours. It is available in a concentrated soluble powder for food or beverage applications. In the Digestive Health category, Danisco won for its Grindsted Fibreline; in Nutrition for Young & Old, Innophos’ VersaCal Clear picked up the award; and for Sports performance, Chr Hansen’s L.Fermentum PCC was the winner. No award was made in the Weight Management category.

foodbev com

DSM Nutritional Products picked up the coveted, overall Hi Excellence Innovation of the Year Award for its Fruitflow ripe tomato extract for healthy blood flow Danisco’s Grindsted Fiberline allows 100% rye bread to be formulated with a soft texture and mild taste similar to that of white bread. Suitable for use on existing wheat bread lines with minimal adjustment, Fibreline gives bakers the opportunity to tap into consumer preferences for white bread while creating products that offer a healthy fibre content. Danisco has also formulated Fiberline in an oat bread concept containing sufficient beta-glucans to qualify for a cardiovascular health claim. The probiotic strain L.fermentum PCC, from Chr Hansen, won the Sport Performance award for its effect on the immune health of

athletes. Proven to reduce illness in athletes after training, PCC, is based on lactic acid bacterium and therefore is a natural compound with no side effects. A clear soluble calcium phosphate, Innophos’ VersaCal Clear opens up formulation possibilities for fortifying waters and juices with calcium phosphate. It provides 14.5 to 15% calcium plus phosphorus, a pH of 3 at 1% concentration, and no sedimentation or effect on the clarity or colour of the finished beverage (see article on Vitamins & Minerals in this issue for further information).

December 2010 www.foodbev.com

Hi Europe

Click here to subscribe Pea is a sustainable source of protein. It is a staple food in our diet and has no allergic effects, said Emily Lauwaert of Roquette who explained that this allowed for natural labelling and the use of words such as ‘source of protein’, ‘lactose-free’, and ‘suitable for vegetarians’. “In the past, pea protein was only used for its functionality, for its binding and emulsifying properties, and its flavour was not a problem because of the small amounts used. But to develop a pea protein for nutritional applications has involved improvements in the extraction of the pea protein and extensive research & development work to identify the specific molecules responsible for any off-taste so that these molecules can be selectively removed.” This work, coupled with optimisation of the pea protein production process has resulted in the clean tasting Nutralys, which can also be blended with whey protein to offer digestion rates that can be tailored to optimum amino acid supply and muscle development, for highly effective sports food & beverage applications. For the show, Roquette had even formulated Nutralys into mild flavoured, crunchy protein nuggets that can be incorporated into cereals, bakery and confectionery. Soy proteins and fibre were the focus of attention on the Solae stand where the company unveiled its new Fibrim 1270 soy

Biovelop’s PromOat beta glucan is a naturally separated, soluble dietary fibre made from oat grains, which can be used to add body as well as health benefits to a wide range of applications

fibre ingredient for baked goods as well as its new soy-based protein nuggets. Solae is targeting bread, tortilla wraps, cakes and muffins with Fibrim 1270, which is a complex blend of insoluble fibre, soluble fibre and protein that can be used to fortify the products with fibre and also offer savings in formulation costs.

Fibrim 1270 has the capability to hold water and so help to extend the shelf life of baked goods by more than two weeks,

has a high 90% protein content (on a dry weight basis), which allows manufacturers to incorporate high levels of protein as well as texture to their products. Solbar targeted protein beverages with its new calcium fortified isolated soy protein, Solbar Q735, which can be used in ready to drink beverages, even if UHT treated, and dry beverage blends or powdered drinks. It has a creamy, offwhite colour and a bland flavour, and can be easily blended in cold water. “Solbar Q735 is an isolated soy protein with highly nutritious protein, containing an ideal balance of essential amino acids,”

said Michele Fite, vice president of global marketing & strategy and specialty business. “Using Fibrim 1270 in combination with other (possibly cheaper) fibres, it is possible to reach levels of 5g of fibre per serving without impacting the organoleptic properties of the end product, which would not be possible with the ‘cheaper’ fibres alone.”

Solbar targeted protein beverages with its new calcium fortified isolated soy protein, Solbar Q735

Food & Beverage International December 2010

Solae’s new Supro Nugget 173 is a protein & multigrain nugget developed using patent-pending technology that combines soy protein (60%) with grains of rice, oat and barley (40%) making it suitable for enhancing bars, snacks, baked goods and cereals products. Supro Nugget 570

said David Kraus, global application manager of Solbar. “The calcium fortification brings the calcium level of Solpro 735 to 3% while the protein level is 80% (compared with 3% protein and 0.12% calcium typically in cow’s milk).”

Healthy grains Many companies have carried out extensive work on grains to create innovative and highly functional ingredients with all the inherent benefits of the natural grains. Biovelop of Sweden’s PromOat beta glucan is a naturally separated, soluble dietary fibre made from oat grains, which

foodbev com

Hi Europe

Click here to subscribe can be used to add body as well as health benefits to smoothies, juices, drinkable yoghurts, non-dairy milk drinks, powdered formulations, sports drinks, energy drinks and functional drinks, as well as meat products, baked goods, patés, dips, sauces and mayonnaises. Also easy to incorporate into beverages, where it can impart 0.75g of beta gluten at a 1% addition in 250ml of product without any negative impact on the organoleptic properties of the product, PromOat taps into the growing consumer awareness of oats, as seen by porridge hitting menus in Starbucks and McDonald’s.

Wheat is the raw material for Beneo’s new BeneoPro vital wheat gluten (VWG), which imparts the nutritional benefits of wheat protein with a wide range of functionalities. It is produced as a co-product of the bioethanol production activities (based on sustainable raw materials) of Beneo’s sister company within the Sudzucker Group, Crop Energie, and can be used to give elasticity and strength to bread doughs, and softness in the finished product. “It allows bakers to process the dough, which can be subjected to stress on the line, and still achieve good volumes. Bakers can even buy one standard flour and add BeneoPro VWG to impart their required protein levels, to make the

PromOat can be used as a fat reducer and emulsion stabiliser, and provides prebiotics for digestive health, and cholesterol lowering properties,

dough stronger and to give different

said David Peters, business development, Biovelop, who explained that PromOat imparts non of the lumpy texture normally associated with oats, which makes it easy to impart the natural health benefits of oats without detriment to the end product. When it is required as an emulsifier or thickener, however, PromOat can impact texture rapidly as was demonstrated by a video, playing on the stand, which showed how it created almost instant texture in a mayonnaise or sauce as the product was stirred before visitors’ eyes.

the flakes stronger and therefore able to

functionalities,” said Tim Van der manager, Beneo. “BeneoPro VWG can also be used for the protein fortification of breakfast cereals whilst also making withstand handling on the processing line and during transit, for example.” Other applications for BeneoPro VWG include the strengthening of pasta dough; improved adhesion of batters; and the

Beneo’s new BeneoPro vital wheat gluten imparts the nutritional benefits of wheat protein with a wide range of functionalities

replacement of meat or other vegetable proteins in meat or vegetarian products where it will impart texture, as well as bind and emulsify.

Kampffmeyer’s range of flours derived from different grains also offers a wide

Kampffmeyer’s range of flours derived from different grains also offers a wide range of functionalities for baked goods, meat products, sauces and soups

foodbev com

Schraelen, marketing communication

range of functionalities for baked goods, meat products, sauces and soups. During Hi Europe, Kampffmeyer introduced its bran product, Softbran Don Minus alongside its Pufarin, flour-based binding systems; Wheatmeat texturised wheat protein (tasted, on the stand, in delicious vegetarian ‘meatballs’ with exotic flavours and a firm texture), and Optigrain wholemeal flours. Softbran Don Minus is milled from germinable wheat, which is said to give a high fibre bran product with a milder flavour and better, smoother mouthfeel than traditional brans. It is particularly suited for fine baked goods such as bread for toasting, and for breakfast cereals with a high fibre content, according to Kampffmeyer, which stresses that as all its ingredients are made from natural flours they are not considered additives and are suitable for natural, clean label applications. Other natural and innovative innovations, including news of a fizzy Omega-3 beverage solution, will be covered in the next issue of Food & Beverage International.

