September 2010 | Food & Beverage International by FoodBev Media Ltd

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The World’s Top 100 Food & Beverage Companies:

Sustainability takes Sustainability takes centre stage centre stage

Supply chain optimisation Technology update: Packaging Processing Ingredients

Developments in low, light and reduced products IPA preview

FoodBev com A world of food and drink

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September 2010

SEPTEMBER 2010 CONTENTS

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Features 5 Editorial

16 The World’s

A cautious optimism prevails when it comes to investment in plant technology & packaging equipment this year

10 Industry news

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

The food & drink industry is the single largest manufacturing sector in Europe, according to new data from the CIAA

9 CIAA report CIAA and 22 other food chain partners adopt Guiding Principles on environmental assessment and communications as part of the European Food Sustainable Consumption & Production Round Table

New developments in fruits, nuts, cereals and inclusions are bringing innovation to many product areas

12 Innovations The latest cakes, breads and biscuits to have been seen on supermarket shelves around the world

44 Processing Cooling and freezing technologies and the production of frozen and chilled products bring challenges and opportunities

38 Packaging

Paris will be the centre of attention for the food and drink industry in October when IPA, the global processing technology exhibition takes place from October 17 to 21, alongside the global finished product event, SIAL; and the semi-processed food products, ingredients, additives & outsourcing solutions show, In-Food

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With consumers demanding indulgent yet guilt-free food for increasingly hectic lifestyles, how can food brands get the low, lite and reduced product challenge right?

30 Supply chain optimisation Sixteen teams competed in the Fresh Connection supply chain competition that calls on the players to focus on all areas of the supply chain network to optimise the performance of a ‘virtual’ ailing fruit juice company. Cadbury stole the prize

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

The latest innovations in intelligent packaging bring time temperature indicators to a wider audience while temperature sensitive inks provide marketing potential

43 IPA and SIAL

Environmental & ethical issues and the sustainability of the food supply chain are key challenges for the Top 100 players in the industry this year

26 Low, lite and reduced product options

Technology updates 33 Ingredients

Cover images: © Sebastian Czapnik; © Rob Bouwman; © Fzy826; © Stanislav Perov; © Juan manuel Ordonez | Dreamstime.com

8 Events

Top 100 Food & Beverage Companies

52 Safety &

analysis

50 Taste of

Quality control and inspection are an imperative part of today’s food production environment, a look at some of the latest developments

expansion

A doubling of its production capacity and number of employees, expansion into new product lines, and a new plant in India are developments that have punctuated activity at Honeytop

55 Pest control The presence of pests creates a substantial problem for food production companies through spoilage of stored products, potential damage to premises, and their presence in food leaving the premises. The Hygiene Group looks at ways to combat them

September 2010 www.foodbev.com

EDITORIAL

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Investment in production: optimism prevails

nvestment is showing signs of a slight increase; long term optimism in the future of businesses exists; yet caution prevails, according to the latest research carried out by IPA earlier this year in readiness for the world food process exhibition, to be held alongside SIAL in Paris, in October (see p43 for more information).

Although a ‘wait and see’ attitude remains among the respondents - 53% from France, 22% rest of Europe, 11% from North Africa and 14% from the rest of the world - in IPA’s 2010 pre-exhibition survey, the size of the potential investments companies are planning to make is greater than it was in 2008. Over half (52%) of the planned projects have an expected value that will be higher than €200,000 (compared with 47% in 2008) and 34% are likely to cost more than €400,000. Process equipment is the main area of interest for future investment followed by primary and end-of-line packaging machines. According to IPA, companies are aiming to bring equipment up to standards and increase safety, but the primary motivation for investment remains an economic one. Sustainable development is a concept even more strongly expressed, however, here again, the underlying thrust is economic, with energy saving, reduction of raw material losses, reduction of water and fluid consumption and waste recovery figuring highly as areas of interest. Somewhat predictably, over 80% of the planned investments are for gains in

currently ‘rather good’, compared with 29% who thought so in 2008. Yet encouragingly, 25% consider that the economic situation will remain ‘rather good’ in the medium term (2 to 3 years) and 33% do so for the long term. These responses demonstrate the mixed feelings influencing decisions in the industry and reflect the wider economic views expressed internationally. What is critical is that there is a will to invest and to continue to expand opportunities, whether right now or in a few months time.

Companies are aiming to bring equipment up to standards and increase safety, but the primary motivation for investment remains an economic one. productivity (88%), and 68.5% for improved production equipment flexibility and further diversification of the product range. Improved safety for personnel (69% compared with 67.5% in 2008) and improved man/machine relations (65.5% compared with 6.3% in 2008) were among the other reasons for investment. Optimistically, over 60% of respondents plan to invest in 2010, but 40% expect to do so in the second half rather than 21% for the first half. This is reflected in their views on the economy with only 15.5% believing that it is

As can be seen in this issue of Food & Beverage International, investment in technology does bring dividends for companies such as Honeytop (p50), which has invested in robots that it says will see payback within a couple of years; The Village Bakery (p48), which has saved €24,000 per year following installation of new drives; and Barilla (p48), which is forging ahead in the US pasta market with its US$100 million investment in a new automated plant. Companies are making investments, and are planning, and the growth is there. And, it is those companies brave enough to invest first who are the ones most likely to reap the quickest rewards when the recovery is truly here to stay.

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

EDITORIAL ADVISORY BOARD Dr Michael Knowles

Karin Östergren

Dr Philip Richardson

Vice president, Global Scientific &

PhD, Scientific Co-ordinator of the

Head of Food Manufacturing

Regulatory Affairs, The Coca-Cola Company

section Sustainable Food Production,

Technologies, Campden BRI

SIK - The Swedish Institute for Food Dr J André de Barros Teixeira

and Biotechnology

The Campbell Soup Company Mrs Helen Sisson

Dr Sebastiano Poretta

(CIES - The Food Business Forum)

President, Italian Association of Food

The Consumer Goods Forum

Technology Mella Frewen

Group technical director, Greencore Group

Catherine François Director, Food Safety Programmes,

Vice president, International R&D,

Dr Paul Berryman

Director General, Confederation of the

Huub L.M. Lelieveld

Chief executive,

Food and Drink Industries of the EU

President, Global Harmonization Initiative

Leatherhead Food Research

(CIAA)

Food & Beverage International September 2010

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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

Click here to subscribe September 2010. Volume 9, Issue 4 Food & Beverage International is published six times a year by FoodBev Media Ltd, 7 Kingsmead Square, Bath BA1 2AB, UK. It is circulated to food and beverage manufacturers in Europe. For companies/organisations that are not manufacturers of food or beverage products, or located outside Europe, the subscription charge is €109 (US$179) for one year, or €218 (US$358) for two years. Cheques should be made payable to FoodBev Media Ltd, and sent to FoodBev Media Ltd, 7 Kingsmead Square, Bath BA1 2AB, UK. No items may be reproduced, copied or stored in any form,

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

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September 2010 www.foodbev.com

EVENTS

2010 September

September 14-16 Sustainable Packaging Forum & Expo will focus on sustainable packaging practices, business strategies, critical issues and key technologies from across the globe that support company growth while meeting today’s sustainability challenges, Arizona, USA. Details from Ms Karen Close, events manager, BNP Media/ Packaging Strategies, 600 Willowbrook Lane, Suite 610, West Chester, PA, USA 19382, USA. Tel: +1 610 935 2183; Fax: +1 610 436 6277. www.sustainablepackaging.org September 15-16 Intrafood, the first edition of the ingredients exhibition, and conference programme, for the food industry in the Benelux and Northern France, Kortrijk Xpo, Belgium. Details from Ms Isabelle Fruy, exhibition manager, Kortrijk Xpo, Doorniksesteenweg 216, BE 8500 Kortrijk, Belgium. Tel: +32 56 24 11 36; Fax: +32 56 20 44 33. www.kortrijkxpo.com September 21-24 Tecno Fidta exhibition of food technology & ingredients, Buenos Aires, Argentina. Details from Ms Laura De Robertis, Indexport Messe Frankfurt SA, Luis Maria Campos 1061, Piso 5, C1426 BOI, Ciudad de Buenos Aires, Argentina. Tel: +54 11 4514 1400; Fax: +54 11 4514 1404. www.indexport.com.ar September 28-30 FachPack, packaging & labelling technology, packaging materials & supplies, test equipment & packaging recycling exhibition, Nürnberg. Details from NürnbergMesse GmbH, Messezentrum, 90471 Nürnberg, Germany. Tel: +49 9 11 86 06 0; Fax: +49 9 11 86 06 82 28. www.fachpack.de/en

Food & Beverage International September 2010

Click here to subscribe September 29-October 1 IIR Conference on phase-change materials and slurries for refrigeration and air conditioning, Sofia, Bulgaria. Contact IIR - the International Institute of Refrigeration, c/o Kostadin Fikiin, Refrigeration Science & Technology, Technical University of Sofia, 8 Kliment Ohridski Blvd, BG 1756 Sofia, Bulgaria. Tel: +359 2 965 33 22. www.tu-sofia.bg

October October 13 The Changing Landscape of Sweeteners conference, Leatherhead, UK. Details from Leatherhead Food Research, Randalls Road, Leatherhead, Surrey KT22 7RY, UK. Tel: +44 (0)1372 376 761. www.leatherheadfood.com/ sweeteners October 17-21 IPA, international food processing technology and equipment exhibition, being held in conjunction with SIAL, Paris, France. Details from communications director, Comexposium, 70 avenue du Général de Gaulle, F-92058 Paris-La Défense Cedex, France. Tel: + 33 1 76 77 13 77; Fax: +33 1 53 30 95 14. www.ipa-web.com; www.sial.fr October 19-21 International FoodTec China/ Interfood Shanghai, Shanghai, China. Details from Wang Weina, project director, SIEC, Shanghai International Exhibition Centre, 8/F, OOCL Plaza, 841 Yan An Zhong Road, Shanghai 200040, China. Tel: +86 21 627 92 828; Fax: +86 21 654 55124. www.interfood.com.cn October 21 Natural Preservation: A Gift from Nature, conference covering the latest in natural preservatives, Leatherhead, UK. Details from Leatherhead Food Research, Randalls Road, Leatherhead, Surrey KT22 7RY, UK. Tel: +44 (0)1372 376 761. www.leatherheadfood.com/ natural-preservation

October 21-22 French Food Market Opportunities, conference, Paris, France. Details from Ms Irene Kraak, Bridge2Food, Jan Van Eijcklaan 2, 3723 BC Bilthoven, The Netherlands. Tel: +31 30 225 2060. www.bridge2food.com

The Netherlands. Details from The World Mycotoxin Forum Secretariat, Bastiaanse Communication, PO Box 179, NL 3720 AD Bilthoven, The Netherlands. Tel: +31 30 229 4247. www.bastiaanse-communication. com /WMF6

October 28-29 International Fresenius Conference - Functional Food, Frankfurt, Germany. Details from Diana Grbic, conference management, Die Akademie Fresenius, Alter Hellweg 46, 44379 Dortmund, Germany. Tel: +49 231 758 96-50; Fax: +49 231 758 96-53. www.akademie-fresenius.com

November 10-12 Food Health & Safety - annual EFFoST/EHEDG conference, covering Hygienic Design; Nutrition & Health; Food Safety; Functional Foods; Functional Foods by-Products, Dublin, Ireland. Details from EFFoST Secretariat, PO Box 8129, 6700 EV Wageningen, The Netherlands. Tel: +44 (0) 1460 259 776. www.effost.org info@effost.org

October 31- November 3 Pack Expo, packaging & processing innovations, Chicago, USA. Details from PMMI, 4350 North Fairfax Drive, Suite 600, Arlington, VA 22203, USA. Tel: +1 703 243 8555. www.packexpo.com

November November 1-3 Global Bottled Water Congress - a healthier environment for bottled water, Gleneagles, Scotland. Details from Zenith International, 7 Kingsmead Square, Bath BA1 2AB, UK. Tel: +44 (0) 1225 327 900. www.zenithinternational.com November 3-6 First International Congress on Food Technology, Catching the Innovations in Food Science & Technology in an Evolving World, Antalya, Turkey. Details from Gida Teknolojisi Dernegi (The Association of Food Technology), Ankara University, Department of Food ˘ Engineering, Campus of Agriculture Faculty, Diskapi (06110), Ankara, Turkey. Tel: +90 312 596 1180. www.intfoodtechno2010.org November 8-10 World Mycotoxin Forum, international conference and networking event for the food & feed industry, regulatory authorities and science, Noordwijkerhout,

November 10-12 Brau Beviale, international trade fair for the production and marketing of beer and soft drinks, Nürnburg, Germany. Details from NürnbergMesse, Messezentrum, 90471 Nürnberg, Germany. Tel: +49 911 86 06 0; Fax: +49 911 86 06 82 28. www.brau-beviale.de November 16-18 Hi Europe, international healthy ingredients exhibition, Madrid, Spain. Details from CMP Information, PO Box 200, 3600 AE Maarssen, The Netherlands. Tel: +31 346 559 430. www.fi-events.com November 18-19 CIAA Congress: Challenges & Opportunities for a more Competitive Industry, will address the socio-economic and environmental challenges that are ‘top of mind’ for the industry and consumers, Brussels, Belgium. Details from the CIAA, Avenue des Arts 43, B1040 Brussels, Belgium. Tel: +32 2 514 11 11; Fax: +32 2 511 29 05. www.ciaa.eu

Your event:

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

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CIAA REPORT Click here to subscribe

CIAA and other food chain partners adopt Guiding Principles on environmental assessment and communications

nvironmental sustainability is of utmost importance for the food chain, which relies on good environmental conditions to thrive and remain competitive. In response to the need to measure and communicate about the environmental performance of food and drink products, a multitude of assessment and communication tools are being used and developed by food chain operators. This diversity of schemes is creating unnecessary burdens for operators along the chain, as well as for consumers who may be confused by different messages. To overcome these challenges and to promote continuous environmental improvement along the food chain, CIAA and 22 other food chain partners, the European Commission and NGOs have joined forces in the European Food Sustainable Consumption and Production (SCP) Round Table (RT). At its annual meeting in July, the Round Table took its first step towards addressing these challenges by adopting the Guiding Principles on voluntary environmental assessment and communication of environmental information along the food chain, including to consumers. The 10 Guiding Principles will underpin the next phases of the RT’s work, which includes the development of a harmonised framework methodology for the environmental assessment of food and drink products and the identification of suitable voluntary business-to-business and business-to-consumer communication tools. The harmonised framework methodology and recommendations for suitable voluntary tools are expected to be finalised by the end of 2011. The work is being carried out by European organisations from across the food chain, in partnership with the European Commission as co-chair and with the support of the United Nations Environment Programme (UNEP) and the European Environment Agency (EEA). Some NGOs, EU Member

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States and the United Nations Development Programme (UNDP) are providing additional expertise. The lead principle upon which the RT’s deliverables will be based is that “environmental information communicated along the food chain, including to consumers, shall be scientifically reliable and consistent,

“an important first step for the food chain to address the challenges set out in the EU’s Sustainable Consumption and Production Action Plan.” The RT involves food value chain members on an equal footing, which allows it to take a life-cycle approach. “The Guiding Principles give us a strong foundation for establishing

understandable and not misleading, so as to support informed choice.” The first four principles, which relate to the voluntary environmental assessment of food and drink products, require operators to take a life-cycle approach as they identify, analyse and assess the environmental aspects and impacts and to apply recognised scientific methodologies. The principles also require environmental assessments to be reviewed and updated periodically.

the food chain as a major contributor towards sustainable consumption and production in Europe and beyond,” stated keynote speaker Aldo Soldi, president of ANCC/ COOP in Italy. He continued, “The inclusive and participative approach we have taken in the Round Table should enable us to produce deliverables that are broadly supported and widely applied by operators along the food chain, and that ultimately satisfy consumer expectations.”

The next two principles on the voluntary communication of environmental information support informed choice by ensuring that operators provide information in an easily understandable and comparable way and ensure clarity regarding the scope and meaning of environmental information. Single-issue communication (referring to one particular aspect of a product life cycle, e.g. carbon foot-printing) is permitted by the Guiding Principles. However, if an operator communicates about a single-issue, it must be made clear that the information pertains only to the single-issue and the communication must not be presented as a representation of the overall environmental performance of the food or drink product.

CIAA has been a founding member of the RT since its inception in 2009 and co-chairs the Steering Committee and the working group, which is developing the harmonised framework methodology.

The last set of principles relate to both assessment and communication and give attention to issues such as transparency, SMEs, innovation, the Single Market and international trade. Soledad Blanco, co-chair of the Round Table and director for Industry at the European Commission’s DG for Environment, welcomed the RT’s Guiding Principles as

Pascal Gréverath, Nestlé, assistant vicepresident for Environmental Sustainability and chair of the CIAA Environmental Sustainability Committee, commented: “Going forward, EU food and drink manufacturers will continue to play a leading role in the work of the RT, actively working in partnership with our colleagues from other parts of the food chain to ensure that we deliver on the key objectives we set ourselves a year ago under this process. We hope that in the future, we will secure greater levels of participation among members of the NGO community in our work and continue to build on the positive collaboration currently in place among the RT and several EU Member States as well as other similar initiatives outside the EU.” For more information on the SCP RT, please visit: www.food-scp.eu

September 2010 www.foodbev.com

INDUSTRY UPDATE

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Food & drink is Europe’s largest manufacturing sector The food and drink industry was the single largest manufacturing sector in Europe in turnover and employment terms, ahead of automobile, chemical and machinery industries, according to the Data & Trends of the European Food & Drink Industry 2009 report from the Confederation of the Food & Drink Industries of the EU (CIAA). Over the past 10 years, the food and drink industry has had relatively limited but stable annual growth both in terms of production (1.8%) and value added (1.1%). Meat, as a single

Kellogg teams with Ajinomoto Kellogg Company has entered into a global R&D alliance with the Ajinomoto Company to develop products aimed at meeting consumers’ health and nutrition needs. Under the agreement, the two companies initially plan to focus on developing products that deliver benefits in the areas of weight management, sugar reduction and sodium reduction. “The potential for synergy between Kellogg’s strong marketing and product development capabilities, combined with Ajinomoto’s excellence in basic and applied research, is unique and exciting,” said Masatoshi Ito, Ajinomoto, president & CEO. Ajinomoto is the sole distributor of Kellogg products in Japan. www.foodbev.com

sector, is responsible for the greatest share of the turnover representing 21% of the total €965 billion generated by the food industry as a whole. ‘Various food products’, including

when it comes to employment

bakery, pastry, chocolate and confectionery products as well as pasta and baby food, accounted for 26% of the total turnover; beverages for 15% and dairy products for 14%.

