Asia Pacific Food Industry October 2018 by PaperplaneCreative

ASIA’S LEADING TRADE MAGAZINE FOR THE FOOD AND BEVERAGE INDUSTRY OCTOBER 2018

Established since 1985 apfoodonline.com

PACKAGING

• PROCESSING • INGREDIENTS • NUTRITION • BEVERAGE • FEATURES

WHAT’S NEW IN THE WORLD OF BAKERY & CONFECTIONERY? > Read Features On Page p60

Cama Group is a leading supplier of advanced technology secondary packaging systems, continuously investing in innovative solutions. www.camagroup.com - CAMA CHINA camachina@camagroup.com ENQUIRY No 4636

ENQUIRY No 4633

22 PACKAGING

INGREDIENTS & ADDITIVES

22 Rich In Water Resources

34 Palm Oil: Challenges, Sustainability And Its Applications

The Romanian stock corporation, Perla Harghitei, just cannot seem to break the

In our globalised world, the realities

habit: over and over again, the mineral

of palm oil production and trade have

water bottlers invest in filling lines

become more complex, thus posing

from Krones. 2017 saw the company

several challenges to the industry, says

commission what is already its seventh

Futura Ingredients.

line in succession.

26 Many Good Reasons For Liquid Dairy To Switch To PET Packaging

Picture courtesy of Matcon

Picture courtesy of Krones

CONTENTS

30 hospitalisations, and social factors can put older adults at risk of malnutrition which makes other health problems worse. By the Food Fortification Initiative.

48 Human Milk Oligosaccharides (HMO): Creating Differentiated Offers In Infant Nutrition Marianne Heer, Scientific Marketing Manager Human Nutrition of BASF SE,

38 Great Fillings Create Those Special Chocolate Moments

discusses the importance of HMOs with molecular structures identical to those

Consumer tastes may differ, but

occurring in human milk for optimal

Liquid dairy manufacturers

indulgence and excitement are always

infant nutrition.

relentlessly seek innovations to achieve

at the heart of confectionery favorites—

product differentiation and a sustainable

preferably with a healthier, more natural

business. To answer those challenges,

profile. By Marco Oomen, AAK’s Global

Sidel can support the companies to

Business Director for Chocolate &

SternVitamin has developed a wide range

switch their liquid dairy production to

Confectionery Fats.

of solutions for different age groups and

President Sensitive Products at Sidel.

PROCESSING 30 Improve Hygiene Standards And Optimise Operational Efficiency With Matcon

Consumers, today, are increasingly seeking products that boast tangible benefits in supporting specific health needs—a concept which has come to be

it is of utmost importance to ensure

known as ‘consumption with a purpose’.

the highest of hygiene standards.

By Michelle Teodoro, Global Food Science

This can be an expensive and time-

& Nutrition Analyst, Mintel.

General Manager & Director of Business Development for the Asia Pacific Region, Matcon.

the human body.

41 ‘Mind’ Your Food: Neuro Nutrition To Flourish In 2018

When producing dairy-based products,

consuming activity. By David Newell,

life phases to deliver micronutrients to

HEALTH & NUTRITION

44 Food Fortification: Benefits Extend Beyond Babies Physical changes, medications,

Picture courtesy of SternVitamin

PET bottles. By Guillaume Rolland, Vice

50 Boosting Immunity And Performance With Micronutrients

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ENQUIRY No 4622

CONTENTS DEPARTMENTS 06 EDITOR’S NOTE

Picture courtesy of USDEC

08 INDUSTRY NEWS 75

PRODUCT HIGHLIGHTS

CALENDAR OF EVENTS

ADVERTISER’S LIST

READER’S ENQUIRY FORM

80 SUBSCRIPTION INFORMATION

Refer to Advertising Index on

BEVERAGES 54 Demand For High-Protein Food/ Drink Products Especially Strong Among Young Adults

Modern leak testing solutions help producers of bakery products prevent even micro leaks and thus, guarantee fresh products to their customers. By

conducted in Asia & Australasia.

Alexander Kampschulte, Head of Marketing

With the rise of social media, the

& Communications, WITT-Gasetechnik GmbH & Co KG.

66 Using Egg Substitutes To Control Costs And Quality In Cakes

speed at which new food and drink

Partial egg replacement can reduce the

trends emerge and change is startling.

cost of cake production and keep recipes

As a result, brands need to innovate

soft, moist and appealing. By Inge Lise

quickly to remain relevant, without

Povlsen, Senior Category Manager for

compromising on product quality or

Bakery at Arla Foods Ingredients.

nutritional value. By Kristi Saitama, Vice President and Team Lead—China, Japan, Southeast Asia, U.S. Dairy Export Council.

FEATURES 60 Will Gluten-Free Ever Turn Mainstream In Asia Pacific?

68 Filling Baked Goods With Care Italian bakery manufacturer, San Giorgio Dolce & Salato, now relies on a fully automated system from Schubert.

70 Exploring Additive Options In Baking Healthy lifestyles continue to drive free-

Gluten-free bakery is still a niche market

from diets, creating ever greater demand

in most Asia Pacific markets—with the

for “cleaner” and healthier products,

noticeable exception of Australia and

especially in segments such as gluten-free

New Zealand. But, as gluten-free bakery

sweet bakery products, say Dr Galanakis,

products continually get better, who

C.M. and Dr Y. Martin Lo, advisors from the

knows what the future will hold? By

Anti Additive Association.

Rachel Park, Marketing Manager, Korea,

for Advertisers’ Enquiry Numbers

Enquiry Form at Pg 79 or enquire online apfoodonline.com/contact

Based on a 2018 GlobalData survey

57 Dairy Proteins And Permeates: Ideal Nutrition-Boosting Ingredients In Ready-to-Drink Beverages

Australia and New Zealand, DuPont.

EXHIBITION HIGHLIGHT

63 Preventing Micro Leaks In Bakery And Confectionery Modified Atmosphere Packaging

69 Food Week Korea 70 Taiwan International Fisheries & Seafood Show

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ENQUIRY No 4601

EDITOR’S NOTE

Is Baking Without Sugar Really Possible?

As a veteran weekend baker, I’ve given sugar-free baking much thought over the years. It’s hard to imagine whipping up a batch of cupcakes without a cup (or three) of sugar, because sugar adds more than just the addictive sweetness to the formula—it gives baked products a delicious crumbly/moist texture, a lovely brown colour, as well as prolongs its shelf-life.

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PUBLISHER

Kenneth Tan

EDITORIAL

EDITOR

Shali S shali.s@epl.com.sg

Taking these three points into account, a feasible alternative to sugar-free baking would be the incorporation of fruits. Fruits are natural substitutes that provide fresh sweetness in their raw forms, on top of the valuable fibre and other nutrients they bring to the pan. Common fruits I’ve personally included in cake recipes include banana (an obvious choice—the riper the better) as well as pineapples. Both these fruits provide all-important moisture to the batter. Add a cup of crushed almonds to the mix for a satisfyingly crumbly sweet mouthful. Further, dried fruit like raisins, cherries and apricots are a great choice to boost the sweetness of a recipe or add extra moisture and stickiness in their puree forms. Another great sugar substitute for baking (synthetic as its name might sound) is xylitol, an extract from hardwood trees that looks and tastes just like sugar. However, this alternative has a lower calorie count when compared to refined sugar and it’s a lovely low-GI treat. If you’re after a sweet indulgence that doesn’t leave your head spinning with a sugar rush, baking with xylitol would be ideal. Be wary of your xylitol intake, though—too much can have an undesired laxative effect! In this issue, we explore industrial baking through various angles, from additive-free baking to tips on how to automate large bakeries. Read our features on page 60.

EDITORIAL ASSISTANT

Sharon Lim sharonlim@epl.com.sg

MEDIA SALES

PUBLICATION MANAGER

Joey Tan joeytan@epl.com.sg

CIRCULATION CIRCULATION EXECUTIVE

Teh Pei Sin peisin@epl.com.sg

CONTRIBUTORS

Alexander Kampschulte, David Newell, Dr Y. Martin Lo, Guillaume Rolland, Han Yew Hock, Inge Lise Povlsen, Kristi Saitama, Marco Oomen, Marianne Heer, Michelle Teodoro & Rachel Park

BOARD OF INDUSTRY CONSULTANTS

Dr Aaron Brody Managing Director Packaging/Brody, Inc

Dr Alastair Hicks Fellow International Academy of Food Science & Technology Professor Alex Büchanan Professional Fellow Victoria University Dr Nik Ismail Nik Daud Head, Food Quality Research Unit Universiti Kebangsaan Malaysia/ President Malaysian Institute of Food Technology

Shali S

Kathy Brownlie Global Program Manager Food & Beverage Ingredients Practice Frost & Sullivan

Stay Updated!

Sam S Daniels Consultant World Packaging Organisation

Latest news, innovations and technologies.

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ENQUIRY No 4642

INDUSTRY NEWS

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

REGIONAL NEWS

All-Natural Whey Proteins From U.S. Dairy An Essential Nutrient Source

Industry IndustryNews QuickBites

Our Top News At A Glance

Consumers in Singapore prioritise the quality of ingredients when purchasing or consuming food KH Roberts (KHR) hosted a study visit by the Ministry of Science and Technology, Thailand Asia’s large format retailers set to expand by 3.3 percent a year to 2022 New Zealand is launching a $40 million initiative to move the agricultural sector from `volume to value’ The Australian Macadamia industry has released findings revealing the most prominent snacking trends within Asia New Zealand’s government has announced that it will phase out single-use plastic bags by 2019 Royal DSM will expand the production capacity of its Vitamin B2 facility in Germany PepsiCo acquires SodaStream in an effort to push more healthy alternatives to consumers StePac is working closely with its partners to implement a comprehensive supply chain solution for the delivery of fresh cherries from farm-to-fork The US FDA has concluded that raw and refined sugar produced from Brazil’s first genetically-modified sugarcane variety is safe consumption

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SINGAPORE—A research study carried out by Nielsen in 2017 revealed that 37 percent of consumers in Singapore prioritise the quality of ingredients when purchasing or consuming food. As part of ongoing efforts to showcase the importance of dairy protein intake for consumers, the U.S. Dairy Export Council (USDEC) released findings highlighting how whey proteins can meet growing demand for quality nutrients in foods and beverages in Singapore and the wider Asia region. Whey protein is a co-product of cheese-making, and can be added into food and drinks to boost nutritional content. A new study published in Nutrition Reviews suggests the beneficial effects of consuming whey protein applies also to women, building upon earlier well-demonstrated nutrition research supporting benefits for men. In this systematic review and meta-analysis of 13 randomised controlled trials totalling nearly 500 adult women, researchers found adding whey protein to a daily diet improved body composition by modest increases in lean mass without influencing changes in fat mass. Additionally, body composition improvements were even greater during reduced calorie diets, which suggest that whey protein may be especially helpful in preserving lean muscle mass during periods of weight loss. Southeast Asian consumers are becoming more conscious and informed about nutritional content when consuming food. This is true across generations. The 2017 Nielsen study showed that regardless of age group—baby boomers (50-64 years old), Generation X (35-49 years old) and Generation Y (25-34 years old)—achieving health and wellness was their top priority. Custom research by USDEC in 2017 further supports this; 38 percent of Singaporeans surveyed stated that living a long and healthy life was their main health goal. Consumers in the region already recognise that protein is an important part of their diet, so having U.S. dairy protein ingredients incorporated in a wide range of finished products can align with meeting their health and wellness needs.

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INDUSTRY NEWS

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

DID YOU KNOW? The amino acids in whey protein (specifically cysteine, glutamate, glycine) also improve the health of the immune system by enhancing the function of neutrophils (biPro.com).

Thai Vice Minister From Ministry Of Science And Technology Visits KH Roberts

SINGAPORE—KH Roberts (KHR) hosted a study visit by the Ministry of Science and Technology, Thailand at its new state-of-the-art integrated flavour manufacturing facility in Singapore on 30 August 2018. The visit delegation led by Dr. Kanyawim Kirtikara, Vice Minister for Science and Technology, also included H.E. Mr. Manopchai Vongphakdi, Ambassador of Thailand to Singapore, senior faculty staff from Kasetsart University and King Mongkut’s University of Technology Thonburi, and senior executives from STI Policy Office. The visit focused on the study of KH Roberts’ successful implementation of Industry 4.0 elements at their new integrated flavours manufacturing facility that features automation and integrated smart manufacturing capabilities. A home-grown flavours house headquartered in Singapore with regional facilities, KHR is a premier creator and manufacturer of food flavours and specialty ingredients. Established in 1968, the company is widely considered to be the pioneer flavour

manufacturer in Singapore and Southeast Asia at that time. The privately owned third generation family business has since expanded their presence regionally with manufacturing facilities in Thailand and Indonesia, and established direct sales distribution offices in Malaysia, China and various markets across Asia. They have since expanded their global footprint to new markets such as Greater China and Europe. Employing critical elements of Industry 4.0 like smart technologies, automation and digitalisation at their new integrated flavour manufacturing facility, KHR is able to reduce reliance on manual labour, extend production uptime, minimise risk of product defects and consistently meet stringent global food safety requirements. The new facility also includes a full-fledged flavours R&D centre, equipped with flavour creation, sensory evaluation, analytical testing, product development and bench-top chemistry capabilities. Integrated to the facility is a dedicated pilot plant space for small scale product development and test production, enabling customers and collaborators to test new precommercial and new technology-based products prior to commercial production. These capabilities help KHR to enhance their agility and speed to market.

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INDUSTRY NEWS

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

Large Format Food Retailers In Asia Set To Grow 3.3 Percent A Year SOUTHEAST ASIA—It has been forecast that Asia’s large format retailers will be set to expand by 3.3 percent a year to 2022. Supermarkets and hypermarkets in Vietnam, India and the Philippines will see double digit growth in the next five years. In all countries except Vietnam, double digit growth is expected to be driven by domestic retailers. Indonesia is set to grow, steadily driven by domestic players. In Vietnam, foreign retailers are believed to be investing to gain leverage in the fast-expanding market. Though it is dominated by traditional way of business, that is rapidly changing as modern retail picks up. Saigon Co.op is growing and will keep its leading position till 2022. In Asia, there is a steady expansion in large format retailers, though they see heightened competition in developed markets. More convenience stores are opening close to residential areas and workplaces, offering good range and prices. Online retailers are also not relenting on gaining new customers and investing their resources. While apart from going to new regions, large format stores are digitising

New Zealand Moves From 'Volume To Value' In Their Food & Nutrition Sector NEW ZEALAND—Damien O’Connor, New Zealand’s agricultural minister said that nation is launching a $40 million initiative to move the agricultural sector from `volume to value’. Currently, New Zealand’s food and fibre industry delivers $42 billion in export revenue and are the backbone of the country’s economy. The initiative is a move to provide more sustainable resources for the use of the future generations. This has led to the creation of the Sustainable Food & Fibre Futures, SFF Futures by the Coalition Government in New Zealand.

physical stores to create a seamless shopping experience. In order to stay relevant, large format retailers need to look at their physical stores and network expansion to keep abreast of their consumers.

O’Connor notes, “We are moving from volume to value. New Zealand’s commodity growth drive has come at the expense of the vital natural resources we need for our primary sector—our soil, water and social license to operate. “With a budget of $40 million a year, SFF Futures provides a single gateway for farmers and growers to apply for investment in a greater range of projects that deliver economic, environmental and social benefits that flow through to all Kiwis.” It is the aim of the New Zealand government that the funding can focus on specific outcomes such as climate change or the environment.

ENQUIRY No 4635

INDUSTRY NEWS

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

DID YOU KNOW?

In 2016, healthy food and drink sales grew double digits in India (11.3 percent, Nielson).

New Research Shows Consumers Are Increasingly Snacking To Manage Their Mood AUSTRALIA—The Australian Macadamia industry has released findings revealing the most prominent snacking trends within Asia, discovering that consumers are increasingly snacking as a way to manage their mood. A new research report conducted by independent research agency Galileo Kaleidoscope across multiple markets, shows that consumers are snacking to destress or unwind, to enhance a social engagement, or as a pick-me up for energy. Participants in the research emphasised the importance of food manufacturers using clean and high quality ingredients in their snacks, which maximise nutritional benefits, and support improved moods and wellness. “In recent years, the snacking category has been redefined with various trends that set the context for product innovation. One trend has remained consistent when it comes to snacking: most consumers want a snack that provides enough energy to sustain them and their frame of mind through their day,” said Lynne Ziehlke, Market Development Manager at the Australian Macadamia Society.

As consumers look for snacks that are mood boosting, early conversations in focus groups indicate that macadamias are a perfect fit for innovating the snacking category. To help bring new concepts to life the Australian Macadamia Industry recently held the world’s first Macadamia Innovation Challenge, which saw a swathe of new ideas come to life, including Matchadamia Berry Balls and Salted Egg Yolk Macadamias. “The Australian Macadamia Industry believes that macadamias are the ideal ingredient for innovative product development that caters to the needs and changing habits of consumers. Whether it be to brighten up a meeting with friends, or to help you relax after a long day, macadamias are a versatile ingredient and deliver on four essential snack attributes; they’re small, indulgent, have associated health benefits and they taste great,” added Ziehlke. Additionally, the nutritional value of snacks and energy sustenance continues to be a dominant motivation for snacking within Asia. “We also know that consumers are living on-the-go lifestyles, and working longer hours than ever before, meaning that a snack can provide a powerful pause moment or mood boost during their day. Macadamias are the ultimate ingredient for nutritional and delicious snacks to cater to both trends identified within the research.”

www.solarturbines.com Phone: +41 91 851 1511 | +1 619 544 5352 infocorp@solarturbines.com ENQUIRY No 4634

INDUSTRY NEWS

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

New Zealand Bans Single-Use Plastic Bags

NEW ZEALAND—New Zealand’s government has announced that it will phase out single-use plastic bags by 2019, a move Greenpeace is calling a win for people power and another big step towards addressing the global plastic pollution crisis. “This could be a major leap forward in turning the tide on ocean plastic pollution in New Zealand and an important first step in protecting marine life such as sea turtles and whales, from the growing plastic waste epidemic,” said Emily Hunter, Oceans Campaigner at Greenpeace New Zealand. The proposal will be open for public consultation until 14 September 2018 and will include options for the date the phase-out is to be complete by, what bags should be included, any retailers that should be exempted. Around the world, governments are implementing strategies to end plastic pollution with measures from levies, bottle deposits to banning a wide range of single-use plastics. “This is a great first step, but now New Zealand needs a broad and comprehensive strategy to eliminate all sources of

plastic pollution. Up to 12.7 million metric tonnes of plastic waste enter the ocean every year—that’s the equivalent of one garbage truck every minute—and single-use plastic bags are just the tip of the iceberg,” said Hunter. “It’s time for the world’s largest governments and companies to recognise that we cannot recycle our way out of this problem. The crisis we’re facing requires comprehensive regulation and corporate action to immediately move away from single-use plastics.”

