Modern Food Processing - August 2010 by Infomedia18

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Modern Food Processing

August 2010

EDITORIAL

Better be safe

n one hand, while globalisation offers food processing players immense opportunities to expand their business, on the other, it demands increasingly stringent safety norms to adhere to as per international quality standards. In fact, a spate of food & beverage related incidences have brought to focus the significance of effective safety standards to ensure the quality of food products as well as the regulatory compliance thereof. As unwanted impurities may enter at any stage from farm gate to food plate, it is essential to test the nutritional and quality aspects of the food products before these reach the consumer. Given this scenario, it is strategically imperative to put in place adequate methods to test food products, the ingredients & raw materials, as well as augment good manufacturing and hygienic practices across the entire food value chain. As a supplement to the changes taking place on the regulatory front, technology can play a game-changer role in improving food safety standards. For example, traceability tools like barcodes and RFID can enable the retailer in tracing a product right back to its source.

Published in association with Editor : Manas R Bastia Assistant Editor: Rakesh Rao Senior Features Writer: Prasenjit Chakraborty Features Writers: KTP Radhika Jinoy (Delhi), Mahua Roy Senior Correspondent: Shivani Mody (Bengaluru) Correspondent: Geetha Jayaraman (Delhi) Copy Desk: Marcilin Madathil Products Desk: A Mohankumar Group Photo Editor & Creative Head: Shiresh R Karrale Design: Mahendra Varpe Production: Vikas Bobhate, Pravin Koyande, Dnyaneshwar Goythale, Ravikumar Potdar, Ravi Salian, Sanjay Shelar, Lovey Fernandes, Pukha Dhawan, Varsha Nawathe, Akshata Rane, Abhay Borkar Marketing & Branding: Jagruti Shah, Ganesh Mahale Chief Executive Officer: Lakshmi Narasimhan Associate Vice President: Sudhanva Jategaonkar Subscription: Sunder Thiyagarajan, General Manager - Copy Sales Sheetal Kotawadekar, Senior Manager Tel: 91-22-3003 4631/4633 Email: customercare@infomedia18.in

In a nut-shell, food safety measures can not only safeguard the bottom line of products & companies, they will also go a long way in enhancing the integrity & reputation of brands. For further details on this vital aspect, turn to the ‘Industry Update’. On a different note, the importance of sugar as an essential commodity has never been out of sight. However, various controls on it (since 1955) seem to have outlived their utility and worse, affecting the growth of this sector. The government’s recent announcement to decontrol it is expected to boost this segment by virtue of investment, expansion, etc. On the flip side post decontrol, the government may have to buy sugar from the open market for PDS. The ‘Sector Watch’ offers more insights into this evolving paradigm. Wondering about what lies ahead for the food clusters and their impact on the growth of the food industry? Take a look at the ‘Roundtable’ for various viewpoints.

Editorial Advisory Board Dr A S Abhiraman Former Executive Director - Research, Hindustan Lever Ltd Prof M Y Kamat Former Head, Food Engg & Technology Deptt., UICT, Mumbai

Manas R Bastia Editor manas@infomedia18.in

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Printed by Mohan Gajria and published by Lakshmi Narasimhan on behalf of Infomedia 18 Limited and printed at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Infomedia 18 Ltd, ‘A’ Wing, Ruby House, J.K.Sawant Marg, Dadar (W), Mumbai - 400 028. Modern Food Processing is registered with the Registrar of Newspapers of India under No. 14798/2005. Views and opinions expressed in this publication are not necessarily those of Infomedia 18 Limited. Infomedia 18 Limited reserves the right to use the information published herein in any manner whatsoever. While every effort has been made to ensure accuracy of the information published in this edition, neither Infomedia 18 Ltd nor any of its employees accept any responsibility for any errors or omission. Further, Infomedia 18 Ltd does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition. No part of this publication may be reproduced in any form without the written permission of the publisher. All rights reserved. Editor: Manas R Bastia

August 2010 | Modern Food Processing

CONTENTS

LEADERS SPEAK “Organised food processing activity on an industrial scale is relatively new, but growth opportunities are huge” ...says Jose Hernanz, Managing Director, Alfa Laval India Ltd

ROUNDTABLE Food clusters: A viable option for developing the industry?

IN FOCUS Hatsun Agro Product Ltd: Cashing in on the white gold

INDUSTRY UPDATE Total quality management: Focus on food safety

MARKET SCOPE

New-age testing methods: Secure way to safe and healthy food Tarang Koppal, Manager (Pan-India Operations) - Marketing & Strategy, MicroChem Laboratory

SECTOR WATCH Decontrolling sugar industry: Need for a balanced approach

INDUSTRY INSIGHTS Indian tea: A refreshing market Shushmul Maheshwari, CEO, RNCOS E-Services Pvt Ltd

FOOD SAFETY Oil & fat processing: Under the protection filter Subhash Vaidya, Proprietor, Dairytech Consultancy Services

MARKET TRENDS Packaged foods: Preserving the freshness Tom Vierhile, Director – Product Launch Analytics, Datamonitor

TECH TRACK - AUTOMATION

Modernisation of rice milling: A necessity for future Courtesy: Buhler India

CASE STUDY - PACKAGING Dry aseptic technology: A solution for bottling complexities Hans-Peter Schiessl, Project Manager - Sales Department, Krones AG

CURTAIN RAISER India Foodex 2010: Offering an assortment of knowledge

R EG U L A R S EC TI O N S Editorial ...................................................... 7 National News ......................................... 10 World News............................................. 16 Tech Updates ........................................... 20 Events Calendar ....................................... 66

5th Anniversary

Product Update........................................ 68 Product Inquiry ........................................ 81 Advertisement Inquiry.............................. 83 Product Index........................................... 85 Advertisers’ List ....................................... 86

Vision 2015: Challenges & opportunities on the way Renowned industry experts review the performance of key industry segments as well as deliberate on the emerging trends and much more... Note:

Modern Food Processing | August 2010

stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise

NATIONAL NEWS BRAND STRENGTHENING

MTR Foods increases focus on instant mixes and spices

MTR Foods, a wholly-owned subsidiary of Norway-based Orkla Group, aims ACHIEVEMENT

Amul ranked as top Indian brand in Asia-Pacific Media Magazine published from Hong Kong and Singapore has ranked Amul as the number one Indian brand, for the second consecutive year, in its list of top 1,000 brands of Asia-Pacific. The brand has jumped to 73rd position in the list of top 1,000 brands of AsiaPacific this year from the earlier 83rd EXHIBITION

Drinktec India 2010 from November 18-20

Messe München GmbH, one of the leading event organisers in the world, will be organising drink BUSINESS INITIATIVE

Australian coffee chain Aromas comes to India Aromas, the Australian coffee chain, plans to expand its presence across the country through a tie-up with Ideal Hospitality Pvt Ltd. The coffee outlet, which is currently operational in Mumbai and Pune, plans to go pan-India with around 100 cafés in the next three years. Ideal Hospitality is promoted by infrastructure major Ideal Road Builders (IRB).

at investing 15 crore, raised through internal accruals, for setting up a new production plant at the Bommasandra Industrial Area in Bengaluru. The objective for the same is to have a national presence, make instant mixes its key brand, and introduce flavours that are popular in the eastern, western and northern parts of India. The company has now introduced a new face of change by redesigning its packaging, so that it appeals more

to India’s modern consumers without compromising on its vegetarian and authentic flavour. In the last two years, MTR Foods has managed to capture 25 per cent of the mixes market and a 36 per cent share of the instant mixes & snacks space in the country. The company, known to have changed the face of ready-to-eat foods, claims to have a major presence in this sector in the country.

rank in 2009. The survey conducted in 10 countries – Australia, China, India, Japan, Korea, Hong Kong, Malaysia, Singapore, Taiwan and Thailand – has placed Amul ahead of other Indian brands such as Kingfisher (rank 140), ICICI Bank (182), State Bank of India (226) and Tata (256) in the list. Indian consumers, too, have given Amul a top rank in the food and FMCG category. Asia-Pacific’s top 1,000

brand listing is based on a proprietary survey by Media Magazine, sponsored by the Wall Street Journal.

technology India (dti), also referred to as Drinktec India, in Mumbai. The event will take place from November 18-20, 2010, at Bombay Exhibition Centre, and for the first time, it will be a trade fair with an accompanying forum for exhibitors’ presentations. Around 80 exhibitors from approximately 12 countries will be showcasing beverage and liquidfood technology at the event,

primarily for the Indian market. dti has tied up with a new partner, the International PackTech India, organised by the Düsseldorf tradefair company represented by its subsidiary Messe Düsseldorf India Pvt Ltd. Togather, drink technology India and International PackTech India will offer an extensive, single business platform for customers from the packaging and beverage & liquid food industries.

According to Jayant Mhaiskar, CMD, Ideal Hospitality Pvt Ltd, the organised coffee market in India is around 1,000-1,500 crore and is growing at the rate of 15 per cent annually. “We will promote the Aromas brand in key metros and tier-I cities including Pune, Hyderabad, NCR, Jalandhar and Ludhiana,” he said. By the end of 2010, it plans to set up nearly 30 outlets. Currently, there are five Aromas cafes that are operational, three

in Mumbai and two in Pune. The coffee chain has two formats - café & lounge.

Modern Food Processing | August 2010

NATIONAL NEWS POLICY DECISION

Government likely to withdraw export incentives given to seafood sector

The Centre may withdraw export incentives given to the marine products PROMOTIONAL CAMPAIGN

OLIVEITUP starts European olive oil promotion campaign in India OLIVEITUP, a three-year campaign financed by the European Union in collaboration with Italy, has been launched in India for the promotion of European olive oil. Accomplished and produced by the Consortium of Guarantee of Quality Extra Virgin Olive Oil (EVC), this campaign provides a series of training activities and PRODUCT LAUNCH

Häagen-Dazs introduces stick bar flavours

Häagen-Dazs, known for its ice cream brand, recently introduced four new stick bar flavours – cookies & cream, MARKET REPORT

$ 30 billion needed to revamp food industry, says Assocham An estimated investment of $ 30 billion is essential to revamp the food processing industry. The projection is made by a study on ‘Emerging opportunities and strategic thrust areas for food processing’, initiated

industry. As part of this, the Commerce Ministry has chalked out a scheme to either withdraw the benefits fully or to reduce them in phases. According to a report, a directive from the Finance Ministry to various departments suggests the withdrawal of additional benefits extended to various export industries. The marine export sector falls under this category, as the total exports in the last financial year crossed $2 billion. The marine export sector at present enjoys a benefit of 5 per cent

entitlement rate under the duty drawback scheme as an incentive under Vishesh Krishi and Gram Udyog Yojana (VKGUY). The industry also gets a benefit of 8 per cent on the total value of exports under the Duty Entitlement Passbook Scheme (DEPB). India exported 6,63,603 tonne of 9,921.46 crore seafood, valued at in 2009-10, recording a growth of 10.08 per cent in volume and value from the 15.26 per cent in previous year.

information services to disseminate correct knowledge of olive oils of European origin, in terms of their quality and health attributes. It includes an array of activities like workshops, training programmes for stakeholders, participation in trade shows, tasting sessions and advertising campaigns to explain the nutritional aspects of olive oil. Naini Setalvad, renowned nutrition and obesity consultant from Mumbai, said, “With fast food and fast-paced

lifestyles, the health quotient of Indians is going down drastically. It is time, we started changing our lifestyle, especially our eating habits. Incorporating olive oil in our cuisines will be a perfect start.”

coffee almond crunch, vanilla milk & chocolate, and vanilla almonds. The products will be available at all existing Godrej Nature’s Basket outlets in Mumbai for 150 each. Different flavours offer a dessert experience with a lingering taste. The cookie & cream flavoured stick bar has chocolate cookies covered with vanilla ice cream with a chocolate milk coating and cookie crunch. Similarly, the crispy coffee almond crunch flavour is filled with the

Brazilian coffee beans roasted and coated with milk chocolate and almond crunch to give the perfect crispiness. The vanilla milk & chocolate flavour has vanilla ice cream and milk chocolate coating. And finally, the vanilla almonds flavour has vanilla ice cream, with a milk chocolate coating and almonds. Häagen-Dazs, which created the super-premium ice cream category in 1961, is today sold in more than 50 countries globally.

by the Associated Chambers of Commerce and Industry (Assocham). The investment will give a thrust to increase the csurrent 2.2 per cent share of processed food trade in fruits & vegetables to 10 per cent, the 26 per cent share of fisheries to 40 per cent, and 6 per cent share of poultry to 15 per cent. Moreover, the funding will also help in raising the 20 per cent share of

the buffalo meat to 40 per cent and that of milk from 35 to 60 per cent by 2015.

Modern Food Processing | August 2010

Naini Setalvad addressing the audience

NATIONAL NEWS SECTOR ANALYSIS

Malted health beverage sector to grow strongly

Frost & Sullivan has come out with its half yearly sectoral analysis on malted health beverages sector. The analysis has covered key points like market overview, competitive analysis, challenges, opportunities and future market outlook. Health products are the latest WORKSHOP

National workshop held on Food Safety & Standards Act The All India Food Processors’ Association (AIFPA) recently organised a national workshop on ‘Food Safety & Standards Act: The step forward’, in association with the Ministry of Food Processing Industries (MFPI) and Food Safety and Standards Authority of India (FSSAI). FOREIGN DIRECT INVESTMENT

FDI in multi-brand retail to trigger growth in food processing

Subodh Kant Sahai

The Union Food Processing Industries Minister, Subodh Kant Sahai, has given FOOD SAFETY

ASEAN food safety model may help India achieve its food safety goal The Indian food processing industry needs to follow suit of the ASEAN food safety measures where the Philippines, Malaysia, Indonesia, Singapore and Thailand have identified five priority segments to improve food safety and are making

fad in the food business worldwide, and this trend is fast catching up in the Indian market as well. With a market 49-50 billion in 2009, the value of total Indian functional foods segment currently is a small percentage of 4,000-billion processed foods the market. The analysis pointed out that despite a small base, the functional foods and beverages market is poised for exponential growth, since health & wellness are the focus areas for market players and consumers worldwide.

The survey observed that the Indian malted health beverages segment has seen fierce competition among its market participants. Taking due note, manufacturers have revamped their portfolios and emerged with new & better products. The survey also inferred that the malted health beverages market is 2,000 crore, with currently worth strong double-digit growth rates. This segment is poised for expansion in terms of product and infrastructure.

The day-long workshop was inaugurated by P I Suvrathan, Chairperson, FSSAI, who highlighted the problems faced by the food industry and the need for consolidation of food laws. The vital aspects pertaining to the industry like labelling, claims & proprietary foods, food additives and food safety management systems were discussed, apart from issues related to licensing & registration of food business.

The workshop witnessed participation from more than 175 representatives from the food processing industry.

a thumbs-up to the foreign direct investment (FDI) in multi-brand retail saying it would help bring down the level of agri-produce wastage and attract more investments. The Ministry of Food Processing Industries had earlier floated a discussion paper on allowing FDI in multibrand retail. India is losing agri-products, fruits and vegetables to the tune of 1 lakh crore annually, which could be cut down by more than half with the establishment of cold chains and back-end infrastructure, the paper pointed out.

“The food processing sector has already started attracting FDI, and it has improved significantly to the tune 225 crore in the last fiscal from of 100 crore the previous year. We expect this to go up further with the opening up of FDIs in multi-brand retail,” said Sahai. Hailing the move, Ashok Sinha, Secretary, Ministry of Food Processing Industries, Government of India, said, “It is a strong step in the right direction. I can see linkages of our farmers with this development”.

efforts for the same at the ministerial level. While addressing the inaugural session of the 5th Food Safety and Quality Summit - titled ‘India the food factory of the World: Food safety challenges and opportunities’, Dr Gopi Ghosh, Assistant Representative, Food and Agriculture Organization, the UN, said, “India could adopt a similar approach to improve its prevailing food standards and align them

to world levels – with clear targets and vision.” The two-day event was organised by CII in New Delhi.