99.1% are small to medium

France and Germany were the leading EU Member states in terms of sales, followed by Italy, the UK and Spain. However, these positions alter

sector’s workforce. The large

with Germany (employing over 500,000) leading followed by Spain, Poland, the UK and France. Of the 310,000 food and drink manufacturers in Europe, sized enterprises (defined as having less than 250 employees); and these smaller companies generate almost half of industry turnover and employ 63% of the companies contribute over 51% of the turnover and provide 37% of the sector’s employment. www.ciaa.eu

Eating & spending habits vary Consumers in the USA and UK have been the most cost conscious when it comes to their food and drink purchases over the first six months of 2010, according to a new report from The Oxford Research Agency (TORA) entitled A Question of Taste.

Cost cutting has occurred during the working day with 64% of workers in the UK preparing a lunch to take with them, compared to 33% in China. Going out to eat at lunchtime is the norm for 38% of the Chinese, while, in the UK 11% go out to eat and 14% go out to buy food to bring back to the office.

Although nearly half of UK consumers have been actively trying to save money, 39% have not changed their spending habits, leaving 16% who are spending more on food and drink this year. In China, Brazil and Germany spenders have outnumbered savers.

Eating meals together with the family at a table is usual practice for 75% of the Chinese and 71% of the French, but this figure drops to 46% for those in the UK. And, in the USA, 35% of those polled sat in front of the television to eat with the family. www.futurethinking.com

Sourcing sustainability Unilever has set the goal to work with its suppliers to source 75% of its paper and board packaging from sustainably managed forests or from recycled material by 2015, rising to 100% by 2020. In Unilever’s new policy regarding sustainable paper and board packaging sourcing, the company requires suppliers to have mechanisms in place to ensure that virgin fibre paper

packaging comes from forests that are not being converted to plantations or non-forest use, where traditional and civil rights are respected, and high conservation values are respected. The policy gives preference to sourcing Forest Stewardship Council certified virgin paper or board. www.unilever.com

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

Food & Beverage International September 2010

In Brief Products containing the disputed ‘Southampton colours’ (Sunset yellow, Quinolin yellow, Carmoisine, Allura red, Tartrazine and Ponceau) must now bear the warning ‘may have an adverse effect on activity and attention in children’ on their labels following the coming into effect of the EU regulation 1333/2008, article 24 on July 20. www.eur-lex.europa.eu Kraft Foods has pledged to double the amount of whole grain in Nabisco Crackers in the USA and, with its Nabisco portfolio, which includes Wheat thins, Honey Maid, Premium and Ritz, to contribute more than 9 billion servings of whole grain to US diets each year. www.kraft.com Danisco has acquired Research Solutions in Cape Town, South Africa, a company renowned for customised ingredients solutions, in particular for the dairy industry. The move will create a new centre of excellence for Danisco’s dairy and frozen desserts activities in sub-Saharan Africa. www.danisco.com Nestlé has entered the global market for clinical nutrition for those suffering from inherited metabolic disorders following its acquisition of the growing clinical nutrition business, Vitaflo in the UK, which has registered a growth rate of 30% over the past three years. www.nestle.com

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INDUSTRY UPDATE

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Advances needed but future looks promising More advances are critical for an adequate food supply, which must nearly double during the next several decades to feed the growing world population, according to a comprehensive report from the Institute of Food Technologists (IFT). But solutions are available.

a result, there are concerns

The report takes a historical look at the food systems, the many challenges ahead, and the crucial role of food science & technology in meeting the needs of the growing world population.

the report points out, and ‘some

“Thanks to food science & technology and modern food manufacturing methods, nutritional deficiencies and inconsistent food availability can be addressed, harvests can be protected, and various commodities can be transformed into new products having specific nutrients for better health and wellness,” said John Floros of the Pennsylvania State University Department of Food Science. ‘However, this success has distanced consumers from the agricultural origins of today’s food products and understanding why processing is important. As

better bacterial detection and

and misconceptions regarding food safety, and the food system’s effect on health and the environment.’ Processed foods & beverages can have positive nutrient benefits beyond those of the raw or home-prepared product, processed products, are better value for the consumer than the fresh or raw product.’ Nanotechnology could enhance food safety, for example, through control methods. ‘With science and technology solutions available to address specific issues throughout the food system, our ability to feed a growing population in a sustainable way, while safeguarding both human and planet health, looks not only possible, but also promising. We must, however, remain steadfast and rational about our approach, to help both humanity and nature,’ says the report. www.ift.org

US recalls eggs The voluntary recall of over 380 million eggs in the USA by Wright County Egg of Iowa in August came just one month after US egg farmers adopted new Food & drug Administration (FDA) egg safety regulations in July. Although, according to the United Egg Producers of the USA, the improvements in egg safety have been considerable during the past 10 years thanks to preventative measures in housing and storage, the

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organisation is optimistic that the new guidelines from the FDA will bring even further reduced rates of Salmonella Enteritidis and other food safety concerns. However, in August, Wright County Egg of Galt, Iowa was forced to recall its eggs due to the potential of Salmonella contamination. So far, the recall represents 1% of the total US egg production. Pasteurised liquid, frozen and dried egg products are not affected. www.eggsafety.org

September 2010 www.foodbev.com

INNOVATIONS

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Milky bread

Better for you cakes for kids Demonstrating that innovation remains strong for private label as well as branded products, Italian retailer Coop has recently launched a range of new lines for young children that include sweet baked goods. Sold under the Club 4-10 bran, the small cakes with milk and fibre are specially formulated (as

the brand name suggests) for children aged between four and 10 years. The cakes are described as a good source of fibre (1g per cake) and contain 10% milk. The formulation is free from preservatives, colours and artificial flavours. A pack of eight 34g cakes, suitable for breakfast or as a snack, retails at €1.89.

Heart health biscuit Barilla in Italy has extended its Alixir brand of functional foods with a new sweet biscuit for heart health. The Alixir range was first introduced in 2007 as a broad umbrella brand covering cookies, crackers, cereal bars and beverages, each with a specific functional health benefit (for example immune support or digestive health). The new Alixir Cor (‘heart’) biscuits are formulated with betaglucans from barley, and are said naturally to help control cholesterol to keep the heart healthy. Each 50g serving delivers 5.3g of fibre, of which 1g beta-glucans. A 300g pack retails at €2.12.

In Argentina, Bimbo has recently introduced NutriTotal Pan Lacteado - a sliced bread that targets children’s nutrition. NutriTotal Pan Lacteado is enriched with calcium for strong bones and teeth (200mg per 50g serving), iron, which can prevent anaemia (2.8mg per 50g), vitamin D to aid calcium absorption, and zinc, which contributes to the growth of muscles and tissue. For each vitamin or mineral, the bread offers 20% of the recommended daily value per 50g serving. The product is also transfat-free, and a 580g loaf retails at the equivalent of €1.25.

Targeting a (very) specific market A savoury cracker has often been recommended as a simple way to fight the nausea associated with morning sickness when pregnant, or indeed that caused by motion or air sickness. Now, the US company, Olympian Labs, has extended this idea with the introduction of its Mother’s Tranquil Tummy crackers. These ‘soothing saltine crackers’ come in a bite size format and contain 250mg of natural ground ginger root, itself an ingredient long associated with a ‘settled tummy’. The package design leaves no doubt as to the product’s target market, and the back of pack

text describes the benefits of a dry, bland cracker as a carrier for ginger - as opposed to pills or ginger ales, both of which can carry calories and artificial flavours. The crackers are predominantly sold via the internet, at a premium price of $6.50 for a 140g pack containing twelve individual portions.

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 September 2010

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INNOVATIONS

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Breakfast biscuits No doubt recognising the success of cereal bars as a viable on-the-go alternative to established ‘cereals with milk’ for breakfast, Kraft Foods has introduced a breakfast biscuit in the UK. Belvita Breakfast is a crunchy wholegrain biscuit with milk, described as a good source of fibre (3.6g per 100g), with added vitamins B1, B6, B9, and minerals. It is said to release carbohydrates regularly over four hours, ‘to keep you going all morning’, and features the tag line ‘designed for breakfast’ on the front of pack, together with a graphic that supports its lasting energy message. The biscuits retail in a 300g pack containing six 50g packets, priced at £2.19, or around €2.49.

Diet cake mix Cake may not be the obvious choice for consumers following a diet, but DHC in Japan has extended its Protein Diet range, which previously focused on drink mixes, into the bakery aisle. The company’s Protein Diet cake mix delivers 184 calories per serving, but is described as highly satisfying and it is rich in nutrients including protein, dietary fibre, vitamins and minerals. The protein content is 14.2g per 49g pack, and dietary fibre 9.4g. Protein Diet additionally contains beauty ingredients including coenzyme Q10, hyaluronic acid

Food & Beverage International September 2010

and placenta extract. The mix is available in five flavours (including tea and milk, green tea, and chocolate), and is designed to be prepared simply with 40ml of water and microwaved for two minutes. It retails at 1,700 yen, or approximately €13.

‘Free from’ foods German company Coppenrath recently entered the fast-growing market for ‘free from’ foods with the launch of its Bewusst Genießen range of gluten-free and lactose-free products, which are suitable for diabetics. The range includes cocoa-orange cookies, made with flour from teff (an Ethopian grain), plantain and rice; and caramel cookies, made with flour from plantain, potato, rice and teff. Both are sold in 125g packs.

Raw food The raw food movement remains niche, but has been an active area of development in many categories as increasing numbers of consumers eschew ‘overly processed’ foods and look for more natural formulations. Raw food enthusiasts argue that uncooked whole foods provide the body with the greatest amount of nutrients and food enzymes for optimum health; and raw food products generally have a strong health positioning. The US company Two Moms in the Raw has launched a line of ‘raw treats to have on the run’, and claims to have ‘found a way to bring extraordinary taste and texture to raw foods’. The company’s Sea Crackers are dairy-, gluten- and wheat-free, and are handmade from 100% raw and organic

ingredients (including flaxseed, pine nuts and the sea vegetable kombu), with no added oils or sugars. They are available in pesto, garden herb, and tomatobasil varieties, in a 4oz (113g) pack retailing at the premium price of over US$7.

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IFT 2010 taste test winners The Institute of Food Technologists (IFT) gathered at the annual Food Expo in Chicago, USA from July 18-20, and Mintel, the global leader in market and consumer intelligence, was there to host its annual Global New Products Pavilion, innovative product tastings and presentations highlighting the latest trends in the food, drink and foodservice industries. This year, Mintel’s new product experts, David Jago and Lynn Dornblaser, presented on the topics of Baby Boomers, Satiety and Simple Ingredient Statements, and the nearly 700 attendees at the presentations and tastings were given a chance to vote on their favourite products in each of these categories.

Baby Boomers “With baby boomers comprising 26% of the population, it makes sense that manufacturers are positioning products just for them,” said Ms Dornblaser. “The trick is to position these products with the needs of baby boomers in mind, without making consumers feel like they have ailments or are ageing.” Smartfood Popcorn Clusters from the USA took first place in the boomer category. While being an indulgent snack, it also serves up some powerful nutrition, such as calcium and fibre. Tripl3 O Antiox Green Tea with Honey from Colombia and Kellogg’s All-Bran Buds Singles from Canada took second and third place, respectively.

Satiety With rising obesity rates and an increase in chronic ailments, wellness & wellbeing is a trend that looks set to stay; and satiety fits this well. IFT attendees chose the EcoSlim Dark Chocolate Bars from Portugal as their favourite product for staying fuller longer. Kellogg’s Special K Sustain Breakfast Cereal from the UK came in second place, followed by Barilla Mulino Bianco Grancereale Fiber Biscuits from Italy.

Simple Ingredient Statements According to Ms Dornblaser, ‘natural’ and ‘additive-free’ have become an intrinsic part of the consumer’s health and wellness vocabulary. It was a tight race in this category with Pepsi Raw Natural Born Cola (UK) coming in first place with its natural plant extracts and new pack design; Yoplait Simply . . . Gogurt Portable Lowfat Yoghurt from the USA in second, followed by the UK’s Planet Lunch Squeezable Fruit containing 100% natural ingredients. www.ift.org; www.mintel.com

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Click here to subscribe enter the middle class, and some 60% of new wealth will come from emerging nations. “The scale of change will be equally sizeable when it comes to the urbanisation and ageing of populations,” said Mr Kent. “Meanwhile there is a fundamental reset of consumer priorities, values and expectations, in which the ‘character’ of companies and how sustainable they are plays an increasingly large role. The implications for our industry are profound.”

Mr Kent’s comments were echoed in conversations throughout the three day event and joined ‘the critical state of the world’s resources’ and ‘climate change’ as headline topics.

The World’s Top 100 Food & Beverage Companies:

Sustainability takes centre stage Environmental & ethical issues and the sustainability of the food supply chain are challenges that form the backdrop for all other concerns for the Top 100 players this year as they grapple with the changing demographics of the world’s consumers, the aftermath of the global recession and a burgeoning new IT generation By Claire Rowan - managing editor

t the first Global Summit of the Consumer Goods Forum, formed last year by the merger of CIES - The Food Business Forum and the Global Commerce Initiative, a thousand delegates from the worlds of both retail and

Food & Beverage International September 2010

manufacturing met to discuss the latest trends, challenges and opportunities facing the industry. Muhtar Kent, CEO, The CocaCola Company, stressed that the next 10 years will see the greatest economic shift in history, as a billion people around the world

“Please make no mistake about this, the health and stability of the global economy ultimately depends upon the resilience of the world’s ecosystems and the durability of the Earth’s limited natural resources,” said His Royal Highness the Prince of Wales in his keynote opening address to the conference. “Whether it be climate change, the growing scarcity of fresh water, the loss of fertility of the soil or the destruction of so many of the world’s vital eco-systems, the behaviour of the consumer is fundamental. Patterns of consumption, the global economy, political stability and environmental sustainability are all integrally linked. And, this is why, in my view, if we are to tackle these problems the food retail and manufacturing sector has to be a central element in the solution.” Providing a graphic illustration of the scale of the challenges faced, the Prince highlighted the depletion of the world’s fish supplies including the United Nation’s Food & Agriculture Organisation figures that show that over 75% of commercially valuable fish stocks are either fully or over-exploited and that, worldwide, in just 50 years, we have consumed more than 90% of the large predatory fish in the oceans. “In many places the numbers of fish like tuna and cod are now desperately low. They are only 10% of what they were forty to fifty years ago,” he said. “Some researchers estimate that, on current trends, virtually all commercial fisheries will have collapsed by 2050, which is not all that far away, unless we take urgent action to put in place a more precautionary approach to the way we manage commercial fishing.” These figures and the suggestions for how such a severe situation can be reversed

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There is a fundamental reset of consumer priorities, values and expectations, in which the ‘character’ of companies and how sustainable they are plays an increasingly large role. The implications for our industry are profound.

Patterns of consumption, the global economy, political stability and environmental sustainability are all integrally linked. And, this is why, in my view, if we are to tackle these problems the food retail and manufacturing sector has to be a central element in the solution.

Muhtar Kent, CEO, The Coca-Cola Company

His Royal Highness the Prince of Wales

provide a blueprint for other industries and food supply chains that are similarly under threat. One of the many different courses of action required in concert with others was the need for food manufacturers to become increasingly rigorous in their sourcing and to demand full traceability for their raw materials. The Prince pointed to the UK supermarkets Waitrose, Marks & Spencers, Sainsbury and the Co-Op which, along with brands such as Findus, Young’s and Birds Eye, are now demanding the use of low impact fishing methods such as line-caught fish.

“And, as the population rises, so too will

are. But by working together - business,

emissions,” he said about the impact of

governments, consumers - we can achieve

consumers on climate change.

collectively what none of us can achieve

“Recent surveys of consumer trust have shown that the public place retailers over and above doctors, policemen, politicians and banks,” said the Prince. “This gives retailers a unique opportunity and a unique responsibility to make sense of complex issues for consumers who are struggling to understand what is the right thing to do when presented with so many different choices. So, it is up to retailers to ensure that their fish and seafood has come from sustainable stocks and been fished according to sustainable practices.” Paul Polman, CEO of Unilever, emphasised that by 2050, there will be 9 billion people on the planet - four times more than there were when he was born.