December 2010 www.foodbev.com

PACKAGING

Click here to subscribe

Hibiscus infusion a first for bottle can L’eau rouge – infusion d’hibiscus in France is the first commercial application in Europe for the wide necked, resealable bottle can, which is the result of the collaboration between Impress Group BV and Daiwa Can Japan begun in August 2009. “This packaging is completely new to the market and breaks with traditional packaging formats used for most energy and soft drinks,” said Philippe Cancel, owner of L’eau rouge enterprise SAS. “The WORC (wide open resealable can) is easy to open and drink from. Its wide top enables an even aroma release.” L’eau rouge, which is sold online; in bars, restaurants and nightclubs in the South of France

and in the trendy store, Colette, in Paris, is available in a 170ml, laminated, necked and threaded three-piece steel bottle with a large diameter aluminium closure. The metal bottle can be hot filled, pasteurised or heat-sterilised, and the system retrofitted to existing food can lines. Other resealable bottle cans in the range include the aluminium Mini Bottle 100ml and New Bottles of 300ml and 500ml. • For infant formula, Impress’ new Easy Scoop has been adopted by Nestlé for its NAN brand of infant formula in Belgium. The Deep Drawn End (DDE) technology from Impress consists of a deep drawn ring with an aluminium foil sealed to the inner part of the ring. This allows an

‘easy scoop’ spoon to be placed on top of the aluminium foil and to be stored separately to the infant formula before and after opening of the can. “We have achieved a breakthrough innovation,” said Jelmer Jongsma, Easy Scoop Impress project manager, who explained that the special combination of drawing and sealing technologies required have both been developed in house at Impress. The new DDE technology is being produced for both 99mm and 127mm diameter products at Impress’ Dutch Hoogeveen plant. Nestlé plans to launch Easy Scoop for its baby formula in Belgium prior to a more extensive roll-out.

The L’eau rouge - infusion d’hibiscus beverage from L’eau rouge enterprise SAS in France is the first European application for the Impress/ Daiwa Can wide-necked, resealable bottle can

Carton is more Eco-friendly Elopak’s Eco carton features two curved Eco front panels and an ergonomic Eco grip, which are designed to help lower the carbon footprint of the new carton by up to 10%, and bring cost savings of up to 5%. Already under production and consumer testing at a beta site in Austria where it is being used for both fresh and ESL (extended shelf life) milk for the regional milk brand Pinzgau Milch, the Eco carton uses lighter board and a lightweight Elo-Cap UE light closure. Elopak estimates that for every one million blanks produced, approximately five to 15 tonnes of CO2 will be saved. “Eco has evolved from the global need to provide packaging and products that are kinder to the environment,

Food & Beverage International December 2010

the consumer demand for improved functionality and the need for cost efficiencies in a highly price pressured market,” said Martin Wieser, Elopak’s Eco project manager, who explained that the Eco is designed with side and front score lines to give an ‘Eco Grip’ for easy handling. The Eco carton and score lines are created on Elopak’s Eco Activator E-PS82, which can be installed on the conveyor downstream from the filling machine. “There is no need for heavy investment or lengthy set-up time, the only requirement is the installation of the Eco Activator, which can be easily integrated within existing Elopak filling lines. It has an on/off switch so producers can use the line for other carton configurations, which gives important flexibility

Elopak‘s new Eco carton uses less raw material and brings CO2 savings of up to 10% and costs savings of up to 5% in production operations,” said Peter Adler, technical project manager. The score lines give a slimmer profile to the carton

and direct any bulging through the front panel, which creates a slightly different shape to the carton on shelf.

foodbev com

PACKAGING

Click here to subscribe

Sports water with sport cap Gerolsteiner in Germany, and Schwarzwald-Sprudel, part of the Edeka Süd group, have both recently introduced new water products featuring the Original 28mm Sport Cap from Aptar Food + Beverage (the new brand name for Seaquist Closures, following the company’s strategic realignment earlier this year - see: http://tinyurl. com/foodbev-aptar). At the same time, Saba, part of the CO.DA.P group in Italy, has selected Aptar’s standard nondrip 38mm cap for its two new syrup products. Initially launched in SouthWest Germany, the new Vitrex

sports water from SchwarzwaldSprudel joins the company’s range of plain and flavoured mineral waters and is set apart with the 28mm Sport Cap with transparent body and red spout, which matches the product’s red and white label. The cap has been selected in order to give differentiation and for ease of use ‘on-the-go’.

In Italy, the almond milk syrup producer, Saba, has used a silver, non-drip 38mm cap for its new line of syrups and new line of coffee enhancers. The 38mm flip-top closure in PE has a ring pull tamper evident element and a pouring beak, which ensures clean dispensing without drips.

Gerolsteiner selected the Original 28mm Sport Cap for its transparent body and coloured spouts for its new 75cl size pack of Gerolsteiner mineral water.

Saba’s line of syrups comes in five flavours in sleeved PET bottles with a partially transparent background that allows consumers to see the products inside. Its coffee

It is using the Sport Cap with a blue spout for still water and a turquoise cap for the lightly carbonated version.

enhancers can be added to coffee, tea, hot chocolate or cocktails and are packed in 700ml PET bottles.

Schwarzwald-Sprudel has selected the Original 28mm Sport Cap from Aptar Food + Beverage

Fills liquids and solids Zacmi has adapted its existing filling technology to handle liquids with pieces such as chunks or cells of fruit or vegetables.

Zacmi’s new preparation vessel and volumetric filler for filling the juice with fruit pieces at a rate of 300 x 240ml slim cans per minute.

Using a two-shot filling system, solids, such as fruit pieces, are filled first using a volumetric filler and then the liquid is added using a gravity filler. Protection of the fruit together with the accuracy of the filling are key to Zacmi’s solution, which has already been taken up by Union Beverage Factory in Dubai for its Maaza brand of fruit beverages containing fruit chunks. “We have adapted our existing equipment and developed a complete solution. We can now offer different filling options depending on the characteristic of the final product. The main issue is to prevent the pieces from becoming damaged,” said Luigi Cavallotti, area manager, Zacmi. Union Beverage Factory operates its existing canning line with

foodbev com

Zacmi has perfected its filling technology for filling cans with liquids and fruit pieces without damage to the fruit

December 2010 www.foodbev.com

PACKAGING

Click here to subscribe

SIG Combibloc‘s full perforations enables consumers to open packs easily without tools

Hauser Weinimport in Germany is using a complete Sidel Predis aseptic line for teas in PET

Perforations make cartons easy to open

Flavoured tea filling line

Easy opening for aseptic products is the latest innovation from SIG Combibloc, which has introduced carton packs with a perforation all the way across the top of the carton. Consorzio Casalasco del Pomodoro, the Italian tomato product manufacturer is the first to take advantage of the new system, which is said to open the door to convenience products, particularly those with particulates, throughout Europe. Consumers are now able to tear the entire top of the carton away without the use of tools or scissors and SIG Combibloc’s CombiblocCompact claims to be the first packaging format to offer this full perforation option in 200, 250, 300, 350, 375, 400 and 500ml volumes. In order to produce the perforation, manufacturers can invest in a modification kit to make one

small adjustment to the filling machine, and cartons can then be filled with or without perforations as required. In order to ensure a greater ease of handling and allow consumers to grip the new ‘easy-to-open’ carton, the gable top has been extended by 5mm. Tomato products and speciality sauces are now available with the full perforation option in Italy, the UK, Scandinavia, Greece and Switzerland, and instant rice pudding, semolina and other products are also potential applications. • In Brazil, Grupo Schincariol has selected SIG Combiloc combiblocMidi 1,000ml cartons with screw cap combiSwift caps for its aseptically-filled Fruthos and Skinka brands of fruit juice drinks and nectars.