Modern Food Processing | August 2010

Workshop in progress

NATIONAL NEWS EXTENSION OF BAN

India extends ban on Chinese dairy products

The Union Ministry Of Commerce & Industry recently said that the AGRICULTURE SUPPORT

Gujarat and Andhra to get agri-clinics for groundnut In order to support farmers in major groundnut growing areas, the Groundnut Promotion Council under the Solvent Extractors Association of India (SEAI) has decided to set up agri-clinics for groundnut promotion in Gujarat and Andhra Pradesh. The apex trade body has identified Junagadh in Gujarat and Adoni in Andhra Pradesh for the establishment of agri-clinics. The two states account

government had further extended the ban on import of milk and milk products from China for another six months. The items prohibited for import into India from the neighbouring country include chocolate & chocolate products, candies, confectionery and food preparations with milk as an ingredient. The ban was notified by the Directorate General of Foreign Trade

(DGFT) in the Commerce Ministry and imposed in December 2008, whereas imports of milk and milk products from China have been prohibited since September 2008. Though the DGFT had not cited any reason for the ban, it is understood that fear of Chinese milk containing melamine, a deadly chemical, was the main reason behind the ban.

for bulk production of groundnut in the country and the regions selected for agri-clinics are the prominent groundnut areas in these two states. In the wake of diminishing quantity of the commodity for crushing, Groundnut Promotion Council had suggested the establishment of agri-clinics for groundnut to help the farmers. The proposed agriclinics would support farmers by providing various information and services including soil testing, recommendation for seed varieties appropriate to soil and climatic

conditions. They will also provide SMS services to the farmers to update them on weather conditions, advisory services of agronomists to farmers for pre- and post-harvest etc.

August 2010 | Modern Food Processing

WORLD NEWS MARKET STUDY

China ranks second in bakery and cereals market

Inherent economy boom are & cereals

strength of the Chinese and resultant consumption driving growth of the bakery market in China, according

ACQUISITION

Brenntag strengthens its market presence in Asia-Pacific Brenntag, one of the leading players in the global food ingredient market has gained a strategic position and local presence in the Asia-Pacific region, with the acquisition of 100 per cent shares of EAC Industrial Ingredients Ltd A/S, a provider of chemical distribution solutions in South and South East Asia. The selling company is CopenhagenOBITUARY

Krones’ founding father Hermann Kronseder passes away

Dr Ing E H Hermann Kronseder

The founding father of Krones AG, Dr Ing E H Hermann Kronseder, passed NEW MATERIALS

Borealis delivers new solutions for food container manufacturing Borealis, a leading provider of chemical and plastics solutions, has recently launched two new generation BorPure materials for transparent food containers. BorPure RG466MO and BorPure RJ377MO are high transparency polypropylene (PP)

to a Datamonitor report titled ‘Product Insights: Bakery & Cereals in China’. It held the fourth position in terms of retail sales and second position in new product launches in the global bakery and cereals market in 2009, with more than 1,500 new product launches in the same year. This trend can be attributed to the keen interest taken by manufacturing companies in the Chinese market in view of the huge potential that exists there. These firms are launching products to cater to the population in general as

well as those belonging to specific segments such as the sub-cultural and economic classes. Moreover, they are adapting local Chinese tastes and offering products in flavours that range from peanut & black sesame seeds to Peking duck & Shanghai crab. “The key to a successful product launch in China seems to be marrying modernity with tradition rather than pitting one against the other,” said Amit Srivastava, Datamonitor Analyst and author of the report.

based The East Asiatic Company Ltd A/S. The purchase price is Euro 160 million on a cash and debt-free basis. With the acquisition, Brenntag will gain access to an established distribution network, active in nine countries, with exceptional growth potential. Through this move, Brenntag has reinforced its growth strategy in the Asia-Pacific region. EAC Industrial Ingredients has local presence in India, Thailand, Vietnam, Indonesia, the Philippines, Malaysia,

Singapore, Cambodia and Bangladesh. In addition, the high level of benefits for Brenntag and EAC Industrial Ingredients on account of the acquisition is expected to further enhance both, customer service and access to world-class suppliers. For 2010, Brenntag expects sales of about Euro 220 million for EAC Industrial Ingredients.

away on July 9, 2010, at the age of 85. Hailing from a family of craftsmen in the Upper Palatinate, Dr Kronseder was a master machinist and electrician in the late 1940s. In 1951, he set up his own company called Krones, in Neutraubling – a ‘craft enterprise for making electricallypowered machines’. He developed semi-automatic labellers from drawings he had self created. In the 1960s, Krones’ turnover doubled every three years on an

average, and export business acquired increasing momentum. In the 1970s, additional plants were built in the Upper Palatinate and the firm began to produce bottle fillers. In 1996, Dr Kronseder moved to Krones’ supervisory board as the Chairman. In 1997, he resigned due to health reasons. Acknowledged as the ’powerhouse of beverage machinery design’ he had received many accolades.

random copolymers targeted primarily at the different market segments of house & kitchenware and thin wall packaging. “BorPure RG466MO delivers a significant change in taste and odour performance. It also offers a combination of excellent stiffness/ impact balance, low warpage, good anti-static behaviour and ease of moulding for complex shapes, making it an ideal solution for food storage

containers,” the company said in a press release. BorPure RJ377MO combines its organoleptic properties with high transparency, drop impact, top load and denesting performance that makes it an appropriate choice for manufacturing thin wall containers and lids.

Modern Food Processing | August 2010

WORLD NEWS SAFETY STANDARDS

FCI’s Thermal mass flow meter receives ATEX, IECEx approvals

The advanced ST75 Flow Meter from Fluid Components International (FCI) is now ATEX and IECEx approved for HEALTHY MOVE

Fastfood chains now serving ‘healthier foods’ McDonald’s, Burger King and Wendy’s are some of the fast food chains moving towards healthier foods, reveals a new study. The latest research from the University of Minnesota School of Public Health looked at trans-fat and saturated fat levels in French fries from five major fast food chains: McDonald’s, Burger King, Wendy’s, Jack in the Box BUSINESS EXPANSION

Tate & Lyle completes EU polydextrose plant

Tate & Lyle has completed a planned European polydextrose manufacturing facility. According to the company, its new EMISSION REDUCTION

SABMiller unveils sustainability strategy SABMiller has introduced a series of projects and schemes to reduce emissions on beer by 50 per cent by 2020, cut water use by a quarter by 2015, and take advantage of lightweight packaging. In its recently published ‘Sustainable Development’ report, it outlined how savings had been achieved in water usage, energy consumption, packaging

safety in hazardous and potentially explosive plant environments. The approval indicates that the flow meter is suitable for applications in hazardous plant areas in the European community and elsewhere worldwide. The IECEx prepares and publishes international standards for electrical, electronic and related technologies, while the ATEX directive specifies design criteria for flow meters and other electricallypowered instruments to help prevent

explosions and fires when combustible gases are present. Designed for line sizes from 0.25 to 2.0 inch, the ST75 Flow Meter combines superior accuracy with a rich set of features. It provides three unique outputs: outputs mass flow rate, totalised flow and media temperature. It is ideal for applications in a wide range of industries including chemical, electric power, food & beverage, advanced materials, pharmaceuticals, semiconductors etc.

and Dairy Queen. It was found that McDonald’s, Burger King, and Wendy’s significantly decreased the trans and saturated fatty acid composition of French fries between 1997 and 2008. The remaining two restaurants have decreased the fat composition since 2008. Research indicates that trans-fats can elevate the risk of heart disease by increasing bad LDL cholesterol and decreasing good HDL cholesterol levels. “It is a good sign that they have not

raised the levels of saturated fats to replace trans-fats,” said Lisa Harnack, Associate Professor of Epidemiology, School of Public Health, and Director, Nutrition Co-ordinating Centre.

facility, located in Koog, the Netherlands, is the only European manufacturing plant for the bulking agent. Tate & Lyle already produces its Sta-Lite polydextrose brand in the US. The new European facility will benefit the customers in the region by way of a shortened supply chain and further reduced costs. Polydextrose is an ingredient with a variety of application in the formulation of healthier foods. It is used as a natural

sweetener in combination with synthetic low-calorie sweeteners. It can also be used to give suitable texture and mouth-feel to products with low fat or high fibre levels. Tate & Lyle’s Sta-Lite ingredient is said to contain 1 kcal/g. It is a soluble fibre having prebiotic properties. It is derived from corn and comes in both, liquid and powder form, with a wide range of food and beverage applications.

& waste and set its targets for the future. It said total energy consumption in 2009 was 23 Terajoules (TJ) - equivalent to 2.3 million tonne of CO2, a 3 per cent improvement from the previous year. The company aims at reducing emissions from onsite energy use by 50 per cent per hectolitre of beer between 2008 and 2020. Schemes to reduce its dependence on coal are underway. At its Alrode Brewery, South Africa, SABMiller has developed a biogas recovery

plant, using an anaerobic digestion process. Besides, in Hungary, waste heat from the brewing process is used for absorption cooling. The report suggested that spent grains – a waste product from the brewing process – could provide a significant proportion of the energy requirements in SABMiller’s plants.

August 2010 | Modern Food Processing

WORLD NEWS ACQUISITION

AkzoNobel buys Swedish can coating firm

AkzoNobel has agreed to acquire a Swedish metal packaging decorator to strengthen its position in beverage LOGISTICS

Danisco streamlines ingredients supply function Danisco is forming a new logistics unit to integrate its three food ingredients divisions covering emulsions, cultures and sweeteners, in a bid to bring greater efficiency in its dealings with customers. The Danish firm announced the formation of Logistics Food Ingredients (LOGFI) to handle the logistics of food ingredients. Karen-Marie Katholm, Vice President-Supply Chain, revealed that DAIRY

China reduces minimum protein levels to combat melamine in milk

China has lowered minimum protein levels in raw milk in its latest effort to NEW FLAVOURS

Omega Ingredients splits tomatoes into flavour variants Flavour supplier Omega Ingredients has developed a new range of tomato flavours from the whole fruit. These flavours can be used in foods and beverages geared towards the ‘natural’ trend and as savoury flavour enhancers. The trend towards natural flavours has been escalating because the

cans and target new growth markets. The deal covers the worldwide assets of Lindgens Metal Decorating Coatings and Inks, including its majority stake in the Server Boya, joint venture in Turkey. The move would add to the company’s coating technology and expertise, particularly in the market for inks printed on the outside of two-piece beverage cans.

The distinctive feature of this container type is that the ink is roll applied to the exterior of the readyformed can. As for other market opportunities opened up by the deal AkzoNobel officials said, “The addition of business in aluminium wine closures provides AkzoNobel Packaging Coatings with an opportunity to increase our presence in this growing segment.”

the aim is to “enhance performance towards customers, and improve efficiencies”. Previously Danisco’s ingredient divisions handled their own logistics, so customers using ingredients from more than one division would have had to deal with Danisco in several ways. “It was more fragmented,” said Katholm. The new system will handle logistics, customer service & planning, and will take a global overview of how to handle each customer in the best possible way.

New arrangements may include combining deliveries of ingredients from more than one division and reassessing the warehousing set-up to ensure that supplies are kept where they are most needed. LOGFI will also work with customers on managing inventories, as per their requirements.

stamp out the use of melamine in the dairy industry. The reform to protein testing has come soon after around 64 tonne of melamine-tainted raw dairy materials were seized from a plant in the Qinghai Province, in northwest China. Much of the contaminated product has been traced to the Hebei Province, which was the source of the toxic infant formula products from the 2008 scare. Authorities have therefore suggested that traders may have bought

contaminated materials that should have been destroyed after 2008, with the intention of processing and selling them. As a consequence, the country has gone on the offensive to prevent any repeat of 2008 when contaminated products affected many people adversely. Chinese health officials have decided to lower minimum protein levels for raw milk from 2.95 per cent to 2.8 per cent. Officials said the new standard is more realistic.

incoming flavour regulation sets out specific definitions for natural flavour terminology. To develop its new tomato flavour range, which can be labelled simply as ‘natural tomato extract’, Omega Ingredients has taken the natural flavour out of tomatoes, then fractionated it into four different components with different flavour characteristics, said Steve Pearce, Managing Director, Omega Ingredients. The four tomato variants offered include cooked tomato; fresh, ripe

tomato; juicy tomato, and a highly concentrated intense tomato extract. The extract can be used not just to create tomato flavours, but also to enhance tomato intensity & savoury notes.

Modern Food Processing | August 2010

TECH UPDATES

A new angle to detecting contaminants in fluids

Pavan Group develops production line for deep frozen fresh pasta

Mettler Toledo Safeline has launched FluidCheK X-ray inspection system for detecting contaminants in fluids. It is equipped with advanced image-scanning software and employs X-ray beams at a particular angle for total quality control. The new system ensures accurate detection of dense contaminants including glass, metal, stone, plastics and rubbers. The approach focusses on inspection of the base area because contaminants, usually denser than liquid, tend to sink at the bottom. Specially designed to inspect glass metal and plastics, it is effective on containers with a domed base. “Horizontal beam X-ray systems are inefficient to inspect containers with dome-shaped base areas, since those areas are denser than the rest of the container. In response to specific customer requests, Safeline developed an X-ray system that achieves optimum contamination detection in packaged fluids while ensuring maximum throughput and ease-of-operation,” said Niall McRory, Sales Manager - New Product Development, Mettler Toledo Safeline. FluidCheK is also equipped with a new software technique called XTP for contamination detection.

Pavan Group has developed a production line for the thermic treatment of fresh filled pasta. The line has been designed to manufacture three types of finished products: fresh pasteurised, pasteurised & pre-cooked and pre-cooked & deep frozen products. The production line comprises two sections - one for raw materials dosage, mixing, kneading and forming of filled pasta using a gravimetric semolina doser that guarantees maximum precision; and the other for heat treatment by using steam or spraying hot water. The line can handle pasta shapes having different weights. Dough scraps, if any, are minced into powder and returned to the mixer to be reworked. The pasteuriser enables low energy consumption and is equipped with steam & hot water spraying bars for product cooking, thus ensuring a highly efficient cooking process and minimising water waste. The process ends with a pre-drying section to dry the surface of the filled product or to remove water from the surface of the precooked product. Further, a computerised system with remote control unit supervises line operation. Production parameters are stored in a computer in the form of ‘recipes’.

Automated Salmonella detection technology for confectionery industry

Resin boosts clarity of PP-based food packaging

The Swiss robotics supplier Xiril and Germany’s Biotecon Diagnostics have developed foodproof RoboPrep+ Series, an automated sample preparation and Polymerase Chain Reaction (PCR) set-up kit for Salmonella testing in chocolate and food products. The system combines Xiril’s liquid-handling instrumentation with Biotecon’s magnetic preparation for efficiency and data security, ensuring high-throughput routine testing of food samples for the pathogen. Sina Kirsanovs, Product Manager, Biotecon, said that the technology has been successfully tested in-house on multiple chocolate & food matrices, and can be easily customised to fit a manufacturer’s specific requirements. The results are generated in about 4.5 hr, following the complete process of sample preparation, set-up and other steps. The system is currently being adapted to enable testing of additional food pathogens such as E. coli and Listeria. The technology enables the protocol to be started with only a few mouse clicks, and then runs unattended with up to 96 samples at a time, claimed the developers. The full system includes the complete robot package (on board PC, flat screen, keyboard and mouse), sample preparation and pathogen detection kits, plastic consumable sets (tips, plates, tubes and buffer containers) and real-time PCR instruments.

Modern Food Processing | August 2010

The US-based plastic packaging supplier Total Petrochemicals has joined hands with Belgium-based Milliken Chemical to develop a new metallocene polypropylene (PP) resin using Milliken’s Millad NX8000 clarifier. The resin can enhance the clarity and sidewall stiffness of low-density PP for food packaging and allows it to compete with other plastic materials on sustainability and aesthetics. Total Petrochemicals officials claimed that its new PP grade, Lumicene M3382MZ, employing the agent from Milliken, can compete with traditional packaging materials like polystyrene (PS) or polyethylene terephthalate (PET) because it offers high clarity coupled with lower density for reduced cost and lower resource usage, as well as fast and easy processing for high productivity. Also, it can be more easily recycled, thereby supporting environmental goals. “Millad NX8000 provides a reduction in haze, while also delivering increased material strength & rigidity, and improved heat & chemical resistance,” the officials added. According to the company, its new PP grade also has ultra-low extractables, improved taste & odour characteristics, and complies with US Food and Drug Administration (FDA) regulations.

TECH UPDATES

Baker Perkins’ new production line for the confectionery market

Spectrometer simplifies cadmium analysis in chocolate

Baker Perkins has claimed that its two new confectionery machinery – ServoForm Gemini Plus and ServoForm Candy Max – offer increased capacity and a greater range of layers, centre-filling and inclusion applications. ServoForm Gemini Plus can be used for two-component ‘long-term’ layered confectionery such as sweets with hard candy on the top and bottom of a xylitol layer. It is equipped with a tripleheaded depositor to enhance the texture and mouth-feel of the sweets. “Innovative lollipop and candy development has been the driver behind the recent resurgence in the confectionery sector and our R&D ensured that Gemini Plus would guarantee highly profitable lines for the big volume producers. The new unit allows a run of triple layer products at the rate of 7-10,000 pieces per minute,” explained Keith Graham, Marketing Manager, Baker Perkins. Similarly, Baker Perkins’ twin-headed ServoForm Candy Max can reach maximum outputs of 1,800 kg/hour as it features two heads that deposit the product into alternate rows of moulds. The machines are easy to clean as the mechanics ensure that little product is left in the depositor head after a run.