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“To those who say ‘can’t we wait until the recession is over?’, I say ‘no’. And, to those who ask ‘why can’t we leave it to government?’ my answer is that no single institution can tackle this problem alone. Of course governments need to act - and many

alone. A shift to low-carbon consumption will not happen by itself, but to argue that the choice is between growth and cutting carbon is wrong. We can grow without carbon, there is such a thing as green growth. To achieve it we need to think afresh and do things differently.” Presenting alongside Terry Leahy, CEO of the retailer, Tesco, which has pledged to cut the emissions of the products it sells by 30% by 2020 and aims to be a zero carbon business by 2050, Mr Polman highlighted that Unilever has reduced its CO2 emissions by 40%, water by 65% and waste by 73% since 1995. “Now we aim to go further,” he said. “We plan to double the size of the business but at the same time reduce our absolute environmental impacts. In terms of CO2, this will represent a reduction of over 60%

We plan to double the size of the business but at the same time reduce our absolute environmental impacts. In terms of CO2, this will represent a reduction of over 60% against our 1995 baseline.

against our 1995 baseline.”

Paul Polman, CEO, Unilever

refrigerants and in the past six years, has

Unilever intends to do this through investment and the company is experimenting with new forms of energy for its factories: biomass in China; solar in Vietnam; and combined heat & power in the UK. It is also looking at new kinds of

September 2010 www.foodbev.com

TOP 100

Click here to subscribe Rank Company

Currency

Year End

Total Sales (local c, m)

Food Sales Total Sales Food Sales (local c, m) ($m) (£m)

Nestle

SwF

Dec-09

107,618

99,798

98,735

91,560

PepsiCo, Inc.

Dec-09

43,232

Kraft Foods

Dec-09

40,386

Anheuser-Busch InBev

Dec-09

36,758

Archer Daniels Midland Company

Jun-09

69,207

32,241

69,207

32,241

The Coca-Cola Company

Dec-09

30,990

Mars

Unilever

Rank Company 51

Hormel Foods Corporation

Keystone Foods

Kerry Group

Morinaga Milk Industry

55 56

Currency $

Year End

Total Sales (local c, m)

Food Sales Total Sales Food Sales (local c, m) ($m) (£m)

Oct-09

6,534

$ Dec-09

6,400

Euros Dec-09

4,521

6,280

Yen Mar-10

585,116

6,255

Oetker Group

Euros Dec-09

7,956

4,353

11,060

6,050

Grupo Modelo (Mexico)

$ Dec-09

6,033

Euros Dec-09

4,171

5,800

C$ Jun-09

6,500

5,700

$ Dec-09

5,531

Dec-08

30,000

Barilla

Euros

Dec-09

39,823

21,009

55,310

29,180

McCain Foods Ltd

Tyson Foods

Sep-09

26,704

Cargill

May-09

116,579

26,500

116,579

26,500

Dr Pepper Snapple Group

SABMiller

Mar-10

26,350

Parmalat

Euros Dec-09

3,965

5,505

Danone

Euros

Dec-09

14,982

20,810

Tate & Lyle

£ Mar-10

3,506

5,470

Heineken

Euros

Dec-09

14,701

20,420

The Hershey Company

$ Dec-09

5,299

Kirin Brewery Co.

Yen

Dec-09

2,278,473

1,874,126

24,345

20,025

Marfrig Group

$ Dec-09

5,140

Asahi Breweries

Yen

Dec-09

1,472,468

1,431,000

15,735

15,290

Saputo

C$ Mar-10

5,811

5,098

General Mills Inc.

May-10

14,797

Yen Mar-10

481,574

460,600

5,145

4,922

Diageo

Jun-09

9,311

14,550

Nippon Suisan Kaisha

Suntory

Yen

Dec-08

1,513,000

1,376,830

14,635

13,320

Itoham Foods

Yen Mar-10

452,454

4,835

Perdue Farms

$ Mar-09

4,600

Bongrain

Euros Dec-09

3,279

4,555

Red Bull

Euros Dec-09

3,268

4,542

Barry Callebaut

SwF Aug-09

4,880

4,477

Maple Leaf Foods

C$ Dec-09

5,222

5,015

4,580

4,400

Euros Dec-09

8,906

3,158

12,380

4,390

JBS

Dec-08

12,745

Kellogg Company

Dec-09

12,575

Vion

ConAgra Foods Inc.

Euros

Dec-09

9,040

12,565

May-10

12,079

Lactalis

Euros

Dec-09

8,500

11,805

Tchibo

Royal FrieslandCampina

Euros

Dec-09

8,160

11,335

Nisshin Seifun Group

Yen Mar-10

443,728

403,111

4,742

4,310

Smithfield Foods Inc.

Apr-10

11,203

Japan Tobacco International

Yen Mar-10

6,134,600

394,600

65,550

4,215

Dean Foods Company

Dec-09

11,158

Premier Foods

£ Dec-09

2,661

4,160

Bacardi

$ Mar-08

4,000

Femsa

Dec-09

15,015

11,110

15,081

11,110

Yen Mar-10

371,178

3,965

Carlsberg

DKK

Dec-09

59,382

11,080

Nissin Food Products

Ajinomoto

Yen

Mar-10

1,170,800

1,031,500

12,510

11,025

Ralcorp Holdings

$ Sep-09

3,892

Sara Lee Corporation

Jun-09

12,881

10,856

12,881

10,856

Corn Products International

$ Dec-09

3,890

Associated British Foods

Sep-09

9,255

6,941

14,460

10,845

QP Corporation

Yen Nov-09

452,239

360,282

4,833

3,850

LVMH

Euros Dec-09

17,053

2,740

23,685

3,805

HJ Heinz Company

Apr-10

10,495

3,740

Nippon Meat Packers

Yen

Mar-10

953,616

10,190

Del Monte Foods Company

Land O' Lakes Inc.

$ Dec-09

10,409

3,731

10,409

3,731

Fonterra

NZ$

Jul-09

16,035

10,025

Sapporo Holdings

Yen Dec-09

387,534

336,240

4,140

3,592

Pernod Ricard

Euros

Jun-09

7,203

10,005

Yili Group

RMB Dec-09

24,320

3,575

Meiji Holdings

Yen

Mar-10

1,124,000

873,900

12,010

9,336

Ito En

Apr-10

332,984

3,560

Schreiber Foods

$ Sep-08

3,500

A$ Jun-09

4,491

3,480

$ Dec-09

3,470

Euros Dec-09

2,486

3,455

A$ Dec-09

4,403

3,415

Yen

Apr-10

Dec-09

5,975

9,335

Euros

Aug-09

6,400

8,900

Fosters Group

Yamazaki Baking

Yen

Dec-09

885,683

826,226

9,465

8,828

Arla Foods

DKK

Dec-09

46,230

8,640

Chiquita Brands International

Grupo Bimbo (Mexico)

Dec-09

8,628

Sodiaal

Coca-Cola Amatil

Maruha Nichiro Holdings

Yen

Mar-10

828,715

801,000

8,855

8,558

Muller Group

Euros Dec-08

2,300

3,380

Constellation Brands

$ Feb-10

3,365

Brown-Forman Corporation

Apr-10

3,226

McCormick & Company

$ Nov-09

3,192

$ Jun-09

79,029

3,114

79,029

3,114

Cadbury

Ferrero

Sudzucker

Euros

Feb-10

5,718

7,950

Brf Brasil Foods

Dec-09

8,093

7,850

8,093

7,850

Danish Crown

Bunge

DKK

Sep-09

44,765

41,510

8,355

7,745

Dec-09

41,926

7,711

41,926

7,711

Dole Food Company, Inc.

Dec-08

7,620

The Procter & Gamble Company

Campbell Soup Company

Aug-09

7,586

Groupe Bel

Euros Dec-09

2,221

3,085

CSM

Euros Dec-09

2,556

2,201

3,550

3,060

Pilgrim's Pride

Sep-09

7,088

Ebro Puleva

Euros Dec-09

2,198

3,055

CHS Inc.

Aug-09

25,700

6,550

25,700

6,550

100

Molson Coors Brewing Company

$ Dec-09

3,032

Compiled by Leatherhead Food Research from its Global Food Markets Database, which contains further in depth profiles of many of these companies. www.leatherheadfood.com

Food & Beverage International September 2010

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One in two customers now has a good idea of what a carbon footprint is, and nearly half said they would seek products with lower emissions. Terry Leahy, Tesco

replaced over 430,000 of its in-store refrigerator cabinets with more climatefriendly alternatives. Again, however, he stressed that no one company will be able to win the ‘sustainable’ challenge alone. He highlighted how combined efforts such as that of the Roundtable on Sustainable Palm would have far greater effect. “If we want to pack a real punch, we need to act together,” he said. “Take palm oil - an essential ingredient in thousands of products. More than 80% of it is grown in Indonesia and Malaysia. The rapid expansion of the industry there over the past 20 years has accelerated the destruction of the rainforest. An area the size of Greece is cleared every year. We have long been convinced of the need to break the link between palm oil and climate change; and by 2015, Unilever will buy all of its palm oil from certified sustainable sources.” To achieve this goal, Unilever has worked with many of the world’s leading retailers and manufacturers to establish the Roundtable on Sustainable Palm oil. The objective is for the companies to work collectively to pay the necessary premium for sustainable palm oil; and to cease trading with those growers who won’t or can’t achieve the necessary standards. “This year, Unilever will buy more than 400,000 tonnes of RSPO (responsibly sourced palm oil) certified oil,” said Mr Polman. “In 2011, we will double that volume.” For all of these initiatives and demands on industry, education of the consumer will be key to making true progress. Tesco has already labelled 125 of its products with carbon footprint labelling showing the emissions connected with them, and intends to add a further 500 to its list. “One in two customers now has a good idea of what a carbon footprint is, and nearly half said they would seek products with lower emissions,” said Mr Leahy, who with Mr Polman, as the Global Consumer Goods Forum’s cosponsor for Sustainability, announced four new initiatives for non-competitive

We are convinced that a company or an industry cannot be successful over time if it does not link up positively with the society at large in everything it does. Paul Bulcke, CEO of Nestlé

Food & Beverage International September 2010

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Click here to subscribe collaboration within the industry. These include establishing a common approach to packaging including a new means of measuring its environmental impact (see FBI October for more news); a common global system for measuring greenhouse gases in the life cycles of products and establishing a shared language to define claims such as ‘carbon neutral’; a move to end deforestation by 2016; and plans to shift refrigeration from the use of hydrofluorocarbons to natural refrigerants throughout the industry. “I ask you to help us in the Forum’s ambition to make our businesses more sustainable, and create a mass movement in green consumption,” said Mr Polman. Paul Bulcke, CEO of Nestlé agreed that companies such as Nestlé have a role to play, and never has their role and their activities been more visible. “We live in a ‘VUCA’ world driven by volatility, uncertainty, complexity and ambiguity. Food safety and security is an increasing concern. There is volatility in finance, energy and raw material prices. Governments are imposing more stringent regulations, while consumers have developed a powerful voice. There are major challenges today: nutrition - including malnutrition and obesity; diabetes; an ageing population; and increasing health costs. The link between health costs and nutrition is understood but still needs decoding. And, with the backdrop of the past few years - where ambition has turned into greed - businesses can only be successful by ‘creating shared value’,” said Mr Bulcke, who stressed that Nestlé’s philosophy of ‘shared value’ goes beyond sustainability, and builds ‘value’ both to the company and to society into its ‘bottom line’. “We are convinced that a company or an industry cannot be successful over time if it does not link-up positively with the society at large in everything it does.” Mr Bulcke highlighted how Nestlé has reduced its own water withdrawal by 58%

between 1999 and 2008 and through its partnerships with ECOM Agroindustrial Corporation, the Rainforest Alliance and IDE (International Development Enterprises) has offered drip irrigation support to 1,500 farmers. Using the 1.2 billion units of product it sells a day, it has also provided carriers for micronutrients in developing countries. “The cost is not in the incorporation of the vitamins and minerals but in the distribution, which we have in place already, so it is not a major cost, yet the impact on the world and on productivity is large,” said Mr Bulcke, who pointed out that Nestlé is also working with governments in 60 countries to educate children in school about nutrition. “We have touched 10 million school children already.” Prince Charles stressed that education was also key in the developed world and called upon food and beverage manufacturers to take on this responsibility to make a difference. “You will have to recognise that you are as much an access point for information as newspapers and television. In fact, possibly bigger,” he said. “Not everybody reads or watches, but everyone shops and how else will people really know what they are buying if you do not tell them.” Yet, this communication to consumers and the ability to engage them in these environmental and ethical messages as well as other brand news is, as always, a challenge in itself and increasingly so in today’s increasingly sophisticated digital world. “In this brave new world, how you engage (with the consumer) is important,” said Zein Abdalla, CEO, PepsiCo Europe, who pointed out that digital consumption has increased by 400% during the past 10 years. “There are far more users of this new technology outside of developed markets. This means a fundamental change in brands’ approaches

If you are going to go digital you have to be ready to be interactive. In the USA, we created a website that allows consumers to post ideas about the planet, education, and community projects, as well as share ideas on best practices for fund raising. Zein Abdalla, CEO PepsiCo

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Click here to subscribe to consumers. Working with word of mouth is about dialogue and engagement. You have to listen as much as you tell, and involve consumers with the brands.”

‘tore up its rule book’ on a successful

The digital age

and developments teams to develop a new

Mike Bosman, CEO of One Digital Media highlighted that Twitter receives 600 million search queries every day; You tube is now the second-largest search engine after Google; and the digital revolution is not restricted to just young consumers.

and launched it online inviting consumers

“During the past year, 200 million people joined Facebook, and many of these were 50 to 60 year old women,” said Mr Bosman. “Word of mouth is the new marketing area, and young kids say that it is their main reason for purchasing. They expect everything to be transparent.”

million entries and four million visits to our

In 2008-09, in order to engage and be transparent with consumers, PepsiCo

taken its Pepsi communications digital via

brand model for its Walkers brand of crisps in the UK. “In the past, we would work in our research flavour. Instead, we put together an idea to feedback on ‘what should be the next Walkers’ flavour?’,” said Mr Abdalla. Responses to the online question included ‘chocolate chilli’, ‘builders breakfast’ and ‘cajun squirrel’ flavours. “We had over one website where viewers spent seven to nine minutes. We had to be prepared for any response, and had to cut our innovation time line from 26 down to four weeks.” For beverages, PepsiCo has also moved away from a traditional ‘ad-led’ model. It has its ‘football heroes’ game, which it launched

together with MSN. In order to allow people to incorporate ‘football heroes’ into their social networking, PepsiCo gives consumers the opportunity to play the game and forward it to their friends on Facebook. “If you are going to go digital you have to be ready to be interactive,” said Mr Abdalla. “In the USA, we created a website that allows consumers to post ideas about the planet, education, and community projects, as well as share ideas on best practices for fund raising.” UK retailer, Asda’s model of communication with consumers gives a taste of what is increasingly becoming the communication norm in the digital age. Its website has received 90,000 product reviews from shoppers during the past year and 7% of its customers have posted a rating for a product. “Our research found that 40% of Asda shoppers visited a social networking site in the past month, and all customers say

Notes on the movers & shakers in the Top 100 By Jonathan Thomas, senior market analyst, Leatherhead Food International • Cadbury (37th spot) will have disappeared from the ranking by this time next year, since it has been acquired by Kraft Foods - a deal, which will propel Kraft into second position behind Nestlé, thereby overtaking PepsiCo. • A new entry at 63 is Marfrig Group, a Brazilian-based producer of meat and poultry products. It has expanded in recent years as a result of acquisition activity, and is set to rise further up the ranking, having acquired Keystone Foods (no. 52) in the middle of 2010. • Another new entry from Latin America is Brf Brasil Foods, at 44. The company is a producer of meat products, and was formerly known as Perdigao. It was formed by the merger in 2009 between Perdigao and Sadia, which created Brazil’s second largest food company. • Another new entry at 74 is Japan Tobacco International (JTI). Although its main business is tobacco, the company also competes in the frozen foods industry in Japan, having previously acquired Katokichi.

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• The growing influence of Chinese food producers is becoming apparent, with the dairy market leader Yili Group now within the Top 100 for the first time. It seems likely that other Chinese companies will start to enter the list as their presence grows. • Premier Foods has entered the ranking at no 75, having become one of the largest UK-based suppliers of food and drinks in recent years as a result of acquisition activity. In the past, the company had assumed control of some of the UK’s best-known and iconic brands such as Ambrosia, Oxo, Batchelors, Homepride, Bird’s custard and Quorn. The largest acquisition of late has been its £1.2 billion of RHM, which included leading bakery brands such as Hovis and Mr Kipling. • Another company which has advanced up the ranking within the past year is Ralcorp Holdings. The company now occupies 78th spot, up from 100 last year, during which time its sales have risen by almost 38% to US$3.89 billion. Some of its more significant acquisitions have included the Post breakfast cereals brand from Kraft Foods, followed by Harvest Manor Farms in 2009.

• One of the biggest fallers within the past year has been Procter & Gamble, reflecting its increasing focus on its nonfood businesses. Sales of the company’s food and drinks products fell from US$4.85 billion to US$3.11 billion in the year ending June 2009, as a result of which it has almost slipped out of the ranking. P & G’s interests in the food industry are now almost entirely confined to the Pringles brand, having sold off its Folgers coffee business in 2008 to JM Smucker for $2.95 billion. • Other movers include the US brewer Molson Coors, which saw its turnover decrease by more than 36% in the year ending December 2009. As a result, the company has fallen from 61st to 100th position. Major dairy firms such as Dairy Crest and Nordmilch have also slipped out of the ranking as a result of declining sales. New entrants have included the US spirits and alcoholic beverages supplier Brown-Forman Corporation (94), and Groupe Bel (97), which has re-entered the ranking largely as a result of increased sales from its business in the Americas. www.leatherheadfood.com

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Click here to subscribe holds enormous potential for the industry to communicate its wider messages. Joanne Denney-Finch, chief executive of the UK’s Institute of Grocery Distribution (IGD) highlighted the IGD’s recent research in France, Germany, The Netherlands, Spain and the UK, which showed that over three quarters of the 3,000 shoppers questioned were interested in the ethics of food.