The first application in Germany of Sidel’s Combi Predis aseptic PET filling line - featuring dry contamination of the pre-forms - is up and running at Hauser Weinimport GmbH’s flavoured tea plant for its ambient aseptic tea beverages. First discussed at Drinktec last year, Sidel’s Combi Predis system includes its latest aseptic technology, Sensofill FMa, in a single piece of equipment dedicated to blow moulding, filling and capping of sensitive products in aseptic conditions. In 2009, Hauser Weinimport adopted PET for its range of flavoured teas, packed without preservatives and sold at room temperature in 0.5 and 1.5 litre formats, with a shelf life of around one year and selected Sidel’s Combi Predis, which ensures 100% decontamination of the pre-forms with hydrogen peroxide vapour (H2O2) rather than water and chemicals. As the preforms

are not subjected to excessive amounts of water and chemicals to ensure their decontamination, the Predis technology provides energy& water savings and allows for more lightweight packaging options. The new line at Hauser Weinimport is equipped with Sidel’s Axo-Smart layer formation system, which manipulates packs by rotation and can handle all forms of secondary packaging in order to cope with the demand for flexibility required by Hauser Weinimport’s ‘discount store’ distribution channels. Further equipment includes Sidel’s Aidlin 24 cap feeder, which operates, a Rollquattro F15 labeller, a TSM2 CPL shrink wrapper, PalKombi palletiser, bottle, pack and palette conveyors, and two AZ-Max accumulation tables. Hauser Weinimport’s line can handle up to 18,000 bottles per hour of 0.5 litre bottles, and 12,000 x 1.5litre bottles per hour.

Catches containers gently The gentle handling of lightweight packs, in particular glass packaging, has been the target of development by Standard-Knapp, which has introduced its Versatron case packer with an incorporated Soft Catch technology. The Soft Catch feature allows manufacturers to reduce the

Food & Beverage International December 2010

shock energy of a conventional drop packer by 80%, which enables the use of thinner gauge bottles and thinner glass. Unlike many traditional case packers that drop containers into their respective packaging, the Versatron case packer has been designed to catch each container gently using a two-axis servo

system to intercept the product as it descends into the case. Cases are held via a lift table in an ‘up’ position until the full ‘grid’ is filled with product. When the grid is filled, controlling strips move to the side and initiate the descent of the bottles into the cases, which are simultaneously lowered at a similar velocity

curve to the lowering of the bottles thus ensuring a gentle ‘catch’ mechanism – much in the same way as a human would move their hands to catch an egg in an ‘egg throwing’ competition. Standard Knapp’s 939S Versatron Case Packer with Soft Catch technology can handle up to 45 containers per minute.

foodbev com

PACKAGING

Click here to subscribe

Pots make pasta convenient Pasta Pronto’s convenient ready-to-eat pasta is now packed in a new two-part container produced by RPC Bebo Plastik. Developed by Buss in Ottersberg, Germany, Pasta Pronto includes two individual containers: one containing 300g of pasta and another smaller container, positioned upsidedown on top of the larger pasta pot, which contains the sauce. Before heating, consumers can pour the sauce out on top of the pasta and microwave the combined product for two minutes in order to create a fresh and tasty pasta meal. Both packs are thermoformed in high

transparent polypropylene (PP), permitting a shelf life of around three weeks. “The advantage of separating the sauce and the pasta into two containers is the possibility of individually cooking ingredients to the optimum point in the factory: the pasta is ‘al dente’, while the sauces are prepared to bring out their rich flavours,” said Manfred Petersen, general manager, Buss. An added convenience of ribbed insulation has been built-in to the pasta container in order to protect consumers’ fingers from being burned once the product is heated and allow the product to be eaten directly

RPC BeboPlastik has worked with Buss in Germany to perfect a new Pasta Pronto convenience product in two separate PP pots from the cup. A cardboard outer sleeve holds the two containers together on shelf and provides the graphics necessary to communicate the brand’s message.

Initially launched in the discount store, Netto, in Germany, Pasta Pronto is available in Spaghetti Bolognese, Carbonara Tortellini, Tomato & Mascarpone Farfalle, and Penne Arrabiata varieties.

ADVERTORIAL

A hand pallet truck for every need

orklift trucks become ever more sophisticated as the demands of today’s businesses press for innovations in productivity and safety. But in another sense materials handling has remained much the same since pallets and other load carriers were standardised. All forklifts have forks, after all. Interestingly, the hand pallet truck has not generally been superseded by powered alternatives and still occupies a key role

in virtually all storage and delivery operations. It is inexpensive, compact, capable, easy-tomaintain, easy-to-use, and can last a lifetime. BT, now part of Toyota Material Handling Europe, invented the modern hand pallet truck over 60 years ago. Much imitated, today’s BT Lifter range, however, offers much that is unique. The BT Lifter LHM230 - BT’s most popular hand pallet truck - comes with a lifetime guarantee on the fork frame. Many businesses today seem to think of hand pallet trucks as disposable but the fact is that BT Lifters are capable of decades of hard work. There are many other models available in the BT Lifter range, all designed to meet the needs of specific applications. The BT Heavy Lifter has a load capacity of three tonnes and the BT Quick Lifter can lift a light load (< 200kg) in just two strokes of the handle. Models with particular characteristics for food and drink production and distribution include stainless steel and galvanised models. The BT Stainless Lifter is ideal for corrosive or clean environments and the BT Lifter Galvanised offers many of the same benefits for a lower

foodbev com

cost. Versions with a weight indicator or full legal-for-trade scales and printer built-in are also part of the range. A recent addition, the BT Lifter Silent is designed for out-of-hours delivery services and is as quiet in use as two people having a conversation. Unique to BT is the remarkable BT Pro Lifter hand pallet truck. A simple mechanism allows the truck to be started in motion using a downstroke on the control handle. This can get a heavy load moving with 67% less effort than would be required with a conventional truck, making this an ideal choice for older or female users. High lifting models (forks up to 80cm) such as the HHM100 are useful for sorting work or feeding production lines. The BT Lifter is also easy to customise. Toyota Material Handling Europe produces unique BT hand pallet trucks for many of its customers, and all standard models are available with a range of useful options. For more information, visit www.toyota-forklifts.eu

December 2010 www.foodbev.com

PROCESSING

Click here to subscribe

Seasoning and distribution for crisps TNA has supplied a comprehensive packaging, seasoning and distribution solution for Shearer Foods’ potato chip production line. The new solution will be used to process the company’s regular and batch-style potato chip brands and extends Shearer’s existing machinery with a tailored system including fully-integrated mechanical, software and hardware technology designed to improve the performance, accuracy and system upkeep. It includes a TNA robag 3 vertical form, fill & seal packaging machine; a TNA roflo and TNA intelli-flav 2 on-machine seasoning system with weight control, continuous automatic bulk density recalibration and

independent tumble drum. This is the first installation for TNA’s roflo vibratory technology (p34 FBI, June 09), which keeps food product agitated to avoid settling and adhesion prior to packaging. “TNA has offered a solution for our conveying and packaging needs. We have looked at many options and the solutions TNA offers using continuous product flow with a state of the art bagging system exceeded our requirements,” said Terry Mustard, vice president of engineering for Shearer’s Foods. “From process discharge conveying and distribution, through seasoning and packaging, TNA offers an efficient, flexible, low energy consumption solution.”

Pumps sugar for beer The Belgian brewery, Brasserie de Blaugies, is using a new 520 Series close-coupled peristaltic pump from Watson-Marlow Pumps Group in order to dose very specific quantities of sugar into its premium beer. The micro brewery recently won an order to fill 20 and 30 litre plastic fermentation vessels with one of its beers and required a precise measurement of liquid sugar for each vessel in order to ensure the optimum blend of alcohol and flavour. It selected Watson-Marlow’s 520 Series close-coupled peristaltic pump, which features MemoDose for accurate single shot dispensing, to dispense the sugar into the vessels at a temperature of 2˚C. Peristaltic technology ensures that nothing but the pumps’ tube touches the fluid, thus

eliminating the risk of the pump contaminating the fluid or the fluid contaminating the pump. The tube is squeezed completely shut after dosing, which gives the pump its positive displacement action, preventing backflow and eliminating the need for check valves when the pump is not running. The 520 Series pump at Brasserie de Blaugies is used in combination with tubing made from WatsonMarlow’s exclusive thermoplastic elastomer, Marprene.