Thermo Fisher Scientific has launched iCE 3500 atomic absorption spectrometer for simple and accurate analysis of cadmium in chocolate. Its innovative Graphite Furnace TeleVision (GFTV) capability allows sample deposition and drying to be viewed real-time inside the cuvette. The system also comes equipped with SOLAAR software enabling easy method development. Samples were analysed following a simple digestion procedure and matrix matched standards were used to accurately determine cadmium concentration. The GFTV facilitated easy optimisation of the position of the injection capillary and allowed visualisation of the deposition of the sample into the cuvette, thus ensuring accuracy and precision. “Experimental results revealed that cadmium was accurately detected in all analysed chocolate samples at concentration levels well below recommended limits for cadmium in foodstuffs,” claimed Thermo Fisher officials. Ingredients in chocolate include milk, cocoa and fats, and each is a potential source of cadmium, a heavy metal that can cause health hazards.

Alfa Laval introduces EHEDG-approved rotary spray head

Magnetic train technology used to measure fat content

Alfa Laval has introduced Toftejorg SaniMidget SB UltraPure rotary spray head, which the company claims to be the first tank cleaning machine of its kind that is certified by the European Hygienic Engineering Design Group (EHEDG) for use by the food industry. With this launch, Alfa Laval leads the way in the area of hygienic processing and food safety, the company added. “Alfa Laval’s focus on innovative design helps the food industry to meet the ever-increasing demands on hygiene and process efficiency. Our SaniMidget SB UltraPure rotary spray head delivers higher cleaning efficiency while using less water, energy & cleaning agents than traditional static spray balls,” informed René Elgaard, Manager - Tank Equipment Competence Center, Alfa Laval. Compared to static tank cleaning equipment, rotary spray heads and rotary jet heads provide higher cleaning efficiency due to the ability to provide higher mechanical impact power over a larger surface area at a faster rate. It offers a combination of physical impact and cascading flow of cleaning fluid to cover all internal surfaces. To ensure product integrity, this device is made of safe and nonreactive hygienic materials.

Scientists at Harvard University applied magnetic levitation or MagLev, best known for enabling high-speed trains to float above tracks, for measuring fat content in food by way of density measurements. Researchers used the technology to analyse the fat content in milk, cheese, vegetable oil and peanut butter, and to estimate the salinity of water & monitor the removal of husk. MagLev was applied to the analysis of food products using a special sensor, about the size of an ice cube. This sensor consisted of a container filled with a solution of paramagnetic ions having two magnets at each end. Samples of different materials were placed inside and the distance they migrated through the fluid provided a measure of their density. The scientists claimed that it was accurate, rapid, & flexible – best-suited for a wide variety of liquids and solids including those with irregular shapes. However, the technique requires a paramagnetic solution that may be incompatible with certain substances. For example, it may cause swelling, extract components or even dissolve the test substance. The scientists noted that, “MagLev may be useful for analysing samples on the basis of density when the need for small volume, portability, simplicity and low costs is of primary importance.”

August 2010 | Modern Food Processing

LEADERS SPEAK

“Organised food processing activity on an industrial scale is relatively new, but growth opportunities are huge” …comments Jose Hernanz, Managing Director, Alfa Laval India Ltd, which offers a bouquet of top line processing solutions for the food & beverage (F&B) industry. He is considered to be one of the most experienced Managing Directors of Alfa Laval and has held several top positions for nearly two decades in Portugal, Spain, South America (as Regional Manager) and most recently in Iberia. In conversation with Rakesh Rao, Hernanz shares his views on the changing dynamics, challenges and potential in India’s most happening sector.

Modern Food Processing | August 2010

LEADERS SPEAK

Current status of the Indian food processing industry… If one observes closely, the ‘health & fitness’ wave is going to be the deciding factor in shaping India’s food habits and its food industry in the coming years. Carbonated drinks are giving way to fruit juices and health drinks; fresh fruits are replacing unhealthy fast food and so on. As a result, not only India, but also the Asia-Pacific market is witnessing the strongest growth in fruit processing sector. This growth is driven by improved living standards, the rising purchasing power of the middle class, and the increased presence of women in workforce. The change has positively spiked demand for more industrially produced readyto-eat foodstuffs and beverages. Another good thing is that this business is less exposed to industrial cyclicity. There is a variety & abundance of raw materials available throughout the year, and the demand for food will never vanish. With increasing government initiatives for boosting the food processing sector and growing focus on setting up of mega food parks and SEZs, schemes are also floated to encourage public-private partnership for creating rural infrastructure in the food preservation and processing sector.

Technology requirements… India has a wide base of agri/horti produce with an insignificant level of processing and value addition as compared to several other countries. Though we have seen remarkable progress in food processing, the sector remains fragmented. Organised food processing activity on an industrial scale is relatively new, but growth opportunities are huge. The need for state-of-the-art technology for production processes, packaging and quality control has become imperative for processors, if they want to achieve consistent quality in their products and global standard of food safety. Also, there is a need for cold chain facility to keep freshness and quality intact.

Challenges faced by food processing machinery manufacturers… The key challenge for the machinery suppliers is to understand the individual processing requirements that are often unique in their own way depending on the product to be processed, required capacity and level of automation desired. For processors, maximum yield at minimum cost is crucial. They also have to deal with the varying availability, quality and characteristics of different types of raw materials – most of which are seasonal products. Producers, therefore, need their facilities to be versatile and flexible, so that they can use the same equipment for varied types of fruits at different times. The supplier, thus, has to consider flexibly applicable systems for a wide range of products, production quantities and systems that ensure consistent product quality for each batch in case of multiple fruits & vegetables line. Demand for continuous production system is increasing. The associated automation level no longer permits manual additions. Instead continuous in-feed of all dry substances and liquids in right proportions are required. With energy and environmental concerns on the rise, the demand for good energy-efficient process equipment, which has low operating costs and takes lesser space, is increasing. Modular structures with expandable systems that are maintenance-friendly are attracting the attention of today’s processors. At the same time, it has to be sterile and hygienic with simple system operations. The specific challenge of this industry is pertaining to processing steps, which involve fruit & vegetable pulps that can be highly viscous. This represents an end-to-end challenge to design equipment for maximum uptime, along with the ability to achieve prime-quality end-product with low operating costs.

The need for state-ofthe-art technology for production processes, packaging and quality control has become imperative for processors, if they want to achieve consistent quality in their products and global standard of food safety. Also, there is a need for cold chain facility to keep freshness and quality intact. Advancements in food processing machinery sector… The emerging trend witnessed universally in the market reflects the booming worldwide interest in natural, healthy foods. To make the most of such commercial opportunities, one has to focus on nectars, pastes, juices and purées of consistently high quality. These products should also look attractive, be easy to use as ingredients and above all have nutritional values that match their source.

Alfa Laval’s offering to the Indian F&B industry… Alfa Laval has decades of experience backed by the benefits of the R&D resources, materials technology and specialist know-how available from the world’s foremost specialist in heat transfer, separation and fluid handling. Alfa Laval equipment and systems are available for processing a large variety of tropical fruits and vegetables. We can supply all the equipment, either as individual units or as complete processing lines, with all sub-processes integrated for maximum end-to-end efficiency. The high quality standard of our equipment, cleaning-in-place and tank cleaning equipment are vital to ensure food safety.

Segments offering growth opportunities… The positive development in food processing industry in totality offers a

August 2010 | Modern Food Processing

LEADERS SPEAK

right business mix to Alfa Laval because we play a key role in fruit processing, edible oil refining and brewery sector. But most important of all, we have the right technology and competence to assist & lead the growth. The industry is on the brink of a technology conversion requiring high-quality solutions.

India advantage for Alfa Laval… India is interestingly one of the global hubs for the manufacturing of certain models of separators and flow equipment. These products are manufactured in India for global market and are sold through our sales office network in other parts of the world.

Latest innovations of Alfa Laval for F&B industry… With Alfa Laval’s diverse product profile, expertise and experience, we undertake the responsibility of building a complete project for processing fruits or vegetables. This can also be stretched

to accommodate multi-fruit processing line in the same plant. One of the most successful innovations of Alfa Laval for food sector is the Foodec decanter centrifuge. This has solved the mango processors’ major issue of maintaining the quality of juice and puree by removing the tiny black spec. After successful trial runs, the product has become popular and till date, we have sold more than 200 decanters to mango processors in just two years. Similarly, our air handling units and unit coolers are now being increasingly used for cold room application for storing potatoes, onions, chillies, and other agricultural produces. These not only guarantee reduced energy consumption, but also they come in compact size that saves on the space. Besides, we have kept the environmental aspect in mind while designing them. Our air coolers have far less environmental impact because

Modern Food Processing | August 2010

they work with natural and nonharmful refrigerants. To cater to the increasing demand of food industry, Alfa Laval has a dedicated factory that manufactures aseptic modules, specially designed with the stringent demands for sterility and hygiene in mind. Alfa Laval has recently acquired a bag-in-box and filling equipment company, which will extend our offering to the potential F&B customers with bulk packaging solutions.

Outlook for food processing machinery market… For a country like India, the need of the hour is to minimise wastage of food and preserve & process food products to feed its huge population. As a result, the outlook is positive at the moment, especially with good support from the government. Alfa Laval on its part is also fully geared up to tap the emerging opportunities.

ROUNDTABLE

Food clusters

A viable option for developing the industry? The development of food clusters is now gaining momentum in the country. As a viable route, these have the ability to boost the growth of Indian food processing industry and increase its export potential. But challenges are abound when it comes to successful development of food clusters. Through interaction with various industry experts, Shivani Mody finds out what lies ahead for the clusters and how these would contribute to the growth of the food industry.

Dr Arpita Mukherjee Professor, Indian Council for Research on International Economic Relations (ICRIER) In the Indian context, the performance of food clusters has been varied across the country. The Central Government has given a thrust to the development of food clusters, but still these clusters have not taken off as expected. One of the reasons for this situation can be the selection of location and the concerned state governmentâ&#x20AC;&#x2122;s policies and incentive schemes. Considering the emerging opportunities, several companies and small & medium enterprises (SMEs) moved into cluster development. However, some attained success, while others are still struggling for survival. For instance, in Pune, the horticulture cluster has performed well, while in some places the potato cluster has no takers. Before developing a particular cluster, one needs to conduct a comprehensive study to understand what will actually work in the field. The development of the ecosystem, logistics system, the right choice of crops et al are other

Modern Food Processing | August 2010

important aspects to be considered. The food clusters will boost the growth of the agro-processing industry. The main benefit of food clusters is access to land for development. In India, logistics and transportation costs are high and the location of the food cluster in majority of the cases does not factor in this issue. The country also lacks proper cold chain facilities, which is a must for successful development of food clusters. The modernisation of food clusters will go a long way in the growth of food processing industry. The Goods & Services Tax (GST) that is set to be implemented in the near future will not include agricultural goods movement, and this might prevent the faster growth of food clusters. The SMEs in these clusters are faced with the problems of high operating costs and lack of advanced technology. Several countries including Canada and Italy have implemented the concept of food clusters and reaped enormous benefits. Similarly, Thailand has developed a horticulture park, which has contributed greatly to the growth of the food processing industry there. But to ensure that this concept becomes successful in India, this sector needs to evaluate the pros & cons, besides creating customer awareness about it. There is a need to identify the specific areas where it can be developed and integrate it with the ecosystem.

ROUNDTABLE

Dr Arun Singh Senior Economist, Dun & Bradstreet India In spite of the rich and diverse resource base in the country for the development of food processing clusters, there is a lack of adequate infrastructural facilities in the supply chain such as cold storage & transportation facilities, packaging & grading centres and adequate quality control & testing infrastructure. Besides, inadequate power supply poses a major impediment to the operations of the small industries within the clusters. Hence, necessary investments on infrastructure are required from Central and state governments for the successful development of the food clusters. As mentioned earlier, India has a wide-ranging raw material base for the food processing industry and most of the production of agricultural commodities takes place in the rural areas. As the agricultural commodities are perishable, most food processing firms are situated in close proximity to the source of raw materials, which in

Dr K G Karmakar Managing Director, National Bank For Agriculture And Rural Development (NABARD) Food clusters have a great potential to ensure remunerative prices to farmers, value addition to farm produce, food habit transformation of urban/rural population and employment creation in secondary & tertiary sectors. India accounts for the production of 15 per cent of fruits and 11 per cent of vegetables in the world. Yet, the country processes only 1.3 per cent of its fruits & vegetables as against 80 per cent in the US, 70 per cent in France and 30 per cent in Thailand. A review of the supply chain management issues in the country reveals a retail mark up of 350 per cent of fruits and vegetables. The major constraints faced by this sector include highly decentralised production (average holding size much below the world averages); absence of primary aggregation, collection & grading centres; and lack of quality warehousing facilities & cold storages. Besides, the absence of a quality certification system and highly government-controlled agri-markets add to the problems. A large share of the food processing industry is also in the unorganised sector, without having any advantage of economies of scale of operations, or any access to modern technology. Organised retailing is confined to a few urban centres only. Although many agencies are engaged in developing industrial clusters, those actually setting up food processing clusters are just handful. Even among the few existing food processing clusters, more than 95 per cent are rice mill clusters.

turn has led to the creation of many natural food clusters in India. Thus, development of food clusters becomes an important channel for the Indian food processing industry to grow successfully. However, this calls for requirements like well-developed core infrastructure such as rural roads, farm connectivity with the market, cold chain & storage facilities and uninterrupted power supply. A cluster development strategy for the food industry would be effective in addressing problem areas, especially related to the infrastructure development. In this regard, public-private partnerships can help in creating the required integrated supply chain infrastructure, garnering necessary institutional finances and providing access to technology for the firms operating in the food clusters.

The development of food processing clusters can be successful only if the following conditions are met: R The small producers to be organised into groups like Self Help Groups (SHGs), producer co-operatives, etc R Necessary infrastructure for storage and processing facilities to be provided near the farm gate R Marketing of agri-commodities should be totally deregulated R High levels of taxation (VAT/excise duty) for processed food to be abolished for 10 years R High quality standards to be set for processed food and quality marking systems to be made available in all food processing clusters R Providing training to farmers on proper handling & storage of agri-commodities and processing of raw farm products R Domestic markets for processed food to be expanded with suitable fiscal/monetary concessions R Private sector investments (internal/external) need to be encouraged to develop this sector R As most food processing units are in the micro, small & medium enterprises (MSME) sector, steps are needed to enhance credit flow to food processing sector with preferential treatment.

August 2010 | Modern Food Processing

ROUNDTABLE

Uday N Borwake Member, Maharashtra Economic Development Council Food cluster aids various stakeholders to come under one umbrella. This is important to enable a synergy for creating a seamless food value chain in a country characterised with agricultural diversity. Farmers will be a major beneficiary, thereby facilitating rural development, which is the need of the hour. Food clusters can offer multiple support as vendors in the form of the much needed pre-processing facilitators to the large food processing industrial units. Individual product clusters like bakery clusters, chikki clusters etc can also be developed. The clusters can also get access to manpower and create localised training centres with help from Central Food Technology Research Institute (CFTRI), Defence Food Research Laboratory (DFRL) and Food Craft Institutes, alongwith technology inputs. Although the concept of food cluster is relatively new, it has slowly started growing due to the government support. Many food cluster programmes have been launched recently in various states.

Vinay Oswal Director, National Agriculture and Food Analysis and Research Institute (NAFARI) The food industry is growing rapidly, and this in turn, is supporting the cluster formation. For providing support to the food industry, NAFARI was established by NABARD and Small Industries Development Bank of India (SIDBI) to look at business opportunities, competitiveness of the industry and provide analytical services. As a non-profit organisation, since last two years, we have been contributing immensely to the cluster development activity by SIDBI in Pune to develop the fruits and vegetables cluster. In the Pune cluster, NAFARI has been providing services related to product development, analysis and market research. Despite the advantages of cluster development, we see many challenges and the industry has a long way to go.

Modern Food Processing | August 2010

According to a NABARD study five years back, India had 21 million tonne of food processing capacity â&#x20AC;&#x201C; but only 9 million tonne were processed, which led to a deficit of produce in the food processing sector. This imbalance could have been avoided, if these food processing units were integrated with farmer groups for seamless supplies from the fields in the relevant production zones of agri and horticultural produce then. Considering the challenges faced in developing food clusters, the investment challenges are addressed through various government schemes. But the major challenge is creation of techno-commercial manpower. In rural India, there is a need to create awareness regarding the various technologies available to access information and decide a fair price for farm produce. The missing link that needs to be addressed is establishment of post-harvest facilitation centres in the villages. This will result in reduced wastage of the harvest. Also, there is a need to develop cold storage facilities for increasing the shelf-life of the perishable farm produce. As a result, the exporters will be able to access fresh, unadulterated agri and horticultural produce from the village post-harvest facilitation centres. It is said that India can become the â&#x20AC;&#x2DC;food basket of the worldâ&#x20AC;&#x2122;, and hence, the food clusters in India are poised for growth.