So, ethical values offer us an opportunity - a big opportunity - to build trust and consumer loyalty . . . to energise our employees and to revitalise growth. In the emerging world, this is even more important. We will only participate in the growth of these countries if we’re seen to be ethical operators. Joanne Denney-Finch, chief executive of the UK’s Institute of Grocery Distribution

that they check on line before buying in store. People are reaching out for help and reassurance from people like them rather than companies like us,” said Andy Bond, chairman, Asda Stores. Yet, with transparency comes the need to respond. If a product receives a negative review it stimulates the question ‘what is the buyer going to do about this?’, and Mr Bond stressed that companies have to be prepared to respond to this. “Transparency equals trust. Yes, there are risks in the whole engagement process.” Mr Zein agreed. “If you are not prepared for criticism you shouldn’t be in the digital arena. But, as you are going to get criticism anyway, you may as well get in there. ‘Engaging with’ consumers is far more effective than ‘talking to’ consumers,” he said. “You have to revisit your business model and invite your internal customer base (employees) for good ideas - ‘engagement’ involves everyone: your colleagues and staff, marketing departments, PR and advertising.” Both Mr Bond and Mr Zein pointed out that a ‘viral online’ campaign can make or break a brand in minutes! As shoppers are also increasingly interested in ethics, sustainability and the ‘bigger’ picture food issues, such viral marketing

Food & Beverage International September 2010

“At least 30% of shoppers mentioned ethical values as one of the reasons to try something for the first time. From the latest Havas Media research we see that 80% of the world’s consumers are willing to reward companies for behaving responsibly and 90% will recommend an ethical brand to a friend,” said Ms Denney-Finch. “So, ethical values offer us an opportunity - a big opportunity - to build trust and consumer loyalty . . . to energise our employees and to revitalise growth. In the emerging world, this is even more important. We will only participate in the growth of these countries if we’re seen to be ethical operators.”

every day.” She stressed that when the spotlight moves on from the economy and back on the big global issues like climate change, water shortages and the others, consumer expectations will rise again. “You really do stand at the bridging point between the maintenance of natural ecosystems, the products dependent upon their healthy functioning and the food security of future generations. The cost to the earth and the cost to future generations must become a part of the calculation of the cost of production,” concluded Prince Charles. “When you look back in 10 years time as business leaders, surely you would want to have made a real difference to our collective future security and to your grand-children’s chances of survival?” www.theconsumergoodsforum.com; www.ecomtrading.com; www.rainforestalliance.org; www.ideorg.org; www.igd.com

However, Ms Denney-Finch pointed out that the credit companies receive for ethical achievements are often short lived, and as each new advance becomes the norm consumer attention quickly moves on to a different issue. “The issues are complicated . . . and the hot topics change quickly and unpredictably. Big companies find it difficult to change long held perceptions,” she said, but added that the rewards are worth it. “We asked our European shoppers to look two years ahead and predict what they expect to spend more on. In all five countries, they expect to spend more on all the ethical areas we asked about. This does show people’s aspirations. They want to make a bigger difference and they want us to help. They’re delegating leadership because the issues are complex . . . but shoppers are ready to play their part. And, our industry touches billions of shoppers

Our research found that 40% of Asda shoppers visited a social networking site in the past month, and all customers say that they check on line before buying in store. People are reaching out for help and reassurance from people like them rather than companies like us. Andy Bond, chairman, Asda Stores

Consumer Goods Forum - Global Summit The Consumer Goods Forum is an independent global consumer goods network. It brings together the CEOs and senior management of around 650 retailers, manufacturers, service providers and other stakeholders across 70 countries. The Forum was created in June 2009 by the merger of CIES - The Food Business Forum, the Global Commerce Initiative (GCI) and the Global CEO Forum. Next year’s Global Summit will be held in Tokyo, Japan, next June 15 to 17. www.consumergoodsforum.com; www.tcgfsummit.com

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HEALTHY CHOICES

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Low, lite and reduced product options With consumers demanding indulgent yet guilt-free food for increasingly hectic lifestyles, how can food brands get the low, lite and reduced product challenge right? *By Mat Lintern, managing director of MMR Research Worldwide

he changing nature of the relationship between consumers and food is an increasingly debated topic with growing obesity levels grabbing tabloid headlines and inspiring government action. While today’s consumers can afford to eat as much as they want, they are also being educated that too much salt, fat and sugar is bad for them. This has led to the twin macro trends of ‘food for pleasure’ and ‘we are what we eat’ sitting alongside the third well-recognised trend of ‘food which fits our hectic lifestyles.’ Low fat (or salt, or sugar) foods are a direct attempt to exploit these trends. But how should

food manufacturers decide which products will flourish from the low/lite/reduced treatment and how should they present them to the market?

The dairy dilemma Dairy is a natural product category heavily challenged by its high fat content and indulgence associations. Here, manufacturers have been motivated to explore several different NPD routes to counter the emerging trend of consumers moving from traditional products such as single or double cream used for scratch cooking or desserts, towards lower-fat alternatives such as crème fraiche.

When MMR Research Worldwide explored the low fat cream market, however, the level of engagement from ‘heavy’ to ‘non users’ was disappointing. The reason is the majority of consumers want cream to be an indulgence; a treat for more special occasions. It seems that while cultured dairy produce for cooking is acceptable, when serving a product that is typically partnered with cream, only the real deal will do. Lower fat options are a compromise that consumers are not willing to make. Consumers believe that reduced fat equals reduced taste. There is also some suspicion that reducing the fat content happens at the expense of the naturalness and purity of the product, delivering more processed cues. In this case, to promote sales of existing core cream products based on quality and treating - a deserved indulgence - would be the best way to realise sales potential. Or alternatively, companies can tap into the recession and post-recession trend of cooking from scratch by promoting regular family meals with homecooked desserts. MMR also learnt in its study of cream that low fat product communication should centre on the delivery of the product, and convey that the taste and texture of the low, lite or reduced options are as good as their full fat counterparts, and are as natural.

Snacking habits A contrasting example to this is bagged snacks, a sector that faces enormous pressure to reduce both the salt and fat content of products such as crisps. MMR’s research demonstrates that low fat and low salt claims are actually motivating, even amongst ‘heavy’ consumers. As long as a ‘same taste’ guarantee is present, there is a higher level of appeal and a higher claimed consumption frequency amongst heavy users.

MMR’s online community were asked how to describe foods that are healthy

Food & Beverage International September 2010

Interestingly, the favoured approaches are those that explain the steps taken by the manufacturers to make the products healthier. This approach is construed as honest and credible, and several step-

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HEALTHY CHOICES

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Taste: Ensure low fat, salt & sugar products need to taste as good as their alternatives

Be honest: transparency is appreciated and lends credibility to product changes

Go slow: make gradual changes to the product resisting instant transformations

Be positive: communicate what is in the product and the benefits it brings rather than on what has been removed

Know your customer: identify the key drivers of purchase for your intended audience. Is it taste, health, quality?

MMR Research Worldwide’s top tips for low/lite/reduced products changes, no matter how small, are more believable than one dramatic reduction. They demonstrate that despite the (inherently unhealthy) nature of the product, the manufacturer is doing what it can to make improvements. At MMR, we recommend using messages linked with development and gradual progress rather than overnight reform.

To reduce or not to reduce In future, to know which products have the greatest potential for reduced salt, fat or sugar versions, and to position and target them effectively, manufacturers will need to understand for which consumers their products are designed. They need to ask: Do I want my product’s ultimate selling point to be quality and enjoyment - healthy enough to be permissible but indulgent enough to reassure on taste? Is it a purchase for a less frequent or special occasion? Are consumers looking for the highest quality ingredients? How much do they care if the ‘good stuff’ is left in or the ‘bad stuff’ taken out? We expect the emergence of three core camps of consumers within the next two years. Consumers that are ‘confidently indulgent’ will be looking for quality first and foremost, either due to a ‘couldn’t care less’ attitude or as part of a healthy balanced relationship with food that gives rise to ‘occasional indulgence’. These are the cream consumers for whom low fat creams would offer very little appeal. Consumers that are ‘quietly healthy but tempted by an indulgent appearance’ will buy into brands such as McCain, Innocent, and Jordan’s whose products are sold on the basis of being environmentally-conscious and healthy but whose core communication centres around quality. Finally, consumers that are ‘hardcore healthy’ will be more likely to buy low fat, salt and sugar products and will be prepared to sacrifice taste for these benefits. People may drift from one group to another during different phases of their lives according to age, dieting missions and affluence, for example.

Know your market To understand the success new products might enjoy, concept testing is critical. All too often this type of testing relies on the traditional metric of liking, as well as benchmarking versus normative data. While important measures, these can result in providing little more than a ‘beauty contest’. Instead NPD testing should take a holistic approach and delve deeper to determine whether new products have the potential genuinely to change consumer behaviour.

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HEALTHY CHOICES

Click here to subscribe Is the product attractive to consumers and will it taste nice (the liking part)? Will it meet real needs and requirements? Do consumers actually want a lite, low salt, low sugar version of this product? Is it better, cheaper or different in comparison to any currently available alternatives? Does it have the power to displace existing low/lite products and/or the full fat/normal sugar/salt alternatives?

Explaining your motives The key message for manufacturers from both of the dairy and bagged snack categories discussed is transparency. Acknowledge the reasons for providing a healthier version of a product and let consumers know how this has been achieved. This is particularly important with branded products that are likely to have a loyal group of consumers. Stress that product changes are having the effect of reducing ‘baddies’ rather than reducing taste or enjoyment. The true success of the new bagged snacks example is the fact that it also contained a ‘same taste’ promise. MMR research shows (see graph) that being healthy is more motivating an endorsement than specific low sugar or salt claims, and while low fat is still one of the most motivating claims overall - 43% of consumers look for products communicated as low fat when they are shopping - healthy foods are far more likely to be associated with balanced nutrients, vitamins and freshness than they are with low fat, low salt or low sugar. We believe that foods that have inferred healthiness due to their high quality nature but that do not compromise on taste are

MMR’s ‘Pulse’ food and drink trend tracking information resource asked over 1,000 consumers what food attributes they looked for when shopping likely to be most popular. Prime examples include Innocent Smoothies, Covent Garden soups, Dorset Cereals and Heinz Baked Beans. We will also see a continuing trend towards more wholesome foods and advertising that communicates inherent product benefits such as naturally occurring Omega-3 and wholegrain. In conclusion though, successful low or lite products of the future will be the ones that entice and reward consumers by promoting existing product properties and providing new consumption benefits.

MMR Research Worldwide *MMR Research Worldwide is a leading research partner for food, drink and personal care companies with offices in the UK and the USA. With expertise in sensory research, product testing, NPD and emotion-based research, MMR Research Worldwide provides innovative, creative and scientifically robust research and advises on all product, brand and packaging strategy decisions. MMR Research Worldwide has recently introduced a new research technique that can identify the likely impact on sales of range rationalisation and extensions. ‘SURF’, which stands for Steal and Unduplicated Reach and Frequency, measures the ‘power to displace’ and sources of ‘steal’ and calculates the predicted impact on sales of any change in the product line-up. www.mmr-research.com

Fat reduction in pastry and meat Two new studies, one at Leatherhead International and one at Campden BRI, have highlighted different methods of reducing fat in short crust pastry and in meat respectively. Initial work was conducted with two commercially available fats with significantly reduced saturated fat contents in order to replicate a retailer’s product, which carried the claim of -10% saturated fat content. Reduction of -4 to -5% of the saturated fat content in the pastry dough was attempted through replacement of

Food & Beverage International September 2010

a certain portion of low-saturated fat with polysaccharide-based fat replacers, but the general outcome was poor. However, Leatherhead International was able to optimise the finished product option through the use of the novel processing technology, cryo-crystallisation, on liquid blends of low-saturated fats and rapeseed oil. The result was the formation of a substance, which was more like a regular pastry fat and could be used to create short-crust pastries with a final saturated fat content of -4 to -5%

Campden BRI’s latest Review - Reducing the fat content of meat products provides a background in fat chemistry and summarises the implications of removing fat from meat products. It outlines the methods used to reduce fat in product trials conducted worldwide, including the use of fat replacers in different products, and reviews the literature concerning methods for reducing the fat content of meat products. www.leatherheadfood.com; www.campden.co.uk

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SUPPLY CHAIN

Click here to subscribe taking part from Cadbury and 12 people from Kraft, in three individual teams.

Cadbury pipped companies such as Heinz and Miller Brands to the winning post in the UK’s first Fresh Connection supply chain competition

Supply chain optimisation Sixteen teams competed in the Fresh Connection supply chain competition that calls on the players to focus on all areas of the supply chain network to optimise the performance of a ‘virtual’ ailing fruit juice company By Claire Rowan

ptimising the supply chain took the form of a game for Cadbury and fellow participants including Miller Brands and Heinz in the UK, in the Fresh Connection competition organised by SCALA consulting, which advises companies on supply chain and logistics; sponsored by AEB International, BiS Henderson and Slimstock and supported by the Chartered Institute of Logistics & Transport UK and the Institute of Operation Management. In the interactive, web-based competition, teams of four were challenged with the task of saving a ‘virtual’, ailing fruit juice company from closure and to develop it into a successful, profitable organisation. Over 180 supply chain professionals took part with the top performing teams meeting to conduct the final three rounds ‘live’ and meet

Food & Beverage International September 2010

their goal of generating the greatest possible return on investment for the fruit juice company’s activities. Already held in Belgium and Switzerland, this was the first such Fresh Connection competition to be held in the UK, and Cadbury scooped the final prize.

“The game started in April and we had signed up to take part before the Kraft purchase was complete, so during that time we had not met our counterparts in Kraft,” said Emma Pawson, continuous improvement manager, Cadbury, who took on the role of supply planning manager alongside colleagues from manufacturing, finance, and project management. “Everyone took on a role within the game that was different to their day to day function. Learning about the different functions was our first challenge. Fresh Connection provided a sufficient overview of the functions and the situation without overwhelming us, but deciding what information we should use and what joint decisions we should make was key.” Through teleconferences and one face-toface meeting, the winning Cadbury team successfully assessed each week, over the seven week period, decisions that ensured that each department performed well individually and that ultimately the whole business profited. “The need for communication between the functions and to make sure that we were all working towards a common goal was important. Fresh Connection gave you an opportunity to take a macroscopic view of the business and how one decision in one area would affect another. By seeing the cause and effect of how a decision impacts in different areas and on overall ROI was a real eye-opener,” said Ms Pawson, who explained that different decisions could be made in each round. “In one month you would be able to make vendor management agreements or consolidation agreements, or invest in a new bottling line, for example. We would look at the proposal from each area of responsibility and come to a concensus on the best decision to submit.”

“The competition has really challenged participants by focusing on all areas of the supply chain network - including operations, sales and procurement - and the role-play format has provided an excellent collaborative platform for team building and developing real understanding of supply chain strategies and tactics within a competitive environment,” said John Perry, managing director of SCALA Consulting. Adding an extra dimension for the Cadbury teams was the fact that there were 12 people

Fresh Connection enables companies to develop strategic thinking in a virtual environment, without risk in the ‘real world’. By doing so, weak areas in the supply chain network can be identified and improved upon so that professionals will be better informed when employing those procedures in their own organisations, according to SCALA. www.thefreshconnection.co.uk

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SUPPLY CHAIN

Click here to subscribe Supply chain themes such as the balance between efficiency and responsiveness, vendor managed inventory (VMI), supply chain risk management, lean supply chain management, push-pull points and sales & operations planning are covered by the Fresh Connection game, which draws on an advanced simulation model to give realistic results.

said Ms Pawson. “If we can assess how

The competition experience and the holistic view of the business that it gives has already had a positive impact on Ms Pawson’s work as part of the customer logistics team within Cadbury where she runs two teams. One team is currently looking at the supply chain capabilities for Cadbury customers and how the company can optimise its systems or electronic platforms or lead times in order to reduce costs for both parties; and another team is looking across our Customer Logistics functions to identify improvements to drive service and cost optimisation.

in one area of the supply chain on another

“We are looking at value stream mapping to really map out, end-toend, our supply chain processes to understand where there are opportunities to reduce waste in the process,”

the process works in reality rather than how it should we can really understand our true processes and make a step-change in efficiency.” With the integration of the two businesses, the streamlining of operations will be vital to ensuring profitable operations. Understanding the impacts of a decision will be vital to ensuring the holistic benefits of any developments. Environmental considerations also have to be made and as a joint enterprise both Kraft and Cadbury have introduced initiatives that improve the environmental credentials of their brands in the supply chain. “We have common goals and together Kraft and Cadbury will have a much stronger portfolio of offers than we have had separately,” said Ms Pawson. www.scalagroup.co.uk

Cadbury is currently looking at how the company can optimise its systems or electronic platforms or lead times in order to reduce costs for both Cadbury and its customers

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September 2010 www.foodbev.com

INGREDIENTS

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Almonds on the rise Almonds are the number one ingredient nut in new products worldwide for the second consecutive year, according to the 2009 Mintel Global New Products Database. Europe continues to introduce more almond products than any other region, making up 38% of the total new products, and the number of almond product introductions in 2009 was up by 27% compared to the total new products with nuts launched in Europe, which increased by 18%.