DID YOU KNOW? Retailers in New Zealand will be given six months to stop providing lightweight plastic bags, or face fines of up to NZ$ 100,000 (USD$ 98,500).

DSM To Increase Production Capacity Of Vitamin B2 In Grenzach, Germany

ENQUIRY No 4625

GERMANY—Royal DSM, a global science-based company active in Nutrition, Health and Sustainable Living, will expand the production capacity of its Vitamin B2 facility in Grenzach, Germany, by 15 to 20 percent to further strengthen DSM’s leadership position for this important vitamin. It is expected that the new capacity will be available in Q4 2019 after an extended shutdown of approximately 2 months for the necessary technical work. Vitamin B2, also called riboflavin, is an essential constituent of all living cells—which, when lacking, can lead to symptoms including fatigue and sore throats. It is one of the most widely distributed water-soluble vitamins. As part of its human and animal nutrition & health solutions portfolio, DSM supplies vitamin B2 as application-based formulation or as premix ingredient to the food, feed, pharma and dietary supplements markets. DSM has strict Quality Assurance procedures and ensures that products are fully compliant with the regulations of all markets worldwide. In addition, DSM’s Quality for Life promise symbolises its commitment to achieving the highest standards of quality, reliability, traceability and sustainability.

INDUSTRY NEWS

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

DID YOU KNOW?

When laid end to end, the 1.25 billion beverage cartons used in the UK each year would wrap around the world six times.

PepsiCo Buys SodaStream In US$3.2 Billion Deal To Make New Inroads

UNITED STATES—PepsiCo acquires SodaStream in an effort to push more healthy alternatives to consumers and give it a stronger foothold in the in-home beverage market, say analysts at Well Fargo. The deal is expected to close by January 2019, according to Ramon Laguarta, CEO-Elect and President at PepsiCo, SodaStream. He notes about this acquisition: “… [it] add[s] to our growing water portfolio, while catalysing our ability to offer personalised in-home beverage solutions around the world.” With this move, PepsiCo is doubling down on its drinks business, as consumers move away from sugary, carbonated beverages. SodaStream gets to expand its distribution through PepsiCo’s global footprint. It now reaches 80,000 individual

retail stores across 45 countries with largest markets are Germany, France, Canada and the U.S. The company helped create the market for in-home sodamaking, but in recent years, it has promoted the product as a tool to make carbonated water, accommodating changing tastes. SodaStream reported quarterly earnings that tripled its earnings forecast for the year, and the news sent the company’s shares up more than 26 percent. Machines sales rose 22 percent in the quarter, to more than 1 million, while sales of gas refill units grew 17 percent, to a record 9.7 million. Prior to the deal’s announcement, SodaStream’s shares had gained nearly 85 percent this year. SodaStream is seen as a healthier and trendier alternative to sugary beverages, as consumers get hooked on sparkling water and this gains ground as the new `it’ drink.

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2018

ISRAEL—StePac is working closely with its partners to implement a comprehensive supply chain solution for the delivery of fresh cherries from farm-to-fork. The company has joined forces with Tadbik Ltd., Israel, to produce the next generation of modified atmosphere resealable lidding film. The new technology is engineered to extend the shelf-life of fresh cherries in aesthetic and functional retail packaging as well as reduce waste. In this collaboration, Tadbik created a “FreshLid” laminated film structure that is sealed to trays containing fresh produce and whose upper layer can be repeatedly peeled back for reuse. The companies then worked together to develop suitable condensation control properties and control film permeability to deliver optimal modified atmosphere compositions (MAP) for high-value fresh produce items such as cherries. This innovative packaging will be marketed under the Xgo line, Stepac’s leading retail brand. Efforts to overcome common challenges in lengthy supply chains and to move toward more responsible and cost-effective delivery processes, is generating increased demand for advanced functional packaging solutions. Meeting these challenges is especially critical when it comes to preserving and extending fresh produce shelf-life and reducing waste.

ENQUIRY No 4626

StePac Leads Responsible Supply Chain With Innovative Packaging

INDUSTRY NEWS

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

US FDA Concludes Review Of Sugar From The First GM Sugarcane Variety

UNITED STATES—The United States Federal Food and Drug Administration (FDA) concluded recently that raw and refined sugar produced from Brazil’s first genetically-modified sugarcane variety, called CTC20BT, is safe. The US FDA focused its safety assessment on sugar because it is the main sugarcane-derived product imported to the US from Brazil. In addition to sugar refining, the Brazilian sugarcane sector uses sugarcane by products domestically to produce ethanol fuel for vehicles and to burn to generate electricity. Centro de Tecnologia Canavieira (CTC) submitted information and studies to FDA that showed that sugar produced from the insect-protected sugarcane was as safe as sugar produced from conventional sugarcane. The insect-protected sugarcane was developed by CTC, a company focused on improving sugarcane varieties and technologies in Brazil. The data also showed that the highly refined sugar was compositionally identical to sugar produced from conventional varieties. The recent US FDA approval followed a similar approval for sugar from Health Canada earlier this year. The sugarcane was first approved for cultivation in Brazil by CTNBio: Brazil’sNational Biosafety Technical Committee, in June 2017 following a detailed review process. The new variety developed by CTC produces the Cry1Ab Bt protein to establish resistance to the sugarcane borer (Diatraea saccharalis), a major destructive pest in Brazil that causes damage and loss estimated at $1 billion/year. The Bt protein found in CTC20BT, has a long history of safe use and has been used widely in global agriculture for over 20 years in biotechnology-derived crops like maize, and cotton, among others.

DID YOU KNOW? Sugarcane is full of antioxidants that help to counteract infections and enhance immunity. It also has calcium, magnesium, iron and other electrolytes which are great for dehydration.

ENQUIRY No 4630

PACKAGING 22

RICH IN WATER RESOURCES THE ROMANIAN STOCK CORPORATION, PERLA HARGHITEI, JUST CANNOT SEEM TO BREAK THE HABIT: OVER AND OVER AGAIN, THE MINERAL WATER BOTTLERS INVEST IN FILLING LINES FROM KRONES. 2017 SAW THE COMPANY COMMISSION WHAT IS ALREADY ITS SEVENTH LINE IN SUCCESSION. Demand in Romania for products and disparate container types is characterised by increasing differentiation and complexity: “Consumption of still water, in particular, exhibits over-proportional growth here. This was why we decided to install another PET line with a higher output and block technology,” explains Szilárd Dietrich, Assistant to the General Director and Proprietor, who proudly gave the Krones team a tour of the plant. Dietrich started the tour by giving some insights into Perla Harghitei’s history: “The mineral water company was founded back in 1974 as an enterprise owned by the Romanian state. In 1994, five years after the fall of the Ceaușescu regime, Árpád Kurkó,

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

my father-in-law, succeeded in taking over the firm in a management buy-out. For the preceding eight years, he had himself been a Managing Director at the likewise state-owned water bottlers, Borsec. At the time of his take-over, Perla Harghitei was operating four relatively small glass lines. From 1996 to 2003, the company was, for the first time, using a (pre-owned) PET line for filling carbonated mineral water in 0.5-litre and 1.5-litre containers. 2002 then saw the installation of the first Krones line, rated at 12,000 containers per hour.” FLAWLESS INSTALLATION

“Installation of the most recent line for water filling went off like clockwork,” says Dietrich. “First we completed the hall for it and laid the floor, then the machines were delivered and erected by our own staff in their correct places, after which the installation team from Krones arrived, linked up the individual machines to each other and commissioned the line.” Even today, the machines and the water-blue floor are still gleaming like new, although the line—in its first year of operation—has already filled over 25 million bottles with still or carbonated water. TWO SIGNIFICANT INNOVATIONS

For Perla Harghitei, this line is something quite special in two respects, the first one being that the company has premiered a blocksynchronised layout.

“We’re changing over step by step from paper to PE labels, mainly for reasons of cost.”

PACKAGING

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2018

early 2018, Perla Harghitei had the existing Canmatic replaced by a Contiroll in the second PET line as well. ALSO APPRECIATED ABROAD

Although exports—accounting for roughly two percent—are rather marginal, they’re all the more exotic for mineral water. “The USA is in first place, followed by Hungary, Canada and China. The reason for this can be found in the extremely high emigration rate: an estimated 20 percent of Romanians left the country in search of better working conditions. In the US and Canada, especially, there is a downright diaspora of Romanian immigrants, who prefer natural mineral water from their homeland to the ubiquitous local treated spring water. In Chinese bars and restaurants, too, our Perla Harghitei in the 0.33-litre glass bottle is a much appreciated, highpriced beverage,” claims Dietrich. He also attaches major importance to pointing out his company’s sustainability-focused philosophy: “For us, sustainability means more than just placing the slogan ‘Perla Harghitei—love nature!’ on our labels. We actually do something to achieve sustainability: in 2014, we changed over to Shorty closures with some help

ENQUIRY No 4617

“Krones persuaded us to give it a try—and we haven’t regretted it,” says Dietrich. “We were afraid of losing too many preforms in the event of a filler standstill. But our fears proved to be unfounded, thanks to the ingenious electronic link installed. The block offers us a better standard of hygiene and high efficiency levels. Overall equipment effectiveness (OEE) is running at more than 70 per cent, which, in view of our greatly diversified product range, is very good. Fierce competitive pressure from the large multinational companies means we have to invest in innovative technologies of this kind, offering as they do both low consumption figures for energy and water and an enhanced level of hygiene. Block technology from Krones meets these expectations to consummate perfection.” The second significant innovation was first-time use of a Contiroll wrap-around labeller. “We’re changing over step by step from paper to PE labels, mainly for reasons of cost. We’re sticking with paper only for exports because here it’s quite possible that legislators in the individual countries may change the specifications involved at short notice, and paper means we’re more flexible with smaller batches,” he explains. This was also the reason why in

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KRONES IS OUR EXCLUSIVE MACHINERY SUPPLIER, AND THAT’S SOMETHING WE WILL DEFINITELY NOT BE CHANGING. OVER THE PAST YEARS, KRONES STAFF HAVE REPEATEDLY DEMONSTRATED JUST HOW EFFECTIVELY THEY ARE ABLE TO SUPPORT US. The line in its first year of operation had already filled over 25 million bottles with still or carbonated water.

“The Contiform Bloc offers us a better standard of hygiene and high efficiency levels. Overall equipment effectiveness (OEE) is running at more than 70 per cent – which in view of our diversified product range can be rates as very good,” says Szilárd Dietrich.

from Krones, enabling us to now use preforms with a lower weight. What’s more, we’re still selling some of our products in returnable bottles, accounting for 20 percent of our production capacities.” GERMAN AFFINITIES

“We have real affinities with Germany,” says Dietrich. This is reflected not only in close cooperation with Krones. When it comes to CSD production, too, Perla Harghitei is opting for German know-how. “We buy our basic ingredients from Döhler for the Allegria soft drinks with a fruit juice content. The fact that our waters are highly mineralised means it isn’t all that easy to produce carbonated soft drinks. So we need the knowledge of experienced specialists,” he explains. The elderflower flavour, by the way, is at the moment the absolute runaway bestseller in the firm’s highly diversified portfolio.

and that’s something we will definitely not be changing. Over the past years, Krones staff have repeatedly demonstrated just how effectively they are able to support us. They have put in place a cando, fast-response service team here in Romania. We absolutely need this local service support.” And his boss and father-in-law Árpád Kurkó, concurs: “We shall be sticking with German technology. I visit Krones in Neutraubling at least twice a year, and feel very much at home there,” says the 70-year-old, who despite his success has remained unassuming and downto-earth. And things are going to stay that way in the future as well. Perla Harghitei is considering new pack variants and thinking about channelling further capital expenditure into its filling capacities. There are plans for installing another line for still water as early as in 2019— this one, too, from Krones.

EXCLUSIVE MACHINERY SUPPLIER

In his assessment of Krones, he goes one step further: “Krones is our exclusive machinery supplier,

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ENQUIRY No 4628

PACKAGING PACKAGING

OCTOBER OCTOBER2018 2018 ASIA PACIFIC FOOD INDUSTRY

MANY GOOD REASONS FOR LIQUID DAIRY TO SWITCH TO PET PACKAGING

ACTING IN A COMPETITIVE MARKETPLACE, TYPICALLY IMPACTED BY LOW MARGINS, LIQUID DAIRY MANUFACTURERS RELENTLESSLY SEEK INNOVATIONS TO ACHIEVE PRODUCT DIFFERENTIATION AND A SUSTAINABLE BUSINESS. TO ANSWER THOSE CHALLENGES, SIDEL CAN SUPPORT THE COMPANIES TO SWITCH THEIR LIQUID DAIRY PRODUCTION TO PET BOTTLES AND BENEFIT FROM INCREASED MARKETING OPPORTUNITIES, WHILE LEVERAGING A COST-EFFECTIVE AND FLEXIBLE PRODUCTION. GUILLAUME ROLLAND, VICE PRESIDENT SENSITIVE PRODUCTS AT SIDEL, SHARES HIS EXPERT INSIGHTS INTO THIS TOPIC. HOW DO YOU JUDGE THE POTENTIAL OF PET IN THE LIQUID DAIRY INDUSTRY?

With expertise in PET, Sidel can leverage a list of business successes—from notable liquid dairy companies—to explain why many industry players active in this segment worldwide have been moving their production to PET. Perfectly defined liquid recipes and processing methods, combined with the right PET bottle and aseptic packaging solutions, can ensure maximum product integrity along the supply chain, while optimising uptime and costs. It is important to understand why PET really is an attractive packaging material for the dairy industry, able to offer great potential in terms of product safety, marketing opportunities, as well as flexible and costeffective production.

Guillaume Rolland, Vice President Sensitive Products, Sidel

DO YOU SEE AN INCREASING PET ADOPTION TREND IN THE LIQUID DAIRY PRODUCTS (LDP) MARKET?

Globally, the use of PET as a packaging material is expected to grow continuously within the liquid dairy sector. Traditionally packaged in carton or HDPE containers, liquid dairy products bottled in PET are forecasted to grow by 4.4 percent in the period from 2018 to 2020 (Euromonitor, 2017). With 13.7 billion package units today, PET-packaged products are estimated to reach 14.9 billion units worldwide in 2020. The adoption of PET started in Europe nearly 20 years ago and has been deployed worldwide now, for chilled and ambient distribution drinks, for UHT milk, flavoured milk or soy milk. The trend is even bigger around on-the-go formats than around family formats. In fact, the bottle sizes up to 500 ml represent more than

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2018

PACKAGING 27

two thirds of those PET packages, meaning 8.3 billion units in 2018, projected to reach 9.6 billion units in 2020 (Euromonitor, 2017).

In China, the world’s N°1 liquid dairy producer, Yili, has released its 6-month shelf-life premium drinking yoghurt in PET bottles.

WHAT ARE THE MAIN REASONS FOR PET WINNING ACROSS THIS SEGMENT?

WITH LIGHT AND OXYGEN AFFECTING MILK- AND PLANT-BASED DRINKS, HOW CAN PET ENSURE A SAFE PRODUCT?

When packaging liquid dairy products like white milk, flavoured milk, enriched milk, plant milk, soy milk or drinking yoghurt, multiple variables can influence their quality, including microorganisms, light, oxygen and temperature. The PET growth can be credited especially to this packaging material’s 100 percent recyclability, its excellent barrier properties and its neck and cap tightness that ensures food safety. Moreover, from transparent to opaque solutions, PET packaging alternatives can ensure top product protection and quality, while delivering the expected shelf-life without need for aluminium foil for a more sustainable business. ARE THERE KEY BUSINESS SUCCESSES WITH LDP PLAYERS THAT YOU CAN SHARE?

It has been more than two decades since dairy producers worldwide have trusted PET bottles to refresh their brands, working with both refrigerated and shelfstable products. Many of them have been working with Sidel, trusting our 40-year aseptic packaging expertise and +35 years of experience in PET production. For instance, LSDH France launched its UHT white milk in PET bottles without aluminium foil in 2007. In Brasil, Jussara switched its UHT white and flavoured milk production from carton to PET, for family and on-thego bottle formats. Later on, this Brazilian company also launched a range of on-the-go, lactose-free products.

It is important to highlight that PET barrier solutions ensure product safety across the supply chain, with good oxygen barrier properties, 15 to 30 times higher compared to monolayer and three-layer HDPE (High Density Polyethylene). Regarding light protection, this is achieved through different preform manufacturing technologies and their light blocking capabilities. One of them is the injection of monolayer preform, using a standard injection tool system, mixing PET material with master batch from various suppliers. The other one is the multilayer preform, which can be produced using either over-moulding or co-injection technologies. Those barrier solutions are adjustable in terms of additives and weight according to product recipe, bottle size, and the desired extended shelf-life to be achieved. ACROSS THE GLOBE, WE SEE A TREND TOWARDS FUNCTIONAL AND HEALTH-ORIENTED DRINKS IN DIFFERENT PACKAGING WITH VARYING SIZES. HOW CAN PET ADDRESS THESE CHALLENGES AND HELP MEET CHANGING CUSTOMER NEEDS?