One major problem is the mindset of those involved in the domestic food industry. Many companies work on a low-cost approach and spend minimally on technology aspects and research. The industry needs to play a more active role and take advantage of the services. For instance, the companies need to understand the certification and legal requirements for different countries for which institutions such as NAFARI can guide them. The food industry is currently facing challenges pertaining to food safety and meeting international quality standards, which need to be resolved. Food clusters based on a well-developed ecosystem has the capability to boost the growth of the food processing industry.The clusters can help in product development, analysis with regard to product failure and corrective actions, alongwith a variety of consultancy services. A food cluster approach is desirable for growth of exports and it can help in tapping the global opportunities as well. But for this approach to show results, we need to have a better financial strategy and infrastructure support.

IN FOCUS

Hatsun Agro Product Ltd

Cashing in on the white gold Hatsun Agro Product Ltd, one of the leading players in the dairy industry, has set its eyes on the growing business prospects in the fast-moving consumer goods (FMCG) segment. With a well-planned infrastructure and supply chain network, the company is strengthening its brand presence in the domestic & export markets. Rachita Jha tracks its successful journey so farâ&#x20AC;Ś

ith renowned brands of ice cream, packaged milk and other dairy products, Hatsun Agro Product Ltd (HAPL) has a strong foothold in the dairy markets of South India. The Chennai-based HAPL, with the biggest state-of-the-art plant near Palacode, Tamil Nadu, is equipped with one of the most modern systems and technologies to process more than 9,00,000 litre of milk per day.

The genesis Founded in 1970, the journey of HAPL started as an ice cream manufacturing company under the brand name Arun. It was in 1993 that HAPL started processing fresh milk and marketing it in pouches under the brand name Arokya. Subsequently, other milk products like curd, buttermilk, etc also followed. In 2003, HAPL forayed into a new dairy segment, when the company began manufacturing skimmed milk powder, whole milk powder, butter, ghee, etc under the brand name Hatsun.

Modern Food Processing | August 2010

Product basket With new opportunities and changing preferences of the consumers, HAPL has always kept its product basket in sync with the emerging market trends. The three major divisions in the company include ice cream, milk & milk products and dairy ingredients. Arun is a leading ice cream brand and Arokya milk is a flagship product under the Hatsun umbrella. Arokya sells 1 million litre of milk per day, making Hatsun one of the largest private sector liquid milk brands in India. The products like ghee, butter and milk powder have provided a competitive edge to the company in the FMCG segment. â&#x20AC;&#x153;Our product development team works closely with the market and undertakes market survey, product studies & testing that gives an idea regarding the mindset of our consumers and their requirements. This helps us develop products as per the market demands,â&#x20AC;? says R G Chandramogan, Managing Director, HAPL. Although Arun ice creams, milk and milk products have presence only in the southern

IN FOCUS

states like Tamil Nadu, Pondicherry, Andhra Pradesh and Karnataka, the dairy ingredients are marketed across the country. These products are even exported to around 38 countries that include Canada, Panama, Egypt, Morocco, Turkey, Singapore, Taiwan, South Korea, Thailand, Mauritius and the Philippines among others.

Milk procurement HAPL has established an extensive direct procurement network for collecting milk from the farmers. Its milkshed area is spread across Tamil Nadu and Karnataka. “The company today collects milk from 3,00,000 farmers every day and has a network of 6,000 collection centres & 62 chilling centres in various parts of Tamil Nadu and Karnataka,” avers Chandramogan. The company works in partnership with farmers and helps them in obtaining loans & financial aids from banks. Apart from this, HAPL has a team of over 100 veterinary doctors, 160 artificial inseminators & 500 procurement staff under its direct employment to provide healthcare services to the animals and look into matters related to breed management, vaccination, clean milk procurement, feed management, etc. This ensures better cattle management and improved quality of products. HAPL is also involved in dairy extension services to farmers for the development of livestock quality and yields. Under this, the company

launched a project called ‘White Gold’ that helps farmers to set up mini dairies comprising 10-30 animals to meet the increasing demand for milk in its manufacturing unit. “The ‘White Gold’ project provides guidance to farmers on water management, fertiliser use, labour management, productivity improvement, etc. The project was started with the mission to motivate the farmers to set up mini dairies, besides bringing in goodwill and loyalty for the company. Till date, Hatsun has been instrumental in promoting 400 mini dairy farms across Tamil Nadu,” adds Chandramogan. The project offers handholding to these farmers to ensure that they supply quality milk in a hygienic environment. In addition, a fleet of more than 1,300 vehicles has been deployed on contract for procurement and distribution of milk; each covering a distance of 200 to 250 km every day.

Processing facility With high-tech processing plants operating at seven locations, Hatsun undertakes rigorous testing of milk before processing. The company is a pioneer in India in world-acclaimed homogenisation processes, where the fat globules are broken and evenly distributed in the milk, making it rich and wholesome. Its commitment to quality has formed the backbone of HAPL business ethics, right from its start. The entire Hatsun staff work in harmony and enforce the tough

R G Chandramogan Managing Director

Our product development team works closely with the market and undertakes market survey, product studies & testing that gives an idea regarding the mindset of our consumers and their requirements. This helps us develop products as per the market demands. standards that the company set for itself as basic guidelines. After procurement, the milk has to undergo a quality test. Then the weight is checked, and by employing superior technologies, milk is subjected to pasteurisation, homogenisation and bacteria clarification. The state-of-the-art processing and packaging plants are located in Salem, Kancheepuram, Madurai & Palacode in Tamil Nadu, and in Honnali & Belgaum in Karnataka. Elaborating further, Chandramogan adds, “We have a total capacity to handle approximately 26 lakh litre of liquid milk per day. The company procures around 1.65 million litre of liquid milk per day by directly collecting it from farmers spread over 4,500 villages in South India. Hatsun has its own infrastructure such as

State-of-the-art processing plants of Hatsun Agro

August 2010 | Modern Food Processing

IN FOCUS

milk collection centres & chilling centres for procuring & handling of raw milk.” Apart from this, HAPL has three factories for manufacturing butter, ghee & milk powder.

& above 10,000 dealers for Arokya, and around 2,500 distribution centres for Hatsun milk.

R 2,500 Hatsun distribution centres

Quality matters

Quality management holds prime Robust supply chain importance in the overall functioning Everyday a fleet of puff-insulated of the company. The quality control trucks takes milk for consumption to team approves every product that gets households across the states of Tamil into the market. Validations of critical Nadu, Karnataka, Goa and Kerala. parameters are also done at its fully Hatsun takes pride in having its large equipped central lab located in Chennai. cold-chain network in India ensuring These ISO 22000:2005; 9001:2000, that every consumer gets fresh milk 14001:2004 and Hazards Analysis day after day. & Critical Control Process (HACCP) HAPL boasts of a strong logistics certified manufacturing facilities have and distribution network for ice cream been regularly upgraded to meet the and milk. Around 850 exclusive Arun requirements & standards of various ice cream parlours are spread across large multinational companies. “We Tamil Nadu, Andhra Pradesh and are proud of our toxicology lab that Karnataka. The company has six cold tests for the presence of toxins in the room distribution points, strategically product, and also for melamine before located for quick & easy distribution the products enter the market. We also of its products. In the milk segment, have a central lab, which independently the company’s distribution network validates the quality of our products by comprises 150 wholesale distributors random sampling from the market and updating the working systems at our factories,” notes Chandramogan. All facilities of HAPL follow regular HACCP quality management system and ensure that safety & hygiene conditions are met without any deviation. Realising that the key to its success is the well-being and development of the farmer, Hatsun helps farmers to get Milk collection and chilling system loans from banks to buy animals. The company also produces cattle feed as per required specifications and supplies it to the farmers at concessional rates.

Building on growth

Panoramic view of Hatsun plant

Modern Food Processing | August 2010

The success of Hatsun is driven by its consumerfriendly approach by understanding the consumer needs and bridging the gaps in the distribution channel

Key features

selling the complete range of Hatsun products 850 exclusive franchisee parlours for marketing Arun ice cream across South India 21 Arun ice cream unlimited parlours providing a new experience for customers 33 company depots across India for servicing the all India distribution network More than 600 distributors across India for distribution of ghee, butter and milk powder to the retail channel Hatsun dairy ingredients are supplied to 38 countries around the world including Canada An extensive cold chain and distribution network of both frozen and refrigerated channels for its various products. The total running kilometre of all Hatsun vehicles is around 3,00,000 km per day

to facilitate fast movement of products to various outlets across India. This has helped the company to expand its footprint and establish its brand in states such as Rajasthan. “Ensuring better returns for the farmers and adapting to the volatile situation of the commodity market were some of the major challenges. We managed to overcome this through our dedicated and persistent approach,” opines Chandramogan. Exports of dairy ingredients and ice creams will be the major focus of HAPL in the current year. Hatsun Agro already has a presence in Seychelles where it markets Arun ice cream. The company also exports ice creams to Brunei. Due to the exponential economic growth, HAPL is ecstatic about the expanding business outlook for the processed food industry in the growing domestic and export markets. Dairy has definitely been a pot of white gold for Hatsun!

INDUSTRY UPDATE

Total quality management With the surge in demand for food and emphasis on quality & health, coupled with the rising occurrences of food contamination, ensuring food safety has become the norm for food manufacturers. Moreover, the stringent regulatory standards, and expanding global trade have underlined the need for adoption of the latest technologies and best practices by these manufacturers for ascertaining a healthy future. Rakesh Rao delves deeper into the issue of food safety and gives insights on the way forward for the food industry.

series of food-related incidences, including melamine contamination in pet & infant foods, residual pesticides in drinking water & carbonated beverages, E. coli-tainted spinach, peppers & green onions, and a Salmonella typhimurium outbreak in peanut products, has brought to light the importance of effective safety standards to safeguard the quality of food products and ensure regulatory compliance. Common sources of food contamination include antibiotics, accumulated pesticide residues, heavy metals, pathogens, and pollutants in soil & water. Unwanted impurities may enter at any stage between production and consumption. Hence, it is necessary to test the nutritional and quality aspects of the food products before serving to the consumer. â&#x20AC;&#x153;The agricultural production has been a necessity for the life on planet Earth. As the population grows, the demand for food increases. To meet these rising demands,

Modern Food Processing | August 2010

various experimentation methods and chemicals are used to get better yield of the crops. At the same time, the advent of technologies has led to the development of preservatives and packaging materials. These, however also indicate the darker side of the consumable food and effects of the chemicals on the hygiene & quality. From tainted milk to contaminated peanut butter, food scares and recalls have been ever-present over the past several years. Consumers are now becoming more concerned about food safety,â&#x20AC;? avers Harsh Chopra, Country Manager (India), Intertek.

Meeting the global standards With globalisation, food processing companies have enormous scope for business expansion. At the same time, implementation of stricter safety norms means that food companies have to meet international quality standards. Philippe Sans, President & CEO, Silliker Group Corporation, says, â&#x20AC;&#x153;The global food industry

INDUSTRY UPDATE

is a complex domain. The shift in food trade in a globalised world and increasing consumer preferences from perishable to processed food products, increased consumer & media awareness about food crises, enforced and new regulations, all have highlighted the need for safer food. Considering the number of matrices available in the market, from raw materials to finished products, bringing in analytical accuracy and reproducibility at all levels of the food chain is a challenging feat. Food safety has gained new significance in the world of globalisation, and with new advancements in technology, the food testing segment is progressing steadily.” Experts agree that with the rise in global trade, the safety standards for food have increased. “The food & beverage industry today faces numerous challenges like synthetic colouring, additives, faulty processing aids among others, which pose threat to manufacturers and affect food safety. Globalisation has without doubt increased the food safety standards, as these products have to pass through various markets where governments have different safety procedures and standards. These diversified procedures have generated greater demand to produce more hygienic food, which will result in overall safety and improvement in the quality,” opines Andrew Tay, President - APAC, Zebra Technologies.

Indian scenario To take advantage of globalisation, manufacturers from the developed world are turning to fast-growing Asian economies - that account for large amount of agricultural, aquaculture and milk production - for more cost-effective foodstuff. As a result, these Asian economies are being invariably held responsible for food scares. Therefore, these countries require a far greater focus on food safety.

Sans observes, “Today in the global food market, compliance to quality and standards has emerged as a by-product of the diminishing borders of trade between countries. And, it is only a matter of time, we will realise the importance of universal food safety and certification system to simplify the complexities of the global food supply chain.” Like other countries in Asia, the Indian food processing & agricultural sector too is expected to make rapid strides in the international trade by providing high-quality products. If India has to achieve this objective, then domestic food processors will have to adhere to global standards. Along with viable policy initiatives, it is equally essential to have enabling disciplined environment in the various states to help realise the cherished objective of total quality management. Although there is a plethora of food laws governing safety in India, the level of awareness about food quality & safety issues is still low. This has also resulted in several barriers for trade of Indian food products both within India and in global markets. Therefore, there is a compelling need to bring all the issues related to food safety under one unified authority, and integrate food laws that is now being done under the Food Safety Penetrate and Standards international markets Authority of India (FSSAI).

Growing demand for food testing As a result of global mergers and alliances between various countries, each country wants to conform to the global testing & compliance systems

Harsh Chopra Country Manager (India), Intertek

From tainted milk to contaminated peanut butter, food scares and recalls have been ever-present over the past several years. Consumers are now becoming more concerned about food safety. to avert all concerns for safety. They need to ensure that the food is tested for the compliance factors on the parameters of concern. India is also gearing up to enforce more vigorous testing of food products, their ingredients & raw materials, good manufacturing and hygienic practices in the food industry. The Ministry of Food Processing Industries is providing financial assistance to both state governments and private organisations to set up testing laboratories across the country. As a result, the demand for food testing services is expected to be high in the near future. Seeing this,

Establish FSMS Compliance with regulatory requirements ISO 22000 Certification Compliance with statutory requirements

Enhance customer satisfaction Compliance with customers requirements

Source: Frost & Sullivan

Figure 1: Advantages of ISO 22000 certification for companies

August 2010 | Modern Food Processing

INDUSTRY UPDATE

Philippe Sans President & CEO, Silliker Group Corporation

Considering the number of matrices available in the market, from raw materials to finished products, bringing in analytical accuracy and reproducibility at all levels of the food chain is a challenging feat.

processing of food raw materials, intermediate products and processed food products. The region has food processors of all scales from small, medium to large-scale companies. Most of the food companies have got corporate offices in Delhi (Gurgaon), which require food testing services for their processing plants located across the country. There are more than 300 small, medium to large-scale food companies operating in the northern region.”

Farm-to-fork approach many international companies are establishing their testing labs in India. Like for example, through its new joint venture with MicroChem, Silliker Group has opened a new state-of-theart laboratory for nutritional chemistry and food & safety in Mumbai. Similarly, Intertek is in the process of opening a food testing facility in the country. Chopra says, “Our Centre of Excellence Laboratory is located in Gurgaon, which is considered to be a hub of primary production and further

While adoption of the latest food testing technology is critical for the compliance to food safety norms, equally important is undertaking quality checks across the entire supply chain. There are various stakeholders along the supply chain, who can hamper food safety, starting from the farmer to the distributor, manufacturer and even the retailer. Most companies across the world tend to react after the onset of a food scare. When supply chain issues occur, the response is to

Four-step safety approach In a study ‘Food quality and safety: Issues and way ahead’, the Associated Chambers of Commerce and Industry in India (Assocham) has suggested the following four steps to realise the goal of safe food practices in India: R Creating awareness: As a first step towards this goal, the study talks

about creating a level of awareness that highlights a common source of contaminants, good hygiene practices, importance of freshness and general do’s and don’ts about outside food. R

Training: In the next step, a well-evolved training programme involving state, district and village-level government machinery, NGOs, chambers of commerce, trade associations and other service providers should be put in place to educate the masses.

Adoption of suggested models/prototypes: The third step should be creation of cost-effective models for preparation, storage and distribution of food in a difficult setting like India.