Watson-Marlow Pumps’ 520 Series closecoupled peristaltic pump has been selected by Brasserie de Blaugies for dosing sugar into its premium beer

Food & Beverage International December 2010

Shearer Foods has selected a comprehensive packaging, seasoning and distribution solution from TNA for its potato chip production

Blends & doses rapidly Shorter processing times, better product results and improved working atmospheres are promised for Bronkhorst’s new Cori-Fill compact fluid dosing system, which combines a CoriFlow or mini Cori-Flow flowmeter with a suitable valve or pump to dose the correct amount of fluid. Suitable for a wide range of batching, blending, dosing and filling applications for additives, flavours and colours, the Cori-Fill can use multiple instruments in order to handle simultaneous dosing of different compounds.

Bronkhorst’s Cori-Fill compact fluid dosage assembly can be used for batching, blending, dosing and filling at flow rates of 0.4g per hour up to 600kg per hour

It can operate at rates of 0.4g per hour up to 600kg per hour. According to Bronkhorst UK, the Cori-Fill uses an advanced batch counting method with directly operated shut-off valves that allow the dosing of precise amounts of compound into the collecting vessel with a very brief reset command required before the next batch is measured and dosed. Its direct mass measurement method eliminates the volumetric variation often caused by changing temperature, viscosity and density of the ingredients and is said to be faster, more compact and accurate than weighing scales. Product results are better due to less evaporation of volatile fluids, according to Bronkhorst. As the Cori-Fill does not require open weighing vessels, it improves the atmosphere in the production plant; and as it is possible to dose a number of fluid additives simultaneously using multiple Cori-Fill instruments, it leads to shorter production times without the need for intermediate ‘zeroing’ procedures. The amounts to be dosed can be easily preset by programming the batch counters via a fieldbus connection.

foodbev com

PROCESSING

Click here to subscribe

PEF on a commercial scale The German Institute of Food Technologies’ (DIL) Elcrack pulsed electric field processing technology (PEF – see p20 for

The German Institute of Food Technologies’ pulsed electric field technology, the Elcrack, can be used for the commercial preservation of fruit juices among other applications

further information) can be used on a commercial scale for the preservation of juices and other liquids or semi-liquid products. The Elcrack, which stands for electric cracking of membranes, technology can effectively achieve non-thermal preservation of a product while retaining its quality and freshness. It involves the application of high voltage pulses in the order of 10 to 30 kilo volts, which induce pores in cell membranes causing a loss of barrier function, leakage of intracellular content and loss of vitality. The treatment is applied continuously for less than one second in a chamber, set-up with multiple electrodes, which

subject the product to the high voltage pulses while it is being pumped through the chamber. Vegetative spoilage and pathogenic micro-organisms can be inactivated by the Elcrack treatment, however it has limited effect on enzymes, spores and viruses; and vitamins, minerals, pigments and flavours are left intact. According to Promatec Food Ventures BV, which distributes the technology in the Benelux, unlike heat treatments, the Elcrack preserves the functionality and nutritional value of proteins; and as no significant changes to the composition or structure of the product occur, a PEF treated fruit juice is not considered as a Novel Food.

DIL has developed industrial scale equipment with treatment capacities of up to 10,000 litres per hour for microbial inactivation and 25,000kg per hour for cell disintegration. Dependent on the type of application, the specific energy consumption is approximately 10-100kJ per litre of product. The smaller the target cells, the higher treatment intensity is required and on a commercial scale the total costs of operation are said to be in the region of €0.1 cent per litre for treatment of plant cells and €1 cent per litre for microbial inactivation, according to Promatec, which points out that, as the continuous process takes up little space, it can be easily retrofitted into existing lines.

Applies moisture barriers consistently Sono-Tek has developed a moisture barrier coating technology for the protection of baked goods during storage. SonoCoat MB is an ultrasonic coating system, which has already been commercially applied at a major US baked goods manufacturer where the system ensures the uniform and accurate, direct application of ultrasonic coating to the food surface. According to Sono-Tek, the spraying technology offers a significant advantage over traditional spraying systems and ensures less bounce back of liquid from the target. The controllable coating of a variable micronic thickness layer also reduces any giveaway of costly coating material. “Sono-Tek’s patent-pending ultrasonic spray coating is based on technology transfer

foodbev com

Sono-Tek has used its medical device coating expertise to develop a direct application technology for applying coatings to frozen baked goods from the company’s experience in medical device coating (for cardiac stents), and in specialty coating of moisture barriers on biodegradable packaging films and trays,” said Dr Joseph Riemer, president, SonoTek. “The equipment can be customised for different product shapes and sizes, and offers a return of investment within 12 months.”

December 2010 www.foodbev.com

FOOD SAFETY

Click here to subscribe

Shelf-life analysis, challenge testing & modelling of foods Any alteration to a formulation or production process will affect the shelf life of a product and it is essential that procedures are adopted for evaluating the effects of the changes and any subsequent hazards to safety *By Dr Paul A. Gibbs & Dr Evangelia Komitopoulou of Leatherhead Food Research

helf-life analysis and challenge testing have different aims, and it is

important to understand and adopt the different methods if true evaluations of the safety of a product are to be made. Shelf-life analysis is used to determine shelflife, i.e. the product during normal storage conditions and targets the normal microbial flora of the food and its development during storage. Any changes to the formulation, processing or normal storage conditions will affect the residual microflora in the food and its development, thus affecting the time for undesirable changes to occur and cause food spoilage or safety issues. Challenge testing, meanwhile, determines whether the food could support microbial growth if inadvertently contaminated during or after manufacture, or during inappropriate storage. If sufficient variations in the formulation of the food (intrinsic parameters such as pH or water activity, for example) and storage conditions (extrinsic parameters such as temperature and gas atmosphere) are tested in challenge tests, then mathematical models of microbial growth or death can be constructed and used to predict the behaviour of the test microbes in this and other foods, although only within the parameters used to establish the model. In shelf-life analyses, it is important to take into account the probable microbial populations of the raw ingredients, the effects of formulations and processing on these organisms during manufacture, the intrinsic characteristics of the food, the storage conditions, and therefore the types of organisms that may form the indigenous and developing microflora

Food & Beverage International December 2010

during storage. These considerations can then be used to define the microbes to be sought and the methods to be used for the shelf-life analyses. It is not sufficient to determine just ‘Total Viable Counts’ as the media and methods used and incubation conditions (e.g. temperature and gas atmosphere), must closely mimic the characteristics and storage conditions of the food. This is especially the case for chill-stored foods, as some psychrotrophic spoilage organisms have a very low maximum temperature for growth (around 22ºC) and are readily killed by pour plating methods - these include Photobacterium phosphoreum and some strains of clostridia. Also, as the microbial flora develops, pH, gas atmosphere, etc, should be determined, since any changes in these can effect changes in the composition of the microbial population that may not be detected by the analytical methods initially chosen. Analyses for pathogens should follow standard methods, but appropriate resuscitation methods should be considered. Where pathogens have been detected, their growth and potential for toxin production must determine the acceptability of the food, and the production methods, HACCP systems etc., must therefore be checked and changed where necessary to eliminate these hazards. However, it is not only safety (ie the microbial numbers) that determine shelf-life, it is also the sensory acceptability of the food or beverage. In some cases, quite low numbers of microbes can result in spoilage odours, e.g. by Alicyclobacillus acidoterrestris in fruit

foodbev com

FOOD SAFETY

Click here to subscribe

juices. The effective end of shelf-life therefore needs to be determined by an evaluation panel and then correlated with microbial types and numbers. ‘Best before’ dates are generally set when approximately 75-85% of the end of shelf-life has expired, thus allowing the consumer some time to store the product before consumption.