For any product type or package format released on the market, PET packaging gives the opportunity to attract consumers with great brand differentiation due to the bottle design freedom offered by the Injection Stretch

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Blow-Moulding (ISBM) technology and by the inherent and geometric properties of the PET raw material itself. Round or square, asymmetric or with specific handling, its high marketing potential opens up virtually unlimited possibilities to design whatever premium or affordable package. While providing a unique communication platform for brands—that are increasingly using labels or the container itself to engage with their consumers—PET bottles are also allowing users to see the content inside, thanks to their transparency. Easy to open and handle, it is a functional and convenient type of package leading to a great consumer experience. As market demands are quickly changing, shifting from standard bottle size towards smaller packages, PET offers sheer endless possibilities to enhance production flexibility with simple and easy changeovers on the production line while refreshing the brand of a complete bottle family from large to on-the-go formats to answer every need. Sidel can help in designing a unique and ergonomic bottle in line with dairy brands’ requirements. We can evaluate PET bottle strength and performance across the supply chain—through laboratory tests under real production and supply chain conditions, we determine the most suitable packaging designs, PET barrier solutions, sizes, shapes, caps, and filling volumes.

high line efficiency over time. Low and high acid products can be bottled on the same Sidel Aseptic PET packaging line, from 0.2 litres to 2 litres formats. Bottles can be sealed with standard flat caps or sport caps from 28 mm to 38 mm, including the possibility to add specific overcaps, to further differentiate the bottles. To ensure a reliable and efficient production, the line is designed to offer maximum flexibility with reduced downtime for product changeovers, and a simple three-hour cleaning and sterilisation period between bottle-to-bottle productions. Working as a versatile marketing tool, the PET bottles offer many possibilities when it comes to decoration. On top of roll-fed labels or sleeve labels, a complete sleeve covering the cap can also be used, as such increasing the communication-facing surface. The same bottle shape can be customised with different cap colours and label decorations in order to easily multiply the SKUs with minor changes in the production process. Adaptable to niche markets or mass production, the Sidel Aseptic PET complete lines are optimised from low to high speed outputs, with a range spanning from 10,000 to 60,000 bottles per hour according to the forecasted production volumes.

TO MANAGE THE BOOMING PRODUCT DIVERSIFICATION AND SKU’S PROLIFERATION, HOW CAN THE DAIRY PLAYERS BENEFIT FROM A FLEXIBLE AND COST-EFFECTIVE PET BOTTLING PRODUCTION?

Starting from a raw material perspective, PET is the most affordable plastic available on the market, with prices that remained quite stable over the past ten years (Plastics News Europe, 2017). In the PET market, supply exceeds demand and preform suppliers are available world-wide, both aspects contributing to a competitive supply chain.

In this industry, production flexibility is particularly key in terms of product recipes, bottle formats and shapes, cap and label applications—all of that without compromising on

WHERE DO YOU SEE POTENTIAL FOR COST-EFFECTIVE AND ECO-FRIENDLY PRODUCTION?

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ASIA PACIFIC FOOD INDUSTRY OCTOBER 2018

It is also notable that the right-weighting potential in PET bottles is huge, as the water industry largely demonstrated. Sidel has been partnering with its customers to define the container’s weight requirements, able to strengthen the product stability through the supply chain, while ensuring the best consumer experience. For instance, aseptically packaging liquid dairy products in PET via the Sidel Aseptic Combi Predis—the patented blow-fill-cap solution with dry pre-form sterilisation technology— ensures packaging right-weighting since the bottle does not suffer any thermal impact due to the sterilisation. For example, the average weight of a 1 litre PET bottle for UHT milk is 24 g, whereas a HDPE bottle for the same application weighs between 28 and 32 g, with no possibility for light-weighting. With the good neck and cap tightness, the sealing does not require aluminium foil; consequently, dairy manufacturers have less raw material and less equipment to acquire. Using no water and almost no chemicals, the Sidel Aseptic Combi Predis globally contributed to save seven billion litres of water and 57,000 tons of PET, while producing a staggering 46 billion bottles. DO YOU OFFER INTEGRATED PROCESS SOLUTIONS FOR LDP PLAYERS?

Sidel’s fully integrated and technically advanced solutions employ the processing equipment and capabilities of Tetra Pak Processing Systems (TPPS). Over the years, Sidel and TPPS have been combining

ARE THERE ANY NOTABLE SOLUTIONS IN YOUR PORTFOLIO WHEN ASEPTIC MATTERS?

A clear proof point of Sidel’s leadership in aseptic applications is the company’s Aseptic Combi Predis. The solution merges dry preform sterilisation with aseptic blowing, filling and sealing functions within a single production enclosure and respects the fundamental concept which underpins state-of-the-art aseptic packaging rules: producing a commercially sterile product, filled in a sterile zone, in a previously sterilised package. It differs from traditional aseptic technology because the package sterilisation takes place during the preform rather than during the bottle phase. Moreover, it also offers many benefits including safety and simplicity, cost-effectiveness, no water and the use of very few chemicals!

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ENQUIRY No 4556

IN THIS INDUSTRY, PRODUCTION FLEXIBILITY IS PARTICULARLY KEY IN TERMS OF PRODUCT RECIPES, BOTTLE FORMATS AND SHAPES, CAP AND LABEL APPLICATIONS—ALL OF THAT WITHOUT COMPROMISING HIGH LINE EFFICIENCY OVER TIME.

competencies and expertise to define and execute more than 100 complete line projects. As such, the company is perfectly established to support the liquid dairy sector in new product launches or in a switch to PET.

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IMPROVE HYGIENE STANDARDS AND OPTIMISE OPERATIONAL EFFICIENCY WITH MATCON WHEN PRODUCING DAIRY-BASED PRODUCTS, IT IS OF UTMOST IMPORTANCE TO ENSURE THE HIGHEST OF HYGIENE STANDARDS. THIS CAN BE AN EXPENSIVE AND TIME-CONSUMING ACTIVITY, BUT THE RISK OF NOT DOING SO PROPERLY IS FAR TOO HIGH. BY DAVID NEWELL, GENERAL MANAGER & DIRECTOR OF BUSINESS DEVELOPMENT FOR THE ASIA PACIFIC REGION, MATCON. The word ‘hygiene’ can cover both the need to keep everything clean and to avoid cross-contamination of ingredients. Manufacturing systems that were suitable a few decades ago are now proving to be cumbersome and not at all flexible to meet the demands of today’s marketplace. To remain competitive, it is necessary to offer a vast array of products to the consumers. This means that manufacturing processes need to be agile to ensure that only the right amount of product is manufactured at the right time and that you are not creating Inventory to do so.

When handling milk powder-based products, there are several risks that add to this complexity:

•

Residual product from previous recipes can remain inside the processing and handling equipment, which then contaminates the next batch through the system. Cross-contamination can occur from airborne dust returning back into the system through open hoppers and exposed transfer points or by operators. Bacterial growth can occur due to moisture still being present in the system after wet cleaning.

Traditional long pneumatic conveying and coupled mixing lines represent a major risk. These are awkward to clean, and thoroughly removing any trace of a previous recipe is very time consuming. When this is completed how can you swab test each surface to ensure it is safe? Commonly, entire shifts can be used for cleaning down, before a change of recipe is allowed, which adds significant costs to the finished product and inflexibility to the production line.

In order to reduce costs and keep the number of clean-downs to a minimum, some companies opt for Campaign Manufacturing: setting their production schedule to start with the ‘blandest’ recipe and getting progressively stronger. This is often referred to as ‘white to black’, but this just results in Inventory and has its own risks of wastage in respect to shelf-life expiration. A REAL CASE FOR HYGIENE

A major manufacturing company, Brothers Illong, who supply the Chinese dairy industry with specialty raw materials and blends for the manufacture of high quality products for both children and adults, was facing these hygiene issues. With a backdrop of a number of scandals in the Chinese dairy industry at that time, they put hygiene and clean-ability top of their list when looking to invest in expanding their production capacity. They certainly didn’t want to find themselves in the news headlines. At the time of their expansion, they had four static ribbon mixers of different capacities ranging from 500 kg to 3000 kg, which matched their order requirements and were designed to keep downtimes to a minimum. They used 6 operators per shift to keep all the mixers running and they tipped all preweighed materials from a mezzanine floor directly into the mixers, ingredient by ingredient. The mixing time was uncommonly long at 1 hour, with a poor flowing product taking longer at 1.5 hours. After mixing, eight operators were then required at the ground level to execute pack-off. During this packoff time, the mixers are standing idle and not adding any value. In addition, the eight operators could only work on one mixer at a time, so the other three mixers had to wait their turn, wasting even more production time. This made it impossible to keep the mixers at a high OEE rate (Overall Equipment Effectiveness). The production process was very complex to manage as there were too many quality control points and the 14

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Sack-tipping

IBC Filling

• FILLING: The sack-tipping unit with sieving is designed to enable dust-tight filling of the Matcon IBC (Intermediate Bulk Container), ensuring a fully contained transfer of material into the container without spilt material. Thus, high hygiene standards are met and contamination risk is reduced. • MIXING: Using an IBC system means that the product is mixed directly within the container itself, so there is no product contact with the blender and no risk of cross-contamination when new containers are mounted on the blender. • PACKING: The packing system comprises a highaccuracy auger filler fed from an IBC on the floor above. Level probes in the Auger hopper automatically ‘call’ for product from upstairs. Cone Valve technology within each of the IBCs means that the blended material is protected against segregation during discharge. This ensures a quality product every time. Dust-free transfers maintain the safety element of the system. • CLEANING: IBC Cleaning provides a quick and safe cleanout at recipe changeover. IBCs are washed off-

ENQUIRY No 4624

operators were working in a busy, dusty environment. Companies that have found themselves in a similar situation have attempted to break up the long pipework or in-line processing equipment by using tilting aluminium totes and/or big bags. They have continued to use the large ribbon mixers, but removed the pneumatic pipework, and used the containers to collect blended material from the mixer and deliver it to the packing lines. This enables the mixer to go straight into cleaning as soon at the last bit of powder has been discharged. This relieves some of the bottleneck, but tends to transfer the problem elsewhere in the process. Due to the open transfers and open-mouthed discharge points of totes and big bags, excessive dust is generated within the working environment. This now means that large-scale cleaning from ‘ceiling to floor’ needs to be done, resulting in unnecessary utility usage as well as risking the fabric of the building itself, and still, the critical contamination points may not be cleaned. In a bid to overcome this, dust extraction has been employed but is often overused, which has then led to poor product yields and moving the problem on further down the line. When Brothers Illong decided to make a capital investment to increase their production, they decided to buy high quality equipment, and chose a system that was already being used by many international infant formula producers. After a reference visit and full-scale testing using their own ingredients, the contract was granted to Matcon. The final solution involved creating four discrete ‘process modules’:

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CONE VALVE TECHNOLOGY WITHIN EACH OF THE IBCS MEANS THAT THE BLENDED MATERIAL IS PROTECTED AGAINST SEGREGATION DURING DISCHARGE. THIS ENSURES A QUALITY PRODUCT EVERY TIME. DUSTFREE TRANSFERS MAINTAIN THE SAFETY ELEMENT OF THE SYSTEM.

line from the main manufacturing line so it does not contribute to production down-time. Because all these manufacturing steps are separated/decoupled, each processing step is independent and can take place simultaneously, resulting in a lean, efficient manufacturing system with high OEE rates. Brothers Illong found that by using a Matcon IBC Blender, batch sizes of up to 1600 kg can be processed much more quickly than before. Because the product stays within the container and there is no product contact with the blender itself, changeovers are virtually instantaneous. Brothers Illong have the capacity to run 3 to 4 batches per hour off the one single IBC Blender, even being able to change the recipe for each batch if required, without the need for a clean down. The IBC blender is able to accommodate different container

sizes which can be matched to the batch size. There is no further need to store excess product and tie-up cashâ&#x20AC;&#x201D; the ultimate in manufacturing flexibility and efficiency. The amount of manpower they require has been halved, with just three people now needed for filling one at blending and three at packing. This new team structure can produce 20 tonnes in a single shift, meeting the same capacity as that of the previous system, whilst allowing for future sales growth. They are also able to perform the cleaning duties during their usual shift, whereas before, they had to work overtime. SMALL BUT MIGHTY

The decoupled modular design of a containerbased system means that Brothers Illong have the ability to increase production volume by adding in extra packing lines, whilst still running with just one

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ASIA PACIFIC FOOD INDUSTRY OCTOBBER 2018

IBC Blending

A CLEARLY DEFINED HAZARD IN DAIRY INSTALLATIONS IS THE RISK OF MICROBIAL CONTAMINATION. IF ALL TRACES OF MOISTURE ARE NOT REMOVED FROM THE SYSTEM, THERE IS A DANGER THAT BACTERIA WILL GROW IN THESE DROPLETS AND CONTAMINATE THE WHOLE PROCESS. IBC Blender. The upside of using a container-based production system is that one blender can feed to many packing lines—the containers are simply sent to where there is a call for product. This is unlike fixed pneumatic conveying systems where one mixer is linked to a single packing machine. Should demand increase further, a second IBC Blender can easily be integrated into the system. MILK AND WATER DON’T MIX

A clearly defined hazard in dairy installations is the risk of microbial contamination. If all traces of moisture are not removed from the system, there is a danger that bacteria will grow in these droplets and contaminate the whole process. With pneumatic conveying or continuous mixers this can result in a very large batch of product that has to be scrapped. At what cost to both your reputation and operations? Matcon has been working with leading manufacturers installing our IBC systems, which overcome these issues thanks to not only changing

the conceptual solution in terms of decoupling the system, but also due to the simple nature of the IBC design itself. Firstly, because all blending takes place within the container itself, there is no time-consuming cleaning of a mixer after each recipe, the blender is simply ready immediately for change after change, switching out each container with no product in contact with the blender. These dirty IBCs are then cleaned off-line, away from the production area. At the Brothers Illong site, they use wet washing to clean the IBCs, but because this takes place off-line, there is no risk of waterborne contamination. There are sufficient IBCs in the system to ensure there is plenty of drying time before the IBCs go back into circulation. THE FULL BENEFITS

Brothers Illong now have a fully hygienic yet flexible manufacturing plant. Production throughput has doubled, yet the number of operators has been reduced by half. This has resulted in the most efficient and hygienic dairy facility in China—a show-piece which satisfies both their customers and the stringent Chinese legislators.

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INGREDIENTS & ADDITIVES

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

PALM OIL: CHALLENGES, SUSTAINABILITY AND ITS APPLICATIONS CHALLENGES

In our globalised world, the realities of palm oil production and trade have become more complex, thus posing several challenges to the industry. Palm oil is known for being rich in saturated fatâ&#x20AC;&#x201D;however, the conscious consumer views this as unhealthy because saturated fat intake and hydrogenated fat are often associated with increased rates of cardiovascular disease. The consequence of this perception is that a greater number of consumers are reluctant to buy foods that contain fats of any sort on its labels, fuelling the low-fat diet phenomenon. On the contrary, fat is extremely important for the human body to function effectively. It helps to move vitamins A, D, E and K around the body and also helps with hormone production. VITAMIN A is important for growth and development, maintenance of the immune system and good vision VITAMIN D is responsible for increasing intestinal adsorption of calcium, magnesium and phosphate VITAMIN E has a few biological functions: for instance, it is an antioxidant, disabling the production of free radicals in tissues, as well as protects lipids and prevents the oxidation of polyunsaturated fatty acids VITAMIN K is a group of fat-soluble vitamins that play a role in blood clotting, bone metabolism, and regulating blood calcium levels

IN OUR GLOBALISED WORLD, THE REALITIES OF PALM OIL PRODUCTION AND TRADE HAVE BECOME MORE COMPLEX, THUS POSING SEVERAL CHALLENGES TO THE INDUSTRY, SAYS FUTURA INGREDIENTS. To prove the necessity of fat in the human anatomy, a meta-analysis was developed by prospective cohort studies to evaluate the association of saturated fat with cardiovascular disease conducted by Siri-Tarino et. al. (published in The American Journal of Clinical Nutrition in 2010). The objective of this meta-analysis was to summarise the evidence of associating dietary saturated fat that potentially leads to risk of coronary heart disease, stroke, and cardiovascular disease through prospective epidemiologic studies. Out of the analysis, twenty-one studies were identified by searching MEDLINE and EMBASE databases that were qualified for inclusion in this study. As a conclusion, it was found that there is no significant evidence to conclude that consumption of dietary saturated fat has an impact in directly or indirectly increasing the risk of coronary heart disease or cardiovascular diseases. While saturated fat is now viewed as acceptable in the field of nutrition, the focus of health professionals has shifted onto the dangers of hydrogenation and transfats in our diet. Hydrogenation is a process to convert liquid oils into spreadable fats or harden fats, and can be categorised into two processesâ&#x20AC;&#x201D;full hydrogenation and partial hydrogenation. It is important to understand that in the full hydrogenation process, there is no formation of trans-

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INGREDIENTS & ADDITIVES 35

fats. Accordingly, it is important for oils and fats players in the food industry to equip their consumers with the right information by working closely with nutritionists. SUSTAINABILITY

Sustainability has been a buzzword for some time now. While there are a number of interpretations of sustainability, it simply means the capability of meeting the needs of the present without compromising the needs of future generations. The Palm Oil industry is frequently linked with sustainability issues including deforestation and open burning to accommodate the cultivation or replanting of oil palm. In 2001, WWF initiated exploring the possibilities for a Roundtable on Sustainable Palm Oil (RSPO). The result of this was the creation of an informal co-operation among Aarhus United UK Ltd., Migros, Malaysian Palm Oil Association and Unilever together with WWF in 2002. After several rounds of meetings and discussions, RSPO was formally established under Article 60 of the Swiss Civil Code in April 2004. Since then, it has created and spread awareness to both upstream and downstream palm oil players to initiate new endeavours in expanding palm oil production with alternate ways of replanting old and unproductive oil palm lots to improve the yield of oil per hectare. Besides RSPO, the Round Table on Responsible Soy (RTRS) Association was founded in Switzerland in

November 2006. In 2010, the first version of the RTRS Standard was launched. The mission of RTRS is to encourage current and future soybean production in a responsible manner, in order to reduce social and environmental impact whilst maintaining or improving the economic status for the producer. As the worldâ&#x20AC;&#x2122;s population continues increasing, it directly impacts global consumption of vegetable oils which has risen drastically from 167 million metric tons in 2013/14, to 189 million metric tons in 2017/18 and this number continues to grow in line with population growth and industrialisation. Hence, the sustainability of edible oils will remain a key focus for the conscious consumer. If we look into the current oil yield per hectare, palm is still one of the best oil crops, as its oil yield per hectare is around 3.5 to 4.5 tons per hectare, as compared to 0.7 to 1.0 tons per hectare for rapeseed, and 0.45 to 0.6 tons per hectare for soybean. A promising alternative to cater for the growing demand of edible oil is cultivation of algae-based oil which seems to be commercially viable in the near future. And is poised to become the best alternative to oil crops as algae-based technology can produce 10 to 20 times the yield that of palm. Sustainability still remains a complex issue. While oil yield per hectare is just one of the variables emphasised, there are other factors affecting sustainability. As a result, it is imperative for various