Certification/registration: In the end, given the diversity of India’s food chain ranging from street vendors to high-end restaurants, the FSSAI is likely to offer simple registration requirement for a broad category of vendors/hawkers and certification/licence requirements for the rest. The registration procedure should be made compulsory as part of the training. Certificate and licence is generally applicable in case of organised food chain participants, and hence, a different module for creating awareness for this category is recommended. Source: Assocham

Modern Food Processing | August 2010

tighten the specifications or increase inspections. However, inspecting and sorting do not comprise an effective long-term strategy, since they do not mitigate the root cause of the problem. What is needed is a comprehensive, ‘farm-to-fork’ approach to food safety. Chopra says, “From the farm to the fork, the entire Indian food industry itself has evolved into a diverse network of multiple channels. More often, the core operational structure, as well as various business processes involved in food production and distribution, fail to communicate & align with one another.” Food processors should consider making food safety and quality a strategic issue rather than managing by crisis. Managing strategically creates the correct culture for the food processor. Farm-to-fork approach is the key for effective food safety strategy. David Highton, Global Scheme Manager - Food Safety, BSI Group, states, “It is undeniable that no element of the food chain exists in isolation from another. Therefore, farm-to-fork has to be an effective food strategy. To achieve this objective, ISO 22000 standard is an ideal choice, since its very approach engenders the inter-relationship between all aspects of the food chain, while at the same time keeping a critical eye on the ultimate safety of the food the endconsumer eats.”

Need for traceability In order to achieve total quality management & meet international standards, it is imperative to establish a principle framework to monitor the path of food. Since food can be rendered unsafe for consumption at any level of the supply/value chain, there is a need for traceability across the entire supply chain. Tay informs, “With safety gaining increased importance among food manufacturers and consumers, deploying the right traceability solution can meet regulatory demands,

INDUSTRY UPDATE

achieve better inventory control, faster processing and turn rate (on items that have tight freshness windows) more accurately and cost-effectively.” The concept of traceability is now entering the limelight, with regulatory bodies, industry participants and consumers increasingly recognising its advantages. Tay opines, “With more label and scan points available through operations and shipping, products can be more easily traced throughout their lifespan. This provides an extra layer of protection and helps determine the faulty product & the source of its inception; thereby enabling businesses to take timely preventive measures. This can save lives in the case of a severe food-borne illness outbreak as well as save time, money and reputation of companies.” Traceability requirement is applicable to all food, feed, foodproducing animals and every participant in the supply chain, including farmers, processors, logistical operations, storage, distributors and retailers. One of the most promising technologies for meeting traceability requirements is radio frequency identification (RFID), which can potentially enable tracking of food products from farm to the platter. Tay informs, “A single printing solution can produce bar code labels for product identification or shipment labelling, add multiple layers of authentication technology for brand protection,

Andrew Tay President - APAC, Zebra Technologies

Globalisation has without doubt increased the food safety standards, as these products have to pass through various markets where governments have different safety procedures and standards.

and encode embedded RFID tags to meet Electronic Product Code (EPC) & other compliance requirements. These capabilities can be combined with the traditional product and shipment labelling solutions to meet complex & emerging supply chain requirements for increased identification and visibility.”

Towards a healthy future Increased awareness on food safety among consumers and stringent

Commonwealth Games: Giving push to food safety With Commonwealth Games due in October this year, the government is gearing up to meet the food safety requirements during the event. Chopra observes, “Commonwealth Games is a mega event that we are going to host in the latter part of this year. Over 10,000 players and delegates will be coming to Delhi and the main dining hall in the Delhi Commonwealth Games Village will give out over 36,000 meals a day. This is an international event and the country’s image & credibility is at stake. It is our responsibility to provide all the required facilities including safe and quality food to all the guests at the event.” The menu would feature food items from all corners of the world and the same will be put through a safety check. “Food testing laboratories will have to take up the responsibilities and play an important role in ensuring continuous supply of safe and quality food. This can be possible by implementing the effective representative sampling and subsequent testing of products in the minimum possible time,” he adds.

safety procedures introduced by the regulatory authorities have resulted in the industry laying greater emphasis on the safety measures in processing, circulating and retailing. Highton says, “For any organisation, one of the requirements is to address food

Modern Food Processing | August 2010

David Highton Global Scheme Manager Food Safety, BSI Group

It is undeniable that no element of the food chain exists in isolation from another. Therefore, farm-to-fork has to be an effective food strategy. To achieve this objective, ISO 22000 standard is an ideal choice. safety across the supply chain. The British Standards Institution (BSI) is increasingly playing a supporting role for ISO 22000-based Food Safety Management Systems (FSMS) by working in partnership with the food industry to develop Publicly Available Specifications (PASs), which will add sector-specific technical requirements to enhance the ISO 22000 requirements.” According to him, many sectors within the food industry consider ISO 22000 (with supporting PASs) to be the way forward, and as a result food safety schemes are being developed around this type of combination. While changes are taking place on the regulatory front, another factor that will contribute to improving food safety standards is technology. Traceability tools, such as barcodes and RFID technology, help the retailer in tracing a product back to the producer. Tay avers, “With disruptions in the supply chain occurring daily, shipment tracking, traceability, advanced business intelligence, and easy interoperation with other software systems are critical components to safeguard products as well as companies’ bottom line, and ultimately protecting the integrity & reputation of brands.” Thus, for a healthy future, manufacturers will have to use new technology and adopt global quality standards to deal with the food safety issues.

MARKET SCOPE

New-age testing methods

Secure way to safe and healthy food The growing awareness regarding food safety is paving the way for new-age testing methods and techniques. Elaborate scrutiny by buyers and regulatory authorities alike has made it necessary for companies in food processing sector to perform in-house tests or avail of the services of external food testing laboratories for determining the quality and safety of their products. Courtesy: North Central District Health Department

Tarang Koppal

uality & safety are among the most vital consumer requirements with respect to any product, and more so, if it is a food item. Further, the stringent regulatory norms and standards to be followed by the food industry have made it imperative to perform tests on food products for ensuring quality & safety. Therefore, the role of a testing laboratory in determining these parameters is significant.

Meeting quality requirements Food quality, in essence, encompasses all characteristics of food that are desired by and acceptable to its consumer. This includes factors such as appearance, size, shape, colour, gloss, consistency, texture and flavour, among several others. It could also mean other chemical and microbial parameters, which have been defined by regulatory authorities in setting grades, standards or specifications for particular products. The Bureau of Indian Standards, for example, has laid down specifications for hundreds of food

Modern Food Processing | August 2010

products â&#x20AC;&#x201C; from salt to drinking water to even some ready-to-eat foods. Food quality checks are also performed to ascertain whether a said product is free from adulteration and contamination. In India, the Prevention of Food Adulteration Act has defined the scope of tests and desired specifications. This covers different types of food including spices, grains, oils, dairy products, sauces and many others. Food quality deals with complete product traceability, right from farm to fork, covering all aspects including raw materials, manufacturing, processing, packaging, logistics, stocking, distributing, suppling and retailing. It also involves shelf-life studies to ensure that the product retains all vital characteristics throughout its declared shelf-life tenure. Food manufacturers & producers engage the services of food testing laboratories to carry out scientific analysis on the samples to determine whether their product quality meets the set standards. Subsequently, certificates of analysis are submitted to buyers, retailers or regulatory authorities whenever the manufacturer needs to provide information about product quality.

MARKET SCOPE

Safety is paramount Considering the overall increase in the global food trade, especially among developing countries, it is not surprising that food safety is now as important as food quality. New adulterants and harmful contaminants can now be detected even when they are present in just trace quantities. As a result, stringent laws based on accurate scientific research are now being laid down to facilitate early detection of contaminants in food, and thus, prevent it from being sold or consumed. Contaminants in food can include foreign matter, pathogenic bacteria, viruses, parasites, toxins, chemical additives, pesticide residues, heavy metals, processing contaminants, etc. Trace permissible limits for all of these for various kinds of foods have been studied and international guidelines are stipulated accordingly. Several new contaminants are being identified constantly and they too are being brought into the regulatory net. Some of the advanced quality checks now include testing for the presence of and/or quantifying veterinary drugs, hormones, Polycyclic Aromatic Hydrocarbons (PAHs), Polychlorinated Biphenyls (PCBs), melamine, cyanuric acid, acrylamides, dioxins and mycotoxins. Besides, Naturally Occurring Toxins (NOTs), allergens, Genetically Modified Organisms (GMO), and unapproved food additives are other contaminants that are checked for.

source at present. Decentralised purchases, uncontrolled farming procedures, seasonal & regional variances and unpredictable availability contribute enormously to inconsistency in quality conformance.

Role of food testing labs The role of newage food testing labs has certainly extended from being just a testing facility that collects samples and submits test reports. Laboratories are now required to act as quality partners to the food industry and evolve from being a service provider to a complete solutions provider.

R R

(proteins, fats, carbohydrates, sugar and calories) Beneficial elements (vitamins, minerals, fibre and antioxidants) Dietary considerations (kosher, halal, vegetarian, etc) Medical conditions (diabetes, heart problems, arthritis, etc) Presence of allergens (dairy, peanuts, shellfish, treenuts, etc)

Challenges involved With such stringent regulatory laws and evolving buyersâ&#x20AC;&#x2122; demands, developing nations such as India are faced with an overwhelming challenge. Implementing food safety guidelines such as Hazard Analysis Critical Control Points (HACCP) and ISO 22000:2005 standards are the need of the hour to ensure safe foods. Another great hurdle lies in achieving traceability especially since not all the ingredients, raw materials, etc can themselves be traced to the

R R R R R R

Trends & interpretation of results Information about regulations Expert technical advice On-site problem-solving Audits, training and consultancies Designing total quality monitoring systems Establishing quality specifications for raw materials & finished products Regional laboratories offering at-site services Complete food quality & safety solutions

Quality assurance

R List of ingredients R Nutritional content

Quality facts Several consumers rely on information regarding quality, particularly to know some or all of the following:

Courtesy: Ballina Shire Council

Testing laboratories are expected to make available fast, accurate & reliable analysis, internationally accepted test reports; and use validated test methods & reference standards. Moreover, they are required to provide relevant laboratory certifications, state-of-theart test equipment & facilities, and technically qualified analysts. New-age laboratories should additionally be able to assist the food industry with:

Though India does not produce substandard foods, maintaining an unfailing consistency in quality and ensuring compliance to ever-encompassing regulatory norms & market demands is indeed a huge challenge. Strong government initiatives combined with active industry collaboration is the only solution to overcome it. As analytical testing in the country moves from a routine quality control role to a more pre-emptive & preventive quality assurance mode, it is only a matter of time before India becomes a global front-runner in this industry segment too. Tarang Koppal is currently the Manager â&#x20AC;&#x201C; Pan-India Operations for Marketing & Strategy at MicroChem Laboratory, considered to be a premier state-of-the-art food testing laboratory headquartered in Mumbai. Email: tarang@microchem.co.in

August 2010 | Modern Food Processing

SECTOR WATCH

Decontrolling sugar industry

Need for a balanced approach Though the sugar industry plays an important role in the national economy, the government’s control has impacted its growth in many respects. However, the government has announced that it intends to decontrol the segment soon, which has been a long-standing demand of the industry. Hence, if the measure gets implemented, the sugar segment will witness a flurry of activities like investment, expansion, etc. Prasenjit Chakraborty provides more insights… Courtesy: The United Nations World Food Programme

ndia is the largest consumer and the second-largest producer of sugar in the world. However, the sugar industry is fraught with many challenges. It is currently operating in antithesis to the economic policy of liberalisation adopted by India. So, the journey has never been smooth for the industry. Despite this, the segment is likely to perform better in the days to come.

Current scenario Sugar production in the country is expected to increase to around 18.8 million tonne in the Sugar Season (SS) 2009-10 (recovering from a low output of 14.5 million tonne in SS 200809). However, with the domestic consumption estimated at around 23.8 million tonne in SS 2009-10, the deficit is expected to be met through imports of about 4 million tonne. Sugar inventories at the end of the year are projected to touch historic lows of about 1.1 months of consumption. CRISIL Research projects sugar production in the country to rise by about 35 per cent in

Modern Food Processing | August 2010

SS 2010-11 to range between 25-26 million tonne, mainly due to an increase in sugarcane acreage and better yields. “With the domestic consumption expected to be at around 24.6 million tonne, we expect the situation in the country to be fairly balanced,” says Sridhar Chandrashekar, Head, CRISIL Research. On the back of higher than initially anticipated sugar production in SS 2009-10, average domestic sugar prices (Mumbai S-30) have declined sharply from about 36-37 per kg in February 2010 to about 26-27 per kg by June 2010, a fall of over 25 per cent. “The sugar prices have started declining because of the various emergency measures introduced by the government during 2009-10 to enhance the availability of sugar for domestic consumption and to check the price of sugar in the domestic market,” points out Vinay Kumar, Managing Director, National Federation of Co-operative Sugar Factories Ltd (NFCSF). The availability of imported sugar on zero duty with no levy obligation or stock-holding duration has led the bulk consumers, who

SECTOR WATCH

were earlier consuming 65 per cent of the national production, to opt for imported sugar. The imposition of stock-holding and turnover limits on sugar traders have also been deterring the sugar traders from bidding for indigenously produced sugar. Consequently, the sugar factories are finding it difficult to sell their released sugar, and as a result, the sugar prices have gone below the cost of production. “This is again leading to accumulation of cane price arrears,” remarks Kumar. Further, the government continues to procure levy sugar for supply through the Public Distribution System (PDS). “With sugar production now at 187.50 lakh tonne; even 16 per cent (of it) will provide 30 lakh tonne of sugar against a requirement of 25 lakh tonne for PDS. The requirement of sugar for army purchase organisation is 1 lakh tonne and for festival quota is 1.25 lakh tonne,” informs Kumar.

Call for free trade The sugar industry is blowing hot and cold over decontrol of this sensitive sector. However, the government’s recent announcement to decontrol the sugar industry has brought in cheer for people associated with the industry. Covered under Essential Commodities Act, 1955, sugar has always been subjected to various controls. Unfortunately, these controls have outlived their utility and in fact are hindering the growth of the industry. Since India has adopted a policy of liberalised economy, the continuation of controls on sugar has an adverse impact on the industry. With the government empowered to fix levy sugar prices, check the price of free sale (sugar) through monthly release of sugar, fix the cane price and so forth, the sugar prices are, most of the time, low. “As mentioned earlier, often the sugar prices go below the cost of production. However, there is no link between sugar price and cane price. Consequently, most of the time,

the factories are in arrears of cane price payment. Decontrol would free the industry from the control of releases, thereby removing price volatility and enabling sugarcane farmers to get remunerative cane price. This will also bring stability and progress in the industry,” advocates Kumar. A reasonable return on sugar will ensure a level-playing field for the sugar industry with other sectors. Besides, it will also ensure that the factories do not turn sick, hence providing ample scope to grow, expand and diversify. According to Chandrashekar, deregulation could happen on three counts: R The regulated release mechanism and levy obligation are removed R Sugarcane prices are either fully decontrolled or linked to endproduct realisations R Sugarcane areas are de-reserved “At present, we believe that only the removal of the monthly release mechanism and the obligation to sell levy sugar is likely to happen,” he adds. Decontrol on the release and levy front will give sugar mills the complete control over the quantum and timing of sugar sales in the open market. They will be able to plan and time their sales as per market conditions, and thereby, realise better market prices, which is not possible under the current system.

Sridhar Chandrashekar Head, CRISIL Research

We do not believe decontrol will reduce the volatility in sugar production. Factors such as sugarcane price arrears, relative attractiveness of sugarcane vis-à-vis other competing crops, and weather conditions would continue to impact sugarcane production. “The financially stronger mills will benefit, as they will be able to hold on to their stocks and release them during periods of higher realisations,” points out Chandrashekar. Additionally, sugar mills would realise better prices as they do not have to sell levy sugar at lower prices for distribution through PDS.

Decontrolling: The pros & cons With decontrolling, the industry is likely to see more investments in the years to come. Experts strongly point out that global capital will flow into domestic sugar industry like it is happening in Brazil. Experts believe that large money flows into any deregulated sector. For instance, the decontrolled sectors like

(million tonne)

(month)

30.0

5.5

25.0

4.5

20.0 3.5 15.0 2.5 10.0 1.5

5.0 0.0

0.5 SS 04-05

SS 05-06

Production

SS 06-07

SS 07-08

Consumption

P: Projected SS - Sugar Season (October to September)

SS 08-09

SS 09-10 P SS 10-11 P

Closing stock as months consumption

Source: NFCSF & CRISIL Research

Figure 1: Domestic sugar situation to be fairly balanced in SS 2010-11

August 2010 | Modern Food Processing

SECTOR WATCH

steel and cement are attracting huge foreign investment. Sugar industry is cyclical in nature. Deficit years see higher prices for farmers while surplus years see delayed payments. Elaborating on the benefits of decontrolling, Narendra Murukumbi, Managing Director, Shree Renuka Sugars Ltd, says, “Decontrolling would help align the payment made for sugarcane (to farmers) with the sugar prices, thereby reducing cane arrears. Sugar prices in India will be aligned to the global sugar prices. Strong linkages between sugar and sugarcane prices will help farmers and millers to share the upside.” Decontrolling will also help bring in efficient technology and increased investments into the sector. Throwing light on disadvantages of decontrolling, Murukumbi states that the government will have to buy sugar from the open market for PDS. Since irregularities cannot be ruled out while buying from open market, there has to be a standard norm for buying sugar from open market for PDS. The industry rightly demands that sugar for PDS should be sourced entirely through competitive open market tendering by the Centre. Moreover, sugar should be removed from the Essential Commodities Act. Considering the fact that households account for just 26 per cent of the

country’s consumption, with the remaining 74 per cent being bought by bulk consumers such as beverage, biscuit and sweet-meat makers, there is no need to view it as an ‘essential commodity’. No doubt, decontrol is a longstanding demand of the sugar industry, however, it alone cannot alleviate all problems of the sugar industry. Surprisingly, while the industry wants freedom to sell sugar as and when it wants, it does not seem wants that the same benefits to percolate down to cane farmers. Currently, each mill is allotted a

The sugar prices have started declining because of the various emergency measures introduced by the government during 2009-10 to enhance the availability of sugar for domestic consumption and to check the price of sugar in the domestic market.