SVZ International, which produces a wide range of fruit products, highlights the growth in demand for added value snack mixes based on dried fruit, nuts and seeds

Healthy snacks on the increase In Europe, the number of new added value snack mixes based on dried fruit, nuts and seeds rose by 22% last year, according to figures from SVZ International, which produces a wide range of fruit and vegetable ingredients including juices, juice concentrates, purées, concentrated purées, compounds, individually quick frozen fruit and Verifruit – dried infused fruit/fruit pieces. Snack mixes similar to the US trail mix products that include dry fruit, nuts, seeds and sometimes chocolate or candy pieces, along with snack packs of dry fruit and nuts in general are on the rise in markets such as Germany and the UK, says SVZ. In Spain and France, dry fruit snack packs are especially popular. “Added value nut mixes (including nuts and dried fruit) are the main reason for growth in the UK snacks market: registering double digit growth,”

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said Joyce van Praat, product group manager Verifruit, SVZ, who suggested that, together with the development of the snack dry fruits and seeds segments, this indicates that there is demand shift towards healthier snack products. “Snack nuts, seeds and dry fruit benefit significantly from a healthy image: research points to their high nutrient content. High levels of iron, magnesium, potassium, zinc and folic acid content are combined with high levels of vitamins and antioxidants.” SVZ’s Verifruit products are available as standard or infused with apple juice concentrate, and come in blackcurrant, sour cherry, blueberry, cranberry and strawberry varieties. For the apple juice concentrate infused products, the product label will only list fruits with a small amount of oil as a coating. www.svz.com

“Consumers are increasingly health-conscious and interested in what they eat,” said Dariela Roffe-Rackind, associate direction, European Region, Almond Board of California (ABC), who pointed out that years’ of clinical research points to almonds’ valuable nutritious profile – claims can be made that ‘almonds are naturally high in monounsaturated fat’, ‘almonds are naturally high in fibre’, and ‘almonds are naturally salt-free’. Recent research by the ABC in the UK, Germany and France revealed that nearly two thirds (62%) of consumers would be more likely to buy a product if it contained almonds, while 64% said products containing almonds were ‘more nutritious’. “This makes them an attractive choice for manufacturers in all kinds of sectors but especially in the confectionery,

baking and snacking industry,” said Ms Roffe-Rackind. In Europe, confectionery remains the top category for almond introductions with 28% of new almond products appearing in this category, according to Mintel. Bakery is the second most important category in Europe with 24% of new products appearing in this sector. “Food manufacturers also seem increasingly aware of almonds’ value and versatility as an ingredient and the fact that almonds are in demand by consumers all over the globe, as evidenced by all the new product activity,” said Stacey Humble, director, North America marketing & global strategic initiatives for ABC. According to the ABC research the primary reasons for manufacturers to incorporate more almonds in their products were consumer demand/appeal (39%) and health attributes (27%). 55% of respondents stated that almonds have a broad consumer appeal and 41% that almonds work across multiple categories. In addition, 56% said that almonds go well with a large variety of flavours while 44% stated that they delivered varying taste and texture. www.almondboard.com

New products containing almonds increased in 2009, and research by the Almond Board of California has revealed that 62% of consumers would be more likely to buy a product if it contained almonds

September 2010 www.foodbev.com

INGREDIENTS

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Chocolate inclusions with a nutrient value Herza Schokolade has worked with its sister companies in the Stern-Wywiol Gruppe, SternVitamin and SternLife, to create a wide range of novel inclusions. “More and more manufacturers are discovering the potential for unusual options – for example, mueslis that boost performance or have a beautifying effect,” said Andreas Broocks, plant manager at Herza Schokolade. “Thanks to intensive co-operation with our sister companies, we can develop chocolate pieces capable of promoting mental and physical fitness. The theobromine naturally present in cocoa is in itself an aid to concentration, and by adding lecithin granulate it is possible to

Food & Beverage International September 2010

improve memory too. Biotin and bamboo extract can be added as ‘beauty food’, and caffeine and similar vegetable substances have a vitalising effect.” One of the advantages of having the active ingredients included in the chocolate pieces, is that it reduces the number of ingredients to be handled by manufacturers of the mueslis or cereal bars for example. Effectively, the chocolate inclusions can be used as a ‘premix’, according to Herza. “By using sugar replacers or fortfiying the products with the natural prebiotic fibre inulin, for example, we can develop special chocolate pieces to meet the requirements of individual customers and the growing

Herza Schokolade offers chocolate pieces fortified with nutrients health market,” said Mr Broocks, who also pointed out that the company can supply functional chocolate pieces fortified with

bioactive substances such as vitamins, Omega-3 fatty acids and other essential nutrients. www.herza.de

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INGREDIENTS

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Wheat concentrate for baked goods Limagrain Céréals Ingredients (LCI) has launched absoluteWHEAT, a nutritional concentrate of white wheat, which allows manufacturers to add the nutritional benefits of white wheat to products such as bread, precooked loaves or baguettes, whole wheat crepes, croissants, pasta, biscuit and breakfast cereals. Produced from speciallyselected white wheat varieties from Limagrain’s (LCI’s parent company) breeding programme, absoluteWHEAT is clean label, has taste and colour benefits and is easy to use. “absoluteWheat is a true concentrate of the nutrients of wheat – such as minerals, vitamins and fibre – and has a big plus in taste and colour,”

LCI’s new absoluteWHEAT is a concentrate of white wheat that imparts nutritional benefits to baked goods said Anne Lionnet, marketing manager for Bakery, LCI. “Because it comes from white wheats, the ingredient has an attractive light colour. The product also has reduced bitterness compared with standard wheats.” www.lci.limagrain.com

Fruit in tiny pieces Taura Natural Ingredients has extended its range of Ultra Rapid Concentration (URC) fruit pieces, flakes and pastes with the introduction of Mini Fruit Bits, which are designed to deliver the taste, texture and health benefits of real fruit in extra small sizes, which ensure a greater distribution of fruit in a wide variety of products. Mini Fruit Bits have been developed specifically for rotary moulded biscuits, chocolate moulding or as a visible sprinkle on cookies and snack bars and are the smallest dice sized fruits in the Taura range. At just 3 x 3 x 2mm in size, the Mini Fruit Bits are designed for ease of processing to ensure even fruit piece distribution throughout the finished products and therefore give a fresh, fruity burst in every mouthful.

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Taura Natural Ingredients has introduced extra tiny fruit pieces, Mini Fruit Bits “Based on market feedback, we knew we needed a solution that enables real fruit inclusions to be completely enclosed in chocolate tablets or thin biscuits,” said Matthias Van Uffelen, sales manager for Europe. The Mini Fruit Bits join the rest of Taura’s URC fruit products, which guarantee a high fruit content, low water activity and bake-stable ingredients. www.tauraurc.com

September 2010 www.foodbev.com

INGREDIENTS

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Fruit-sweetened cranberry inclusions Natural fruit-sweetened dried cranberries have been introduced by Ocean Spray for cereals, trail mix and baked goods applications. Launched at the IFT exhibition in Chicago in June, the dried cranberry pieces are infused using a patented process with pineapple syrup as a natural sweetener, which avoids the need for sugar to be highlighted on the ingredients listing. As with all Ocean Spray cranberry ingredients, the new fruit-sweetened pieces have high process tolerance and are easy to incorporate into a wide range of production processes. They are made from superior grade cranberries and dried to a specified moisture content, depending on the characteristics required. “This latest addition to our extensive ingredient portfolio is based on customer demand for

Sipal Partners has extended its Sipal range of concentrated cereal bases for beverages with a new organic oats base for drinks.

Ocean Spray has launched fruitsweetened dried cranberries in response to customer demand for all-fruit ingredients ingredients with all-fruit appeal,” said Marion Burton, marketing manager, Ocean Spray, which provides sweetened dried cranberry ingredients such as BerryFusions Fruits, 100% cranberry purée, cranberry concentrate and cranberry powder - all of which offer the health benefits associated with cranberries. www.oceanspray.com

Replaces fruit pulp National Starch Food Innovation Europe has introduced a new fruit pulp replacer that is said to offer cost-savings for mango fruit juice beverages.

gives pulpiness and good stability over the products life as well as a neutral flavour profile that ensures the freshness of the fruit beverage.

Precisa Pulp 02 is a low cost-inuse beverage texturiser, which

“Exotic drinks, such as mango fruit juice, continue to grow in popularity. This has created the need to optimise formulations to offer consistent quality, texture and flavour,” said Mona Rademacher, European marketing, beverages National Starch Food Innovation.

Precisa Pulp 02 from National Starch Food Innovation has been developed to provide a cost efficient fruit pulp replacer for mango beverages

Food & Beverage International September 2010

Concentrated oat base for beverages

“At a time when beverage manufacturers continue to focus on value, we’ve developed Precisa Pulp 02 to help our customers deliver authentic beverages while keeping costs in check.” www.foodinnovation.com

Sipa-Oat 35 makes it possible for formulators to create a 100% vegetable beverage, which is free from lactose, cholesterol or added sugar. It can be formulated by diluting with water and combining with other ingredients such as oil, flavours or emulsifiers, to create an oatbased beverage that is ready for processing or filling. Produced using a natural, clean process without demineralisation, which ensures the preservation of the nutrients in oats, Sipa-Oat 35 syrups are concentrated at a low temperature to preserve the

Sipa-Oat 35 is the new organic oat base concentrate for beverages from Sipal Partners flavour of the oats for use in products such as beverages, but also desserts and ice-creams. Sipa-Oat 35 contains 75% dry matter, and is also available in conventional as well as organic form. It joins Sipal’s rice base for beverages in its range of over 25 cereal and dried fruit concentrates. www.sipalpartners.com

Optimised bakery fillings For creating texture in bakery fillings, Cargill has worked with its pectin and starch ingredients to develop systems which provide an optimum performance. “Whereas traditionally pectin and starch are offered in competition to each other for bakery filling applications, Cargill can offer the best solution – whether this is a single ingredient or in combination,” said Virginie Langendorff, processed fruit application leader for EMEA at Cargill, which has worked to design new textures and functionalities to suit a wide range of different filling applications. The new solutions are obtained by using specific combinations of the company’s Unipectine pectins and starches from Cargill’s C*Tex, C*CreamTex and C*PolarTex ranges and can be developed for

ready-to-use bakery fillings and highly tailored formulations. The pectin-starch formulations are suitable for the gamut of different bakery fillings, from acid to neutral, with high or low solubility, and for bake stable to post bake applications. Cargill can also draw on the other hydrocolloids in its range such as locust bean gum, guar gum, carrageenan or alginate in order to fine tune recipes. www.cargill.com

Cargill has pooled its knowledge of pectins and starches to optimise its Texturising options for bakery fillings

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INGREDIENTS

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Soy protein concentrate expands options Solae has introduced a new line of soy protein concentrates with new properties and characteristics that extend the benefits of soy protein concentrates to products such as ready-to-drink and dry blended beverages, frozen desserts, puddings, cream fillings, cheeses, yoghurts, sauces and confectionery. Created using a new proprietary and patented membrane processing technology, with water extraction, similar to dairy industry technology, the ALPHA 5800 range of soy protein concentrates offers excellent taste and texture attributes and a high protein content. “We hold the patent for this technology to create unique soy protein concentrates that can be used in a wide range of applications compared with standard soy protein concentrates, which are traditionally only used in meat or meat analogues,” said Andrea Burr, product line management, Solae. “Compared with other soy products, the ALPHA 5800 line is a little sweeter and imparts a more cereal flavour, which enhances the flavour of soy.” The ALPHA 5800 line is also said to have many of the same characteristics as whole bean extract, but with a far

Solae’s new Alpha 5800 line of soy protein concentrates are high in protein and suitable for use in a wide range of product applications higher protein and lower fat, carbohydrate and sodium content. “ALPHA 5800 has a stable 78% protein content (on a dry weight basis), so, it is possible to make soy protein beverages, for example, without additional protein fortification,” said Ms Burr. “It gives a lovely creamy mouthfeel. So it really opens up the possibilities for the use of soy.” According to Michele Fite, vice president of global marketing & strategy & specialty business, Solae, “The ALPHA 5800 product line is a great solution for alternatives or complements to dairy proteins. These products help food manufacturers achieve ingredient cost savings and margin improvement while providing high-quality ingredients, great taste and nutritional benefits for the end consumer.” www.solae.com

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September 2010 www.foodbev.com

PACKAGING

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Time temperature indication OnVu, the time temperature indicator (TTI) emblem developed by BASF in partnership with Freshpoint is an active ink technology that provides a dynamic, real time indication of the temperature and time that a product has experienced during its life time and therefore highlights whether it is suitable for consumption or not (see p45.FBI.June 2006). Since FBI first wrote about the technology in June 2006, it has been taken up by numerous players in the industry; been optimised for use in the cold supply chain by food manufacturers, distributors and retailers; and developed for use for frozen products. Kneuss Güggeli was the first producer in Central Europe to introduce an OnVu label for its range of chicken products. In the USA, OnVu is already used in store at the retailer Harris Teeters and a major retail customer in Europe will be introducing OnVu at the

end of this year, according to BASF, which with its other partner in the development of OnVu, Bizerba - a leading supplier of labelling equipment, has developed equipment that allows the integration of the smart OnVu emblem into existing thermo price/weight labels. The technology is said to allow this integration of OnVu without added complexity or work for manufacturers. “During the various transitions from loading to shipping to a new cold store, to an interim storage facility and finally to the end consumer, a lot can happen - it is a long journey,” said Daniel Kneuss, CEO of Kneuss Güggeli. “With the OnVu TTI, we can show evidence of whether anything has gone wrong in the various stages. With these labels, we give consumers the means to check the freshness and quality of our products.” While OnVu is primarily used on the item level as a tool to support consumers with their chilled products, the OnVu Logistic label can be used for monitoring the entire supply chain for both chilled and frozen applications. It is a low cost, easy to use tool that highlights the true state of the product throughout the supply chain and can be applied to each item, carton or pallet for all perishable foods requiring refrigeration. Designed to be used in conjunction with a defined ‘hand over’ policy, the OnVu Logistic label - by changing

OnVu shows at a glance whether a product has been transported and stored correctly during the supply chain or after purchase. A dot turns a lighter colour than the surrounding area if the admissible temperature has been exceeded for a prolonged period and the product is no longer fit for consumption

Food & Beverage International September 2010

colour at a rate determined by the temperature conditions the food has been exposed to - allows each party in the chill chain to see the product’s state of freshness. This allows manufacturers, distributors and retailers to ensure that the food they are receiving and/or selling has been correctly handled up until each check /hand over point. “Compared to data loggers currently widely used, OnVu Logistics provides an upto-date (rather than historic) visual indication of whether the product conditions have been abused or not prior to any given checkpoint in the supply chain,” said Martin Angehrn, senior manager head marketing & sales - TTI. “In certain parts of the chain, such as transport or storage, the OnVu label is applied to every box and stays there along the complete chain all the way to retailer.” The latest development, the OnVu Thaw Indicator is used to provide a visual indication of whether a frozen product has thawed during its lifetime. Once applied to the frozen product and activated at the point of packaging, the OnVu Thaw Indicator goes through a clear, irreversible colour change of the active intelligent ink if any major temperature abuse has occurred.

Metal based TTI BASF’s development partner, Freshpoint, which specialises in the development of intelligent packaging solutions, has also recently perfected several further technologies. Freshpoint’s CoolVu Thaw & Sell (T&S) TTI is based on aluminium rather than coloured ink technology. Essentially two labels are applied to a pack

As CoolVu is based on metal rather than chemical technology it lasts longer - even years, so can be used on long shelf life products

with the top label being made of aluminium and the bottom label containing an active component that can gradually ‘etch’ away the aluminium above. “With the CoolVu metal technology there are many variables that can be changed easily. By making the aluminium thicker, for example, you can extend the recorded length of shelf life of a product,” said Yoav Levy, CEO of Freshpoint. “As CoolVu is based on metal rather than chemical technology it lasts far longer – even years, so it is suitable for longer shelf life products.” CoolVu T&S can be used for products that are stored frozen before defrosting ready for sale, and whose ‘best before’ or ‘use by’ date is determined from the point of thawing - products such as baked goods including pastries, cakes, muffins; pizzas;

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PACKAGING © 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.

Click here to subscribe sausages, seafood; ready to eat meals,

modified atmosphere pack. The first

signal when read by means of a proprietary

fresh fruit and others. Applied at the point of

O2Sense is an eye-readable indicator

reader situated on the production line. It

packaging, the CoolVu T&S is not triggered

that gives a clear, visual indication - by

is designed as a quality assurance tool

until the products are thawed for sale. At this

means of a colour change - if the amount

for producer to ensure that each pack

point its time temperature ‘clock’ begins to

of oxygen present in a sealed pack is

contains the correct level of oxygen, and

tick and ultimately provides a clear visual

within the specified limits. It is intended

as with the first O2Sense, is suitable for

indication of the end point of a product’s

to alert producers, retailers or consumers

use on meat, fish, ready to eat meals, dairy

shelf life.

if there has been a breach of integrity in

products etc. Both O2Sense systems are

the package that could lead to an unsafe

able to detect levels of oxygen from zero

product. For manufacturers, a second

to 100%.