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OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

parties (e.g. NGO, researchers, stakeholders, etc.) to work collaboratively to determine the mid- and long-term development plans to cultivate sustainable vegetable oils in order to meet the growing future needs. APPLICATIONS

Palm oil is very versatile, and finds uses in food, feed and industrial applications worldwide. In food, it is used primarily as cooking oil, in production of margarine, spreads, imitation creams, and food emulsifiers. It is transformed into calcium soap for animal feed, and widely as bases for soap, detergent, personal care products and cosmetic ingredients. Food emulsifiers, as defined by the FDA, are substances which modify its surface tension in the component phase of an emulsion to establish a uniform dispersion or emulsion. Therefore, emulsifiers are used within food systems where stabilisation of two phases are required, for example, as a stabiliser of water-in-oil emulsions, such as margarine and spread, and as a stabiliser of oil-in-water emulsions for ice cream products. In terms of applications, we will focus primarily on the application of food emulsifiers in oils and fats products. Distilled monoglycerides (DMG), lecithin, polyglycerol esters (PGE), propylene glycol monostearate (PGMS), sorbitan tristearate (STS), polyglycerol polyricinoleate (PGPR), and LACTEM are some of the commonly used emulsifiers in oils and fats products. Distilled monoglycerides (DMG), lecithin and polyglycerol polyricinoleate (PGPR) however, are more commonly used in production of margarines and spreads. The functions of DMG in margarines and spreads are mainly to promote crystallisation and emulsion stabilisation. Lecithin and PGPR on the other hand, are used to facilitate emulsification and stabilise emulsions in food products. To promote fat crystallisation, DMG is used in pastry margarine to

enhance plasticity, which also improves the lamination of the dough and fat, and promotes lifting and aeration during baking. The aeration capability of cream margarine is affected by the blend of fats and type of emulsifiers used. Lauric fats such as coconut oil and palm kernel oil enhance its whipping properties, on the other hand, alpha tending emulsifiers such as polyglycerol esters (PGE) and propylene glycol monostearate (PGMS) will enhance the aeration capability of cream margarine, and stabilise the foam generated during whipping process. Apart from PGE and PGMS, LACTEM and polysorbate are good alternatives to enhance whipping properties. The use of partially hydrogenated fats is gradually being phased out globally, due to the adverse health impact of trans-fats. However, as trans-fats are being phased out of food formulations, there are challenges that need to be addressed by food formulators as transfats influences the melting profile, texture and oxidation stability of margarines and spreads. Finding healthy, direct substitutes for trans-fats while still achieving the same desired physical and organoleptic qualities makes it the ultimate goal for the oils and fats industry. There are two possible solutions to this challenge of trans-fats elimination in margarines and spreads. The first option is to employ a different manufacturing process, to this end the industry has employed fractionation, chemical and enzymatic interesterification technology. The second option is to introduce a fat crystalliser into the margarine or spread formulation. The addition of 1 percent to 2 percent of fat crystalliser, either singly or together with DMG,

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ASIA PACIFIC FOOD INDUSTRY OCTOBER 2018

manufacturers to balance the economic, social and environmental needs to meet the wider social imperative. If any of these three factors are ignored, we will not be able to sustain needs of the planet, businesses or quality of life for the people of today and the generations of tomorrow.

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induces nucleation within a given set of processing conditions, and the outcome is favourable in improving the crystallisation rate of trans-free fats. This method is fairly straightforward and allows fats to reach a targeted Solid Fat Content (SFC), however it is unlikely to completely resolve crystallisation and processing issues. Aside from margarine and spreads, food emulsifiers are used in cocoa butter, cocoa butter alternatives (i.e. cocoa butter substitute, cocoa butter replacer, and cocoa butter equivalent), as well as cooking oils derived from palm. Food emulsifiers, specifically sorbitan tristearate (STS) is used in the cocoa butter, cocoa butter substitutes and cocoa butter replacers to delay fat bloom development in chocolate and compound chocolate. Although fat bloom in chocolates and its compounds do not pose any food safety risks, the whitish hazelike appearance on the surface renders the product unattractive to consumers. This challenge can be solved with the addition of STS, which helps retain the fat crystals in cocoa butter substitutes, cocoa butter replacers and cocoa butter in its desired form. STS is deployed to delay the polymorphic transformation of these fats. A key quality parameter in cocoa butter substitutes and replacers are a low free fatty acid (FFA) content, as it impacts overall product stability. In response to the quality requirements of the oils and fats industry, STS with a maximum acid value of 1 mg KOH/g has been designed and commercialised. In a similar vein, STS can also be used in palm derived cooking oils (i.e. palm olein) to delay oil crystallisation or clouding at lower temperatures. To sum it up, palm oil is highly versatile ingredient used widely in food applications due to its unique physical qualities and cost efficiency in use. Palm oil is also currently the most sustainable option in terms of yield and organised industry practices to fulfil the needs of generations to come. It is the duty of responsible

INGREDIENTS INGREDIENTS&&ADDITIVES ADDITIVES

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3838

GREAT FILLINGS CREATE THOSE SPECIAL CHOCOLATE MOMENTS

CONSUMER TASTES MAY DIFFER, BUT INDULGENCE AND EXCITEMENT ARE ALWAYS AT THE HEART OF CONFECTIONERY FAVORITES—PREFERABLY WITH A HEALTHIER, MORE NATURAL PROFILE. BY MARCO OOMEN, AAK’S GLOBAL BUSINESS DIRECTOR FOR CHOCOLATE & CONFECTIONERY FATS. ALTHOUGH chocolate means different things to different

people, there are, according to recent surveys, some points that chocolate lovers tend to agree on. Three of them stand out. First of all, chocolate is moving out of the snack category and becoming more of a premium luxury. Secondly, exciting creative tastes and textures are a must—perhaps with the addition of a few nuts and a healthier, more natural profile. And finally, trans fats are a no-go, with almost a third of consumers often checking the ingredient labels before they buy. Another indication is that consumers have moved beyond the solid chocolate bar that was popular a decade or two ago. Today, filled chocolate and confectionery products are preferred. While this gives manufacturers a fantastic playground for developing new sensory experiences, it also raises a set of technical challenges that must be solved before a new product can become a true consumer favorite. Very often, the solution to such challenges lies in the filling fats.

AN EVERYDAY AFFORDABLE LUXURY

In an AAK survey of European and US consumers conducted earlier this year, more than 65 percent of the respondents described chocolate as a permissible indulgence. Some see it as their daily affordable luxury. In other words, they have high expectations of the chocolate they buy—and their expectations must be met each time.

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INGREDIENTS & ADDITIVES 39

So, when manufacturers produce chocolate and confectionery with fillings, they aim to excite consumers with soft, hard or aerated textures, flavors with controlled release, as well as a creamy or cooling sensation in the mouth. All of these characteristics depend on the choice of filling fats, their interaction with the other ingredients in the recipes and the processes used. In other words, production of a perfect filling requires a thorough understanding of all the parameters that influence the taste and quality of the final filled chocolate. This is the key to a world of opportunities, where fat plays an essential role along with the other ingredients used. OVERCOMING THE TECHNICAL CHALLENGES

IN AN AAK SURVEY OF EUROPEAN AND US CONSUMERS CONDUCTED EARLIER THIS YEAR, MORE THAN 65 PERCENT OF THE RESPONDENTS DESCRIBED CHOCOLATE AS A PERMISSIBLE INDULGENCE. SOME SEE IT AS THEIR DAILY AFFORDABLE LUXURY.

When nuts are added to the recipe, for example, it can be a real challenge to maintain quality throughout the productâ&#x20AC;&#x2122;s shelf-life. Consumers love nuts for their premium, healthy image, delicious taste and crunchy texture. But nut oil is well-known for its tendency to migrate from the filling and into the chocolate coating. Unless a special bloom-retarding fat is used in nutty fillings, bloom will often appear in no time. Another parameter to consider is texture. Should it be hard, soft or aerated and should crunch be added? The filling fat is the key to create the perfect texture. With softer fillings, the challenge is to maintain quality

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Figure 1: Sensory and appearance of filled chocolate

FILLED CHOCOLATES ARE NOT JUST CHOCOLATE ANYMORE. TO CONSUMERS, THEY ARE ABOUT ENJOYING LIFE, SPECIAL MOMENTS AND INDULGENCE. throughout the product’s shelf-life. This is simply due to the faster migration of the filling’s oil content to the surface of the chocolate shell. When that happens, the filling becomes dry and the chocolate surface will turn grey, dull and less appealing—a phenomenon known as bloom. CO-DEVELOPMENT OF INDULGENCE AND HEALTH

AAK supports chocolate and confectionery manufacturers with all these considerations and technical challenges through the co-development of exciting new fillings. Several parameters need to be considered when producing fillings for the special chocolate moments that consumers seek (figure 1). Filled chocolates are not just chocolate anymore. To consumers, they are about enjoying life, special moments and indulgence.

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‘MIND’ YOUR FOOD: NEURO NUTRITION TO FLOURISH IN 2018 TODAY, CONSUMERS ARE INCREASINGLY SEEKING PRODUCTS THAT BOAST TANGIBLE BENEFITS IN SUPPORTING SPECIFIC HEALTH NEEDS—A CONCEPT WHICH HAS COME TO BE KNOWN AS ‘CONSUMPTION WITH A PURPOSE’. BY MICHELLE TEODORO, GLOBAL FOOD SCIENCE & NUTRITION ANALYST, MINTEL. AS food links directly to health management, functional food and drink products commonly cater to the concerns of health-conscious consumers. Over the years, people’s concerns have focussed on heart health with a shift towards digestion and, more recently, cognitive function. According to Mintel Global New Products Database (GNPD), global food and drink launches carrying brain and nervous system claims remained niche over the last five years, with less than one percent carrying such a claim. Neurological disorders such as Alzheimer’s disease, mental fatigue and memory problems are prevalent across the world, and this opens the door for brands

to provide tailor-made products which cater to consumers’ desire for better neuro nutrition. Neuro nutrition is relevant to everyone, from seniors looking to improve their mental well-being, to younger consumers, parents, and adults who seek increased mental agility. In fact, Mintel research reveals that as many as two in five urban Thai consumers are motivated to use functional food and drink for cognitive health improvement, while one in three parents in China with children aged 4-12 are eager to give their kids supplements which will help to bolster their mental development. In the US, over one in four seniors are focusing on improving their mental well-being.

NEURO-NUTRITIVE FOOD AND DRINK PRODUCTS FOR VARIOUS DEMOGRAPHICS FOCUSAID DIETARY SUPPLEMENT BEVERAGE, USA

Focusaid Dietary Supplement Beverage is a doctor developed product that claims to contain targeted supplements and is made with raw organic blue agave. The product is formulated with American ginseng, which supports learning and memory; Rhodolia rosea, which supports concentration and is a nootropic; gaba, which helps with stress, clarity, concentration and focus; alpha GPC, which helps with memory, cognition and contains nootropic; acetyl-l-carnitine, neurotransmitters; vitamins C and D, which contain antioxidants and support the immune system; yerba mate and green tea, vasodilators and sources of natural caffeine; and full B complex and folic acid which support focus and endurance.

BABY BISCUITS FOR BRAIN POWER

Plasmon Oasi Nella Crescita Baby Biscuits from Italy are suitable for toddlers aged six months and up. It claims to contain calcium and B vitamins with iron, both of which contribute to normal cognitive and immune system development.

BRAIN GUM FOR SENIORS

Lotte Xylitol Hani Tsukinikui Mint Anti-Stick Gum from Japan is formulated with Ginkgo biloba-derived flavonoid glycosides and terpene lactones, which can help give middle-aged and older consumers a memory boost.

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ADAPTOGENS AND NOOTROPICS CARRY THE TORCH FOR NEURO NUTRITION

Adaptogenic and nootropic substances are key to good neuro nutrition as they optimise and enhance brain functionality and health—in particular memory concentration, focus and alertness. The potency of substances such as the lion’s mane mushroom, holy basil and B-vitamins, will continue to encourage more research on their use across various categories. In order to effectively tap into people’s desire for improved cognitive health, recognised substances such as caffeine and L-theanine seem like a good place to start. In the US, half of consumers say that ‘natural’ is the most important purchase factor when shopping for food and brands should emphasise their natural and functional profile to appeal to these consumers. TAKING INSPIRATION FROM NEURO-FOCUSED DIETS

Brands offering neuro nutritive benefits are also taking inspiration from diets which help to improve cognitive function. Such examples include the MIND diet designed to lower the risk of Alzheimer’s disease and Korean Temple Food, of which emphasis upon simple, wholesome ingredients and mindful cooking practices is meant to improve mental clarity and aid meditation. Diets like these encourage a more general shift towards healthy eating habits, giving them widespread appeal and the ability to provide numerous benefits aside from brain health. Mintel research reveals that over three in four US consumers who are not diagnosed with gluten

intolerance/sensitivity are still eating, or used to eat, gluten-free foods as they feel that it is better for their health. On top of this, over one in three consumers in the UK who eat free-from foods say they consume them because it makes them feel better. It is therefore safe to assume that consumers see a healthy diet plan as an in-road to obtaining a healthy lifestyle, or as a good way to cater for a specific health need. The famed low-carb ketogenic diet, a talking point among health professionals and consumers alike, is not only associated with weight loss but is also ideal for

PRODUCTS SUITABLE FOR NEURO NUTRITION-RELATED DIETS

WHOLE GRAINS FOR THE BRAIN

Plookluck Organic Sangyod Rice from Thailand is said to have higher fibre content than other rice varieties, helping it to protect against cardiovascular problems and Alzheimer’s disease.

FOR VEGANS

Carpe Diem White Tea Drink with Curcuma and Yuzu from Switzerland contains spicy curcuma with fruity yuzu, which is said to meditate not only the body but also the mind.

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THE OPPORTUNITY

Neuro nutrition is expected to see increased coverage over the course of 2018, especially as awareness of neurological disorders such as Alzheimer’s disease and mental fatigue grows. Brands looking to move into the neuro nutrition market should reformulate their products with brain-boosting

THE FAMED LOW-CARB KETOGENIC DIET, A TALKING POINT AMONG HEALTH PROFESSIONALS AND CONSUMERS ALIKE, IS NOT ONLY ASSOCIATED WITH WEIGHT LOSS BUT IS ALSO IDEAL FOR MAINTAINING GOOD BRAIN HEALTH. ingredients such as adaptogens and nootropics, while popular diets such as MIND, ketogenic and Temple Food diets could offer immense inspirational scope. Currently, Mintel GNPD reveals that dairy and hot beverages are the categories rifest with products carrying neurological benefit claims and this opens the door for more cross-category expansion, with on-the-go convenience—in the form of snack bars and multi-serve offerings—being of particular interest.

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maintaining good brain health. Brands have clearly seen the potential of keto diets in the past. Quest Nutrition, for instance, offers keto-friendly products while Bulletproof offers its keto coffee and water variants. Know Brainer Foods, known for its ketogenic c re a m e rs a n d o r g a n i c g ra s s - fe d b u t te r, h a s partnered up with Nestle to create a multi-serve, keto-friendly product with added collagen protein, which boasts convenience and offers a plethora of cognitive benefits. With the success of the ketogenic diet and consumer preference for functional foods and convenience, opportunities exist for brands to expand their functional repertoires across multiple categories, offering a robust platform for delivering neuro nutrition innovation.

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OCTOBER OCTOBER2018 2018ASIA ASIAPACIFIC PACIFICFOOD FOODINDUSTRY INDUSTRY

FOOD FORTIFICATION: BENEFITS EXTEND BEYOND BABIES PHYSICAL CHANGES, MEDICATIONS, HOSPITALISATIONS, AND SOCIAL FACTORS CAN PUT OLDER ADULTS AT RISK OF MALNUTRITION WHICH MAKES OTHER HEALTH PROBLEMS WORSE. BY THE FOOD FORTIFICATION INITIATIVE. FORTIFYING food is often seen as a strategy to help young people because children and women in their child-bearing years require vitamins and minerals for healthy growth and development. Yet physical changes, medications, hospitalisations, and social factors can put older adults at risk of malnutrition which makes other health problems worse. Consequently, fortifying food is as important for the aging population as it is for children and women who may become pregnant. The aging population is particularly noteworthy in Asia. With decreasing fertility rates and increasing life expectancy, the World Economic Forum notes that more than half the world’s people over age 60 years live in Asia and the Pacific. By 2050, “nearly two-thirds of the world’s older people—close to 1.3 billion—will live in Asia-Pacific, and one in four people across the region is expected to be over 60. In north-east and East Asia, this proportion will be more than one in three people.”

While an aging population has many implications for a country’s economy and health system, aging increases the likelihood of individuals having a chronic disease. Heart disease, diabetes, and osteoporosis are a few of the illnesses that people are more likely to experience as older adults than as youth. Proper nutrition plays a role in preventing diseases, and good nutrition contributes to quality of life and lessens the disease’s effects. Fortification involves adding essential nutrients to foods as they are processed. A key advantage is that consumers do not have to change their shopping or eating habits to benefit. They simply continue to enjoy eating their favourite foods. “Globally, we have emphasised good nutrition during the first 1,000 days of life, meaning from conception through a child’s second birthday. While that is a critical time, the need for nutrition does not stop at age 2,” said Scott J. Montgomery, Director of the

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HEALTH & NUTRITION 45

Food Fortification Initiative. “Food fortification gives people of all ages additional vitamins and minerals to help them remain healthy through the life span.” B VITAMINS—NOT JUST FOR BABIES

Folic acid (vitamin B9) reduces the risk of birth defects of the brain and spine. Consequently, women of childbearing age are encouraged to take 400 micrograms of folic acid every day. This amount of vitamin B9 is nearly impossible to consume daily from unfortified food alone, consequently flour and rice are often fortified with folic acid. Yet the recommended daily intake (RDI) for adult men and women of all ages is 400 micrograms of folic acid. This nutrient helps people produce and maintain healthy cells and prevent anemia from vitamin B9 deficiency. One neurologist’s research shows that in older adults, “Vitamin B9 deficiency contributes to ageing brain processes, increases the risk of Alzheimer’s disease and vascular dementia and, if critically severe, can lead to a reversible dementia.” Fortifying with folic acid has nearly eliminated anemia from vitamin B9 deficiency among older adults in the United States, where most of the wheat flour, maize flour, and rice is fortified with folic acid. In a geriatric healthcare facility in Japan, 28 of 68 residents were deficient in vitamin B9. They were given rice that was fortified with folic acid, and within 6 months, none of them had this deficiency. Moreover, people need vitamins B9, B6 and B12 to lower homocysteine levels. This is important because elevated homocysteine levels are associated with dementia, heart disease, stroke, and osteoporosis. In Australia, homocysteine levels were significantly reduced among people older than 65 years after wheat flour was fortified with vitamin B9 (folic acid). Also, in Sakado City, Japan, rice fortified with folic acid resulted in decreased homocysteine levels

VITAMIN B9 DEFICIENCY CONTRIBUTES TO AGEING BRAIN PROCESSES, INCREASES THE RISK OF ALZHEIMER’S DISEASE AND VASCULAR DEMENTIA AND, IF CRITICALLY SEVERE, CAN LEAD TO A REVERSIBLE DEMENTIA.