Managing Director, Shree Renuka Sugars Ltd

Decontrolling would help align the payment made for sugarcane (to farmers) with the sugar prices, thereby reducing cane arrears. Sugar prices in India will be aligned to the global sugar prices. Strong linkages between sugar and sugarcane prices will help farmers and millers to share the upside.

Limiting factors Sugar is one of the most controlled industries in India. Attempts to decontrol the sugar sector were made in 1971-72 and again in 1978-79, only to be rolled back. Over the years, controls were eased on major industries such as steel and cement but sugar industry did not come into this foray. The Union Government dictates the portion to be released by each sugar mill for the government’s ration shops (currently 20 per cent), the price in this regard, and how much of the rest may be sold every month. A penalty is levied if a mill does not sell the given quota within the stipulated month. There are other controls on the purchase and sale of sugarcane as well.

Vinay Kumar Managing Director, National Federation of Co-operative Sugar Factories Ltd

Narendra Murukumbi

specified area, called cane reservation area, from where it can purchase cane. Chandrashekar observes, “We do not believe decontrol will reduce the volatility in sugar production. Factors such as sugarcane price arrears, relative attractiveness of sugarcane vis-à-vis other competing crops, and weather conditions would continue to impact sugarcane production.”

Technological advancements The average capacity of sugar mills in India is much lower than global standards. However, as

Modern Food Processing | August 2010

far as technology is concerned, there is not much difference, especially in the case of large mills. “Nevertheless, greater use of mechanised harvesting would help to increase sugar recovery,” exhorts Chandrashekar. In the words of Murukumbi, “There has been no major change in the milling technology.” However, the industry has witnessed considerable progress in the field of cogeneration, especially high-pressure boilers, which help in reducing fuel consumption and boosting the surplus power available. The surplus power, thus generated, can be sold that can help the mills in increasing their revenues. “When it comes to technology, NFCSF is playing an important role in technological upgradation of the sugar industry. It has technical experts, who have been engaged in making project reports for setting up new sugar factories, expansion of existing factories and setting up ethanol and cogeneration plants abroad. India is highly advanced in sugar technology. NFCSF is also keeping itself updated on all technological progress. Moreover, the Government of India is providing loans from Sugar Development Fund for research & development in sugar industry,” informs Kumar.

SECTOR WATCH

Addressing key concerns Apart from decontrolling, there are other issues plaguing the sugar industry. For instance, over the years, the government has kept increasing sugarcane prices, irrespective of the realisation earned by mills from the end-product. Consequently, sugar mills face sharp declines in profits and cash flows during periods of surplus production. Linking raw material prices to the eventual realisation earned by a mill from the sale of sugar and other by-products would be beneficial for the industry. “There are many issues troubling the sugar industry. But I strongly feel that there is an urgent need to impose custom duty on imported sugar and lift the stock-holding duration on bulk consumers, so that stalemate in sale and dispatch of sugar comes to an end,” opines Kumar. An ideal import policy should be such that it protects the interests

of both - the farmers and the consumers. If the domestic sugar price gets aligned to the global sugar price, then the demand & supply situation will regulate the import/ export of sugar. For example, in the years of deficit, India will import sugar, thus reducing the domestic sugar price. In years of surplus, India will export sugar, thus providing a base for domestic sugar in terms of global sugar prices. Kumar strongly feels that India should import only raw sugar when the domestic sugar production is not able to meet the requirement, and this import should be under Advance Licensing Scheme or under Open General Licence (OGL). “The duty structure should be calibrated in a manner so as to ensure payment of competitive cane price to the farmers vis-à-vis other crops, so that the country is self-sufficient to meet the domestic requirement of sugar,” he adds.

Taking the right step The recent developments in the industry have made the players optimistic of the future. Its morale was further boosted when the government announced its intention to decontrol the industry. “Even if there is partial deregulation of the industry in the form of removal of the release mechanism and obligation to sell through levy quota, we believe it would be a step in the right direction,” opines Chandrashekar. However, linkage between sugarcane and sugar prices is also necessary for the long-term financial health of the industry. Considering the increased area under sugarcane, the sugar production during the next two years is expected to be good. “The industry will go through consolidation and move towards being more integrated,” concludes Murukumbi.

August 2010 | Modern Food Processing

INDUSTRY INSIGHTS

Indian tea

A refreshing market The Indian tea industry has been consistently witnessing positive growth trends in terms of production, consumption and exports. Hence, it is believed that tea will continue to be the market leader among favourite beverages in the coming years. With the government and private players becoming more focussed in terms of quality, the day is not far when Indian tea will rule the global beverages arena. Courtesy: Bundy’s Shoping

Shushmul Maheshwari

ndia, known for its unique flavour and aroma tea, has emerged as the second-largest producer of tea in the world. This wonder beverage is produced for commercial and domestic purposes. With an annual turnover of around 100 billion, the Indian tea industry has seen a rise of 250 per cent in production since independence. In 2009, the production reached nearly 979 million kg. Moreover, the tea trade contributes immensely to the country’s economy. It also provides employment to a large network of tea producers, distributors, auctioneers, retailers, exporters & packers and others who are into ancillary activities, value-addition and marketing of tea.

The ‘tea-gardening’ Being one of the oldest organised industries in India, around one million acre of land is under tea cultivation, which comprises approximately 14,000 tea estates. The increased production

Modern Food Processing | August 2010

of tea is supported by favourable geographical factors for the production of high quality varieties of tea ranging from the original orthodox (leaf tea), crushed-torn-curl (CTC) to aroma and flavour tea that remains unparalleled in the world. With respect to specialty, the country produces three varieties namely, Darjeeling, Assam and Nilgiri tea. In addition, green tea and organic tea are also produced in small quantities. In the Indian domestic market, the CTC type of tea contributes over 80 per cent (approximately 780 million kg per year) of the total production. Tea is cultivated mainly in 13 states, with Assam being the major tea producer state-wise. West Bengal, Tamil Nadu, Kerala and Karnataka are the other major tea producing states, with extensive tea plantations. The regional analysis of tea plantation reveals that North India is the major producer, with the NorthEast region (almost 82 per cent of the total plantation area) accounting for 76 per cent of total tea production. While the majority of tea production can be witnessed in the big estate

INDUSTRY INSIGHTS

gardens, the contribution of small grower segment has increased over the years. Many small farmers in Assam, Northern Bengal and Bihar are shifting their attention towards tea production. Further, the industry has its plans to expand geographically to regions that share almost the similar type of soil and climate needed for producing quality tea.

It is tea time! Tea is one of the most economical among all beverages in India. The per capita consumption of tea stands at 0.8 kg, with over 85 per cent of the total households consuming tea. The taste and preference of Indians vary as per their region. For instance, dust tea is popular in the South and Central India, while good quality loose flavoured tea is preferred in Gujarat. Similarly, consumers in Maharashtra represent a big market for packet and unbranded tea as compared to the Eastern states (West Bengal and Orissa) where people give preference to CTC broken tea. The consumption of tea in India has significantly risen over the past few years, with around 840 million kg consumed domestically in 2009. The consumption growth rate has been more than three per cent for the past

Courtesy: Cebuwoman

few years due to the fact that the tea industry has remained largely insulated from the global economic meltdown. Realising that the future of tea consumption largely depends on the younger generation, the Tea Association of India (TAI) has asked the Tea Board of India and the government to allocate funds for promotional campaigns targetted at specific consumer groups. In order to boost the consumption, sustained generic promotional campaign is the need of the hour for making the consumers aware of the health benefits of tea consumption.

0.3%

1.2% 12.2%

36%

32.3% 17.9%

Assam Kerala

West Bengal

Tamil Nadu

Karnataka

Others Source: RNCOS

Figure 1: Estimated share of leading tea producing states (2009) 17% 47% 9%

Tea patronage

12%

Tea export has been an important source of foreign exchange for the country. India witnessed an inherent growth of export earnings amounting to 25 billion in 2009. Russia continued to be the largest export destination in terms of value, accounting for about 17 per cent of the total export in 2009, followed by the UK and UAE.

Fact file Tea, being indigenous to India, the country accounts for 31 per cent of the global tea production and has been sustaining its leadership position for the last 150 years.

As far as variety is concerned, the country exports CTC variety mainly to Egypt, Pakistan & the UK and the premium orthodox variety to Iraq, Iran & Russia. The main drivers for the growing exports from India include high global prices and downfall in shipments from other exporting countries. Regionally, the exports from South India are more significant than those from Northern states, as the supply from the former has enhanced to a great extent. The shipments from Tamil Nadu, Karnataka and Kerala are the highest as compared to other states. Considering the competition, Sri Lanka, Kenya, China and Indonesia are the major players in the global tea

Russia

UAE

Iran

USA

Others

Source: RNCOS

Figure 2: Major tea export destinations (2009)

industry in terms of export of green tea, CTC and orthodox tea. To counter its rivals, the Indian tea industry needs to look at more acquisitions to boost the nationâ&#x20AC;&#x2122;s overall tea output annually.

Governmentâ&#x20AC;&#x2122;s initiatives The Indian tea industry is rapidly growing on the back of government initiatives by way of a number of developmental schemes for enhancing the productivity, quality and marketing of tea produced in the country. The government has made plans to develop an umbrella brand for Indian tea. The Tea Board of India, a statutory body of the government, is endowed with the responsibility of developing the tea industry. The Board has already implemented a number of developmental schemes to raise production, improve quality and adopt marketing strategies. Besides, it has given emphasis to the production of quality tea varieties, especially orthodox tea. Many media campaigns have been initiated to create awareness among

August 2010 | Modern Food Processing

INDUSTRY INSIGHTS

Courtesy: Mercy Corps

consumers about Indian tea. These campaigns have extended promotional support for Indian exporters to market their brands in major exporting destinations. The government has also taken some measures to address the problems of small tea growers. These measures include fixation of a price sharing formula between the manufacturers and small tea growers to help the small growers receive a reasonable share of the price. The government has implemented a price subsidy scheme and developed a ‘special tea term loan’ package to deal with the problems of small tea growers. The Tea Board has also taken the same route by implementing a scheme for product diversification and quality upgradation aimed at the modernisation of tea factories. In a recent move to yield more dividends for the exporting community, the government has decided to come up with a new logo for the Indian tea brand that will not only reflect the rich heritage of Indian tea, but will also present quality parameters attached to it. Another new development in the industry is electronic auction (eauction). It implements the latest technology in tea trading in India, thereby, enhancing the means of tea trading. E-auctions have not only enabled ‘sharing of lots’ for the first time in the country, but have also facilitated the setting up of a ‘minimum price’ option. Further, it

has given the advantage of buyer anonymity, which was not possible earlier in manual auctions.

Industry shortfalls Although the tea industry has been witnessing noteworthy growth for the last few years, some roadblocks still exist that may hamper its smooth movement. These constraints can have a direct impact on the production

The market for premium tea varieties will emerge, as people from elite classes have started preferring tea compared to aerated drinks due to health concerns. and quality. For instance, old age of bushes, with more than 30 per cent of the tea area being above the economic threshold age limit, is a serious threat to the Indian tea industry. Further, the slow pace of replantation at the rate of less than 0.5 per cent against the desired level of 2 per cent is a major concern for the tea industry in India. The industry has also been affected by the consistent fall in auction price, which has an adverse effect on the investment in the plantations. In addition, increasing input costs and productivity downfall are responsible for closure of many gardens. Poor management practices

Modern Food Processing | August 2010

have been one of the major concerns for the industry. Although the country earns well from tea exports, it accounts for less than 20 per cent of the total domestic production due to the large local market. The country’s exports have also suffered in recent years owing to the imposition of various tariff and non-tariff measures by some tea importing countries. Lower off-take by Russia in view of changing consumer preferences and lower production of orthodox tea (which has a huge demand worldwide) have hit the tea export badly. India has to deal with higher production costs and prices to increase the export of tea. Besides, there are quality issues like lack of standardisation, poor packaging, pesticide and Maximum Residue Level (MRL) problems that have negatively affected India’s tea export. To address the aforementioned issues, the following corrective measures have been identified, which if implemented, can potentially improve the overall industry outlook: R Effective promotion of tea brands for global recognition can lead to increase in the tea trade R Acquisitions of small tea gardens by big players can solve the problems of lack of replantation due to cost issues R To make Indian tea globally competitive, the Indian government should reduce tariff rates R Production of tea as per the demand in terms of variety should be taken care of

Courtesy: SustainabiliTEA

INDUSTRY INSIGHTS

The country should target untapped export markets such as Latin American, African countries, etc R Per hectare cultivation should be enhanced by providing advanced technological assistance to the tea growers The annual demand for tea is rising at a rate of 3.5 per cent, which causes the shortfall of tea supply. Therefore, more production of premium varieties of tea should be encouraged. To substantiate the shortfall, in early 2010 the government has announced the establishment of a Special Purpose Tea Fund (STPF) for large scale replanting or rejuvenation of tea bushes across about 2,12,000 hectare in ‘uneconomic tea areas’. The government will share the cost for nurturing the tea estates.

Market outlook The Indian tea industry is anticipated to grow vibrantly in the next few years. It is projected that the tea production will reach around 1.2 billion kg by 2013. The rural areas will emerge as new markets for the tea industry. The expansion of distribution networks to rural areas will increase the sales of tea since the urban market for products like tea is almost saturated. Other measures that will help increase sales in rural areas include offering trial packs at low price points, promoting different varieties of tea through village fairs, and targetting the women folk, among others. Further, several other factors like rising population, greater urbanisation, increase in income and better living standards will facilitate a massive increase in the domestic consumption. The market for premium tea varieties will emerge, as people from elite classes have started preferring tea compared to aerated drinks due to health concerns. In addition, the growing awareness regarding health issues among Indians will urge tea producers to come up with healthy solutions. Consequently, companies will be offering functional teas that contain ‘ayurvedic’ ingredients. Moreover, the changing tastes of Indians will also see a growing demand for flavoured tea and iced tea. Hence, tea will continue to remain an all-time favourite beverage in India for the times to come. This will enable India to sustain its leadership position in terms of production, consumption and export of tea. Shushmul Maheshwari is the Chief Executive of RNCOS E-Services Pvt ltd, a market research & information analysis company with global presence. He has spent more than 15 years working in the senior management teams of both Indian and multinational companies. He has gained expertise in research & analysis field and actively participated in various national and international conferences and discussions organised by business and trade-related associations. Email: shushmul@rncos.com

August 2010 | Modern Food Processing

FOOD SAFETY

Oil & fat processing

Under the protection filter India is one of the leading consumers of edible oil in the world. However, there are health concerns associated with oils & fats. Hence, it has become mandatory for vegetable oil manufacturing companies to strictly adhere to regulatory norms and standards established by health organisations to prevent contamination and keep adulteration in check. Courtesy: CondĂŠ Nast Digital

Subhash Vaidya

ils & fats are considered to be essential nutrients for human diet as they provide a source of energy and consist of fat-soluble vitamins. The major sources of fat in diet include meat, dairy products, nuts and vegetables. Fruits contain only a small amount of fat. Primary animal sources of fat comprise red meat, poultry, fish, milk & milk products and eggs. The vegetable sources of fat include oil from soyabean, cottonseed, canola, olive, sunflower, mustard, corn, groundnut, etc. Palm and soyabean oil account for almost 50 per cent of the total oil consumption. Fats consist of a wide range of compounds that are soluble in organic solvents and insoluble in water. They have lower densities than water. Oil usually refers to fat that is liquid at room temperature, while fats are solid at room temperature. Lipids include both liquid and solid fats.