Challenge Testing The ability of a food matrix to support microbial growth is another complex process that is dependent on a number of different factors, both intrinsic and extrinsic, and their combinations. Knowledge of the values of these factors, and the minimum and maximum limits for growth of specific microbes, is an important feature of risk assessment relating to the possibility of growth of microorganisms in a particular food. In challenge testing it is important to know the values of these factors in order to choose the most appropriate test organisms, which are generally pathogens. A laboratorycontaminated batch of food can be stored under the intended storage conditions and also under mild abuse conditions - such as a slightly elevated chill temperature - and analyses for the inoculated organisms carried out during the intended storage time. For a challenge test to be effective, the pre-treatment of an inoculum must be carefully considered. For example, in the CIMSCEE code for challenging sauces, pickles and mayonnaises, challenge organisms are required to be pre-adapted to the concentrations of acetic acid and pH values of these specific products. Such pre-adaptations can be a lengthy process, but are essential if the results of the challenge tests are to be realistic. In some cases, e.g. determination of thermal death, it may be desirable to allow some growth of the chosen organism(s) in the food matrix, prior to carrying out thermal death trials. If a particular strain of challenge organism was isolated from a food or beverage, and had developed or possessed specific characteristics permitting growth or survival in that type of food, then the cultivation or storage of that strain would need to maintain those characteristics, e.g. tolerance of low pH or high sugar (low Aw). There are no specific guidelines for preparation of a challenge inoculum. For beverages it is quite simple to re-suspend a centrifuged pellet of cells in the beverage at higher concentrations than required to

foodbev com

Any changes to formulation will affect the microflora in the food and its development over time inoculate the product, and then dilute them in other samples of the beverage. This will largely overcome problems with alterations in pH, dilution of salts or sugars (altering the Aw) or any natural or added antimicrobials. However, for solid foods, this is not a suitable method and suspending the inoculum in an appropriate diluent must be considered. If possible, the cells should be suspended in a diluent that closely mimics the aqueous phase of the food, i.e. pH and type of acid, salt and/or sugar content (Aw), anti-microbials, etc, and perhaps allowed to equilibrate under non-growth conditions, before the food is inoculated. The inoculation should be distributed, in small volumes (ca. 0.05mL), evenly throughout the food sample. Samples of the challenged food should be sufficiently large in amount (ca. 25g) and well-replicated (at least triplicate samples, with a trial being repeated at least twice on independent occasions) to minimise any uneven distribution of the inoculum or growth conditions within the food. The other problem with inoculated food trials is the ability to identify and selectively count the inoculated organism(s). Use of highly selective indicator media may not be appropriate due to the lethal effects on already stressed cells, or difficulties in distinguishing the inoculated organisms from the natural microflora. The use of specifically marked strains, e.g. antibiotic resistant strains, or those possessing some additional biochemical characteristic such as Green Fluorescent Protein (GFP) or luminescence, may be suitable, but the addition of these markers should be clearly and unequivocally shown not to change the growth or death characteristics from those of the parent (native) cells. Double antibiotic-resistant strains of some

pathogens have been developed during the validation of predictive mathematical models in real food systems, and used successfully. In some cases, it is desirable to carry out challenge trials in a factory or pilot plant in realistic conditions. In these circumstances, it is not appropriate to use pathogenic strains and the use of surrogate strains may be considered. However, as in the case of specifically marked strains, it is essential to demonstrate the equivalence of growth or resistance characteristics. There are limitations to challenge trials that include it being time-consuming and quite expensive in the planning of the laboratory effort and required analyses of results, but also the fact that the results are only applicable to the particular set of conditions tested. This latter limitation may be overcome by the development of mathematical models from many challenge experiments in broth culture systems that have been validated by trials in ‘real food’ systems. A major set of predictive models, mainly for food-borne pathogens, is available for free download from the Institute of Food Research, Norwich, UK, and is being continuously expanded to cover more conditions (e.g. modified atmospheres) and non-pathogens (e.g. some food spoilage microbes such as yeasts). The use of such models is strongly recommended before any alterations to food product formulations or processing are put into practice. *Leatherhead Food Research is an independent organisation delivering innovative research, scientific consultancy and regulatory guidance and interpretation. Services are built around five platforms: regulatory; food innovation, food safety, nutrition research; knowledge transfer.

December 2010 www.foodbev.com

SUSTAINABILITY

SAB Miller India’s project in Rajasthan involved the construction of three dams in a wasteland area, to replenish water aquifers using the natural terrain and geology to trap water

Challenge and opportunity Many NGOs (non-government organisations), governments and companies are talking about the need for sustainability but, like so many things, talk is cheap and it is delivery that is important and invariably a lot more difficult By John Fawell*

ndividuals in the food industry are increasingly recognising the need to take sustainability seriously and to be proactive and co-ordinated rather than just reacting to the latest media hype. Earlier issues of Food & Beverage International have highlighted this and reported on the initiatives senior figures are taking to seek and form partnerships to help to improve sustainability and to make sure that their efforts are recognised.

and WWF to address water use. This very public partnership means that in hard economic times it will not easily be possible for the company to abandon the objectives it has agreed in return for short-term financial reward. Sustainability requires longterm thinking. Consumer values and expectations are changing and part of that change is linked very closely to sustainability.

A significant example is the partnership between The Coca-Cola Company

Yet, what do we mean by sustainability? There is a wide range of views on this,

Food & Beverage International December 2010

but if anything is to be achieved we must look at where society is now alongside the aspirations for a better life of citizens of developing countries. Sustainability does not mean zero impact on the environment as that has never been possible. Professor Dalia Štreimikiene˙ of the Lithuanian Energy Institute wrote of sustainable development:

Sustainable development is perceived as a compromise between environmental, economic and social goals. This allows society to ensure well-being for present and future generations without damaging the environment and jeopardising the ability of future generations to meet their own needs.

foodbev com

Source: SAB Miller

Click here to subscribe

SUSTAINABILITY Click here to subscribe This latter sentiment could equally apply to developed societies and provides a challenging objective for the food industry. However, it requires a much broader examination of food industry operations. The industry is rightly proud of its food safety record ‘from farm to fork’ and sustainability needs to be put into the same framework from farm to fork. So sustainability does not just mean using less but using what we have wisely and efficiently through the whole food chain while also taking into account international social goals, including aiding developing countries. This can be partly achieved by individual companies but isolation is not tenable and it is vital that the industry works together on many areas that are of common interest and of common benefit. The three areas of sustainability that are most widely recognised are waste generation, water footprint and carbon footprint. These are recognised by consumers and NGOs and provide easy headlines for the media. Targeting zero waste is difficult but potentially straight forward, however, the last two both need to be considered in a broader sense and there needs to be a sound scientific and technical basis for assessing both. In addition, one can impact on another. It is easy to talk about food miles and embedded water but it is also easy to take a superficial view, which can lead to flawed policies and legislation. CIAA (Confederation of the Food & Drink Industries of EU) and ILSI (International Life Sciences Institute) are already providing a forum for discussing these issues. However, there is also a vital need for joint research projects to aid the development of these sound and sensible frameworks for assessing better and more sustainable approaches through the food chain. These frameworks will need to achieve a broad measure of agreement by the food industry if they are to be successful.

in 15 years; while Kerrygold has reduced its carbon footprint by 15% thanks to its modern cheese factory, which has designed-in energy efficiency. Danone has achieved a reduction in energy consumption of almost 18% per tonne of product in four years. These examples show what can be achieved very quickly, and also highlight just how much saving there is to be made. These initiatives can be considered examples of the ‘low hanging fruit’ that are vital for demonstrating that progress can be made and providing the encouragement needed for companies to continue. However, savings and efficiency gains become increasingly difficult to achieve when initiatives approach areas where only small gains are possible. These activities require long-term planning and they should be started now in order to deliver what are still very important results. In this context, the need for broader thinking is now being recognised. The reduction in waste is one high profile area that is open to creative thinking. The key is turning waste into a resource and several companies, including Nescafé, Remo-Frit from Belgium and breweries on both sides

Energy use Many companies are already making significant steps to reduce their energy use and, therefore, energy bills. It makes sound economic sense to operate in a smarter way to reduce costs as well as increase the sustainability of the operation. Unilever is targeting a 60% reduction in CO2 generation over its 1995 baseline and has achieved a 33.5% reduction in energy consumption

foodbev com

Coca-Cola Japan launched this lightweight 18g bottle for water brand I Lohas. The square shape of the product aims to save storage space in refrigerators and increase efficiency of transportation by making CO2 savings. The bottle also uses up to 30% renewable plant-based materials, reducing dependence on the non-renewable resource, petroleum

Unilever claim to have saved the equivalent of 117 trees by switching to recycled carton paper for Knorr Stock Pot packaging in Mexico

of the Atlantic are using what was once waste in order to generate power - thereby turning something that needed disposal into a valuable renewable energy source. SAB Miller has publicly stated its aim of being a zero waste operation and this is based largely around it treating waste as a resource. Such thinking can be used to reduce the environmental footprint of the operation as well as to deliver reductions in costs and overheads.