CoolVu’s T&S label is designed to eliminate the need to place date codes on products at the point of thawing, and protects brand owners by ensuring that expired products can be identified and removed from display, according to Freshpoint. Freshpoint’s CoolVu metal TTI technology can also be effectively applied to turn a standard barcode into a smart traceability tool for the refrigerated supply chain, which is activated by time and temperature. Depending on predefined parameters, time or temperature abuse will cause the CoolVu Active Barcode to change its optical properties - this could make an additional part of the barcode become readable, for example. The message/messages from the barcode can be read electronically at any point in the supply chain to provide crucial ‘go’ or ‘no-go’ information. The barcode is flexible in size and design and can be used on cartons or crates. It is compatible with any industry standard barcode protocols and requires no software adjustments to existing barcode generation or supply chain software. CoolVu metal TTI technology-based RFID systems that enable monitoring and transmission of the temperature history of product are currently under development. Other pipeline technologies from Freshpoint include the Time-IT, low cost, smart device for consumers to use when opening packages at home. The device indicates the time lapsed since it was activated, which informs consumers when the product it is applied to, and they have just opened, must be used. The indicator is activated the moment the product is opened and is suitable for use on all products that have a limited shelf life after the package seal integrity has been breached. Still under development, Freshpoint’s O2Sense is a range of patent-pending oxygen sensing products that communicate how much oxygen is present in a sealed

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O2Sense system is a machine readable indicator that elicits a clear electronic

www.onvu.com; www.freshpoint-tti.com

PACKAGING

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Oxygen barrier for sensitive beverages Invista has received regulatory clearance in both the USA and EU for its OxyClear barrier resin, which is said to give the clarity and shelf life performance of glass to a PET container. Suitable for use for oxygensensitive products such as juice, wine, beer, dairy and fortified water as well as ketchup, sauces and other condiments, OxyClear barrier resin is an oxidisable, polyester-based, high-capacity oxygen absorber. Our customers repeatedly asked for a clear, polyester-based oxygen ingress barrier resin to replace glass, multi-layer barriers and other containers for oxygensensitive foods and beverages. Our answer is OxyClear barrier resin,” said Chris Hamman, president of Invista Polymer & Resins, which claims that

colourless and tinted containers made from OxyClear barrier resin showed the same clarity as containers made from standard PET. In its tests, Invista demonstrated that 500ml, 35g PET bottles with 2% OxyClear barrier resin preserves the taste and protects the flavour of water for at least six months; preserves the freshness and taste of beer for at least six months; and preserves vitamin C in juice for at least nine months. In 750ml, 50g bottles, the same amount of OxyClear preserves the taste of wine for at least 18 months at room temperature. OxyClear operates as a two component barrier system. Up to 3% of OxyClear resin is blended at the injection machine with Invista’s well-proven barrier

resin used in beer packaging, PolyShield. The oxygen barrier is activated on addition. OxyClear contains no nylon or nitrogen that can contribute to yellowing during recycling, and demonstrates significantly reduced yellowing during the recycling process compared to other commercial oxygen scavengers, according to Invista. In the EU it can be used for all food types for hot fill up to 100˚C, with subsequent cooling below 70˚C within 15 minutes; and filling and storage at room temperature up to 40˚C and below. www.invista.com

Invista’s new oxygen scavenging technology is said to give PET the same properties as glass in terms of clarity and shelf life

Protection against oxygen and light ColorMatrix has introduced its new oxygen scavenger with barrier properties for oxygensensitive products and a light blocking technology for PET dairy packaging, which ensures high performance light-blocking properties at low addition rates. Amosorb SolO2 is ColorMatrix’s high performance PET barrier technology, specifically developed to help extend the shelf life of oxygen-sensitive beverages such as beers, wines and juices where empty bottle storage may be required. It combines oxygen scavenging with barrier properties to give protection from O2 ingress and CO2 loss, and therefore prevent product degradation. Compared to PET with standard Amosorb, it can delay CO2 egress by up to 30 days and protect from O2 ingress for up to four months

Food & Beverage International September 2010

longer. It is suitable for use with any type of PET resin and is suitable for both mono-layer and multi-layer PET containers, and is said to offer good container clarity while providing exceptional scavenging capability. For single and multi-layer PET containers, ColorMatrix’s new light blocking technology, Lactra, gives protection from UV and visible light at wavelengths of up to 550nm, which is critical for prolonging the shelf life of milks, yoghurts and dairy beverages. Unlike traditional opaque white colourant systems that are typically dosed at around

20%, Lactra has an optimised particle size that allows it to be used at an addition rate of only 6 to 8% yet provide the same light blocking performance in the finished product. Lactra is dispensed using ColorMatrix’s latest generation liquid carrier system, CoolRun, which ensures consistent colour distribution and highly stable processing at reduced temperatures, which can help to minimise or eliminate the development of AA (acetaldehyde) often associated with PET processing at high Oxygen scavenging and protection for sensitive product applications, and UV & visible light protection for PET containers are the focus of new developments from Colomatrix

temperatures and therefore helps to prevent any off-taste in the finished product. CoolRun’s capabilities combine with Lactra’s improved dispersion properties and enhanced pigment particle size to give an even colour distribution and stable processing conditions even at reduced temperatures, and give maximum light reflection from minimal product. Depending on the degree of opacity, visual appearance and container type required, Lactra can be supplied in several different options: Lactra:Silk, Lactra:Matt and Lactra:eXtraShield, which gives the optimum light protection and balance of aesthetics and opacity, according to Colomatrix. www.colormatrix.com

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PACKAGING

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Thermochromic ink indicates temperature Grolsch worked with Rexam Beverage Can Europe to develop its 330ml cans of beer featuring a ‘Cool meter’ (‘Koel meter’) that uses thermochromic inks to indicate when the beer inside is cold enough to drink. The ink, which was developed in partnership between Grolsch and Rexam, begins to change colour at 11˚C, and turns blue when the beer has reached the ideal drinking temperature (between 6-8˚C). “The ink has been reformulated and improved to provide a better depth of colour at the required temperature,” explained Ann Bonner, market manager, Rexam. “For the consumers it means that the colour of the ‘Cool meter’ is more clearly visible and therefore it is easier to check when the beer is chilled, giving the ultimate, pleasurable drinking experience.” The temperature change interval is set by Rexam in consultation with Grolsch, and the colour of the ink changes back to the

original colour of white when the beer becomes warmer. “With the ‘Cool meter’ Grolsch makes the consumer aware of the temperature of his or her beer in a unique way,” said Jan Nales, director of marketing at Grolsch. “It adds value to our cans, which many will enjoy.” Rexam has also supplied Carlsberg with limited edition cans that draw on thermochromic ink technology for Carlsberg’s Somersby Apple Cider in Denmark. The 330ml aluminium promotional cans are produced by Rexam’s Fredericia plant in Denmark and feature a golden tree that turns blue when the product inside is at the correct cool temperature for drinking. “The thermochromic ink on these limited edition cans functions as a perfect indicator for the cider’s drinkability,” said Marc Larsen, marketing consultant for Carlsberg. “It is a way to ensure that consumers enjoy ultimate refreshment in the hot summer months.” www.rexam.com

Grolsch and Carlsberg have worked with Rexam to create cans featuring thermochromic inks to let consumers know when their products are at the right temperature for drinking

Easier opening for cans Impress has extended its range of easy-open ends with the introduction of its OptiLift, easy to pull ring end for cans. Compatible with a range of different customer processes, OptiLift is the result of Impress’ ongoing activities to improve the performance of its can ends to address consumer convenience for consumers of all ages and to ensure a reduction in packaging weight. Featuring a patented mechanism, OptiLift has a flexible panel, which is convex

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before seaming and becomes concave after sterilisation. This development results in a gap between the panel and the tab, which provides a ‘finger well’ that is said to guide the finger to the correct position for ease of opening. During Impress’ research in Germany and France, 75% of consumers who tested the end expressed a preference for it - consumers with long finger nails and those suffering from arthritis were said to be particularly happy with its performance.

The OptiLift end is also based on a new technology that enables lower thicknesses of steel to be used but give performance values comparable with currently existing ends, according to Impress. It is available in a full range of diameters of steel easy open ends - 65, 73, 83 and 99mm, and the 73mm version offers savings of 10% in weight compared with the Soft Lift

Impress has improved the ease of opening of its can ends with the introduction of the patented OptiLife end and EZO lids currently available from Impress. www.impressgroup.com

September 2010 www.foodbev.com

PACKAGING

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Valves dispense sauces with bits For condiments with vegetable pieces, Zeller Plastik UK has perfected a new lightweight hinged flip-top dispensing closure with a specially designed silicone valve.

Heinz Condiment Sauces are dispensed through the new closure from Zeller Plastik UK

Already being used by Heinz for its range of eight Condiment Sauces, including four new varieties launched earlier this year, the new 38-400 polypropylene closure is said to be 20% lighter than Zeller’s original version. It provides an increased flow rate of 125% due to the extended length three-slit design of the valve, which allows vegetable particles of up to 4mm to be dispensed easily. Heinz’s Condiment Sauces, including cocktail, barbecue, curry mango, American and

exotic are packed in 220ml squeezable PET containers, with the new Zeller closure, and are distributed in Germany, France,

Belgium, Spain, The Netherlands and Scandinavia. Zeller Plastik UK can provide tamper evidence for both PET and PP multilayer

bottles with either Lift n’ Peel or peelable induction heat seal liners. www.ucpzeller.com

Laser perforations possible

Multivac can now offer its FreshSAFE packaging concept for cheeses, baked goods, fruits, vegetables and mushrooms with the enhanced option of laser perforation technology, which produces microperforations on normal plastic film inline before sealing on thermoforming or tray-sealing packaging machines.

which ensures that smooth, clean

The use

edges are produced.

of laser

According to Multivac, compared to the traditional method of perforating the film with needle rollers, laser technology can produce microperforations with precision at any point of the utilised upper web, in the desired number, and with precisely defined diameters. The concentrated light beams of the lasers produce microperforations on the upper

0.1mm, accuracy is key, and the

web by melting the material,

Food & Beverage International September 2010

Microperforated film is used to extend the shelf life of fruit, vegetables and mushrooms that have high levels of respiration; to improve the crispiness of baked goods; or allow the formation of desirable white mould on soft cheeses or Harzer cheeses, for example. With required perforation diameters of less than laser technology can ensure that microperforation is consistent, as well as flexible and virtually maintenance free, according to Multivac.

technology is suitable for automated solutions where rapid adjustment of the film permeability is necessary. It allows labels to be placed anywhere on the packaging with the microperforations simply being omitted from the area where the label is to be placed.

Multivac has perfected the use of lasers for creating microperforated plastic film inline before sealing on thermoforming or traysealing packaging machines

The technology can be

“After adjustment, the laser

integrated into a packaging

perforation requires no further

machine without changing the

maintenance,” said Matthias

components and is controlled

Maisel at Multivac’s Applications

directly from the user interface

Centre. “Even after 30,000 hours

on the packaging machine.

a laser works as precisely as it

According to Mutivac, all current

did on the first day.”

upper webs can be adjusted

by means of the laser perforation technology to the specific permeability required in each application, which provides greater control of shelf life and less waste. www.multivac.com

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SIAL & IPA PREVIEW

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Food Industry gathering Paris will be the centre of attention for the food and drink industry in October when IPA, the world food process exhibition, will take place from October 17 to 21, alongside the global finished product exhibition, SIAL; and the semi-processed food products, ingredients, additives & outsourcing solutions event, In-Food, at Paris Nord Villepinte

eing brought together for the first time this year, the IPA, SIAL and In-Food exhibitions will allow visitors to discover the latest developments in all sectors of the industry from the finished food or beverage product through to the technology and ingredients required

technology, materials and equipment, as well as packaging technologies, machinery and materials as the 600 exhibitors at IPA take the opportunity to demonstrate their innovations in Hall 7. The solutions on offer will cover: 44% food transformation; 9% packaging; 8% command & control of manufacturing;

to produce it.

8% design, construction & maintenance of factories, hygiene; 8% energy & fluid processing & production, and environment; 7% harvest - slaughter & first transformation; 7% handling & storage; and 7% industrial catering, food sales equipment.

“Displaying the whole food processing chain, starting from processes with IPA up to finished products with SIAL will provide all industry players with a comprehensive and consistent offer encompassing the whole food industry,” said Adeline Vancauwelaert, group director, for the SIAL exhibition, which will house 19 product sectors in five halls. Visitors will be able to discover the latest innovations in beverages, cured meats, preserved foods, grocery products, gourmet foods, fruits & vegetables, organic products, seafood products, health products & supplements, dairy & egg products, frozen foods, bakery, pastry & confectionery, delicatessen products, meat, wines, poultry & game, In-Store solutions & services, and nutrition & health. Over 5,500 exhibitors will demonstrate their activities at SIAL to an expected 148,000 trade visitors. A special Sustainable Development area in Hall 1 will provide an overview of world issues involving social & environmental responsibility and stewardship in the food sector, including biodiversity, carbon reporting, eco-friendly products and packaging, environmental impact disclosure and more. Information on the latest social and environmental issues that the food industry is having to face as a result of economics, consumer behaviour and legislative developments will be discussed in the Sustainability in Food Business conference programme. Around 44,000 food industry professionals are expected to discover the latest in processing

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The Innovation Research Forum has been created to bring a free conference programme to visitors looking for news of the latest research & development work; technological advancement in process engineering, with innovation specifically applied to the food processing industry. The results of over 20 European research projects will be unveiled in the mornings of both Tuesday, 19th October and Wednesday, 20th October. Presentations on the challenges and progress of the European Food for Life platform will be given along with news of combating pathogens (PathogenCombat project); improvements in the sanitary safety and quality of bovine meat (ProSafeBeef); assessment of risk of chemical contamination by packaging (TrueFood); the effects of new packaging-related non-thermal conservation technologies on the quality and safety of ready-to-eat products (HIGHQ RTE), and the design of innovative biodegradable packaging solutions (Novel Q). Further innovations will be unveiled on Monday, 18th October when the results of the IPA Innovation Competition, which is open to exhibitors at the show, will be made and the winners awarded. In the Process & Equipment category shortlisted companies include Clauger for its combined hot & cold production skid; JBT FoodTech for its SuperAgi system for rotary sterilisers; and Sammode for its Celsius, LED lighting range

IPA opens its doors alongside SIAL for the first time this year, bringing the industry the latest innovations in processing technology and finished products together at Paris Nord Villepinte

designed for extremely low temperatures. Nominated for the Research & Technology Award are: JBT FoodTech for its CCM3 insulating ceramic coating alternative to conventional rock wool insulation; Photoclean Quartz for its low temperature Compact AirPur stand-alone low temperature resistant air decontamination unit; and Realco for its Biorem C+12 biofilm. Bizerba France and PBCSoft are nominated in the Process Management & Control Award for their CWP-Neptune, single belt, and innovative Enviro Suite software, respectively. Bizerba France has also been nominated for its automated, vision-based control system in the Packaging Award category along with Coltivia for its aerosol packaged pasteurised fresh egg liquid; and Montajes Conserveros de Galicia for its irregular can vacuum sealer. www.ipa-web.com; www.sial.fr

September 2010 www.foodbev.com

PROCESSING

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Chilling for baked goods Heinen has adapted its Arctic spiral cooler for use in the baking industry. The Arctic bread cooler is designed to give continuous and precise control of the climate within the cooling chamber including air temperature, air humidity and air speed to very tight operating tolerances to ensure the highest finished product quality. Run independently from the production room, the internal climate control system ensures a consistent production environment is maintained within the chiller regardless of the prevailing weather or processing conditions and ensures consistent production of a wide range of baked goods up to 18cm in height. The Heinen Arctic spiral cooler has also been designed to prevent product from drying out as a result of the low

temperatures or high air speed and is available in belt widths of 660mm, 760mm, 914mm, 1,067mm and a number of tiers from 12 to 32. The cooler operates at air temperatures of 15 to 25°C, with a relative air humidity of 55 to 75% and air speed of less than one metre per second. The insulated chamber features overpressure to counter contamination from non-filtered air entering the enclosure, and all incoming air is filtered. A horizontal and laminar air flow through the whole system guarantees a gentle and uniform cooling of the product, according to Heinen, which has optimised the software for the air conditioning unit not only to control the climate, but also to ensure the best air mix and energy usage. Product can dwell from 30 minutes to four hours within the chamber according to the

Heinen’s Arctic spiral cooler has been developed to handle a wide range of baked products up to 18cm in height variable belt speeds, which can be adjusted to move at 5m per minute up to 25m per minute depending on the application, and to spiral upwards or downwards according to plant requirements. Heinen’s Arctic spiral cooler technology for conditioned bread

has already been implemented at a customer in Poland where 1,600 x 1kg bread products per hour are cooled from 90 to 26°C. This particular 7/20 cooler unit has a footprint of approximately 7 x 8m and a height of 5m. www.heinen.biz

Weighers for frozen lines Ledo, Croatia’s leading frozen food manufacturer has invested in three weighing and packing lines from Ishida Europe for its frozen vegetables, fish and pastry.