Vegetable oil industry The production of oil involves various processes. Some of the general activities performed in the vegetable oil industry are as follows: Extraction: Oil is extracted from seeds, nuts, grains, beans and fruits. The raw

Modern Food Processing | August 2010

materials are subjected to vigorous inspection for meeting the quality norms laid down by the company. It is stored in appropriate conditions and the storage requirement varies according to the type of raw materials. Moreover, the raw materials undergo processes that include cleaning, drying, crushing, conditioning and pressing. During the processing, environmental, health and safety issues such as those pertaining to emissions and solid waste are carefully monitored. Oil extraction can be performed by boiling fruits, pressing seeds and nuts or in combination. The extraction is normally followed by skimming or filtration and separation of crude oil from the solvent oil mixture. Hexane (a hazardous gas) is removed from the oil by distillation. The recovery processes for flakes that are intended for animal feed typically use conventional distillation to remove additional residual hexane from flakes, but result in more emissions than the conventional process. Refinement: The crude oil is refined to remove undesirable impurities like gum, free fatty acid, trace metal, colouring components, etc. Chemical refining results in a better product, in terms of lower free fatty acid level, longer shelf-life and more authentic process. Hydrogenation: The process of hydrogenation adds hydrogen atoms to

FOOD SAFETY

unsaturated fats. To improve their oxidative stability and increase their melting point, vegetable oils are subjected to hydrogenation. Most companies carry out hydrogenation to produce fats with superior retention qualities and higher melting points. The resultant hydrogenated fats are filtered to remove the catalyst and deodorised before they can be used for edible purposes. Deodorisation: During deodorisation, the bleached oil is steam distilled at low pressure to remove volatile impurities, including undesirable odours and flavours. The vapours from deodorisation process contain air, water vapour, fatty acids and other variables. Fatty acids and volatile matters partly condense on the scrubbing droplets or alternatively on the packing material. Thus, the fully refined edible oils and fats are produced.

Food safety application in the industry There are various guidelines pertaining to Safety, Health and Environment (SHE) issues developed by bodies such as the Codex, World Health Organization (WHO) and Food & Drug Administration (FDA) for the vegetable oil processing industry. The major

Courtesy: Testo

areas of concern associated with the operational stages of the oil processing industry include: Solid waste and by-products: Significant quantities of organic solid waste such as empty fruit bunches, waste palm kernels and other forms of waste get generated during

Extraction of oil from palm fruit Palm fruit is processed to produce crude fruit oil and palm kernel oil. Palm fruit oil is extracted from pulp and palm kernel oil from the seed. The heat sterilises the fruit to prevent bacterial enzymatic activity from attacking the oil. The total time taken for sterilisation depends upon the size of the maturity of fruit. After sterilisation, the fruits are removed from the stem and then washed before being transported to a twin-screw press, which squeezes palm fruit oil. The extracted palm fruit oil is clarified in a decanter or settling tank to remove water and soil matter. The kernels are then cracked and the meat is separated from the shell, by mixing the kernel into aqueous slurry of clay or salt, so that the kernel floats and shell sinks. Heavier shells pass out from the bottom and the lighter meat floats on top. The meats are then dried and sent for storage before being pressed in screw presses to produce palm kernel oil.

vegetable oil manufacturing process. Other solid wastes include soap stock and spent acid from chemical refining of crude oil. The amount of waste depends upon the type of raw material. It is essential to dispose of contaminated sludge through wastewater treatment at a sanitary landfill or by incineration. Incineration should be conducted in permissible facilities as per the specified standards. The nickel catalyst used in the hydrogenation process should be either recycled or recovered for reuse. It is also vital to collect residues right

from the raw material processing phase and reprocess them to yield byproducts such as animal feed, soaps and other useful items. Wastewater treatment: Techniques like the grease traps, skimmers or oil water separators (for removal of floatable solids), and flow & load equalisation & sedimentation (for suspended solids) need to be employed for wastewater treatment. Emissions: Dust and volatile organic matter constitute the principlal emissions from vegetable oil processing. Dust results from the processing of raw materials, including cleaning, screening and crashing of volatile organic compounds. Emissions are caused during oil extraction due to the use of solvents, normally hexane. Solvent emissions arise from several sources within the vegetable oil processing plant including the solvent recovery unit. Therefore, it is necessary to ensure proper maintenance of cleaning, screening and crushing equipment, including any ventilation and air handling system, to reduce emissions of fugitive dust. Material handling and transportation: Vegetable oil processing involves the transport, storage and use of bulk quantities of acid, alkali, solvent and hydrogen during extraction and refining. The transport, storage and handling procedures that are followed may lead to spills or other type of releases, with potentially negative impact on soil and water resources. Hence, care needs to be taken while undertaking such activities to prevent any untoward incident.

Occupational health & safety There are many occupational health & safety hazards involved in vegetable oil processing. These include: Chemical hazards: Vegetable oil processing activities may present a risk of inhalation of hazardous chemicals or explosions resulting from volatilisation of solvent dissolved in oil (ie hexane).

August 2010 | Modern Food Processing

FOOD SAFETY

It is, therefore, necessary to give adequate training to employees in chemical handling. Temporary workers should also be trained before they work with chemicals. In oil extraction areas, it must be ensured that there is adequate air circulation to reduce the concentration of solvents. Leaks and spills of oil must be prevented in the extraction plant, the flash point temperature of extracted oil must be controlled and temperature control maintained by all facilities receiving solvent extracted oils. It is also necessary to monitor the levels of pesticides, fertilisers and other chemicals used. Physical hazards: The physical hazards in a vegetable oil processing unit are similar to those in other food industry sectors that include dust, insects, metal parts, etc. Hence, proper prevention measures need to be adhered to.

Public health and safety With product safety programme in place, a company can protect itself against product adulteration contamination and impact of product recall. Vegetable oil processing should implement food safety standard in accordance with principle of Hazard

Courtesy: Chewing The Flaxfat

Analysis Critical Control Point (HACCP). The proper and complete adoption of HACCP prerequisites include good manufacturing practices, chemical control, customer compliance, etc. If a company can trace its products back to specific lot number, then the recall is a matter of removing all products associated with that number. Food safety and hygiene is important for any food industry. Hence, it is mandatory to follow good house-keeping & manufacturing practices and high-quality hygiene measures. Some of the ways to go about it efficiently are as follows:

Food safety and hygiene is important for any food industry. Hence, it is mandatory to follow good house-keeping & manufacturing practices and high-quality hygiene measures. Pest control: Godowns, factory premises, storage areas are prone to different kinds of pests that could contaminate or destroy raw materials, in-process goods and finished products as well. Various chemicals and technologies such as insecticutors, air curtains and PVC curtains are available today to eliminate the pests. Employee hygiene: It contributes immensely to food safety. Employees need to wear uniforms, caps and other accessories that would ensure food safety. Food manufacturing companies must ensure that all the employees are regularly screened for communicable diseases. Storage of raw materials and finished goods: This requires regular monitoring. Raw materials should always be kept on plastic pallets and away from walls. Those which require lower temperature should be stored in cold room.

Modern Food Processing | August 2010

Drainage systems: Good drainage systems have to be designed for ensuring the smooth flow of wastewater to the collection pit. Effluent and sewage treatment plant must be installed as per requirement. Metal detection: Magnets should be installed wherever required to detect metal particles in raw materials or finished products. Water quality: Water used in the plant, whether directly or indirectly, has to be checked for purity and potability. Filters are to be used and these should be checked at regular intervals. Cleaning of utensils and equipment: All utensils and equipment used in the plant must be cleaned at regular intervals, as required, and sanitised to maintain hygiene. Building design and maintenance: It needs to be ensured that the walls of the plant are crack proof and floors are tiled with proper slope to drain water. The design of the building has to be such that it will prevent pest infestation. The lighting outside should be such that it does not attract insects in the factory premises.

Conclusion There is a health risk associated with trans-fat, which can be found in partially hydrogenated vegetable oils (vanaspati), stick margarine, cookies, etc. It poses health hazards such as heart diseases, cancer, diabetes, allergy, etc. Therefore, there are regulations suggested by the WHO that would maintain its quality for human consumption. Edible oil industry is regulated under different standards. If one follows these guidelines, the product will be deemed safe for human consumption. Subhash Vaidya is a Senior Consultant for food, HACCP & ISO 22000 food safety management system. He is also a Consultant for the dairy industry. Email: dairytech@rediffmail.com

MARKET TRENDS

Packaged Goods

Preserving the freshness With people getting more health-conscious than ever, the packaged food industry is undergoing a sea change. The consumers have become cautious about what they eat and the way food is handled before reaching them. This has resulted in new trends influencing the food market, be it developing new flavours or launching new products or the way food is packaged. Courtesy: BASF

rom ingredients to packaging, there seems to be a sustained movement towards healthier and ‘greener’ products. Multiple trends can be currently witnessed in the packaged goods segment, according to Datamonitor’s Product Launch Analytics. For instance, it is predicted that 2010 will be a banner year for products sporting the ‘free range’ label, as a growing number of food companies will be hailing humanely raised protein products. The year is also expected to witness a new generation of biodegradable plastics that may succeed in greening the image of plastic water bottles. Among the leading emerging trends expected in the near future are new generation superfruits like ‘baobab’ and ‘borojo’, growth in the use of sustainable ingredients like bamboo, and a renewed ‘back to basics’ approach when it comes to product ingredients.

Modern Food Processing | August 2010

A more humane world Animal rights have emerged as a growing worldwide concern as consumers want to know more about how meat and meatbased food is prepared, particularly how the poultry & livestock are reared. For example, the ‘free range’ product claim commonly used to identify how poultry is raised has nearly doubled in 350 300 250 SKUs

Tom Vierhile

200 150 100 50 0

2005

2006

2007 Year

2008

2009

Source: Datamonitor’s Product Launch Analytics

Figure 1: Products worldwide claiming to be ‘free range’ or use ‘free range’ ingredients

MARKET TRENDS

frequency for new food products launched worldwide since 2006. This trend is believed to accelerate in 2010 as food service chains follow the trail blazed by leading-edge consumer packaged goods (CPG) companies in the area of humanely raised products. 200 180 160 140

SKUs

120 100 80 60 40 20 0

2005

2006

2007 Year

2008

Moreover, ‘free range’ products are expected to gravitate into other new consumer packaged goods markets. For instance, a trio of recent pet product launches in North America has highlighted the opportunity for ‘free range’ pet food. The dog food Nature’s Variety Bison Formula Raw Frozen Diet for dogs is formulated with grassfed, free-range bison. Whiskas All Natural Temptations Treats for cats are now offered in a ‘free range’ chicken flavour in Canada, while Castor & Pollux Pet Works offers many products featuring ‘free range’ ingredients including Chicken Flavour Organic Dog Jerky made with organic ‘free range’ chicken.

2009

Source: Datamonitor’s Product Launch Analytics

Figure 2: ‘Shot’ products released in the US 30 25 SKUs

20 15 10 5 0

2007

2008 Year

2009

Superfruits in this table include baobab, maqui, borojo and yumberry Source: Datamonitor’s Product Launch Analytics

Figure 3: New food and beverage products in the US containing ‘superfruits’ in the ingredients

Percent of ‘new’ food products

12.0% 10.0% 8.0% 6.0% 4.0% 2.0% 0.0%

2005

2006

2007 Year

2008

2009

Source: Datamonitor’s Product Launch Analytics

Figure 4: Percentage of new food products (excluding beverages) launched in the US that make ‘gluten-free’ or ‘no gluten’ claims

Meat: The new boss Meat is definitely all set to be the ‘new boss’ in 2010. Meat’s growing popularity on the flavour front helps to explain part of what is going on. In the US, bacon has climbed over 20 positions in the food flavour charts during the last four years, according to the Product Launch Analytics. This rise helps explain some of the bizarre product launches over the past few months including meat-flavoured lollipops (Das Lolli Man Bait), potato chips (Mackie’s Scotland Haggis and Cracked Black Pepper Potato Chips), chocolate candy (Mo’s Dark Bacon Bar) and even vodka (Bakon Premium Bacon Flavoured Vodka). In addition, the innovative launches continue way into mid 2010, with a pair of US-based introductions. J&D’s Bacon Pop – bacon flavoured microwave popcorn – is considered to be a delight for bacon lovers, while at the same time make claim of being ‘safe for vegans

and vegetarians’. In a similar realm, Boom Magic! Microwave Wheat Snack is a wheat pellet-based snack offered in myriad flavours including a pellets bacon flavour that looks like a slice of bacon. Given these developments, can meat-flavoured ice cream, yogurt or fruit juice be far behind?

Degradable plastics One of the great attributes of plastics is that it lasts – for what seems like forever. But that is also one of its greatest drawbacks. Plastic that is not recycled often ends up in landfills where it can remain for centuries. But this situation is changing now. New types of degradable packaging enable plastics to biodegrade in years, not centuries. The key is additives like EcoPure or Reverte that help plastics to biodegrade more quickly and safely than it would otherwise. The bottled water market has been ground zero for this trend with the launch of products like Aquamantra Natural Spring Water and State of Mind Bottled Water in biodegradable bottles. The Coca-Cola Company is giving the movement some momentum with its new PlantBottle packaging that is being used for the company’s Dasani bottled water and Coca-Cola soft drink brands. The bottle is said to be made using an innovative process that turns sugarcane and molasses into PET plastics. Due to the use of these ingredients, the PlantBottle contains up to 30 per cent plant-based material that replaces non-renewable petroleum or fossil-based resources. Other firms are looking towards older packaging technologies to bring environmental benefits. The US-based Boxed Water Is Better sells its branded water in gabled milk-style cartons, noting that 76 per cent of each carton is made from a renewable resource – trees. Such a trend is likely to speed up in 2010 and move beyond the bottled water market to other categories.

August 2010 | Modern Food Processing

MARKET TRENDS

More muscular functional drinks A decade ago, a brand called Red Bull took the soft drink market by storm, creating a new niche for energy drinks. One would wonder whether history is about to repeat itself with a drinks brand called Muscle Milk. The protein-enhanced exercise recovery drink brand from Cytosport has attracted a following that suggests significant crossover potential for socalled ‘muscle beverages’ that have long been aimed at weightlifters and power athletes. Muscle Milk and similar healthy and active lifestyle beverages could be the next hot niche within the functional drinks market. Already, ready-to-drink liquid protein supplements are making a big splash in the market. Sales of these products grew 28 per cent between 2008 and 2009 in the US, according to Consumer Reports magazine. Factors contributing to the growth of protein supplement drinks include the perceived health risks as well as growing environmental concerns associated with meat consumption.

Trends to watch for in packaged foods in 2010 R Free range products that give

priority to how food is prepared, with a thrust on humanely raised products R

Meat and meat-flavoured items to become the new boss

The trend of use of degradable plastics to go beyond bottled water industry

Muscular functional drinks to rule the market

Exotic superfruits antioxidants

Focus on fewer ingredients

New relaxation ‘shots’ that offer a non-alcoholic way to reduce stress

Products that are gluten-free

with

high

Regarding the latter, the United Nations Food and Agriculture Organization found that the rearing of livestock generates more greenhouse gas emissions than the entire transportation sector (18 per cent versus 13 per cent) on a worldwide basis. Then again, safety issues could also be a problem for liquid protein supplements as recent testing by Consumer Reports magazine found measurable amounts of heavy metals including arsenic, cadmium, lead and mercury in tested protein supplements – an issue that could derail the market’s recent growth spurt.

With ‘natural’ and ‘organic’ product claims displaying growth patterns, the conundrum for packaged food and drinks companies lies in surviving the competition & focussing on the ingredients. Superfruits get more exotic The exploration through rain forests, jungles and the wilds of South America, Southeast Asia and Africa in the eternal quest to find exotic superfruits by certain enthusiasts has led to the discovery of fruits like: R Baobab: A tart African fruit high in antioxidants R Borojo: A natural energiser from the jungles of South and Central America R Maqui: A berry native to South America said to have eight times the antioxidants of blueberries R Yumberry: Technically ‘yang-mi’

Modern Food Processing | August 2010

Courtesy: Givaudan

fruit – a super-high antioxidant tree fruit from China R Coffee fruit: Coffee beans are actually the seeds of coffee fruit and the fruit itself has high Oxygen Radical Absorbance Capacity (ORAC) value Baobab may be one of the more intriguing new superfruits on the horizon, with the fruit used in preparing a variant of yogurt and a cola soft drink (Pepsi Baobab Cola Drink in Japan) through the first half of 2010.

Ingredients: The fewer, the better With ‘natural’ and ‘organic’ product claims displaying growth patterns, the conundrum for packaged food and drinks companies lies in surviving the competition & focussing on the ingredients. The new technique is to bring down the number of ingredients used to make a product. The ingredients that sound more at home in a chemistry lab is ignored and ingredients that majority of consumers recognise take up their place. Haagen-Dazs’ 5 Ice Cream illustrates the trend with just five ingredients for each ice cream flavour. Several other packaged food and drinks makers are expected to follow suit in terms of cutting down on product ingredient lists in 2010 and beyond.