Water use As energy costs have risen, and are likely to continue to rise for some time to come, they have provided an increasingly clear incentive for companies to look at their energy use. Water is now being considered in a similar fashion partly because of cost but also because there is increasing pressure on water resources. Conflict over water rights and water availability is increasingly common on a local and regional scale and the food and beverage industry is not immune. Food production is often quoted as being the major source of water demand and as the effects of climate change remain uncertain, companies that plan to stay in business will need to plan for the changes to water availability that will surely occur. A number of big companies are now looking closely at their water use. The Coca-Cola Company has already been mentioned, but a number of other companies such as the brewery, SAB Miller, have formed partnerships with WWF to minimise their water footprint - accepting the importance of water as an ingredient but targeting the demand for water associated with the production process. Much of the activity centres on reusing and recycling water within the factory environment but these companies also recognise the need for maintaining quality and ensuring that the quality of the product

December 2010 www.foodbev.com

SUSTAINABILITY

is not affected and, importantly, is seen not to be affected. ILSI Europe’s Health and Environment Task Force began the process of addressing this topic and in 2008 published guidance on assessing the quality of alternative sources of water as well as the re-use of various kinds of wastewater (Considering water quality for use in the food industry report http://tinyurl.com/ilsi-emergingtechreport). ILSI’s work was built around the concept of ‘water safety plans’ that form the basis of the World Health Organisation Guidelines for Drinking-Water Quality and have become accepted best practice all around the world. Identifying the quality needed for different operations within the factory provides a significant opportunity for companies to reduce the water used in their processes and at the same time reduce the volume of water they discharge as waste. It also allows them to begin to address the criticism directed at the industry that it ‘has not taken its impact on water demand seriously’. The approach advocated not only applies to the factory but also to the water used in agriculture. As the pressure on water resources grows there will be greater attention focused on the amount of water used for irrigation and greater need for ‘new’ water sources. These sources may have a lower starting quality and could include re-used wastewater, which is increasingly accepted wherever water resources are under pressure.

Addressing water footprints also leads companies to consider the sustainable sourcing of crops in terms of their water consumption. ILSI Europe’s Health and Environment Task Force has supported a project aimed at developing a framework for assessing the water sustainability of crops using oil crops as an example. The major technical input for the project came from the Earth Systems Science & Climate Change group of Wageningen University. The project, Water use of oil crops - current water use and future outlooks, which will be published in 2011, examined a number of oil crops, their water requirements and the way in which those requirements can be met in the regions in which the crops are produced. It distinguished between green water and blue water - the former from rainfall and the latter from irrigation using water from rivers and underground aquifers. Although rain fed agriculture would seem to be the ideal, other climatic conditions such as sunshine and temperature also have a huge impact on yield. The project looked at crop water requirements and actual water use in relation to yield. The instances where oil crops are potentially grown under conditions that are not water sustainable were identified and it is apparent now that the areas in which some crops are grown will shift in the future to areas where the crop is more water sustainable. It was clear during the research that first appearances can be deceptive and care is always required in assessing any area of

Source: Visit Cumbria

Click here to subscribe

To produce clean waste water from the production of Nescafé specialty coffees, Nestlé invested £845,000 in an advanced treatment plant at their Dalston factory. The by-product from this process is used as fertiliser by local farmers ‘sustainability’. In some cases, issues were found not to be directly related to water availability. Palm oil, for example, grown in some tropical areas to replace native tropical forest, may cause carbon loss from the soil and impact drainage as well as the native plants and the natural ecology of the land. This must be balanced against the fact that the growth of oil palm in small locally-owned plantations can also be a significant force for regional development and can help raise small farmers out of poverty. A number of other issues in which there are information gaps became apparent in the studies, including how to improve the efficiency of irrigation. A simple flow diagram was developed to aid in sourcing oil crops sustainably from different regions and this diagram can be adapted to a wide range of crops to identify sustainable sources in different parts of the world. Such complexities are going to play an increasing part in achieving the sustainability of the food industry. However, while they present a significant challenge, they also present an opportunity to reduce costs and develop secure and long-term sources of energy, water and crops. It is clear that this can be best achieved through a high degree of co-operation within the food industry and in partnership with other expert groups that also have an interest in how we achieve sustainability.

After opening it’s new £30 million (€35 million) factory in May last year, The Kerrygold Company has saved 15% in the company’s carbon footprint

Food & Beverage International December 2010

*John Fawell is an independent consultant on drinking water and the environment, including sustainability issues in the food industry; and non-executive chairman of WCA-Environment Ltd. John.fawell@johnfawell.co.uk

foodbev com

SUSTAINABILITY Click here to subscribe

Bringing substance to sustainability Nowadays, an impressive sustainability record is an essential part of a successful business model. With sustainability high on the agenda, businesses must be able to provide tangible examples of their policy in action in order to satisfy stakeholders and stand out from the crowd

ustainability is most widely associated with environmental measures, but increasingly this is

seen as a limited interpretation. For DSM Nutritional Products, the world’s largest provider of health and nutrition ingredient solutions, sustainability also has an important humanitarian element. Here, Anthony Hehir, global marketing manager at DSM Nutritional Products, discusses the company’s unique approach to sustainability and why actions speak louder than words.

Commitment to sustainability Along with quality, reliability and traceability, sustainability forms an integral part of DSM’s Quality for Life promise. The first three factors form an integrated risk management system which guarantees the best products and service for the customer. Sustainability runs through all three and as such is a core part of DSM’s approach to business. The Quality for Life seal underpins all of DSM’s activities and marks the company’s commitment to operating in a way that benefits customers, employees and partners, as well as the planet and its people.

Respecting the planet Effective environmental measures are key for manufacturers keen to ensure longterm prosperity in the functional food and nutraceuticals market. With so many elements in the supply chain, minimising environmental impact is no easy task. Reducing emissions to air and water, maintaining biodiversity and establishing partnerships with relevant outside bodies are just some of the steps needed for companies looking to become more environmentally friendly.

foodbev com

At DSM Nutritional Products, our commitment to minimising impact on the planet is exemplified by the fact that we are surpassing many of our environmental targets. Indeed, by the end of 2009 we had already met five of our seven environmental targets for 2010, including a 70% reduction in dinitric oxide versus a target of 40% and a 50% reduction in land-filling of non-hazardous waste versus a target of 5%. It is not just our own internal targets that confirm our successes. This year, DSM was once again named the number one company on the Dow Jones Sustainability Index, a prestigious external recognition which is a recognisable marker for customers of our environmental and humanitarian achievements. Forward thinking companies keen to reduce their carbon footprint must think of how future activity will impact the environment. DSM’s approach, for example, is centred around the broader ethos of meeting the needs of the

present without compromising the needs of the future. Our Global Supplier Sustainability Programme (GSSP) makes sure that all third party suppliers’ environmental activity is in line with DSM’s high standards, meaning we only move forward with suppliers who contribute positively to our environmental work.

People matter The humanitarian aspect of sustainability is often forgotten, but as a specialist in human nutrition it is impossible to overlook the people side. To this end, DSM has a duty to address the issue of micronutrient deficiency or ‘hidden hunger,’ and is involved in a number of humanitarian initiatives as part of its Nutrition Improvement Programme. One such scheme is the MixMe innovation. MixMe is a ready to use vitamin and mineral powder, providing often impoverished recipients with micronutrient deficiencies with a dose of essential vitamins and minerals that they would not get from their daily diet. This project and others like it demonstrate how DSM’s extensive commercial expertise can be used to effectively address widespread malnutrition. Although ingredient suppliers can provide a large amount of scientific and technical expertise, partnerships with external organisations are necessary if all aims are to be met. DSM Nutritional Products is a close partner of the UN World Food Programme when it comes to staple food fortification. Furthermore, it has also recently been announced that DSM’s CEO, Feike Sijbesma was awarded the prestigious Humanitarian of the Year Award from the UN. This recognition demonstrates that corporate social responsibility is a major consideration, even at the highest levels of the company.