Ledo has invested in three weighers from Ishida Europe to reduce giveaway and increase production of its wide range of frozen products

Food & Beverage International September 2010

With four production sites in Zagreb, Daruvar, Bejlovar and one in Citluk (Bosnia) Ledo was looking to improve the quality and efficiency of its production. Using its existing multihead weighers, Ledo was experiencing a typical overweight of 10g per 500g bag of both frozen pastry and vegetables. With the new Ishida weighers it is achieving an accuracy of within 0.7g on 500g bags of frozen vegetables and 1.7g on 500g packs of frozen

pastry. In addition to reduced giveaway, production capacity on these two product lines has doubled while staffing levels have reduced by half. The frozen vegetable line at Ledo’s Zagreb factory now uses a CCW-R-216B-2M/30WP multihead weigher with three litre hoppers. It is capable of handling two separate products for discharge into the same bag and can handle 500g bags at up to 100 packs per minute. The frozen fish and seafood line at the Daruvar factory features an Ishida CCW-R-214W-S-70WP weigher with seven litre hoppers operating at up to 50 weighs per minute for 500g bags, while the frozen pastry

line in Zagreb uses an Ishida CCW-RS-210-S-50WP with five litre hoppers to handle specialist products such as gnocchi, strukli (a typical Croatian cheese pastry) and croissants in a variety of pack sizes from 500g to 2.5kg at speeds of up to 30 bags per minute. All three weighers are WP waterproof versions, specifically developed for the hygienic handling of frozen product and offering fast and easy cleaning to enable quick changeovers, which is critical for Ledo where product changeovers occur on average three times per day. www.ishidaeurope.com

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PROCESSING

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Air used to cool product Sonic Air Systems has developed an inline cooling system that allows its proven blower and air knife technology to be used as an alternative to compressed air or water-based cooling methods for cooling and drying food products. Sonic Air Systems’ Sonic Cool-Air In-line Air Cooler delivers precisely-controlled air temperatures using its pressure blowers and high velocity air knife delivery systems. These inline options are said to offer the same performance as the liquid cooling of certain products, which use high quantities of water during operation; or expensive compressed air for other cooling requirements. Applications include the cooling of candies, which have been applied with powdered sugar when hot and need cooling in order for the sugar coating to adhere. Sonic Air Systems worked with a major international candy manufacturer, which needed to remove the excess powdered starch from jellied candies after the moulding phase, and discovered the benefits of Cool-Air. The confectionery manufacturer installed a Sonic blower, air knives and HEPA filter to blowoff excessive starch prior to the candy entering the sugar applicator drum – where a powdered sugar was to be applied. However, the 110°F heat from the blower raised the temperature of the jellied candies well above their 70°F (21°C) target, which prevented the coating from adhering effectively – above 70°F, the sugar did not evenly coat the candies. The company installed Sonic’s Cool-Air in-line Air Cooler between the blower and

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the HEPA filter, which helped reduce the temperature and allow the sugar coating to adhere more uniformly to the candies as well as remove the starch effectively. “Sonic blowerpowered air knife systems are already used for drying products on conveyors after they are cleaned, rinsed, lubricated or cooled with water (such as the drying of bottles and cans prior to labelling and packing),” said Daniel J VanderPyl, president, Sonic Air Systems. “However, there are a wide range of other applications for which manufacturers are eager to find an alternative to spraying or bathing their product with water as a cooling media.”

Sonic Air Systems’ has developed its Sonic Cool-Air in-line Air Cooler as an alternative to compressed air or water-based cooling methods for cooling and drying food products

The Sonic Cool-Air in line water to air heat exchanger reduces the blower air temperature to almost as low as a food plant’s cooling water supply that passes through it. Now, high velocity blower and air knife systems can offer cooling benefits, and when coupled with Sonic’s inline-HEPA air filter, deliver the highest quality and lowest cost air supply available, according to Sonic Air Systems, which has worked to optimise the velocity, temperature and volume of air required in order to break any boundary layer of heat and accelerate the product cooling process using just air. For Leafy vegetable drying, the Sonic Cool-Air in-line Air Cooler with Sonic blowers can be used to dry the delicate, leafy vegetables quickly and gently without the need to use centrifugal spin dryers. www.sonicairsystems.com

September 2010 www.foodbev.com

PROCESSING

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Cold store switches refrigerants As all companies respond to the new legislative requirements, Modena Terminal, which stores parmesan cheese and other local staple food products such as meat, has switched from HCFC-22 refrigerants to Forane 427A from Arkema in order to comply. The Italian cold storage facility, which has five polyvalent cold rooms that operate between zero and -20°C and has the capacity to store 3,000 tonnes of meat in a total volume of about 8,800m3, uses one direct expansion evaporator per cold room. A corridor connecting the various cold rooms to the outside has a temperature of 14°C maximum (and a volume of 5,880m3). A large cold room, called the Cellone, has a capacity of over 6,000

tonnes of frozen meat and is kept at a temperature of -18 to 20°C, and has 10 direct expansion evaporators working to cool the 54,400m3 volume. Further cooled areas include the loading and unloading bay with a volume of 5,450m3 and a temperature of 14°C; and a tunnel for freezing/deep-freezing fresh meat at -40°C, which has a capacity of 20 tonnes per 18 hours. The tunnel features a flooded evaporator with four heat exchangers, and a tunnel antechamber to cool the beef quarters before freezing and packaging for storage in the cold rooms. To ensure the optimum performance of the facility, four screw compressors (with 330Kw refrigerating power each) were

installed, each equipped with a water-cooled oil cooler with a capacity of 300,000 kcal per hour. One week before the switch to the new refridgerant, the cold rooms were filled to the maximum load capacity and their temperature lowered to its minimum. The rooms subsequently remained closed for the 36 hours of the system’s shutdown. Twenty four hours before shutdown, two of the four compressors were shut down, their filters changed and the mineral oil replaced with a synthetic polyester lubricant. Once the shutdown was initiated, the company began recovering 3,600kg of R-22; and removing & replacing the oil in the two remaining compressors. Filters were replaced with new, equivalent

Arkema has worked with the Italian cold storage company Modena Terminal to switch from HCFC-22 refrigerants to Forane 427A filters, and the system verified for water-tightness before being tested under vacuum for 10 hours. After the 10 hours, charging with Forane 427A was started and then the system started up and expansion valves adjusted. According to Arkema, after 36 hours of shutdown, the temperature in the Cellone went from -22 to -20.5°C. www.arkema.com

ADVERTORIAL

A colder outlook D uring the past decade it has been acknowledged that things have been warming up in the food market - or at least things have been less cold. There had been a trend away from frozen food towards faster-moving chilled food, with a wider variety and choice for increasingly discerning consumers.

However it seems that yet another consequence of the troubled world economy over the past two years is an apparent shift in that trend, with consumers starting once again to favour frozen goods, almost certainly in an attempt to make lifestyle economies. Juggling this change in demand requires not only an increase in available cold storage capacity for the food distribution industry, but also the need to ensure that handling equipment is fit-for-purpose. Toyota Material Handling Europe (TMHE) has a strong track record in providing machinery that is specifically engineered for cold and chilled storage applications.

Food & Beverage International September September2010 2010

This is particularly true for the BT-branded warehouse truck range where all models - from pallet trucks and stackers to order pickers, reach trucks and VNAs - can be supplied to cold store specification. Toyota electric counterbalanced forklifts can also be specified for cold storage environments. Simple economics dictate that cold store operators should carefully consider their options when planning a facility. The more empty space in a coldstore the more expensive it is to maintain the required temperature - which for deep frozen goods can be as low as -35˚C. Therefore options such as very narrow aisle storage or even aisle-free storage can be attractive financially. TMHE offers the unique BT Radioshuttle unit for work in coldstore environments, maximising storage density and also reducing

the amount of time that an operator has to spend moving goods, as the remote shuttle unit works automatically. However if many different stock lines are carried, a more flexible solution may be required, and very narrow aisle trucks are a viable option. BT VNA trucks can be adapted to provide an ambient drivers’ cabin, which means normal shift patterns can be operated. This gives two advantages. Firstly, the truck is working more continuously in the coldstore, reducing the damaging impact of condensation that forms when trucks are continuously moving in and out of the cold environment. Secondly, the operators do not require the frequent rest periods normally associated with coldstore operations. Other trucks, such as BT Reflex reach trucks can also be equipped with coldstore cabs to achieve similar advantages. www.toyota-forklifts.eu

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Rapid handling of seafood Cabinplant has developed a robot-supported solution for the handling of fish and shrimps, and has worked with North Island Mussel Processing Ltd in New Zealand to optimise and expand the company’s cooking and chilling of greenshell mussels. Cabinplant claims to have taken a new approach to the handling of seafood with the introduction of its robot-supported system that combines processing and packing into one operation. Product is transported on an elevator conveyor from a bulk container and onto a vibratory conveyor where it is spread across the width of the belt. On the belt, a camera records the position of each individual product and determines its length, with this data in turn being used to calculate the product’s weight without the use of scales. The belt carries the product to the operating area of the robots (ELAU PacDrive P4 pick-andplace robots equipped with iSH servomodules – integrated drives, which combine servomotor and drive electronics in one single assembly), which pick up the products individually and perform all the necessary preparation steps using a multifunction device that includes a cutting tool to remove the head and tail (only heads for shrimps) and a suction tool to remove the viscera. Fully processed product is then placed by the robot into an awaiting pack on the conveyor, which moves to allow the packs/ cans to be filled continuously and moved along the belt. According to Cabinplant, single or multiple robots are capable of placing products, such as sardines, belly side upwards into cans on both sides of the conveyor belt, for example. Product can be packed in alternating directions within the cans.

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“Use of this method can reduce the giveaway by 1012% compared to traditional solutions,” according to Henning Ingemann Hansen, R&D director, Cabinplant. “Depending on product type, size, and weight, the robot can process and pack 40 to 50 products per minute. Using cascading multiple robots, the total input of the machine can be increased in a linear ratio to the number of robots.” Cabinplant is currently designing a system to process sardines for a customer in Greece, which will use ten P4 robots and handle 400 to 500 products per minute. “This will give an output of 80 to

Cabinplant has optimised production of fish and seafood with robotics and a customised system for cooking & chilling mussels

120 cans per minute, depending on the size of the fish,” said Mr Hansen, who explained that as the system is modular it can be expanded easily without additional wiring in the control cabinet. “The elimination of transfer steps between the individual processing operations saves time and the system is extremely compact relative to its output. According to our calculations the investment costs for such a machine will be amortized after only one to 1.5 years.” Cabinplant has also worked with North Island Mussel Processing Ltd (NIMPL) to expand production and use heat recovery to ensure the best use of energy for its cooked and chilled mussels. Using a tailor made solution that includes a pre-cooker and an integrated cooker/cooler, NIMPL can now process 6,500 kg of mussels per hour, bringing them down to a temperature of 1012°C. The warm cooling water is used for the preheating in the cooker ensuring a reduction in energy and water consumption. www.cabinplant.com

Pump increases ice cream production Hungarian ice cream manufacturer, Magic Ice, has increased productivity following the installation of a Verderflex Smart F30 tube pump, which can accommodate several pump heads. Currently Magic Ice has a twin head Verderflex Smart F30 on the production line, but as the pump can easily be expanded to up to four heads if the need arises there is built-in room for expansion. Each head delivers the same flow rate as they all run at the same speed from a single drive, which reduces the cost involved with running several independent pumps, according to Verderflex.

The pump is used to give Magic Ice precise dosing and metering and provides a repeatability of +/-1% and metering capabilities of +/-5% for pumped milk product, which remains within the sterilised tubing at all times and does not come into contact with any of the pump’s moving parts. As there are no moving parts to clog, maintenance time is reduced, and as the pump has a specially designed, top-loading tube clamping mechanism, it allows for rapid changeover of the tube. A single Verderflex Smart F30 pump head is capable of flow rates of up to 6,900ml per minute. www.verderflex.com

September 2010 www.foodbev.com

PROCESSING

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US pasta production automated In the USA, Barilla has invested in a new US$100 million, automated, pasta manufacturing facility in the State of New York, where up to 100,000 tonnes of pasta a year can be produced. The new plant uses Italian equipment from Fava and is based on automation solutions from Rockwell Automation that handle production from the point of raw ingredients entry, through

the production of the different pasta varieties, to the packaging of the end product ready for distribution. Following laboratory analysis of the incoming flour, each load is coded and off-loaded through a pneumatic system and directed to a specific silo. All the information is then recorded in a database. The flour is then handled automatically

Drive boosts production The Village Bakery (Nutrition), the gluten-free baked goods specialist, is said to be saving £20,000 (€24,000) per year following the installation of an ABB general drive on one of its production lines. The new drive controls the speed of a depositing line, which is a conveyor-based system that divides the dough into the correct weights to make various rolls and loaves. The bakery, which now produces around 250,000 loaves a week, began production almost two years ago with a single depositor. However, Installation of ABB’s general drive on one of its depositing lines has brought savings of €24,000 per annum for The Village Bakery

the new drive has enabled the company to optimise its operations with the addition of a second depositing line based on a reconditioned machine, according to ABB. “The old drive was so slow and inaccurate that the machine had to start spraying greasing agent before it ‘saw’ each tin,” said Christien Jones, director & projects engineer, who said that the first saving to be made following the installation of the new drive was a 10% reduction in tin greasing agent. “Now more of the greasing agent ends up where it is supposed to.” As the ABB drive can also optimise the speed of the conveyor to match the size and throughput of different products more accurately, and in this case the unit is programmed with four different speeds, it has led to cost savings of around 25% in the running costs of the line.

and transferred to the kneading machinery as required, with each batch being tracked through the manufacturing process using its code. Each section of the plant is divided into single areas, each run by its own electric control panel; and more than one thousand remote input/outputs (I/O) are collected by one Control Processing Unit, which is based on an Allen-Bradley ControlLogix PAC from Rockwell Automation. The PAC also controls 30 Allen-Bradley PowerFlex drives, chosen for their reduced power consumption and high control capabilities. The components are linked together through Devicenet, while Ethernet technology is used to connect to the Allen-Bradley PanelView user interfaces, which allow operators to monitor and alter the production process. To speed production, changes in the type of pasta production can be initiated using pre-stored recipes, with the production machinery then configuring itself automatically. Allen-Bradley PowerFlex 40 and PowerFlex 700 drives control the speed of the production process. While components are linked using the DeviceNet, a ControlNet protocol communicates directly with the PAC. The end panels and supervision PAC use Ethernet

technology to communicate with the managing software of the plant, and to allow Fava to provide a remote tele-assistance service to Barilla’s supervisors in case of production problems. Using the connection, Fava’s specialists can also access the control system remotely to diagnose and even correct problems. Barilla selected case packaging machines from Ricciarelli, which are capable of packaging 20 x 5kg boxes of pasta and 10 x 10kg boxes of pasta per minute. AllenBradley’s ControlLogix PAC was used to manage the automation of the machinery. Zucchini supplied the specialist case packing machinery, which can handle 20 different types of boxes and package up to 250 boxes per minute. “Rockwell Automations products help meet most automation requirements and feature reliability and simplicity in programming, improving all operations,” said Massimo Santoni, industrial manager, Fava. www.rockwellautomation.com

Having a second depositing line has also reduced downtime at the bakery since production staff can shut down each line independently for cleaning without halting production. www.abb.com

Food & Beverage International September 2010

Barilla’s new US pasta facility uses modern pasta equipment from Fava in Italy based on automation solutions from Rockwell Automation

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PROCESSING

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Honeytop’s latest innovations include honey chocolate pancakes

Taste of expansion A doubling of its production capacity and number of employees, expansion into new product lines, and a new plant in India are developments that have punctuated activity at Honeytop in the UK during the past two years By Claire Rowan, managing editor

et-up in 1984 as a family firm producing long life baked goods, Honeytop has branched out into naan bread, tortillas and most recently morning goods such as pancakes and crumpets and has just completed a £7 million investment in a new plant in Dunstable. It now commands 70% of the UK naan bread market producing under own label for all the big retail players as well as food service and catering; employs 400 people and generates 15% of its business from outside the UK. “We are ambitious and entrepreneurial and want to move ahead. The move into pancakes and crumpet production has taken us from a niche supplier to a mainstream baker,” said David Laurence,

Food & Beverage International September 2010

joint managing director of Honeytop, which is now supplying UK retailers, Tesco and Asda, with 100% of their crumpets and pancakes. “We are striving for quality for retailers’ own brands and ensure a 99.8% service level for deliveries to depot. We are a major supplier of baked goods to retailers but with a family feel.” The new pancake and crumpet lines were created in response to demand from retailers who had supply and quality issues and were looking for something new, according to Honeytop, which embarked on an 18-month development plan that involved its in-house engineering team building several bespoke hot-plate lines for the baking of batter-based products. Combining traditional methods with state-

of-the-art technology such as high speed robots (see FBI.June 2010.p49 - the ABB Flex-pickers are capable of picking 110 pancakes per minute), the new plant allows the company to offer several different varieties of baked goods and respond rapidly to retailer demand. In addition to traditional Scotch and Maple Syrup pancakes, the company’s range can include flavoured options such as chocolate chip, blueberry, Summer fruits, lemon and raisin. “As we can build and design our own production equipment, we can be highly innovative and produce quickly,” said Mr Laurence. “The robots have improved hygiene standards and reduced picking errors. Although this development represents a huge investment in the first place, it offers huge benefits in the long term; and the robots are likely to see payback within a couple of years.” During the past seven years, Honeytop’s inhouse R&D team has increased from one to seven people to ensure it delivers on rapid innovation and flexibility. It now operates several pancake lines and has also, as part

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Click here to subscribe of its 18-month development plan, invested in what it claims is the world’s fastest tortilla line following discussions with the major retailers to supply their own-brand product range. “At the same time as we were discussing Pancakes with the retailers, we were also presented with the opportunity to supply a premium quality tortilla, addressing quality issues which were being experienced such as breads sticking together and translucent ‘fatty’ patches. We also investigated a resealable pack solution providing added convenience for the consumer,” said Pauline Catterall, director of new business for Honeytop. After extensive research, Honeytop began work with one of the leading tortilla specialists, Lawrence Equipment of California, USA, to create a tortilla line capable of producing large volumes of tortillas to the highest specifications and at record speeds. To guarantee customer satisfaction, the tortilla line has built-in, hightech computerised scanning devices throughout, which check against a control picture of a perfect tortilla and reject any that fall outside the stipulated size, shape or texture parameters. The production process is fully automated from ingredient mixing to packing in resealable zip-lock bags straight off the production line, which is said to ensure the product freshness and quality.