ENQUIRY No 4621

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and reduced medical costs by decreasing myocardial infarction, stroke, dementia, and fracture. Other nutrients for which the RDI does not change as adults age include selenium, zinc, iron, iodine, thiamin, riboflavin, niacin, pantothenate, and vitamins B12, C, E, and K. The four nutrients for which the RDI increases as adults age are calcium and vitamins A, B6, and D. The following information focuses on these four vitamins and minerals. CALCIUM

important for normal vision, immunity, reproduction, and proper functioning of the heart, lungs, kidneys, and other organs. Though too much vitamin A can be dangerous, the daily “recommended safe intake” for women increases from 500 micrograms of retinol equivalents per day from 50 to 65 years to 600 micrograms of retinol equivalents per day after 65 years. The recommended safe intake for men remains at 600 micrograms of retinol equivalents from age 19 years through the rest of the life span. The Philippines includes vitamin A in its standard for wheat flour and cooking oil. It is typically less expensive to fortify edible oils or margarine with vitamin A than to fortify flours with vitamin A.

Calcium is needed for healthy bones. The mineral is also necessary for performing key tasks, such as transmitting nerve messages, enhancing muscle function, and clotting blood. The RDI for calcium remains at 1,300 micrograms per day for women from age 51 years through the rest of their lives. For men, the RDI increases from 1,000 micrograms per day from 19 to 65 years to 1,300 micrograms per day after 65 years. Dairy products are natural sources of calcium, and some breakfast cereals, juices, and other foods are fortified with calcium. Adding calcium to flours can be challenging as the compounds do not flow well through milling equipment. Also, calcium is usually added to flour at higher levels than other nutrients. Together, this means calcium can clog the mill’s fortification equipment. Mills can solve this problem by having separate equipment for the calcium addition.

Vitamin B6 facilitates enzyme reactions involved in metabolism and assists with immune function. It is also one of the vitamins that prevents the accumulation of homocysteine. A woman’s RDI of vitamin B6 remains at 1.5 micrograms per day from 50 years of age throughout the rest of her life. For men, the RDI increases from 1.3 micrograms per day from 19 to 50 years to 1.7 micrograms per day after 50 years. Poultry, fish, potatoes, and noncitric fruit are good sources of vitamin B6. In countries where these foods are commonly consumed, vitamin B6 deficiency may be uncommon. People in countries where diverse foods are not accessible or affordable may have vitamin B6 deficiency and would benefit from foods being fortified with vitamin B6.

VITAMIN A

VITAMIN D

Vitamin A deficiency is the leading cause of preventable childhood blindness. For adults, vitamin A is

VITAMIN B6

Vitamin D is sometimes called the sunshine vitamin because people produce it when their skin is exposed to

HEALTH & NUTRITION

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2018

FORTIFICATION ADDS NUTRITIONAL VALUE TO FOOD, WHETHER THE PERSON IS INDULGING AT AN EXPENSIVE RESTAURANT, MAKING INSTANT NOODLES AT HOME, OR EATING A MEAL WITH OTHER RESIDENTS AT A SENIOR LIVING FACILITY.

sunlight. People who mostly stay indoors, including some elderly people with limited mobility, are more likely to develop vitamin D deficiency. Women’s RDI for vitamin D increases from 10 micrograms per day from 50 to 65 years to 15 micrograms per day after 65 years. For men, the RDI for vitamin D increases from 5 micrograms per day from 19 to 50 years to 15 micrograms per day after 50 years. Vitamin D is essential for bone health because it helps people absorb calcium. As a result, vitamin D deficiency in adults contributes to osteoporosis, which is marked by weak and brittle bones. This often leads to broken bones, most often of the wrist, spine, and hip. Women of Asian and Caucasian descent are more prone to osteoporosis than other ethnic groups, according to the International Osteoporosis Foundation. To increase vitamin D intake in Canada, fortifying milk and margarine with vitamin D is mandatory. In the United States, including vitamin D in infant formula is mandatory, and fortifying other foods such as milk, orange juice, and breakfast cereals with vitamin D is voluntary.

adds nutritional value to food, whether the person is indulging at an expensive restaurant, making instant noodles at home, or eating a meal with other residents at a senior living facility. Table: Number of countries that include select nutrients in maize flour, oil, rice, and/or wheat flour fortification standards

Calcium

Vitamin A

Vitamin B6

Vitamin D

Source: Global Fortification Data Exchange (GFDx). The data reflects both mandatory and voluntary fortification.

SILVER MARKET

Asia’s aging population has been called the “silver market”. The label implies that older adults have high disposable incomes and can afford to purchase expensive items. Other researchers conclude that several factors could make the economic impact of Asia’s aging population positive or negative. A key benefit of mandatory food fortification is that if the mandate covers commonly consumed foods and it is well implemented, consumers benefit regardless of their age or economic status. Fortification

Map: Countries with standards to fortify foods with one or more of the nutrients for which the recommended daily intake increases as adults age.

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HUMAN MILK OLIGOSACCHARIDES (HMO): CREATING DIFFERENTIATED OFFERS IN INFANT NUTRITION MARIANNE HEER, SCIENTIFIC MARKETING MANAGER HUMAN NUTRITION OF BASF SE, DISCUSSES THE IMPORTANCE OF HMOS WITH MOLECULAR STRUCTURES IDENTICAL TO THOSE OCCURRING IN HUMAN MILK FOR OPTIMAL INFANT NUTRITION. THERE is broad consensus that breast feeding is the best nutrition for newborn infants. Not only does it assure normal growth and development during infancy, it is also associated with favorable mid- to long-term outcomes, e.g., lower risk of respiratory or gastrointestinal infections, allergy, diabetes or obesity in later life. For mothers who cannot breastfeed, infant milk formulas could be the next best alternative to breast milk. Intense research is ongoing to identify specific components of human milk and to make them available as ingredients for formula—always with the objective to narrow the nutritional gap between human milk and cow’s milk-based infant formula. DESIGNED BY MOTHERS, DISCOVERED BY SCIENTISTS Human Milk Oligosaccharides (HMO) is a breakthrough differentiator: they are the third largest solid component in human milk, following

lactose and fat. The amount is about 300 times higher compared with bovine milk. HMOs were discovered many years ago, however, it was only during the last decades that detailed insights into the complexity of the structures were gained, thanks to the availability of more precise analytical methods. The HMO composition of human milk is complex and varies significantly among mothers, over the course of lactation and according to their genetic set-up. The HMO concentration in early milk is highest and it declines by about 30 percent over the course of lactation. In mature human milk, the content may still be as high as 5 – 20 g/L compared to less than 0.05 g/L of bovine milk. Today, more than 200 HMO molecules have been identified, of which 2’-fucosyllactose (2´-FL) is the most abundant in most mothers. Up to now, galactooligosaccharides (GOS) and fructooligosaccharides (FOS) have often

Parents are concerned about healthy growth and development of their babies – meeting this demand is the basis for creating differentiating offers in infant nutrition

been added to infant formula to mimic HMOs. However, both do not occur in human milk. On the other hand, fucose and sialic acid which appear to be important structural and functional components of HMOs are absent in infant formula with GOS/ FOS. Thus, the availability of HMOs with molecular structures identical to those occurring in human milk is a breakthrough in infant nutrition. THE FIRST SUPERFOOD FOR BABIES’ HEALTHY DEVELOPMENT During infancy, HMOs are important to shape the microbiota by promoting the colonisation of beneficial bacteria, mainly bifidobacteria. More and more ongoing studies show the clinical relevance of deviations from “normal” microbiota, especially during early life (e.g., dysbiosis preceding allergic diseases, metabolic syndrome or obesity). Thus, developing a microbiota close to that of breastfed infants is the objective. Healthy immune functions are a pre-requisite for the prevention of infections and allergies. About 10 years ago, it was found that Campylobacter diarrhea—one of the major causes of diarrhea during infancy—occurred less often in babies whose mother’s milk contained

SPONSORED FEATURE

BASF - The only ingredient player with end-to-end know-how of the development and large-scale production of 2’-fucosyllactose

from rodent models, in which 2’-FL was shown to have a positive effect on learning and memory functions when supplemented during infancy. HUMAN MILK OLIGOSACCHARIDES: PRECIOUS COMPONENTS FOR INFANCY AND BEYOND Despite the encouraging results from clinical and experimental studies, HMO research is still in its infancy. Given the various functions and benefits already discovered for 2’-FL, this molecule is a promising ingredient not only for infants, but also for children and adults in various life-stages, meeting consumer’s desire for ingredient solutions inspired by nature. The availability of 2’-FL for use in infant formula is an important first milestone to make this happen. When developing the 2’-FL fermentation at BASF, we focused on upscaling characteristics right

Due to the selection of a stable fermentation strain, there is no need for the use of antibiotics during production and therefore, BASF’s 2’-FL is 100 percent free of antibiotics.

from the start: the 2’-FL fermentation has been developed as a platform technology which is available for further molecules as well. BASF has successfully mastered the complete in-house development of 2’-FL, based on the capabilities of our central research network in Ludwigshafen, Germany. Serving the infant formula market, product safety is clearly of utmost importance. This is exemplified in the way we deal with potential microbiological contaminations, considering the most rigid standards (e.g. (EC) 2073/2005). Due to the selection of a stable fermentation strain, there is no need for the use of antibiotics during production and therefore, BASF’s 2’FL is 100 percent free of antibiotics. BASF’s leadership in sciencebased solutions, production technology and operative excellence, ensures reliable and efficient production setup, providing the flexibility required to consistently meet customer needs, especially in fast-growing markets. Protecting our customer’s most precious and vulnerable consumers is a commitment we make in our vision to provide the right nutrients to the right people at the right time.

ENQUIRY No 4643

high levels of 2’-FL. In the meantime, mechanistic studies shed light on this observation: due to the specific molecular structure, 2’-FL is able to act as a decoy receptor for pathogens. Instead of binding to the carbohydrate receptors on the intestinal cell surfaces, pathogens bind to 2’-FL and the adhesion to the host cells—the first step of infections—can be prevented. Moreover, 2’-FL can directly modulate intestinal cell responses and the thus strengthen the mucous barrier. Recent data suggest that 2’-FL can directly attenuate inflammation in experimental models. This confirms HMOs as being an “innate” immune system of human milk whereby the mother protects the vulnerable newborn child. 2’-FL can also represent a novel preventative active to reduce mucosal inflammation associated with diverse bowel disorders. Allergies are on the rise in many countries and besides genetic predisposition, environmental factors play an important role. Observational studies suggest that fucosylated HMOs may have a preventive role in infants with high allergy risk. Further promising results stem

HEALTH & NUTRITION

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

Micronutrients especially for seniors

BOOSTING IMMUNITY AND PERFORMANCE WITH MICRONUTRIENTS STERNVITAMIN HAS DEVELOPED A WIDE RANGE OF SOLUTIONS FOR DIFFERENT AGE GROUPS AND LIFE PHASES TO DELIVER MICRONUTRIENTS TO THE HUMAN BODY.

HEALTH and balanced nutrition are not mere trends. They are established, ongoing consumer interests, and more and more people are choosing foods that support their physical and mental wellbeing. Consequently, products that offer healthy enjoyment are the strongest growth drivers in the food and beverage category. Individual concepts—meaning products that are tailored to the personal health profiles of individual consumers—are especially promising. Personalised foods that are both tailored to individual needs and also improve personal performance and wellbeing thus have very good market potential. EFFECTIVE RELAXATION FOR STRESS

For some years, vitamin and mineral specialist SternVitamin has been developing micronutrient

premixes for different needs and target groups. Its Relax premix is one example. This is intended primarily for professionals and for students during exams, but also has its place in everyday life, especially for people who live in crowded cities and must cope with traffic congestion and air pollution. The ingredient complex has a positive influence on concentration and stress perception. In hectic situations, it helps people relax without making them tired. On the contrary, they stay wide awake, but are less nervous and stressed. This effect is achieved with vitamins B6, B12 and C, niacin and pantothenic acid, magnesium, zinc and plant extracts. According to Sabine Hildebrandt, Head of Research & Development at SternVitamin, “B vitamins are considered anti-stress vitamins that are good for the nerves. They perform essential tasks in energy

HEALTH & NUTRITION

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2018

provision and stimulus transmission. Vitamin B deficiency leads to poor concentration, poor memory, tiredness and exhaustion. Folic acid, vitamins B6, and B12, and pantothenic acid (B5) are especially important, and they are the B vitamins that our Relax premix is formulated around.” Magnesium also protects the nervous system from stress, and in literature is sometimes called a “salt of inner peace”. Magnesium inhibits a chain reaction that causes stress, including the secretion of adrenaline and noradrenaline. This reduces fatigue due to stress, and counteracts tiredness. Under stress, the body uses more magnesium, which can result in an insufficiency that needs to be compensated. Classic vitamins, minerals and trace elements

NEW MENTAL ACUITY

Every day, at work or at school, in learning or on the job, we demand top performance from our brains. As the control centre of the body, the brain also regulates the functions of all organs and systems. To accomplish this, around 100 billion brain cells—called neurons— are in constant contact with each other. They need a continuous supply of oxygen and energy. They also need

ENQUIRY No 4631

PRODUCTS THAT OFFER HEALTHY ENJOYMENT ARE THE STRONGEST GROWTH DRIVERS IN THE FOOD AND BEVERAGE CATEGORY.

will continue to play the central role in nutritional supplements, but will increasingly be combined with other ingredients like plant extracts, fatty acids, amino acids and other functional ingredients. “For example, in our Relax premix, we use the positive effects of ginseng (panax ginseng) to make the body and mind more resistant to stress and fatigue,” says Dr Hildebrandt. This is in addition to nerve-strengthening B vitamins through secondary plant substances like ginsenosides, along with 25 other substances. For their part, hops and melissa plants contain secondary plant substances that have balancing and calming effects in situations of anxiety and nervousness.

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OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

certain micronutrients as construction materials and lubricants, for transport and to deliver energy. “Taking antioxidant micronutrients early on can counteract age-related loss of mental function,” notes Dr Hildebrandt. Other concentration and memoryboosters round out SternVitamin’s mental fitness product offering, for a targeted nutritional supplement that can help older people make full use of their potential for as long as possible. “According to the latest knowledge, plaques of small, misshapen protein molecules called beta-amyloid peptides play a major role in dementia diseases like Alzheimer’s,” states Dr Hildebrandt. “Free radicals are probably the triggers for the deformation of normally harmless protein molecules.” Special antioxidants can help prevent this, including vitamin C, which protects nerves and brain blood vessels from damaging oxidation processes. The trace element zinc also assists in antioxidative defence. Polyphenols, such as those found in grape seeds, green tea and elderberries, are likewise antioxidants. These secondary plant substances contribute to preventing the accumulation of deformed protein molecules in the brain where they can damage nerve cells. Studies indicate that they can also reduce the

The Relax micronutrient premix reduces stress and fatigue

risk of neurodegenerative diseases like Alzheimer’s, if taken regularly in sufficient concentration. The B vitamins, especially folic acid, also improve the memory performance of older people. The coenzyme Q10 plays an important role in mental performance. It is heavily involved in energy metabolism at the cellular level, and can even be said to drive energy generation. Iron is also important for mental fitness. This trace element is responsible for transporting oxygen, without which nothing works in the brain. Typical symptoms of iron deficiency are general fatigue and lack of energy, and mental performance deficits like forgetfulness and lack of concentration. “Turmeric is very important for special brainpower mixes,” says Dr Hildebrandt. “This oriental spice contains secondary plant substances, in particular curcumin, that promote the formation of new nerve cells in the brain. Curcumin is also a powerful antioxidant, as well as being effective in the fight against plaque formation in the brain.” Omega-3 fatty acids and lecithin (phosphatidylcholine) also boost cognitive functions. STRENGTHENING THE IMMUNE SYSTEM AND STAYING FIT

Staying active and full of energy takes not just mental but also physical fitness. Stress as well as environmental influences like high humidity and heat, overcrowded cities, heavy traffic and air pollution are challenges for the immune system.

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53 Customised micronutrient premixes for beverages like juices, fitness and energy drinks, flavoured water and tea

STERNVITAMIN HAS DEVELOPED A WIDE RANGE OF SOLUTIONS FOR DIFFERENT AGE GROUPS AND LIFE PHASES, FROM COUPLES TRYING FOR CHILDREN TO PREGNANCY, BREASTFEEDING, CHILDHOOD, SCHOOL, UNIVERSITY, PROFESSIONAL LIFE AND SENIOR LIFE. “The immune system uses highly reactive free radicals to destroy pathogens,” explains Dr Hildebrandt. “But the radicals don’t just eliminate pathogens, they also cause inflammation and damage to cells in the body. The body needs antioxidants to counteract the formation of excess radicals.” Vitamins A, C, E and carotenoids like beta carotene reduce this oxidative stress. Citrus fruit and green tea supply secondary plant substances like flavonoids and anthocyanins, which are especially effective at strengthening the body’s defences against free radicals. Trace elements like selenium, zinc, copper and manganese are involved in this fight, as they are required for antioxidative enzyme systems. The immune cells themselves have a higher metabolic rate when they are in action. This increases the need for micronutrients, especially folic acid, vitamin B12, zinc and iron, as these are important for the formation of immune cells. ADDED VALUE FOR ALL CONCERNED

The targeted combination of different micronutrients results in new ingredient complexes that meet the specific needs of individual target groups. SternVitamin has developed a wide range of solutions for different age groups and life phases, from couples trying for children to pregnancy, breastfeeding, childhood,

school, university, professional life and senior life. Dr Hildebrandt comments: “Personalised foods that address special health aspects have high added value but the market is looking for much stronger differentiation. A single multivitamin tablet for everybody—those days are over. The trend is more and more towards personal food.” Conceivable product examples are yogurt with beauty vitamins for the skin, power drinks with selected minerals for mental performance, or special snacks for older people who have trouble chewing and swallowing. Target group concepts like these bring advantages for all concerned—consumers get products tailored to their expectations, manufacturers can generate additional revenue potential through portfolio diversifications, and ideally healthcare costs can be reduced. SternVitamin offers customised micronutrient premixes for food and beverage manufacturers. These ingredient complexes can be individually dosed and are suitable for enriching many products, from beverages, teas and dairy products to snacks, cereals, confections and ready meals.