Summary DSM Nutritional Products has already achieved much with regards to our sustainability policy. However, for us sustainability strategy is a way of life, and if we are to continue with this success, we must continue to work hard into 2011 and beyond.

December 2010 www.foodbev.com

SUSTAINABILITY

Raising the bar

Click here to subscribe

Consumers’ growing appetite for chocolate has generated increased global demand for cocoa beans. Today, cocoa farmers produce about 3.5 million tonnes of cocoa each year, with global agricultural processor Archer Daniels Midland Company grinding approximately 16% of the total harvest

est African farmers meet some 70% of this demand, but their work is exceptionally challenging. An estimated one-third of the global cocoa crop is destroyed by pests and disease each year. Access to the latest agricultural technologies is limited, and relatively few farmers have the business training to effectively manage their operations. What’s more, many communities are beset by social issues ranging from poverty and chronic disease to inadequate education and tough working conditions. As one of the world’s largest cocoa manufacturers, ADM believes addressing these issues and encouraging sustainable farming techniques will help ensure the long term future of cocoa and improve the lives of cocoa farmers and their communities. For Alain Fredericq, director of global business development and sustainability, ADM Cocoa International, the sheer number of producers makes these issues even more challenging: “There are two million producers in four main cocoa-producing West African countries, all operating under distinct national rules, regulations or marketing systems,” he said. “It is both difficult and illogical to apply a uniform business standard to them all. “But,” he added, “by working with farming co-operatives, NGOs, industry partners and governments, we at ADM are helping to address some of the most pressing social and business issues.” Fredericq said ADM has created and implemented several initiatives to help ensure the cocoa it sources from West African farms is produced responsibly - that is, in ways that help ensure both a higher-quality crop and a better quality of life for the growers and communities who satisfy much of the world’s demand.

Food & Beverage International December 2010

The company’s flagship initiative is its Socially and Environmentally Responsible Agricultural Practices Programme, or SERAP, which offers financial incentives to West African co-operatives that implement sustainable agricultural practices. To date, the programme has provided more than US$4.5 million in incentives to co-operatives that benefit individual farmers in Côte d’Ivoire. “By providing incentives at the co-operative level, at least half of which go directly to individual famers, SERAP encourages growers to work together to address social and environmental issues,” said Fredericq, noting that participation in the programme had doubled from 6,000 growers in 2005 to 18,000 in 2010. Moreover, an analysis of several cocoa bean quality criteria — including moisture and free fatty acid content — showed that SERAP participants have achieved strong results in virtually every category. The SERAP programme not only trains growers on sustainable farming methods but also has a strong social component that, for example, provides guidance to help prevent the spread of HIV and AIDS.

• The Cocoa Livelihoods Programme is a $40 million campaign launched in 2009 by the World Cocoa Foundation, the Bill & Melinda Gates Foundation and various industry participants. The aim is to help approximately 200,000 cocoa farming families in west and central Africa boost their incomes. • The Sustainable Tree Crops Programme, managed by the International Institute of Tropical Agriculture and funded by industry and USAID, is training thousands of cocoa farmers on labour standards, business practices and improved farming methods. • The School Meals Programme, managed by Friends of the World Food Programme in partnership with ADM, provides direct financial support to schoolchildren in Côte d’Ivoire. “By providing nutritious meals to students, the programme encourages school attendance, which in turn strengthens families, communities and economies,” Fredericq notes. Since 2008, ADM’s contributions to the programme have provided meals for more than 100,000 school children.

In addition to SERAP, ADM recently developed a comprehensive workplace health programme in partnership with the sustainable development organisation GTZ (Gesellschaft fur Technische Zusammenarbeit) at ADM’s new processing facility in Kumasi, Ghana. The programme aims to reduce the spread of tuberculosis, malaria, HIV/AIDS and other infectious diseases, and toincrease access to government health and social services. Beyond ADM’s own programmes, the company is participating in a host of other cocoa sustainability initiatives in collaboration with NGOs and industry partners, including:

foodbev com

SUSTAINABILITY

foodbev com

December 2010 www.foodbev.com

SUSTAINABILITY Click here to subscribe

Study highlights fish efficiency Norwegian seafood has a relatively low impact on the climate compared to meat products, according to a recent study conducted by researchers at SIK and SINTEF Fisheries & Aqualture in Norway, which highlighted that salmon, mussels, and white fish such as haddock and cod have approximately the same impact while herring and mackerel have less. “The purpose of the study was to produce comparable results for a series of products and to learn more about the methodology and what is important or less important,” said Friederike Ziegler, SIK researcher, which studied the full supply chain

including fishing, farming, cultivation, and transport within Europe and as far afield as Asia. Although fuel is still the most significant contributor to the carbon footprint of many food chains, it was found to be a relatively low consideration for fishing, which often uses passive equipment. However, the air transportation or the long distance sea journeys involved in the fishing supply chain were found to be highly ‘climate intensive’ whether the product was frozen or chilled. What retaining the fish in a frozen condition used in extra energy was balanced by the additional transport required for chilled

Dairy carbon footprint calculation guide A Common Carbon Footprint Approach for Dairy: The International Dairy Federation (IDF) Guide to Standard Lifecycle Assessment Methodology for the Dairy Sector was launched at the World Dairy Summit in Auckland, New Zealand on 5 November.

area,” said Richard Doyle, IDF president. “These achievements are concrete outcomes of that decision. This is a major effort that will continue for many years to come, and I encourage everyone in the industry to adopt and use the new Guide.”

The new life cycle Guide is based on the best available science and current international standards and will allow stakeholders in the dairy sector worldwide to set consistent and comparable data on their carbon footprint. These measurements are designed to allow effective management and reduction of greenhouse gas emissions in the dairy sector.

To help companies use the new Guide, the IDF has also launched

“IDF has been active in putting environmental issues at the top of its priorities. In 2008, we developed a strategic plan focusing on the environment and identified the need to undertake further work in this specific

Food & Beverage International December 2010

a new website: http://www.IDFLCA-guide.org. The Guide can be downloaded from this site, which also presents interviews with dairy-sector stakeholders on the importance of the Guide to their operations. The Guide was developed under the leadership of the IDF Standing Committee on Environment (SCENV) in close collaboration with the Food and Agriculture Organization of the United Nations (FAO) and the Sustainable Agriculture Initiative Platform.

fish, which involves transporting ice and therefore reducing the amount of product that can be carried. In addition, as the fish is already frozen it is possible for it to be transported more slowly – so loads can be taken by sea to Japan instead of by air, which is a far more ‘climate intensive’ mode of transport. Similarly, processing the fish prior to transport was found to be more efficient as by-products

can be more readily used, and electricity in Norway often has a lower climate impact. Throughout the study, refrigeration was highlighted as having a significant impact. “A surprisingly large contributor is the older generation of refrigerants, which have been phased out on land, but are still being used at sea,” said Mr Ziegler. The study highlighted the need for freons to be replaced with climate-neutral refrigerants.

estlé has launched an initiative along with the Rainforest Alliance to increase sustainable coffee production and make sustainable coffee farming more accessible and attractive to a new generation of farmers. Nescafé Plan involves investment from Nestlé of US$336 million over the next ten years, and aims to increase Nestlé’s supply of coffee beans without clearing rainforest, using less water and fewer agrochemicals.