“We have more than one tortilla line now and will expand whenever necessary,” said Mrs Catterall. “We are always evolving. There is continuous investment in production lines and capacity. Our objective is never to be at full capacity and never to let capacity stop us from taking on new business. We work 24 hours a day, six days a week ; and our products are delivered into the retailers on a daily basis.” According to customer requirements, tortillas can be flow wrapped or packed in the resealable zip-lock bags, or can be supplied with an extended shelf life of six months - packed in a dedicated clean room facility and packed in hermetically sealed packaging with a protective atmosphere. To continue to meet the increasing demands of its customers, Honeytop has also recently worked with a packaging specialist, Cornwallis, to save 10 tonnes of plastic packaging for one retailer. “We are reactive, innovative and flexible, so we need to work with partners who are like that,” said Mr Laurence, who pointed out that the new lines were up and running within three months from specification to the first pancakes and crumpets being produced. “We are fortunate to have extensive expertise in-house and project manage our own factory build.” The company is now working with Taste’L Fine Foods in a joint venture in India, which will see Honeytop supply chapattis and naan bread to the Indian market.

Honeytop has invested £7 million on new facilities, which include bespoke lines for producing pancakes and crumpets

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Honeytop worked with Lawrence Equipment in the USA to create what it claims is the fastest tortilla line in the world

“We are in the final stages of putting together a bakery in India, 200km North of Mumbai,” said Mr Laurence. “The first container has been delivered to India, but eventually we will supply out of our own plant. Taste’L Fine Foods already manufactures pickles, sauces and ready meals to India so this is the perfect partnership.” It is just such a partnership that brought the first taste of success to the fledgling Honeytop enterprise when, back in the mid 1990s, it began working with Sharwood‘s in the UK to produce 13-week shelf life baked breads in protective atmospheres to complement the Sharwoods range of sauces and pickles. Despite the prevailing difficult economic times, the company has come a long way since those early days producing in a factory in Hackney in London to the new state of the art premises it occupies today. “The expansion has seen the business develop in new and exciting ways,” said Mr Laurence of the latest investments. “We are extremely happy with how things are progressing. Up until the end of 2008 we occupied 70,000ft2 across two sites, now we have 200,000ft2 of space but we are always on the look out for when new sites become available as we plan our further expansion and continuous growth.” www.honeytop.com

September 2010 www.foodbev.com

QUALITY CONTROL

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Safety is top concern Food industry executives surveyed in the Food Safety Survey 2020 said that food safety will remain the top concern among consumers over the next 10 years - above food prices, health and wellness, environment, and food security. Survey respondents ranked food prices second and health and wellness third in order of concern for consumers. They ranked environment fourth, and food security fifth. More than 700 respondents across 53 countries participated in the survey, conducted by Diversey Inc in partnership with the Global Food Safety Initiative (GFSI). By 2020, 68% of respondents said consumers will have full access to regulatory inspection reports and consumer ratings for retail and restaurant businesses. When asked if they expected consumers to reject nanotechnologies and ask for regulations within the next 10 years, respondents were largely torn with 39% saying that they do expect consumers to reject nanotechnologies and push for regulations while another 38% were unsure. The survey data and other information will form the basis of a book to be released at next year’s Global Food Safety Conference in London in February. The book will provide a roadmap to help food business professionals to manage food safety effectively and efficiently in the context of environmental, economic and population changes. It is to be the companion volume to the book released at the 2010 conference, which reviewed improvements in food safety management in the past decade. www.tcgffoodsafety.com

Reads pH and colour simultaneously Mettler Toledo’s new LiquiPhysics Excellence density and refractive index meters can be used to determine the pH and colour of food products automatically and simultaneously. The highly automated instruments combine density with refracto-, colour- and/or pH-meters to meet the needs for measuring different parameters simultaneously in the high throughput food production arena. New sampling technology automates the measurement procedures necessary and is said to reduce or even eliminate the time consuming cleaning procedures usually involved.

Food & Beverage International September 2010

A One Click user interface allows quick, simple and direct access to all routine tasks and provides clear user information using shortcut buttons to operate tasks rapidly. Measurement results are automatically converted into user-defined units such as Brix or alcohol concentrations and special barcode functions determine sample data and ensure the correct measurement method is used.

Shimadzu’s new GCMS-QP2010 Ultra provides high speed and sensitive gas chromatography mass spectrometry analysis

Rapid & sensitive GC/MS Shimadzu has launched its new GCMS-QP2010 Ultra gas chromatography mass spectrometer (GC/MS), which provides fast data measurement speed with five times higher sensitivity than previous models, and fulfils the growing demand for accurate separation for unknown samples. In addition to offering improved laboratory productivity for highspeed analysis, it is also said to be the first GC/MS system to feature built-in environmentallyfriendly performance. The GCMS-QP2010 Ultra incorporates Shimadzu’s new GC-2010 Plus, which is said to set new standards in speed, efficiency, precision, sensitivity and ease of operation. Its AFT (Advanced Flow Technology) allows the GCMS-QP2010 Ultra to combine the highest

separation efficiency with increased productivity and reduced analysis time. The combination of the GC-2010 Plus’ high-speed GC method and high-speed ‘double jet cooling system’ also dramatically reduces the analysis cycle - in the case of volatile organic compounds, for example, by more than half from 37 to 17 minutes. In terms of its environmental efficiency, the GCMSQP2010 Ultra reduces power consumption in standby mode by 36% and use of this ‘ecology mode’ over a period of one year can reduce total power consumption by up to 26%, according to Shimadzu. Annual CO2 emissions have been cut by 30% and helium consumption by over 300 cylinders per year. www.shimadzu.eu

Mettler Toledo has introduced its new LiquiPhysics Excellent instruments for determining product density and refractive index simultaneously

User identification and access control is performed using biometric identification via a finger print reader to ensure the security and traceability of operations. www.density.com

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Enzyme combats acrylamide To develop measures to counter acrylamide, the Pavan Group has worked with Novoymes to assess the effect that Novozymes’ Acrylaway asparaginases has on acrylamide formation in extruded pelleted potato-based snacks.

Acrylamide is formed as a byproduct of the Maillard reaction during frying or baking which sees the amino acid asparagine react with glucose and fructose to form acrylamide. Novozymes’ Acrylaway converts the asparagines into the amino acid aspartic acid, thereby reducing its conversion into acrylamide without affecting the properties of the end product. During the trials on Pavan’s extrusion equipment, increasing dosages of the enzyme were added during the snack pellet production process prior to the extrusion step. Acrylaway was added together with water to the dry raw materials and the resulting dough was incubated for 15 minutes, during which time it was stirred. Depending on the enzyme dosage, asparagines was shown

Pavan and Novozymes have worked together to optimise the performance of Novozymes’ Acrylaway enzyme on the reduction of acrylamide formation in potato-based extruded snacks

to reduce acrylamide by 10 to 62% in the snack pellet samples. “One particular trial used four different Acrylaway dosages,” said Peter Mueller, customer solutions manager, Novozymes. “And, depending on the dosage, it led to an acrylamide reduction of between 46 to 75%.” In an additional trial, the frying time of the snacks was increased

from six to 15 seconds and this led to an increase in the acrylamide content. However, the addition of Acrylaway led to an acrylamide reduction of 44 to 94% in these snacks. Novozymes is now also looking to extend the use of Acrylaway to French fries. www.pavan.com; www.novozymes.com

Checks meat slice quality Luceo has introduced a new module for inspection of the appearance of sliced meat products. Prior to packing in a tray, products, such as sliced pork and poultry, are inspected for defects including: visual quality: the presence of fat particles, blood spots or detached rind; damage to the products such as holes, tears, folds or misaligned slices; or fat content exceeding preset production limits. The inspection process takes place at high speed immediately after the slicing operation and any defective product is ejected before packing. The new ScanFood module ensures that a product

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appears perfectly in its pack using reliable and accurate computer vision technology developed by Luceo Inspection Worldwide. It joins Luceo’s ThermoSecure range of pack inspection machines, which include a stand-alone inspection machine (inspection and ejection), an independent inspection camera, and a camera that can be integrated into a thermoformer - for further quality control. The ThermoSecure Label Inspection verifies label position, print quality and film misalignment regardless of the orientation, format or colour of the pack. It checks variable label data, include barcodes of all fonts or formats. The weight and price

data on variable weight packs (such as meat, cheese, delicatessen products etc) can also be checked automatically at high pack rates. ThermoSecure Seal Inspection machine inspects the seal area and detects packs where the seal has been contaminated by particles of the packed products. All images captured during inspection and monitoring the packaging line are archived during production by the ThermoSecure, which produces regular reports and helps achieve full traceability. www.luceo-inspection.com

Luceo’s new ScanFood module inspects meat slices prior to packing and joins its ThermoSecure range of pack inspection technologies

September 2010 www.foodbev.com

QUALITY CONTROL

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Versatile tank cleaning Meat checked for fat and shape The new HydroWhirl Orbitor CIP (clean-in-place) rotary tank cleaning device from the nozzle specialist, Bete Ltd, is designed for simple and versatile operation together with extended operating life and reduced life-cycle costs, for cleaning tanks in the food, dairy and beverage industries.

Self-cleaning and selflubricating, the HydroWhirl is compact and can be fitted through small, restricted access flanges and is also suitable for cleaning tanks up to 40m in diameter. It offers optimum cleaning with reduced cycle times and low water, energy and chemical consumption, according to Bete, and has been designed for use in food and dairy for cleaning raw milk storage tanks, spray driers, and process & storage vessels; and in beverage production & brewing for cleaning process vessels, bright beer tanks, coppers and maltings. The HydroWhirl has been built with a minimum number of moving parts and can be completely stripped down

Foss is helping companies improve their quality control in the meat industry with the introduction of two new developments.

Bete’s HydroWhirl Orbitor tank cleaning machine is designed for low maintenance, simple and effective CIP tank cleaning and rebuilt on site in less than 15 minutes, which reduces the time required for maintenance and servicing often associated with other rotary tank cleaning devices that have to be returned to the supplier for maintenance. There are 10 models available in the HydroWhirl range, which come with two or four nozzles, variable cycle times, male & female connections, and 360° wash patterns, including 180° down and up wash patterns to ensure the optimum cleaning operation. www.beteuk.com

New software in Foss’ MeatMaster in-line fat analyser now allows it to assess the size and shape of cuts of meat as well as their fat content. Pork belly pieces, for example, can be placed on the MeatMaster belt and scanned using X-ray technology, which displays information about the fat content, weight, length, width and thickness of the product on the instrument screen along with a picture of the pork belly shape. The meat is also scanned for foreign objects. A range of criteria - such as ‘fat content under 22%’ or ‘thickness less than 3cm’ and ‘width under 18cm’ - can be programmed into the MeatMaster and meat pieces subsequently sorted according to the criteria and routed for

specific processing applications. The system can scan up to 1,500 pork belly pieces per hour and the software is also suitable for grading of pork legs for production of dry ham products. The advantages, according to Foss, include objective grading, improved curing due to the optimal use of raw material and improved consistency in the finished product. For efficient fat analysis, Foss has introduced its MeatScan analyser a compact and robust near infrared (NIR) analyser, which can be used for small-volume production. With measurements taking just one to two minutes, the MeatScan helps users to cut costs through rapid analysis of the fat in incoming raw material, which helps ensure that end products match specifications consistently and allows manufacturers to formulate recipes more precisely without overuse of expensive lean meat. www.foss.dk

Foss’ MeatMaster in-line fat analyser now allows manufacturers to assess the size and shape of cuts of meat as well as their fat content

Cleans zero trans fat spoils Ecolab has developed a breakthrough cleaning programme designed to clean zero trans fat food oil residue from processing equipment and environmental surfaces. The patent-pending programme has been demonstrated to reduce cleaning times in half during initial testing and is said to be the first product of its kind

Food & Beverage International September 2010

to address the emerging issue of cleaning difficult zero trans fat oil versus traditional oils. “As the use of zero trans fat oils has rapidly increased, removal of cooked-on oil from processing equipment has proven to be a time-consuming and difficult challenge for food processors,” said Timothy P Mulhere, Ecolab’s senior vice

president & general manager, food & Beverage North America, who explained that as the zero trans fat oils break down during the frying and baking process, they coat surfaces with stubborn soils and can create a sticky, varnish-like coating on equipment. Ecolab’ Exelerate ZTF breaks down the difficult polymerised

oil soils on fryers, ovens, mixers and other plant surfaces enabling them to be cleaned more thoroughly. The gelled product application clings to equipment and surfaces to dissolve zero trans fat oils, making it easier to clean even hard-to-reach areas. www.ecolab.com

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SAFETY

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Pest control The presence of pests creates a substantial problem for food production companies through spoilage of stored products, potential damage to premises, and their presence in food leaving the premises, which can have disastrous commercial and legal ramifications *By Neil Brown, technical director of Hygiene Group

he ultimate responsibility for any pest problem lies with the food production or processing facility owner, even if any cleaning or pest control is outsourced. Regulation (EC) 852/2004 states that businesses must ensure the layout, design, construction and size of food premises should permit good food hygiene practices, while Regulation (EC) 178/2002 deals with any food considered to be injurious to health or unfit for human consumption. Pests consist mainly of rodents and invertebrates, all usually seeking water, food, warmth or somewhere to live. Any action to deny those will rapidly reduce infestation risk.

Dealing with rodents Grain containers entering food premises can accommodate many mice and rats, which eat some grain and soil the remainder. Meanwhile, a mouse can get through any hole into which a pen can be inserted, making gap sealing a key exclusion method. External doors should therefore be fitted with brush strips, and any gaps sealed using a hard, gnaw-resistant material. (Rats and mice are good climbers and their presence above production equipment can be even more damaging than if they are at ground level). Doors and windows should be kept closed at night and during any inactivity, with pest screens fitted to doors or windows left open regularly. Rodents can also enter via uncovered drains and dry toilets so these should be

covered or sealed. Broken drains allow rats easy access so drains should be well maintained. Mopping up spills immediately, thorough cleaning at shift ends, and regular deep cleaning, will remove the source of free meals. Products should be stored in sealed containers, and kept at least 150mm off the floor and away from walls. Waste should be removed immediately and placed in sealed bins. Tell-tale infestation signs include droppings; gnaw marks on food packaging or building structures; greasy smear marks along the bottom of walls; and the sight of rodents themselves. Bait boxes can be used to verify rodent presence, but are only as effective as their placement. Furthermore, commercially available baits are not adequate for food businesses and can be a contamination source.

Detecting invertebrates Many invertebrates can cause problems in food facilities. The development of cockroaches will be affected by food quality, humidity and temperature - their presence can usually be noticed by streaks of brown, irregular excreta, while adhesive traps can confirm an infestation. A localised congregation of adult flies often indicates a nearby breeding site. The larval food of flies must be moist, so drainage channels, gully traps, and floor areas where residues may collect, should be thoroughly inspected. Flies also leave marks on windows, doorframes or lights. Antsâ&#x20AC;&#x2122; nests can be detected by following worker ant trails, usually around door thresholds, sinks and cupboards. Inspection

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Pest control requires a strategic approach and expert advice for stored product insects should begin in raw materials stores, and finish at the despatch department. All machinery interiors should be checked, as well as under machines, between floorboards, behind cupboards, between sacks and pallets and in undisturbed areas. Disturbing bags, sacks and pallets may reveal beetles or moths. Mites are only usually detectable at high infestation levels, via a fine dust layer on surfaces. Meanwhile, flour moths may only be noticed when they create structures not unlike spider webs as part of their reproductive cycle. Facilities managers can select from various monitoring traps and detectors. Catch tray or adhesive film analysis of electric fly-killing units can provide information on species, numbers, seasonal fluctuations, likely infestation foci, and hygiene or process shortcomings. Pheromone traps are available as funnel traps and adhesive traps, to intercept male insects. Auto-confusion systems coat male insects. And, there are many more traps and detectors. Ultimately, pest problem elimination requires a strategic approach, based around appropriate cleaning, staff training, enhanced facilities management systems and expert advice on monitoring device deployment and further action. The Hygiene Group, with 25 years of experience is a leading supplier of contract cleaning services and hygiene management to the food production sector. www.hygiene.co.uk

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.

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NEXT ISSUE

Coming up in the next issue of Food & Beverage International Vitality: Formulating for Health & Beauty There is a lot of activity in the area of ‘beauty from within’ using traditional food products to provide beauty enhancing benefits, yet what is the real potential of these products in the market? Find out about some of the success stories of products from around the world and the ingredients available to formulators.

Monitoring & Measuring ‘You cannot control what you cannot measure’ continues to apply. A round-up of some of the latest solutions available to help manufacturers monitor productivity; reduce losses on the line and discover the gains that can be made from monitoring & measuring.

Environmentally-friendly packaging How environmentally sound is a product’s packaging based on a full analysis of its life cycle, and what solutions are available to help companies tackle this ever increasing challenge? A look at some of the latest developments taking place in the industry and pointers for the future.

Plus: The Ingredients, Packaging, Processing and Safety & Analysis sections will also bring news of: • Flavours, Colours & Extracts • Vegetable Processing • Bottling & Filling Solutions • Avoiding Contamination There will be a round-up of the latest beverage innovations to have appeared on supermarket shelves throughout the world and bumper filled pages that will Preview activities taking place at: • Hi Europe • Brau Beviale Keep your finger on the pulse of the industry - its news and trends; and find the solutions to your processing & formulation 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

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Important dates for October issue Editorial deadline: 1 October Advertising closing date: 12 October Contact the editor: Claire Rowan claire.rowan@foodbev.com

September 2010 www.foodbev.com

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Food & Beverage International advertiser index

ABB Almond Board Armfield Berndoff Band Boyer Brau

Page

31 13 45 22 20 7

Cargill Cocoa DSM EPI Euromonitor FoodBev.com GEA Niro

60 19 21 32 49 29

Page

Hi Europe Klüber Lubrication Krones Materne Sensus Shimadzu

56 11 39 15 34 6

Page

Sial Siemens Syral Tate & Lyle wi awards 2010

25 2, 5 27 35, 37 59

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Food & Beverage International September 2010

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