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BEVERAGE

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

DEMAND FOR HIGH-PROTEIN FOOD/DRINK PRODUCTS ESPECIALLY STRONG AMONG YOUNG ADULTS BASED ON A 2018 GLOBALDATA SURVEY CONDUCTED IN ASIA & AUSTRALASIA PROTEIN in a bottled water format is a convenient onthe-go solution that combines protein with hydration benefits, making it ideal for before and after workouts. A 2018 survey commissioned by GlobalData, a leading data and analytics company, reveals that when choosing food/ drinks, 39 percent of consumers in Asia & Australasia prioritise “high protein” claims before exercising while 32 percent of them prioritise such claims after exercising. When drilling down to specific consumer segments, the findings highlighted that the ‘high protein’ claim is particularly important among 18 to 24-year-old consumers with 48 percent (before exercising) and 33 percent (after exercising) sharing this sentiment. However, in consumers aged 65+, the levels of interest were very low: 19 percent before exercising and 22 percent after exercising.

As consumers look to incorporate protein into their diets, the demand for convenient, on-the-go solutions that accompany exercise create a niche for functional, but natural and simple hydration products. According to GlobalData, new product launches in soft drinks sector with “high protein” claims have increased at an annual growth rate of 27 percent from August 2017 to August 2018. Traditionally, dairy-based protein-rich beverages have been more popular; however, growing consumer demand for protein is opening the door to broader applications of the concept, such as protein water. Some of the protein water recently launched in the Asian market include Optimum Nutrition Protein Water, Meher Protein + Water, Prowater Protein Water, Bodiez Protein Water, Fonterra High Protein Water, and Myprotein Water.

ASIA & AUSTRALASIA: WHICH OF THE FOLLOWING CLAIMS DO YOU PRIORITIES WHEN CHOOSING FOOD/DRINKS

Before Exercising Source: GlobalData 2018 Q3 Consumer Survey

Before Exercising

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2018

WHEN DRILLING DOWN TO SPECIFIC CONSUMER SEGMENTS, THE FINDINGS HIGHLIGHTED THAT THE ‘HIGH PROTEIN’ CLAIM IS PARTICULARLY IMPORTANT AMONG 18 TO 24-YEAR-OLD CONSUMERS. WEIGHT MOTIVATIONS WILL DRIVE DEMAND FOR “NATURAL”, “LOW CALORIE” PROTEIN WATER

Those with conscious weight-management goals are more likely to consume protein water to support these efforts. Although protein shakes/powders are widely available in the market, these are often high in sugar, artificial additives and calories. Today’s informed and health conscious consumers are trying to cut down or limit the intake of villain ingredients such as sugar and artificial ingredients. As established in GlobalData’s 2017 Next Generation Emerging Markets consumer survey, 44 percent of consumers in Asia are trying to limit/moderate their consumption of sugar. In this backdrop, protein water offer ways to consume protein without adding significant calories/sugar. THE WATER FORMAT OFFERS CONVENIENT PROTEIN INTAKE THROUGHOUT THE DAY

ENQUIRY No 4640

Water works as a sports/exercise aid, or just as a means of satisfying general hydration needs. In the latter case, it can deliver functional benefits to consumers whose schedules/routines may not facilitate occasions or behaviors that allow other, more structured intake of functional foods or beverages. Bottled protein water (especially in the small format bottles) can become part of normal daily consumption behavior, especially for those 13 percent of Asian

BEVERAGE

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

BOTTLED PROTEIN WATER (ESPECIALLY IN THE SMALL FORMAT BOTTLES) CAN BECOME PART OF NORMAL DAILY CONSUMPTION BEHAVIOR IN ASIA. consumers who eat lunch and dinner while travelling/ commuting a few times per month (GlobalData 2018 Q3 Consumer Survey). Thus, bottled protein water is likely to help meet the daily protein requirement of these time-poor consumers. BRANDS CAN FOCUS ON MARKETING EFFORTS TO MAXIMISE OPPORTUNITIES

The benefits of and familiarity with proteins show some generational/age variation. Older consumers are increasingly proactive with health, and take greater care in planning their diet. However, survey data shows that familiarity with protein and its benefits is low for this demographic. This highlights that more awareness needs to be created and more targeted positioning to maximise market opportunities. Likewise, younger

generations are more receptive to functional products and recognise protein’s advantages, but there is still room for the growth here too. Furthermore, despite protein’s known role in aiding muscle repair and recovery, the survey findings show that consumers seek out “high protein” claims in products for consumption before, rather than after, exercising. With concern around muscle tone high—and a significant proportion interested in buying products to address this issue—opportunities exist to capitalise on interest through more targeted positioning of protein water.

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BEVERAGE

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2018

DAIRY PROTEINS AND PERMEATES: IDEAL NUTRITION-BOOSTING INGREDIENTS IN READY-TO-DRINK BEVERAGES WITH THE RISE OF SOCIAL MEDIA, THE SPEED AT WHICH NEW FOOD AND DRINK TRENDS EMERGE AND CHANGE IS STARTLING. AS A RESULT, BRANDS NEED TO INNOVATE QUICKLY TO REMAIN RELEVANT, WITHOUT COMPROMISING ON PRODUCT QUALITY OR NUTRITIONAL VALUE. BY KRISTI SAITAMA, VICE PRESIDENT AND TEAM LEAD—CHINA, JAPAN, SOUTHEAST ASIA, U.S. DAIRY EXPORT COUNCIL.

WITH CONSUMERS FOCUSING MORE ON THE PRODUCTS THEY’RE CONSUMING, MANY ARE NOW ACTIVELY LOOKING FOR FOOD AND DRINKS THAT WILL GIVE THEM HOLISTIC NUTRITION.

IT is no secret that Asian consumers are becoming increasingly health-conscious in terms of the foods they choose to eat as well as their daily lifestyles. This shift is linked in part to rising rates of obesity, which have become a major health concern in Asia in recent years. According to a report by the Asian Development Bank Institute released in 2018, two in five adults in the Asia Pacific region are now overweight or obese. Governments in the region have taken note and introduced nationallevel initiatives to ensure citizens are opting for healthier lifestyles and are more careful with their diet. The region is also grappling with an increasingly aging population, with a recent study forecasting that Asia is on track to have the oldest population in the world by 2030. This too is driving the importance of nutrition up the consumer agenda. With consumers focusing more on the products they’re consuming, many are now actively looking for food and drinks that will give them holistic nutrition. This has fuelled a surge in global demand for protein—one of the most crucial components for a healthy diet. CONSUMERS CRAVE CONVENIENCE

Diets high in protein can help promote satiety, curb hunger and preserve lean body mass. As consumers embrace these benefits, formulators can help optimise dietary protein intake all day through the development and introduction of wider choices of easy-to-consume foods and beverages.

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OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

Ready-to-drink (RTD) beverages offer the advantages of convenience and portability to today’s busy consumers. They also provide an opportunity to incorporate innovative and exciting functional ingredients and packaging technologies. While this category includes both refrigerated and shelf-stable beverages, demand is stronger for shelf-stable products which offer ease of distribution and storage. However, refrigerated beverage sales are surging, as they can be perceived by consumers to be fresher and more natural than shelf-stable products. As multinational food and beverage companies are looking to diversify protein sourcing for these applications, choosing the right protein ingredient is imperative to delivering on key attributes consumers want: balancing nutrition with taste. Thus, many formulators have turned to the advantages of U.S. dairy ingredients. DAIRY PROTEINS IN THE RTD BEVERAGE MARKET

U.S. dairy proteins are often the preferred source for RTD protein beverages because of their excellent nutritional qualities, mild flavour and unique functionality in beverage systems. U.S. dairy proteins are completely natural co-products that enrich the body. They are high-quality, complete proteins that contain all of the essential amino acids the body needs. Compared with other proteins, U.S. whey protein is a leading source of the amino acid leucine, which is important to kick-start muscle protein synthesis.

Research has also shown that whey proteins support post-exercise muscle repair and recovery. Because of this, beverages developed for the sports nutrition market are particularly likely to contain whey proteins, but these products are no longer reserved for professional athletes. There is a large and growing body of published nutrition research studies that affirms dairy protein’s benefits across life stages, such as supporting weight management, enhancing post-exercise recovery and assisting in muscle maintenance for healthy aging. New research has shown dairy proteins have great benefits for women—without adding the bulk—as well as older individuals. These benefits make dairy proteins a great choice for medical and therapeutic nutritional beverages as well. CLEAN LABEL BENEFITS

U.S. dairy proteins are not only functional and nutritious, but versatile enough to bring creative and tasteful food solutions that consumers desire—offering formulators opportunities to innovate and create regionally tailored applications that highlight local flavours. According to research conducted by North Carolina State University, U.S. dairy proteins are mild-flavoured and exhibit sweet, aromatic and milky attributes while plant sources exhibit beany, earthy, sulphurous and sour notes. These differences in sensory perception allow dairy proteins to offer a beneficial and more versatile sensory experience because they complement, not overpower, the flavours of the foods and beverages to which they are added. RTD refrigerated coffees and teas are increasingly fortified with protein for added nutrition and consumer appeal. From low-acid drinks like milk and honey combinations and café mochas, to high-acid beverages such as clear, mango-flavoured green tea, U.S. dairy proteins are an obvious fit to ensure enjoyment is not compromised. Unlike other ingredients, the fresh, neutral flavour and creamy texture of proteins from U.S. milk easily enhance the taste of products they are added to. In many applications, plant proteins may require the use of flavour maskers and stabilisers to achieve consumer acceptance, resulting in longer and more complicated ingredient statements. This should be a key consideration for food and beverage brands looking to improve their on-pack labelling, as more Asian consumers are swayed by the ingredients in their food and show a preference for foods that are unprocessed and free from additives and preservatives. THE POTENTIAL OF PERMEATES

During the process when dairy proteins are produced, there is another co-product that is also created—permeates—which is creating attractive new

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2018

opportunities for food and beverage manufacturers to use in wide-ranging applications. Also known as “dairy products solids,” permeates are high in lactose and can either be produced in the form of a whey permeate or milk permeate. Permeate is gaining popularity as a cost-effective, mineral-rich ingredient that has both flavor-enhancing and sodium-reducing properties. Possible uses for permeate include baked goods, soups, sauces, confectionery, dry mixes, meats, dairy foods and beverages. Because 76-85 percent of permeate is lactose, the functionality of permeate is really dictated by the lactose content. The ash contains calcium, phosphorus and other valuable minerals, which will contribute to the overall mineral profile of a food product. Fat content in permeate is very low, so there is no added functionality from the fat. With the rise of social media, the speed at which new food and drink trends emerge and change is startling. This has compressed the R&D timeline that many food and beverage brands work towards for new launches—in short, brands need to innovate quickly to remain relevant, without compromising on product quality or nutritional value. One trend of note in the region is the rising demand for milkbased beverages, fuelled by Asia’s growing middle class and increased overseas travel. Innova Markets Insights in March 2018 for Asia revealed that milk and milk drinks placed top in the preference for new product launches in dairy. Another emerging dairy trend is the growing popularity of fruit flavours in milk and RTD beverages such as super fruit lychee, white peach, kiwi and blueberry. These trends speak to the importance of a ‘glocal’ approach— combining the best in global products and processes with a deep understanding of local taste profiles and consumer habits. Consistent supply availability is a key consideration for buyers and manufacturers when selecting and sourcing ingredients. As the world’s largest single-country producer of cow’s milk, the source for whey and milk protein ingredients, the U.S. dairy industry is well equipped to reliably deliver safe, high-quality, nutritious and functional dairy ingredients specific to Asia’s needs. It’s for this reason that the United States Dairy Export Council (USDEC) is pursuing innovation partnerships in Southeast Asia—a development hub for broader Asia. Earlier this year, USDEC launched a collaboration with Singapore Polytechnic’s Food Innovation and Resource Centre to pursue thorough research and development into innovative dairy food products for the Southeast Asian market— combining U.S. dairy ingredients with local flavours such as pandan and gula melaka to create something new and exciting for the region. U.S. dairy ingredients are poised to be a star ingredient as Asian consumers continue to seek nutritionally advantageous, natural products with a local twist, and brands that embrace a ‘glocal’ approach to partnership and innovation will be best placed to capitalise on this.

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ENQUIRY No 4639

MEETING THE DEMAND FOR ‘GLOCAL’ FLAVOURS

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WILL GLUTEN-FREE EVER TURN MAINSTREAM IN ASIA PACIFIC? GLUTEN-FREE BAKERY IS STILL A NICHE MARKET IN MOST ASIA PACIFIC MARKETS—WITH THE NOTICEABLE EXCEPTION OF AUSTRALIA AND NEW ZEALAND. BUT, AS GLUTEN-FREE BAKERY PRODUCTS CONTINUALLY GET BETTER, WHO KNOWS WHAT THE FUTURE WILL HOLD? BY RACHEL PARK, MARKETING MANAGER, KOREA, AUSTRALIA AND NEW ZEALAND, DUPONT.

Far more people in the world follow a gluten-free diet than those who actually need to. While consumers with gluten intolerance or celiac disease need to avoid it, it’s becoming more mainstream across the globe to go gluten-free. However, if you scan the bakery shelves in many Asia Pacific stores, you’ll have a hard time finding that gluten-free lifestyle trend. Here, indulgence and natural fortification still rule—and the sensory shortcomings often associated with gluten-free bread, for example, keep sales to a minimum. As with all rules, though, there are exceptions. In this case, it’s Australia and New Zealand, which stand out in the Asia Pacific region as markets where gluten-free has become a popular lifestyle choice. The overview of bakery product launches from Innova Database puts gluten-free among the top three packaging claims in these countries. From 2012 to 2017, gluten-free bakery launches in Australia and New Zealand grew 19 percent overall. SUCCESS UNDER TOUGH CONDITIONS

What’s interesting about this grow th is that Australia and New Zealand have some of the toughest

labelling laws in the world. Oats and malted glutencontaining cereals are not permitted, and ingredients derived from gluten-containing grains must be declared on product labels, no matter how small the amount used. Still, gluten-free manufacturers are experiencing considerable success despite having to meet these stringent requirements. As in other gluten-free growth markets, the bakery category is driving the trend. One of the reasons why the segment has moved from niche to mainstream in recent years has got to be the vast improvement in quality. Bakers have proven that gluten-free bread, cakes and cookies can be almost as good and tasty as standard gluten-containing ones. A NEW SET OF GOALS

Now that bakers have reached that milestone, new goals have appeared on the horizon—borne by consumer expectations for gluten-free products that offer additional health benefits. The movement towards healthier gluten-free bakery was one of the key findings of a recent consumer survey commissioned by the specialty ingredients business,

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That’s a good starting point for taking the next step and meeting consumer demand for extra nutritional benefits. As the results from the DuPont survey confirm, many consumers perceive a nutrition claim on glutenfree labels as a sign of higher product quality. And they are usually right. MORE APPEAL AND NUTRITION IN ONE

DuPont Nutrition & Health. Although the focus was four European markets—France, Italy, Spain and the UK— they share many Western attributes with Australia and New Zealand. That makes the findings of interest, both to the already established gluten-free markets of Asia Pacific and to other regional markets where bakers may see future opportunities to differentiate their range with gluten-free options. Like Australasia, the average incidence of celiac disease in Western European countries is around 1 percent. Yet, according to Mintel market research, the percentage of consumers who buy gluten-free products is considerably higher—11 percent in Italy and UK and 8 percent in France and Spain. Findings from the DuPont consumer survey point to healthy living as a main driver of gluten-free sales in these markets. The sur vey also showed something else: that consumers are still hunting for even better quality and wider availability of gluten-free bakery products. THE SEARCH FOR BETTER QUALITY

But, before going more deeply into that, let’s start by taking a brief look at the history of gluten-free baking. In fact, you don’t have to go many years back to find the time when gluten-free bread was a product that many gluten-intolerant consumers would probably prefer to avoid. Gluten-containing wheat flour is often replaced by combinations of maize, rice, tapioca and potato starch. In the early years of gluten-free baking, bread was typically dense and crumbly and rapidly turned dry. These texture defects can be par tially of fset by the addition of sugar and fat—at the expense of nutrition. As time has gone by, many industrial bakers have taken another route, compensating for gluten through the addition of hydrocolloid blends containing cellulose gum, xanthan, guar, locust bean gum, pectin and psyllium. In this way, many bakers today produce gluten-free breads with a relatively high volume, better softness and a reduced tendency to dryness right after baking.

When improving the nutritional profile of glutenfree bread, there are two main ways to go. Bakers can add fibre or protein—or a combination of the two. Whatever they choose, they will often find that the addition of fibre and protein both makes their products healthier and optimises the softness, structure and look of the final baked bread. Fibre has long been a popular nutrition claim on bakery products, and gluten-free bakery is no different. Mintel reports that 25 percent of European gluten-free breads were labelled with an added fibre or high fibre claim from 2014 to 2016. In the UK alone, 44 percent of gluten-free consumers expect the products they buy to have a high fibre content. Each of the hydrocolloids used in gluten-free bakery blends is a fibre source in its own right. Following a review of scientific literature, the US Food & Drug Administration has declared that all of them satisfy its definition of dietary fibre and may be declared as such on food product labels. At DuPont, application trials have also explored the use of polydextrose for fibre enrichment of glutenfree baking. Comprising 80 percent soluble fibre, polydextrose is already used for the production of white bread with a high fibre claim, thus appealing to consumers who dislike the taste and feel of whole grain. In gluten-free bread or cake recipes, the waterbinding capability of polydextrose contributes to the softness and moistness of the final product. In lowmoisture products such as gluten-free biscuits, on the other hand, polydextrose acts as a crisping agent, thanks to its high glass transition temperature.