Swedish climate certification In Sweden, where the production and distribution of food generates approximately 20% of the country’s total greenhouse gas emissions, a climate certification system for food has been established by KRAV (the organic certification body) and Swedish Seal (Svenskt Sigill) in co-operation with Milko, Lantmännen, the Federation of Swedish Farmers, Scan and Skånemejerier. The purpose of the certification system, which covers Swedish and imported products, is to reduce the negative effects of the

food chain on the climate and give consumers the opportunity to make direct climate choices based on the certification and communication on packs. The standards set will be continually updated as information becomes available on methods to mitigate the climate impact within food production and distribution with any changes taking place as of January 1, 2011 at the earliest. The full criteria for compliance are available at: www. klimatmarkningen.se/in-english

Further news and details of some of the projects mentioned will be covered in the new and regular Sustainability pages in FBI

foodbev com

SUSTAINABILITY Click here to subscribe

Unilever’s Sustainable Living Plan Unilever has unveiled three key initiatives within its new Sustainable Living Plan to halve its environmental footprint, help more than one billion people to take action to improve their health and wellbeing, and to source 100% of its agricultural raw materials sustainably. In its Sustainable Living Plan, Unilever sets out over 50 social, economic and environmental targets. As the company has identified that over two-thirds of its greenhouse gas emissions and half of the water used in its products’ lifecyle come from consumer use, Unilever’s targets involve halving the greenhouse gas emissions, water and waste not only of the company in its direct operations, but also its suppliers and consumers.

“People tell us they want to reduce their environmental impact but find it hard to change their behaviour and don’t know how they can make a difference. As our products are used two billion times a day in nearly every country in the world, our consumers’ small actions add up to make a big difference,” said Paul Polman, CEO, Unilever, who explained that the company would not be operating alone, but actively working in partnership with its customers, suppliers, governments and NGOs. “We are already finding that tackling sustainability challenges provides new opportunities for sustainable growth: it creates preference for our brands, builds business with our retail customers, drives our innovation,

oca-Cola’s £93 million (€110 million) bottling plant in Northern Ireland has cut CO2 emissions by 66% following the installation of a Combined Heat & Power plant, which is one of 20 the company is installing across its operations in 28 countries. The full project, once it is completed, is expected to give direct savings of more than 250,000 tonnes of CO2.

grows our markets and in many cases, generates cost savings,” said Mr Polman. Already the company has teamed up with the vegetable oil-based ingredients supplier, Unimills, on a long-term supply agreement for Segregated Certified Sustainable Palm Oil (CSPO), which Unimills sources from its parent company, Sime Darby. The oil will be used by Unimills to create specialty fats, such as hardstocks, which are then used by Unilever in its products. “We see in Sime Darby a like-minded partner who is as dedicated to operating sustainably and responsibly as we are,” said Marc Engel, chief procurement officer at Unilever, who pointed out that Unilever is ahead of its plan to source all of its palm oil from certified sustainable sources by 2015. “We are both founding members of the Roundtable on Sustainable Palm Oil.” Unilever also picked up Ethical BioTrade’s Biodiversity Award

Training available on sustainable agriculture The Sustainable Agriculture Initiative Platform (SAI Platform) and the Dutch Sustainable Trade Initiative (IDH) has joined forced with the research and learning Centre for Sustainability Management (CSM) run by IMD to launch training to help companies to embed sustainable agricultural strategies in their businesses. The first Masterclass Workshop took place in October and covered ‘understanding the business context explains

foodbev com

sustainable agriculture’s strategic relevance’ and ‘how to build a business case for sustainable agriculture’. Case studies included Unilever’s move to 100% sustainable tea in its Lipton supply chain. ‘Knowledge brokering’ was outlined by Dr Jason Clay, vice president for market transformation, WWF. The workshop was shaped around findings from both the SAI Platform and CSM, which highlighted that the main barriers to implementation of sustainable agriculture strategies were

related to fixed mindsets and knowledge barriers, not only at the farm level, but also amongst managers in food & beverage organisations: be they procurement, marketing/ sales or other functions. According to IMD, these findings are encouraging as they demonstrate that companies can act on this issue and overcome what are essentially internal barriers; and they demonstrate the need for knowledge sharing in this area.

for Innovation at Hi Europe in November for its Allanblackia project, which involves working with rural producers and local biodiversity in Africa in the development of a new vegetable oil. Grown naturally in the wet tropical forest of Africa, allanblackia seeds are rich in oil, which is unique in its composition and melting behaviour. Spreads containing allanblackia oil (such as Unilever’s Flora and Becel brands - now sold in Europe formulated with allanblackia) remain stable at room temperature and melt quickly on eating. Unilever buys the oil at a guaranteed price, helping to create jobs for farmers and support local businesses. Its partners in this initiative include the United Nations Development Programme (UNDP), the International Union for Conservation of Nature (IUCN), international and local NGOs, regional and national governments and other companies.

epsiCo UK has achieved its ‘Zero Waste to Landfill’ target, which it set in the Spring of 2008 and now recycles 98% of all the waste it generates with the remaining 2% generating energy in waste to power incinerators. The company has a sustainability manager responsible for energy, water and waste in every one of its sites, with Waste Marshall’s on every shift trained and empowered to take ownership of the waste issue at a local level. The company’s recycling project has generated £500,000 in savings this year and more are expected.

December 2010 www.foodbev.com

CLASSIFIED ADVERTISING

Click here to subscribe

Products and services Reach thousands of decision makers in the food and beverage industry worldwide by advertising in the Food & Beverage International marketplace. To book your advertisement or to discuss other options, contact: Paul Tschornow on +44 (0)1225 327863, or paul.tschornow@foodbev.com

William Ransom & Sons PLC Alexander House 40a Wilbury Way Hitchin Herts, SG4 0AP UK

Krones AG Böhmerwaldstr. 5 93073 Neutraubling Germany

Your innovation partners

Tel: Fax:

+49 9401 70 0 +49 9401 70 2488

Tel: Fax:

E-mail: info@krones.com Website: www.krones.com

Subscribe today - visit www.foodbev.com/magazines Call +44 (0)1225 327871 or email subscriptions@foodbev.com

+44 (0) 1462 437 615 +44 (0) 1462 420 528

E-mail: info@williamransom.com Website: www.williamransom.com

Food & Beverage International advertiser index ADM Armfield Armor Proteins Beneo Palatinit

Page

49 39 27 9

Page

BI functionaldrinks Awards Cargill Cocoa Gordon Brothers Group Husky

6 13 35 2

Page

Interpack Klüber Lubrication Palsgaard Siemens

7 17 18 5, 25

Syral Tetra Pak William Ransom

Page

23 60 15

foodbev com A world of food and drink

Latest photo stories from the food and beverage industry FoodBev.com/galleries 50

Food & Beverage International December 2010

foodbev com

NEXT ISSUE

Food &

Beverage

International

Click here to subscribe

Coming up in the next issue of Food & Beverage International Supply chain squeeze As margins continue to be squeezed so companies must look ever more closer at every element of their supply chain from procurement through production to final consumer offering in order to close any gaps, to reduce wastage and bring savings.

Salt & fat reduction Reducing the ‘unhealthy’ nutrients in products continues to be a holy grail as governments and retailers put the pressure on manufacturers to help with the fight against obesity. So, what can be done? What resources and ingredients are available to manufacturers to help them formulate products effectively with less salt and fat? And who is doing what successfully in Europe?

Robotics & automation When looking at improvements to plant and production, manufacturers increasingly face the challenge of whether and what, to automate, or not. Robotics and cutting edge automation solutions already bring significant benefits to many players and the payback on investment has in most cases proved rapid and attractive.

Plus: The Innovations, Ingredients, Packaging, Processing and Safety & Analysis sections will also bring news of: • Dairy developments • Lubrication technology • Portion packs • Sweetening solutions • Combating contamination

Sustainability We will also be launching a new, regular Sustainability section bringing manufacturers news and solutions to help implement and build-on their sustainability strategies Keep up-to-date with the industry issues, news and trends; and discover the solutions to your operational and NPD challenges

Don’t miss out, register for your copy today! Contact Sharon at: sharon.bulled@foodbev.com +44 (0)1225 327858 Or for more information visit www.foodbev.com/magazines

foodbev com

Important dates for the February issue Editorial deadline: 7 January Advertising closing date: 21 January Contact the editor: Claire Rowan claire.rowan@foodbev.com

December 2010 www.foodbev.com