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THE CONCLUSION? THAT CONSUMERS WOULD BUY EVEN MORE GLUTEN-FREE BAKERY PRODUCTS IF THERE WERE A WIDER RANGE TO CHOOSE FROM. IN OTHER WORDS, THEY WANT MORE OF EVERYTHING—MORE QUALITY, MORE NUTRITION, MORE FLAVOURS AND MORE PORTION SIZES.

A GOOD PROTEIN OPTION

When it comes to protein addition, some large bakery companies use soy protein to delay staling and improve the colour of their gluten-containing white bread. This functionality plus the excellent nutritional quality of soy make it a good option for protein enrichment of gluten-free bread, too. The only drawback is that soy protein is an allergen that some consumers need to avoid. So, depending on the target market, there may be a case for using an alternative protein source that offers similar technical and nutritional benefits. GLUTEN-FREE GAPS TO FILL

Findings from the DuPont survey suggest there are still gaps for industrial bakers to fill, even in Europe’s biggest gluten-free markets—and that better nutrition is just one of them. For the survey, DuPont interviewed groups of men and women between the age of 20 and 45 about their gluten-free shopping and consumption habits. They were also asked to evaluate some of the gluten-free bakery products currently on sale in European stores:

white and brown bread, a wrap, cake and biscuit. The conclusion? That consumers would buy even more gluten-free bakery products if there were a wider range to choose from. In other words, they want more of everything—more quality, more nutrition, more flavours and more portion sizes. Some also look for products with a shorter ingredient list, thus supporting a forecast from Innova Market Insights that clean label will be a major driver of future new product development within the gluten-free segment. THE ROAD TO INDULGENCE

For ambitious gluten-free bakers, it seems there are still many avenues to explore for new product development. The suggestion is that, if bakers can meet consumer needs by bringing more innovative products to market, they will continue to ride the gluten-free growth trend in Western and Western-style markets, including Australia and New Zealand. As for the rest of Asia Pacific, there is no sign of an emerging gluten-free movement at the moment. But, who knows? As the quality continues to improve and more nutritional claims are added to product labels, perhaps there is a chance of a gluten-free breakthrough sometime in the future. That will be the day when gluten-free bakery products finally rank among the indulgent.

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ASIA PACIFIC FOOD INDUSTRY OCTOBER 2018

FEATURES 63

PREVENTING MICRO LEAKS IN BAKERY AND CONFECTIONERY MODIFIED ATMOSPHERE PACKAGING MODERN LEAK TESTING SOLUTIONS HELP PRODUCERS OF BAKERY PRODUCTS PREVENT EVEN MICRO LEAKS AND THUS, GUARANTEE FRESH PRODUCTS TO THEIR CUSTOMERS. BY ALEXANDER KAMPSCHULTE, HEAD OF MARKETING & COMMUNICATIONS, WITT-GASETECHNIK GMBH & CO KG. Packing under modified atmospheres has established itself as the standard in the food industry. Even more than that: this proven method is becoming more and more important worldwide. Particularly for bakery products, this packaging technology offers several benefits, but it can only fulfil its task efficiently if the packages are really leak-tight. Modern leak testing solutions help producers of bakery products prevent even micro leaks and thus, guarantee fresh products to their customers. T he mo di f ie d at mo sphere in t he p ac k ag e counteracts the growth of microbiological organisms and bio-chemical reactions and the consequent spoilage of the goods. However, this modern packaging technique makes comparatively high demands on the packaging process. Most notably, the sealing process contains various sources of error which can lead to leaks: defective temperature or pressure distribution, improper sealing tool arrangement, impure or worn out tools as well as seal contaminations.

Even worse, defec tive material can lead to undetected serial leaks. Premium manufacturers undertake comprehensive leak detection tests during the final inspection, not least because major grocers put increasing emphasis on proven quality control of producers. WATER-BASED SAMPLE TEST AS AN ENTRY SOLUTION

The easiest solution is a water-based sample test. This method is very common and popular because itâ&#x20AC;&#x2122;s simple but effective. The test product is placed into an acryl chamber filled with water. The test device evacuates the air space in the chamber above so that a vacuum results. If the product is leaking, air or filling gas will bubble out. This method is not only extremely reliable but also offers a valuable additional benefit: the leak can be localised precisely. This makes this simple test unique. The system is also economical. Installation and commissioning are easy, without any need for calibration or special training. To produce the vacuum, some devices use an electric vacuum pump. Products like LEAK-MASTER EASY from WITT are easier and safer

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some devices in the market that are based on the pressure differential test but up to now, this is not the preferred solution for many food producers. This solution is not that flexible in terms of different packaging forms and sizes and has limits regarding micro leaks. In addition, these solutions are very expensive compared to others. Lastly, this method can be used only for sample leak testing. LEAK TESTING WITH TRACE GAS

as they use just water and compressed air, without any need for an electrical connection. On the other hand, there are some disadvantages. The water-based sample test is not the fastest possible test and is has limits when it comes to micro leaks. And, of course, it’s a test that depends on the human tester. To achieve faster and standardised test procedures, it’s possible to combine devices like the EASY with an electronic control. As a result, the results will get documented automatically. PRESSURE DIFFERENCE AS A SPECIAL OPTION

The pressure differential test depends on air or gas inside the package. The product is placed in a chamber and the chamber is evacuated. If there is a leak, gas will escape from the package. In contrast to the trace gas method, the sensor does not directly detect the gas, but only a change in pressure in the test chamber. The method allows standardised test procedures and, of course, digital documentation. There are

DEFECTIVE MATERIAL CAN LEAD TO UNDETECTED SERIAL LEAKS. PREMIUM MANUFACTURERS UNDERTAKE COMPREHENSIVE LEAK DETECTION TESTS DURING THE FINAL INSPECTION, NOT LEAST BECAUSE MAJOR GROCERS PUT INCREASING EMPHASIS ON PROVEN QUALITY CONTROL OF PRODUCERS.

This solution is different with methods that rely on trace gas to detect leaks. Besides the classic water bath, these variants are widely used to check bakery packaging as a sample test or as an inline test. Sample test equipment usually works with CO2 sensors. The test product is placed in a test chamber. The chamber is then evacuated via a vacuum pump. In the event of a leak, gas flows out of the packaging. Highly sensitive gas sensors detect even the smallest leaks in this way. The measurement takes place within a few seconds, whereby the packaging is not damaged. All test data can usually be captured and saved and exported for documentation purposes. The method allows a standardised test process independent of the tester. INLINE LEAK TESTING FOR 100 PERCENT SAFETY

Only leak testing packages completely put through the final inspection offers genuine safety. There is a choice of solutions with CO2, hydrogen or helium. CO2 is often used as it is already included in most inert gas packaging. Helium and hydrogen offer advantages in inline testing regarding speed and leak size. But these gases are not a genuine part of the modified atmosphere; they are expensive and require additional technical equipment. Although solutions with helium and hydrogen are available at the market, they have not really been successful. Thus, the standard trace gas has become CO2. It’s easier, cheaper and absolutely reliable. Also working with this gas, the systems detect even the smallest of leaks. Especially the leak sizes that are relevant to most food producers. W h e n u s in g CO 2 , t h e r e ar e t w o di f f e r e n t technologies available: putting the packaging under pressure with a kind of role, or placing the packing inside a vacuum chamber. The role allows higher speed and is useful for testing single packages—but it can’t be used for every kind of packaging because the role stresses the packaging and can destroy it.

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ASIA PACIFIC FOOD INDUSTRY OCTOBER 2018

Another big disadvantage: high speed t e s t in g i s o nl y p o s s ib le w h e n checking for big ger leaks not micro leaks. This is possible with vacuum chamber machines. They work e x ac t ly like t he s ample te s t devices: the product is placed into a chamber and a vacuum is generated. If the packaging is leaky, gas will escape and be detec ted by CO2 sensors. The fastest machine on the market is the MAPMAX from WITT offering a speed of up to 15 cycles per minute and a measuring range between 0 and 5,000 ppm.

If a product is leaky, the system can directly trigger a pusher to sort out a faulty package. Since testing of boxes and complete shipping cases is also possible, insufficient speed is usually not an obstacle anymore. The LEAK-MASTER EASY has already proven successful in numerous trans-European installations and is very often used for quality control of bread.

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ENQUIRY No 4627

THE LEAK-MASTER EASY HAS ALREADY PROVEN SUCCESSFUL IN NUMEROUS TRANS-EUROPEAN INSTALLATIONS AND IS VERY OFTEN USED FOR QUALITY CONTROL OF BREAD.

FEATURES

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

USING EGG SUBSTITUTES TO CONTROL COST AND QUALITY IN CAKES PARTIAL EGG REPLACEMENT CAN REDUCE THE COST OF CAKE PRODUCTION AND KEEP RECIPES SOFT, MOIST AND APPEALING. BY INGE LISE POVLSEN, SENIOR CATEGORY MANAGER FOR BAKERY AT ARLA FOODS INGREDIENTS. Egg prices are going through an extended period of volatility. A number of events in the global egg production industry have impacted market conditions. In 2017 and 2018, for example, scares in the US and Europe involving Salmonella and the pesticide Fipronil caused big fluctuations in supply levels and prices. Looking forward, there are fears the EU could place import levies on egg powder in 2019, which would most likely exacerbate the situation. This is bad news for bakers, for whom eggs are an essential ingredient. To address this situation, bakery experts at Arla Foods Ingredients have extensively researched the use of specially-formulated natural egg substitutes based on whey proteins in cake recipes. Subsequently, they have developed a range of tailored solutions that not only help bakers control their raw material costs but also deliver quality benefits. In trials, Arla Foods Ingredients’ experts have tested the performance of these whey protein-based egg replacers—called Nutrilac—in pound cakes (although they can be used in a wide range of cake applications). Three recipes were tested: • 50 percent Nutrliac + 50 percent eggs • 50 percent standard WPC 80 + 50 percent eggs • 100 percent eggs (reference)

It is generally recommended that bakers should aim to replace no more than 50 percent of the eggs in a recipe because market insights show that consumers globally continue to view eggs as a desirable ingredient on product labels. Since the eggs used by industrial bakeries may be in liquid or dried powder form, we have developed a calculation key for egg replacement supported by Nutrilac (see Figure 1).

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ASIA PACIFIC FOOD INDUSTRY OCTOBER 2018

texture. As shown in Figure 4, there was no significant dif ference in homogeneity and crumb structure between the Nutrilac cake and the reference. On the other hand, the springiness of the crumb was noticeably improved in the Nutrilac recipe. In addition, crumb fragility was also improved, meaning the Nutrilac cake would be less crumbly. Overall, the sensory panel perceived a significant improvement in freshness and moistness in the Nutrilac cake. By contrast, the WPC 80 cake was considered to have a dryer, more fragile crumb, lower resilience and a stickier mouthfeel. This underlines the difference between using a standard whey protein and a whey protein solution that has been tailored specifically to bakery applications. The pound cakes evaluated in our trials were manufactured using the same process parameters. The Nutrilac cake had a similar volume and appearance to the reference samples, while batter stability was also slightly improved. The volume of the cake produced from the WPC 80 recipe was noticeably smaller. In addition to sensory benefits, the improved crumb strength and springiness of the Nutrilac cake aided sliceability, stability and de-panning of the final product. All of these aspects can contribute to a reduction in waste. Meanwhile, all cakes in the trial had similar dry matter and water activity, indicating that microbiological status was unchanged when using Nutrilac. This is in spite of this cake delivering a moister, fresher mouthfeel than both the reference and the WPC 80 recipes. This demonstrates that shelf-life will not be affected by the use of Nutrilac egg substitutes, an important factor when considering profitability. A TAILORED SOLUTION

HIGHER CRUMB STRENGTH

Texture profile analysis was used to measure crumb strength and resilience. This is a mechanical test in which a cake sample is subject to a double compression, simulating the first and second bite in a sensory evaluation. In our trial, the Nutrilac cake displayed a slightly higher crumb strength compared with the reference cake, while crumb resilience was no different (see Figures 2 and 3). In the standard WPC 80 cake, crumb strength was similar to the reference. However, the crumb resilience was significantly lower, indicating that the cake texture would likely collapse when the first bite was taken. Sensory evaluation by trained panels and texture profile analysis were used to measure taste and

Industrial bakers are under pressure to keep costs down and quality under control on their cake production lines. Our trials show that using Nutrilac whey proteins as a 50 percent egg substitute in cake recipes creates a more price-stable environment with less reliance on the volatile egg market. Furthermore, as shown in our sensory tests, quality can also be improved. The results of the sensory panel evaluation, however, also underline the need for a tailored whey protein solution, as opposed to a standard WPC 80. For the many consumers who enjoy them, cakes are all about indulgence. As such, for industrial bakers, success will be measured by their ability to produce cakes that stay soft, moist and appealing for six months or longer after production.

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FEATURES 68

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

FILLING BAKED GOODS WITH CARE ITALIAN BAKERY MANUFACTURER, SAN GIORGIO DOLCE & SALATO, NOW RELIES ON A FULLY AUTOMATED SYSTEM FROM SCHUBERT. San Giorgio Dolce & Salato was the first manufacturer to introduce pre-baked, filled and frozen croissants to the gastronomic market. To succeed with this product innovation, the company needed a system that could gently inject different fillings into the baked goods and efficiently combine this operation with the final packaging process. A system developed by Gerhard Schubert GmbH for the new Italian customer is ideally suited to this challenging task. Long before coffee-to-go became en vogue in the rest of the world, the working day in Italy always started off with a visit to the local bar for a fortifying morning cappuccino and croissant. Consequently, a study published by Agrifoodmonitor found that awayfrom-home consumption currently represents one third of total F&B consumption in Italy. In the decade 20052015, the value of food consumption increased overall by 13 percent to 230 billion Euro, a growth that is mainly related to away-from-home consumption (+ 30 percent), which amounts to a value of 130 billion Euro. Even in Italy, people are in more of a hurry these days. Baristas often serve deep-frozen croissants and other pastries that they simply heat up in the oven. This allows them to offer their customers an extensive selection of oven-fresh baked goods. In its GAIN Report, the American USDA (United States Department of Agriculture) stated that changing Italian lifestyles have given a boost to the food service industry. Italy is thus moving towards trends and lifestyles seen in other European countries, and it is forecast that an increasing number of consumers will eat out during their breaks. In order to combine good taste with the fast pace of modern life, San Giorgio Dolce & Salato was the first manufacturer to develop pre-baked pastries and bring them to the Italian gastronomic market. The prebaked dough pieces are handy for the baristas, who can quickly bake the frozen croissants and serve them to their customers. They not only save considerable time in preparation, but also benefit from a very highquality product with great taste.

IMPRESSIVE: HIGH-QUALITY, INTEGRATIVE AND SCALABLE TECHNOLOGY

A new, fully automated system, which could efficiently fill and package the baked goods while handling the products extremely gently, was necessary to bring the innovation to the food market. At the Ipack-Ima 2015 trade fair, San Giorgio Dolce & Salato looked into possible technologies and became aware of the Schubert company and its products. D ur in g t h e b id din g p ha s e , t h e p a c k a g in g specialis t impressed the It alian manufac turer with its professional project support. Right from the beginning, the Schuber t exper ts focused on the product’s special features. One challenge was to integrate an injec tion station from machine manufacturer, Canol, into the system’s design. With this in mind, Schubert’s Sales and Project Manager, Antonino Lanza, worked closely with Canol. The result is an injector that is precisely matched to Schubert’s robot-based technology. Additionally, the customer was impressed with the gentle, safe gripping technology and the characteristic flexibility of Schubert machines. This makes it possible for the machine to inject different fillings into the croissants as well as other baked goods. In addition to the technological

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ASIA PACIFIC FOOD INDUSTRYOCTOBER OCTOBER2018 2018

benefits, the trusting collaboration that was in place from the startâ&#x20AC;&#x201D;between two family businessesâ&#x20AC;&#x201D;was also important to the customer. PICK-AND-PLACE ROBOTS WITH GENTLE GRIPPERS

The system that Schuber t developed for the customer consists of four sub-machines. Within the system, three pick-and-place robots and two F2 robots take over the handling of the croissants. This begins immediately after baking: the baked goods are moved from the oven to the first machine for pre-grouping. There, a 2D image recognition system first checks the position of the products and transmits the data to the F4 robots at the next station. Controlled by two servomotors, these can execute any movements in a two-dimensional working field. Since the croissants are delicate baked goods and vary in height, density and consistency, the robot needs to handle them carefully. This is ensured by four grippers and flexible damping on the robot tools, which do not dent or damage the soft and still warm products. The picker arms grasp the croissants one at a time and place them on the Transmoduls in 12 rows

with even spacing. These transport robots bring the croissants to the injection station, where a component fills them with jam, chocolate or vanilla cream. A robot positions the croissants, and the component with 12 injection needles approaches and punctures the croissants. Flexibility is required here as well: the needles are adjustable in height, and it is also possible to determine how deep they need to inject the filling into the baked goods. Thanks to plug-in connections, the injection system can be completely removed from the main system to enable cleaning and conversion to other fillings. Once the croissants have been filled, F2 robots place them in groups of twelve on the belt. Then they go through a froster. In the final step, the deepfrozen products are packed in flow-wrap bags either individually, in packs of three, or in cartons at the next Schubert system. IDEALLY POSITIONED FOR THE FUTURE

Thanks to this automation solution, San Giorgio Dolce & Salato can fill and package 160 croissants per minute. This efficient combination of injection and final packaging process is of great benefit to the Italian company, as is the flexibility that enables different baked goods to be filled and packaged in the same system and/or in the same manner. San Giorgio Dolce & Salato is therefore able to expand its range of pre-baked pastries as needed. This example clearly shows that state-of-the-art production and packaging facilities are a key success factor to further the growth of the family business.

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FEATURES 70

EXPLORING ADDITIVE OPTIONS IN BAKING HEALTHY LIFESTYLES CONTINUE TO DRIVE FREE-FROM DIETS, CREATING EVER GREATER DEMAND FOR “CLEANER” AND HEALTHIER PRODUCTS, ESPECIALLY IN SEGMENTS SUCH AS GLUTEN-FREE SWEET BAKERY PRODUCTS, SAY DR GALANAKIS, C.M. AND DR Y. MARTIN LO, ADVISORS FROM THE ANTI ADDITIVE ASSOCIATION. FOOD additives have been used for decades to perform specific functions in foods, extend their shelf-life, and feed the fast-growing population of the world. The fortification of foods with additives has substantially reduced food waste and food loss. However, consumer demand is making it a necessity for manufacturers to reformulate recipes without additives. Over the last years, ‘clean label’ has become a buzzword to food industries and many big food companies have committed to remove artificial food

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

additives. To this end, formulating products with simple labels using recognisable ingredients is a growing commercial necessity. The utilisation of compounds that exist inherently in foods sounds healthier to consumers. In some developed countries, however, the overusage and over-consumption of synthetic food additives is the current practice. Bearing in mind that all chemicals are potentially toxic and there is a minimum level of exposure above which unfavourable health effects may occur. Although many of the synthetic additives have been approved by corresponding authorities for the fortification of foods, the long-term impact of their consumption on human health still remains unknown. The use of food additives is regulated by specific European Union (EU) laws, considering chemical characterisation and purity, maximum content levels and the respective food where it can be applied (Commission Regulation (EU) Number 1129/2011; Directive 95/2/EC). SYNTHETIC ANTIOXIDANTS IN THE FOOD INDUSTRY

Antioxidants are common food additives and their implementation is widespread in the food industry in a wide variety of foods. The addition of antioxidants is known to delay or inhibit the deterioration of food products and benefit consumer by prolonging their

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2018

FEATURES 71

antioxidants might trigger some side effects to the health of consumers. Moreover, despite their superior efficacy and high stability, these compounds do not exist inherently in foods. USING NATURAL EXTRACTS FROM OLIVE PROCESSING BY-PRODUCTS IN BAKERY PRODUCTS

The utilisation of compounds that not only exist inherently in foods but also have been recovered natur ally ha s at t r ac ted much at tent ion from consumers, showing a preference similar to organic foods. Natural antioxidants such as polyphenols have been recovered from relevant sources (olive cake, olive kernel, OMW) and used for the fortification of food products and the production of nutraceuticals. For instance, the insoluble dietary fibre of olive processing by-produc t s has been proposed as a source of fermentable sugars in order to fortify bakery products, whereas the soluble one (pectin) has been used as fat replacement in meatballs due to its gelling properties (Galanakis, 2018). The efficacy of commercially available polyphenols recovered from olive mill wastewater (in a powder containing 10 percent polyphenols and

ENQUIRY No 4637

shelf-life (e.g. bread producers use them to extend the shelf-life of bread up to 4 weeks). Primary synthetic antioxidants such as butylated hydrox y anisole and butylated hydrox y toluene have been used in the food industry (especially in oil, fats, meat and bakery products) over the last 50 years. Some antioxidants have no danger at the dosages used as food additives, but the use of other

FEATURES

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2018

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

THE PURPOSE OF ADDITIVES USED FOR BAKED GOODS COULD GENERALLY BE CATEGORISED INTO THREE PURPOSES: (1) TO PRESERVE; (2) TO ENHANCE THE TEXTURE/TASTE; AND (3) TO MAKE THE PRODUCT APPEALING. 5 percent hydroxytyrosol) against other natural (but synthetically produced) antioxidants (namely ascorbic acid and tocopherols) to inhibit microbial growth of bread and rusks during storage has been investigated in bread and rusks (Galanakis et al., 2018). According to the results, a concentration of polyphenols of 200 mg/ Kg flour was able to extend the preservation of both bread and rusk samples. Ascorbic acid and tocopherols had no real effect to the overall bread preservation in both assayed concentrations (500 and 1000 mg/Kg). Concerning rusk preservation, tocopherols and ascorbic acid were efficient at higher concentration (600 mg/ Kg). The results of this study revealed the possibility of applying polyphenols from olive mill wastewater as an antimicrobial agent in bakery products. Commercially available polyphenols (basically hydroxytyrosol) from olive mill wastewater can be found by CreAgri (US) and GenosaI+D (Spain). Other natural extracts containing antioxidants (polyphenols) and formulators (fibres, aromas) recovered from fruit and vegetable residues (unsellable fruits with defects) are commercially available by Indulleilda (Spain). Grape skin and seed flour (containing polyphenols) recovered by wine grapes pomace and seeds are used

as additives in gluten-free baked goods (commercially available by WholeVine, US) (Galanakis et al., 2015). More insights about the fortification of foods with natural extracts from food processing by-products can be provided by the Food Waste Recovery Group. CONCLUSION

“Healthy lifestyles continue to drive free-from diets, creating ever greater demand for “cleaner” and healthier products, especially in segments such as gluten-free sweet bakery products. Creating tasty, additive-free and reduced fat/sugar formulations will remain an important challenge,” says David Jago, Director of Innovation & Insight, Mintel. Fur ther, Dr Y. Mar tin Lo from Anti Additive Association has demonstrated that additive-free industrial baking is definitely possible. The purpose of additives used for baked goods could generally be categorised into three purposes: (1) to preserve; (2) to enhance the texture/taste; and (3) to make the product appealing. For preservation, such as preventing mould growth, a product could be handled with improved storage and display, or even by modified atmosphere packaging or even controlled release active packages with antimicrobial agents embedded. For texture and taste, there are known natural emulsif iers such as soy lecithin or novel gelling agents derived from natural edible fibres. For product appearance, one could use natural edible coatings such as pectin polysaccharides to generate a shiny, attractive appearance to the consumers.

ENQUIRY No.

7605

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EXHIBITION & EVENTS

ASIA PACIFIC FOOD INDUSTRY OCTOBER 2018

PREVIEW

COEX FOOD WEEK KOREA 2018 KOREA’S LEADING TRADE SHOW ENTIRELY DEDICATED TO PROFESSIONALS IN THE FOOD SERVICE INDUSTRY. WHERE Coex Convention Center

COUNTRY Seoul, South Korea

DATE November 28—December 1, 2018

categories. Halls A and B, located in the convention centre’s first floor, will hold the Local Food Zone and Food Business Trend Zone where goods such as Korean traditional food, HMR and food packaging will be showcased. Halls C and D, on the third floor, will host the GLOBAL market, DESSERT Market, Culinary fair and more. The Overseas Pavilion will also be divided into zones including, the “ASEAN PAVILION”, “Indian Festival”, and “Italian Culinary Zone”. The concurrent “Korea Dessert Show”, will present the best premium dessert show in Korea with buyers able to visit the Lounge, Dessert Collection and Sweets & Snack Pavilion. The show will emphasise new dessert trends and developments with conferences, food demonstrations, and presentations.

COEX’S Food Week Korea 2018 will take place at Coex Convention Center November 28th to December 1st, the annual show’s 13th edition. More than 1,000 organisations are participating in the international food and beverage exhibition which will take place in Coex’s exhibition Halls A through D. The event is an UFI-approved (The Global Association of the Exhibition Industry) exhibition and is Korea’s leading trade show entirely dedicated to professionals in the food service industry. In addition, collocated shows including the “Dessert Show”, “Kitchen Fair ”, and “HMR Fair ’, are expected to boost the scale of this year ’s Food Week Korea with their diverse scheduled events

Program is managed by the Food Week Korea Secretariat and a team committed to helping domestic and international exhibitors and buyers find potential business partners. An easy-to-use online platform is available to support exhibitors and buyers in arranging B2B meetings with new and existing clients. The Official 1:1 Pre-arranged Business Matching Program will run for two days from November 28 to 29 in the Buyer’s Lounge.

A Business Platform Powered By The Coex Team The four-day exhibition is a one-stopdestination for industry stakeholders to network, observe the latest market trends, and uncover new business opportunities. The 1:1 Pre-arranged Business Matching

A Dessert Hall Featuring Local And Global Trends The 1,000 participating organisations come from over 30 countries—to accommodate these visitors, the exhibition halls will be divided into sections by various themes and

ENQUIRY No.

7701

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EXHIBITION & EVENTS

OCTOBER 2018 ASIA PACIFIC FOOD INDUSTRY

PREVIEW

TAIWAN INTERNATIONAL FISHERIES & SEAFOOD SHOW

TIFSS WILL FOCUS ON BUSINESS OPPORTUNITIES FROM INNOVATIVE SMART TECHNOLOGIES

WHERE Kaohsiung Exhibition Centre

COUNTRY Kaohsiung, Taiwan

TAIWAN External Trade Development Council and My Exhibition has coorganised the 4th Taiwan International F isheries & Seafood Show (TIFSS 2018) that will be held at Kaohsiung Exhibition Centre from November 21 to 23. Five zones have been planned, including fishing tools, aquaculture te c h n o lo g i e s , s e a fo o d , s e a fo o d processing equipment, and fisheries biotechnology. 200 exhibitors have been recruited for 330 booths. Taiwan is known as the “Kingdom of Fisheries” as the annual output value of its deep-sea fisheries is top three in the world. In recent years, the Taiwan’s fisheries industry has begun developing smart aquaculture, unmanned vehicles, remote monitoring, smart cage net, and information management systems that apply smart technologies. The comprehensive upgrade of Taiwan’s fisheries technologies will be presented during the event and is expected to create great business opportunities.

DATE November 21-23, 2018

Last year, there were extensive reports on the TIFSS in international media, including Japan’s Suisan-Keizai Daily News, Minato, the UK’s Aquafeed, and Germany’s intrafish. Major exhibitors that have confirmed they will be participating in the event include Taiwan Fishing G e a rs M a n u f a c t u r i n g I n d u s t r i e s Association, Fish Breeding Association of Taiwan, Toford Plastic Manufacturing Corporation, Chihfu Fishery Enterprise Limited, Sonho Pump MFG Company Limited, Ching Fa Fishing Implements Factory Company Limited, and Taiwan Twine and Rope Company Limited. TIFSS is the largest trade show i n Ta i w a n , a n d b r i n g s t o g e t h e r negotiations, procurement, forums, and an abundance of stage activities. Exhibitors from 21 countries participated in the event last year (2017), and a total of 6,732 foreign and local buyers from 56 countries visited the three-day event. The top five buyers were from

Vietnam, Japan, China, Malaysia, and Indonesia, showing that frequent dealings between Taiwan’s fisheries industry and major fisheries countries in Asia has gained recognition from buyers of nearby countries. TIFSS 2018 will showcase the diverse developments in fisheries technology, and is expected to attract over 7,000 visitors. Vendors in the fisheries industry are welcome to participate or visit the exhibition.

ENQUIRY No.

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Kemin: NATURFORT TRLG 101

EPI Ingredients: EPIPROT 60 UL

Kemin Industries introduces NaturFORT TRLG 101, a solution for deep-fat frying to the Asian market. A plant-derived ingredient blend, NaturFORT TRLG 101 is scientifically proven to provide better oil protection during deep-fat frying, maintain quality and extend frying cycles. Tertiary Butyl Hydroquinone (TBHQ) is an antioxidant commonly used to stabilise the oxidation of oils, slowing the onset of oil degradation and extending shelf-life. TBHQ is highly effective but also highly regulated. It can only be used in 0.02 percent of the fat or oil content of food. ENQUIRY No. P721

As consumer interest in protein continues to grow, their new expectations in terms of sustainability, transparency, animal welfare and the like, are transforming the market and urging food, beverage and nutrition manufacturers to continuously innovate. To support them, Epi Ingredients is now launching its first ever protein concentrate, EPIPROT 60 UL. This innovative native ingredient fits into the companyâ&#x20AC;&#x2122;s new protein range, EPIPROT, which also includes caseinates and acid caseins and will soon feature additional offerings of milk protein concentrates and isolates. ENQUIRY No. P723

Emerson: Rosemount CT4215 In response to industry demand for increased quality in food and beverages at every level, Emerson has introduced the Rosemount CT4215 Food and Beverage Leak Detection system. The Rosemount CT4215 is the first quantum cascade laser/tunable diode laser (QCL/TDL) continuous, inline detection system designed to help assure quality and safety, maximise production volume and decrease product waste for food and beverage products. The Rosemount CT4215 tests the seal and integrity of every bottle or package on a production line, detecting leaks at

ENQUIRY No 4641

a sensitivity as low as 0.3 mm and automatically rejecting any defective bottle or package without slowing down production.

ENQUIRY No. P722

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SIG: CombiLink

Baumer: Hygienic Pressure Sensor PP20H

By connecting every machine in a filling line, SIG’s combiLink collects unlimited data and shows it in preconfigured or personally designed reports. Customers can view charts showing operational and technical efficiency and view downtime incidents from their desktops, tablets or smartphones. Smart notifications can alert the team to incidents thus avoiding bottlenecks and costly downtime. With the same connectivity used in IoT applications, combiLink seamlessly connects every machine in a filling line. This means producers get a single end-to-end window to view current and historical levels of efficiency and performance, while also seeing where improvements can be ENQUIRY No. P724 made in the future.

The Hygienic Pressure Sensor PP20H has a robust, IP69Krated stainless steel housing which is designed to handle a variety of applications, and is equipped with a condensateproof silicon measuring cell. Its scaled pressure ranges from -1 to 40 bar and wide range of process connections make it extremely versatile. It is available with 4 ... 20 mA signal and IO-Link. It complies with the strict hygiene requirements in the food and pharmaceutical industries and is CIP and SIP-capable. Together with its excellent temperature insensitivity and long-term stability and high accuracy, the sensor guarantees demanding hygienic processes are monitored, controlled and regulated safely. ENQUIRY No. P726

ABB: Ability Smart Sensor

KH Roberts Plant-type Flavours

The ABB Ability Smart Sensor converts traditional motors, pumps and mounted bearings into smart, wirelessly connected devices. It measures key parameters from the surface of the

Purple Sweet Potato and Roasted Almond flavours—crafted for plant-based foods with KH Roberts’ flavour creation expertise. These flavours provide excellent application performance in

equipment which can be used to gain meaningful information on the condition and performance of the equipment, enabling users to identify inefficiencies within their system and to reduce risks related to operation and maintenance. Maintenance can now be planned according to actual needs rather than based on generic schedules. This extends the lifetime of equipment, cuts maintenance costs and reduces or prevents unplanned downtime due to breakdowns. ENQUIRY No. P725

instant beverages and bakery fillings. The honey and caramelic profiles of sweet potato as well as nutty and sweet profiles of roasted almond offer exceptional performance in applications in the health and wellness market category.

ENQUIRY No. P727

UPCOMING EVENTS

CALENDAR OF EVENTS 2018/2019

OCTOBER

NOVEMBER

16 – 18: INDUSTRIAL TRANSFORMATION ASIA PACIFIC 2018

13 – 15: FOOD&HOTEL CHINA

17 – 20: ALLPACK INDONESIA

21 – 23: TAIWAN INTERNATIONAL FISHERIES & SEAFOOD SHOW

Singapore Expo Convention and Exhibition Centre, Singapore Web: industrial-transformation.com

JIExpo Kemayoran, Jakarta Email: jovita.marcella@kristamedia.com Web: allpack-indonesia.com

21 - 24 & 25 - 27: CHINA FOOD & DRINKS FAIR

Empark Grand Hotel Changsha & Changsha International Convention and Exhibition Center respectively Changsha, China E-mail: Alan1997@163.com Web: cfdf.org

25 – 27: FOOD JAPAN

Suntec Singapore Singapore Email: sales@oishii-world.com Web: oishii-world.com/en

SNIEC Shanghai, China E-mail: uly.Liu@ubmsinoexpo.com Web: fhcchina.com

Kaoshiung Exhibition Centre Taiwan Web: taiwanfishery.com

21 – 24: SIAL INTERFOOD

JIExpo Kemayoran, Jakarta Email: info@kristamedia.com Web: sialinterfood.com

28 – 1 DEC: FOOD WEEK KOREA COEX Hall A to D Seoul, Korea Web: koreafoodweek.com

30 – 1 DEC: WORLD FOOD EXPO 2018 KINTEX Exhibition Centre Korea Web: worldfoodexpo.co.kr

30 - 2 DEC: HONG KONG BAKERY EXPO Hong Kong Convention and Exhibition Centre Hong Kong Web: hkbakeryexpo.com

JANUARY 2019

24 – 26: PROPAK PHILIPPINES

World Trade Centre Metro Manila Pasay City, Philippines Email: michael.blancas@ubm.com Web: propakphilippines.com

FEBRUARY 2019

17 – 21: GULFOOD

Dubai World Trade Centre Dubai Web: gulfood.com

MARCH 2019

19 – 21: PROPAK VIETNAM

Saigon Exhibition & Convention CentreHo Chi Minh City, Vietnam Web: propakvietnam.com

*All details are subject to change without notice. Please check with organisers for updates.

NOTE

To be considered for a listing in the Calendar of Events, send details of event including: name of event, date, venue and organiser’s contact details to the address given below.

Eastern Trade Media Pte Ltd ((Asia Pacific Food Industry - Editorial Dept) 12 Hoy Fatt Road, #03-01 Bryton House, Singapore 159506 Tel: +65 6379 2888 Fax: +65 6379 2886 Email: apfood@epl.com.sg

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ADM ASIA-PACIFIC TRADING PTE LTD

4627

AMETEK BROOKFIELD

4643

BASF SOUTH EAST ASIA PTE LTD

4636

CAMA GROUP

4601

CARGILL MALAYSIA SDN BHD

4629

CLEARPACK SINGAPORE PTE LTD

4642

FESTO PTE LTD

4637

GERICKE PTE LTD

4624

GEBO CERMEX

4639

GREEN HOUSE INGREDIENT

4625 & 4626

HEAT AND CONTROL PTY LTD

4641

INDUSTRIAL AUCTIONS BV

4622

KALSEC INC

ENQ NO

ADVERTISERS

PAGE

4638

KHS ASIA PTE LTD

4621

KRONES AG GERMANY

48 & 49

4640

NOVABAY PTE LTD

4632

PALSGAARD

4631

RPC CONTAINERS LTD

4630

SHANGHAI MASTER EXPO EXHIBITION CO.LTD

4623

SIDEL

4634 & 4635

SOLAR TURBINES SWITZERLAND SAGL

4556

SWECO ASIA

17/19

4628

UBM ASIA THAILAND-PROPAK PHILIPPINES 2019

4617

VLAM FRIES

4600

YAMATO SCALE

IFC 5 11 7

9 13/15

OBC

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

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Asia Pacific Food Industry October 2018

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Asia Pacific Food Industry October 2018