MARKET TRENDS

Shots aim for success While the shot format has been around for some time in various world markets for dairy-based drinks, the format has exploded in popularity in several other markets. Almost single-handedly, shots have elevated the energy drink market to new heights. The latest ‘shot’ trend is the polar opposite of energy drinks – new relaxation ‘shots’ that offer a non-alcoholic way to reduce stress. Examples include Koma Unwind Chillaxation Shot and Tranquila Relaxation Shot. Overall, the number of new products featuring the words ‘shot’ or ‘shots’ has doubled since 2006, as per reports.

A gluten-free world Given the experience of food fads from the past such as low-carbohydrate foods that declined in popularity in no time, one is always reluctant to anoint the next famous ‘free from’

food trend. But one needs to give credit to the gluten-free movement, as it continues to strengthen each year. With the incidence of food-related allergies on the rise, things look good for sufferers of celiac disease, who are seeking products they can enjoy. Datamonitor’s Product Launch Analytics reports a doubling of new gluten-free products since 2005 with major consumer packaged goods companies now jumping on the bandwagon. How long this can go on is anyone’s guess. In the US, a whopping 15.6 per cent of new food launches (excluding beverages) in 2010 have made ‘gluten-free’ product claims, which is up from 6.4 per cent of products making similar claims in 2007. These numbers would appear to be unsustainable for a malady estimated to affect less than 1 per cent of the American population. A lot of consumers who do not have

celiac disease have gravitated towards these products, though some of that behaviour may be based on a misconception. A January 2010 Harris Poll found that 43 per cent of adults in the US, who were surveyed, incorrectly identified gluten as a food allergen, indicating confusion over food sensitivities (like gluten) and food allergens to the extent that consumers may believe that gluten can trigger a deadly allergic-type reaction. The movement to gluten-free products could be vulnerable once the risks are better understood. Tom Vierhile is the Director – Product Launch Analytics at Datamonitor. He is an internationally recognised expert on new product marketing and has authoured many articles on new products for a variety of trade publications. For details, contact Alan Sott on email: asott@datamonitor.com

August 2010 | Modern Food Processing

TECH TRACK Automation

Modernisation of rice milling

A necessity for future The growing demand for rice has shifted the attention of producers towards rice processing operations, which hold the key for optimising yield. Automation is the way forward for upgrading the milling process, and thereby leveraging the benefits in terms of improved quality & productivity, and cost & energy savings. Courtesy: Buhler India

ice is the staple food of one-third of the world’s population. It is gaining more popularity in the West, as it is considered to be healthy, comprising most of the vital nutrients. Rice is usually grown in the wet regions of the tropics and the major rice producing countries include China, India, Indonesia, Thailand and Vietnam. China (193 million metric tonne) and India (130 million tonne) alone account for half of the total global crop production of 630 million tonne of paddy per annum. Outside Asia, rice is produced in Po Valley in Italy, Louisiana, the Carolinas, and California in the US. The worldwide acceptance of rice has led to an increase in its demand but the climatic and geographic requirements hinder certain countries from cultivating rice. This coupled with the rising population has been compelling the producers worldwide to look at ways by which the demand for rice can be met. One option would be to look at new agricultural fields for cultivation, and another would be to optimise the yield from the existing produce by focussing on rice processing. The rice miller’s motto should be ‘Remove as little as

Modern Food Processing | August 2010

possible and as much as necessary from the rice grains’.

Conventional rice milling process Before the rice grains are fit for consumption, they undergo numerous processes. Rice processing (drying, cleaning, hulling, whitening) is predominantly an agricultural activity. Paddy rice is cleaned, husked and graded. Then the clean but brown rice grains are milled until they are white (whitening process). These white grains are further polished either superficially or until they are glossy, as per the customer preference. Rice loses around 30 per cent of its weight after undergoing these processes. Prior to packing, broken rice grains are eliminated by an optical sorting operation – in this process the discoloured grains too are removed. This further reduces the yield. The yield is primarily determined during the whitening and polishing process operations. Hence, the whiteners and polishers form the core of a rice processing facility. The quality of these operations depends on the technical quality and the stability of the machines & the fine-tuning of the process. Customers using modern processes from highly reputed companies can gain handsome returns on

Automation TECH TRACK

their investment vis-à-vis the customers who invest in local machines for the initial cost benefit.

mill with frequency drives & soft starters would require approximately 25-30 units only depending upon the configuration of the machines.

Customised milling solution Though rice is a popular food in all Asian countries, preferences do differ widely. Long grain rice is preferred in India and Thailand, whereas round, medium along with long grain rice are the main varieties consumed in China, depending on the region. The Japanese use round grain rice. The difference in preferences calls for corresponding variations in the design of rice processing plants. Depending on the varieties consumed and exported, the rice processing plants require customisation. Till date, there is no such thing as an efficient and welldesigned ‘off-the-shelf’ rice processing system. This precisely is the reason why established machinery providers believe in customisation in design and construction of plants. More so established largescale mills prefer to entrust turnkey projects to reputed manufacturers rather than buying part machines to have a plant, which is efficient and trouble-free.

Non-automated machines: Higher production costs Non-automated mills have various limitations in reaching optimum capacity. The per tonne operating cost is high due to higher power consumption per tonne of production. The use of centrifugal fans results in increase in power consumption. The total connected motor rating for the centrifugal fans in a mill is almost equal to the connected motor rating of main processing machines. The deployment of frequency drives instead of normal starters for centrifugal fans, use of soft starters for main processing machines (like whiteners & polishers) can enable considerable power savings. Generally, a non-automated mill requires approximately 35-40 units of electric power per tonne of paddy processed. However, an automated

Automation: Success mantra for rice millers A number of factors need to be observed while building a new rice mill. Any new facility should be built in proximity to the rice growing areas and the workforce should be available locally. The tax structure, infrastructure (power supply, communication & transportation) and the stability of the local government and its policies too are vital in deciding the location.

Advantage modernisation The milling cost of rice reduces significantly as a result of efficient milling through the usage of modern machinery on two accounts: R Reduction in milling cost R Increased production of head rice

As per industry experts, the miller can gain about 6 per cent additional gross revenue through modernisation. This would not only justify the investment on modern machinery, but would also lead to relationship building measures with the suppliers of paddy (farmers/brokers) to reduce the risk of supply. Farmers can also gain a share of the benefits of the modernisation drive adopted by the millers in the long run. This would be reflected in remunerative farmgate prices of paddy.

Most importantly, the success of a plant depends on the machinery and processes deployed. Automation is a logical step to address the growing demand for good quality rice. Better machines and automation bring in higher efficiency and yield to the rice milling process. State-of-the-art rice processing systems are typically fully automated and optimally adapted to meet the customers’ needs, right from start-up.

Better utilisation of manpower An automated rice mill of 5 to 10 tonne per hour (TPH) capacity paddy input would require only two persons (an operator & helper) to run the mill, excluding the manpower required for paddy intake and bagging the finished products. Automated plants take care of bin filling, avoid overload of machines/conveying elements by controlling the product flow through level switches in bins/hoppers and sensors in conveying elements. The control system handles the automatic start & stop of sections, depending on the product levels, so that all sections are optimally utilised – no section is idle for want of product. This enhances the plant utilisation to optimum capacity. The operator can concentrate on the machine setting and monitor & control the quality of the product at different stages. But a non-automated mill requires more manpower to monitor the product flow into the bins. The operators manually check the bin filling to avoid material overflow as well as to prevent sections being run empty. It is impossible to reach the optimum capacity of the mill, even with more number of mill operators due to human limitations. Hence, the adoption of automation is critical to improve rice processing and gain better yields. By increasing the level of automation and energy balance, rice millers will be able to increase productivity, while reducing costs, manpower, power usage and wastage. Courtesy: Buhler India Buhler, one of the leading global leaders in food processing industry, offers latest automation solutions for rice millers. In addition to equipment automation, it has made considerable advancements in making of ‘smart machines and systems’. For details, contact Sujit Pande (Marketing Manager, Buhler India Pvt Ltd) on email: sujit.pande@buhlergroup.com

August 2010 | Modern Food Processing

CASE STUDY Packaging

Dry aseptic technology

A solution for bottling complexities With an aim to upsize the capacity of its plant, the fruit juice company, Agrozumos, adopted the latest state-of-the-art technologies from Krones. For its bottling line, the company opted for Krones’ dry aseptics technology in the shape of the PET-Asept-D featuring gaseous hydrogen peroxide (H 2 O 2 ). Additionally, for ensuring efficient warehousing operations, it adopted a fully automated high-bay warehouse.

Hans-Peter Schiessl

s the first vendor to offer fruit juices in soft packages, Agrozumos, a Spanish subsidiary of the German Riha Group, had revolutionised the Spanish fruit juice market. Located in Lekunberri in the north of Spain, the company was founded in 1981 as a bottler of juices and squashes. In 1994, the German Riha Group took over Agrozumos, with the aim of enabling international retailing chains to sell their house brands all over Europe. Today, Agrozumos exports its wares to several EU nations, and produces approximately 250 million units of soft drinks a year, most of them with a juice content. They are aseptically and non-aseptically filled in soft packages, glass and PET, on six softpackage lines, one glass line, a PET line, and the new PET-Asept-D line. “Soft packages still account for the highest proportion. But PET is most definitely gaining ground. In 2010, our PET sales will equal cartons, while glass will continue to decline,” states Christian Theis, Managing Director - German Operations, Agrozumos.

Modern Food Processing | August 2010

Selling house brands all over Europe Agrozumos’ main business is with dealer’s brands for Europe’s major food retailing conglomerates. And since Lekunberri is located near France, the company serves not only the Iberian peninsula, but also the south of France. The second major line of business is copacking for prestigious brand-name companies, such as Granini. An agreement concluded in 2008 between Riha and Eckes-Granini for contract filling of Granini-brand products in PET for Spain and Portugal formed the basis for deciding to install an aseptic PET bottling line. Promptly, negotiations were initiated with possible system vendors early in 2008. Riha was convinced of the capabilities of Krones after installing six PET bottling lines at its facilities in Germany. These also included aseptic lines, though they were wet-aseptic ones featuring peracetic acid disinfection.

Wastewater at the limit For the facility in Spain, limiting the wastewater was out of question because, as a direct discharger with its own wastewater treatment

Packaging CASE STUDY

plant, Agrozumos is permitted only a limited discharge volume for its effluent. “We would in fact just about have managed to cope with a wetaseptic line, but then we would have closed the door on any future capacity upsizing,” explains Theis. Wet-aseptics requires fresh water for rinsing the bottles, which has to be discharged as effluent. However, with dry-aseptics, no effluent is produced. This tipped the scales. “Krones submitted a persuasive quotation, especially with the completepackage solution, including both, the new PET-Asept-D line and the fully automated high-bay warehouse,” he comments. This was the first time that Agrozumos had opted for the ‘dry process’ using solely gaseous H2O2, whereas in the German facilities of Riha, two dry processes featuring condensed H2O2 were already being employed. “One of our paramount criteria was that Krones guaranteed a residual peroxide content of less than 0.5 milligram per litre. That is a significantly better result than what is derived with other dry-aseptic systems.” As a part of its preparations for this new technology, Agrozumos sent the operators to Krones Academy for an introductory course in aseptics.

The market gets what it wants The line is used to run two 0.33-litre sizes at a speed of 25,000 containers an hour, two 1-litre sizes and one

1.5-litre size at 18,000 containers an hour, which have been validated since mid-2009. The products comprise juices and squashes, which most definitely demand aseptic filling when an alternative to hot filling is sought. “Dealer’s brands are cost-sensitive. The energy and the container costs are significantly higher when one undertakes hot-fill PET. Above all, the quality requirements would not have permitted hot filling. Almost all the brand-name companies in Spain are meanwhile running PET-aseptics, while for the dealer’s brands, this is just starting to take off. The market wants it, and so the market gets it,” avers Theis.

Wet-aseptics requires fresh water for rinsing the bottles, which has to be discharged as effluent. However, with dry-aseptics, no effluent is produced. In Germany, too, Riha indubitably played a pioneering role in the market launch of aseptically bottled dealer’s brands in PET, gaining plenty of valuable experience. “We are now represented with PET in Spain as well, in a segment where significantly fewer vendors are vying for the marketshare than is the case for carton packages,” he adds.

Krones guaranteed a residual peroxide content of less than 0.5 milligram per litre - a significantly better result than what is obtained with other dry-aseptic systems

Aesthetically appealing sleeve labels The line has been installed in a newly built, appealingly light and spacious hall. The Contiform S 14 blow-moulding machine is not BLOC-synchronised with the filler, but positioned several metres away and linked to it by air conveyors. It produces both - multilayer and monolayer containers. Directly behind the Aseptic-D monobloc, comprising a steriliser, filler and capper, are the entire requisite peripherals with the process technology, some of which Riha configured. Here, Krones supplied the sterile-water UHT system, the Cleaning in Place (CIP) system and the hygiene centre. “When it comes to continuous running times, we are achieving the contractually agreed 72 hours,” asserts Theis. Further down the line, Agrozumos has an option for dressing the filled containers either in paper or film wraparound labels on a Prontomodule with one labelling station. The other option is using half- and full-sleeve labels on a downstream Sleevematic inline linear machine with a steam tunnel. “Spain is an innovative country when it comes to packaging. The demand for aesthetically appealing sleeve labels is huge, in fact they are almost a standard,” explains Theis. To coincide with installation of the aseptic line, Agrozumos also built a new high-bay warehouse, with external dimensions of 76 metre in length, 37 metre in width and 29 metre in height.

The Contiform S 14 produces both multilayer and monolayer containers

August 2010 | Modern Food Processing

CASE STUDY Packaging

It was designed as a two-deep fork-lift warehouse with five automatic storage and retrieval units.

Fully automated high-bay warehouse The operations involved the intralogistics for combining the production output from both the existing lines and the new PET-Asept-D line and storing it in a shared high-bay warehouse. At all line discharge points, pallet elevators were installed to convey the product pallets upwards, thus keeping the lifttruck paths free below for supplying the lines. After being checked, the product pallets are conveyed on the platform at a height of over six metre towards the high-bay warehouse. This platform links all the discharge lines from all production operations. In the high-bay warehouse, the pallets are then fed to the five storage and retrieval units, and stored in one of the 14,060 slots provided on eleven levels. Besides the product pallets from the facility’s own production lines, pallets from outside are also handled. Moreover, up to 146 pallets from in-house production can be stored per hour, while the total output for retrievals is 165 pallet per hour. The storage and retrieval units are fitted with two-deep forks, enabling each of them to handle 34 double cycles for storage and retrieval per hour. The retrieved pallets are distributed

among the twelve dispatch tracks using a transverse travelling carriage. The outer dispatch tracks are each fitted with flush-grid-belt conveyors, enabling the pallets to be loaded with either short or long side leading. Particular priority was attached here to ensuring strict retrieval sequences. A large proportion of the product pallets consists of half-pallet pairs, which on this route must also be relieved of their euro carrier pallets and unstacked; an extra bypass has been provided for this purpose. Thanks to the bidirectional capability, the external incoming goods zone can also be used as a dispatch track or for express transfer retrievals whenever required. A new high-bay warehouse of Agrozumos

Existing block-type warehouse serves for overflow storage Another retrieval destination provides a further option for stock transfer between the retained block-type warehouse and the high-bay warehouse. “The blocktype warehouse offers us another 4,000 slots, which enabled us to dimension the high-bay warehouse as a correspondingly smaller and more affordable building,” comments Theis. “The aim is to use the full capacity of the high-bay warehouse as first choice, and to operate the block-type warehouse as an overflow store. At present, we are using the high-bay warehouse only for storing finished goods, not for raw materials and supplies.” The entire management

Order-picked consignments account for up to five per cent of total sales

Modern Food Processing | August 2010

functions for the block-type warehouse have now also been integrated into the warehouse management software from Krones. In addition, mixed-palletising operations are supplied automatically with products from the high-bay warehouse. Order-picked consignments account for up to five per cent of the total sales. They are handled by the warehouse management system and executed by the operator using a hand-held terminal. Here, too, intricate functionalities have been provided.

A complex job neatly done “The mechanical construction of the high-bay warehouse components is excellent, the software is of high quality. The support we received from Krones during the erection phase was outstanding,” affirms Theis. After a short start-up phase, an average of more than 43 trucks could be loaded here per day, with peak figures of more than 60 trucks. Krones has thus succeeded in meeting the stringent requirements and providing solutions with highly complex functionalities. Hans-Peter Schiessl is the Project Manager (Sales Department) at Krones AG. Email: hans-peter.schiessl@krones.com

Change is not just about looking different,

Dec 10- 13, 2010

Nov 19-22, 2010

In association with

Jan 7-10, 2011

Indore

Mar 11-13, 2011

Chennai

www.engg-expo.com

SMS EXPO to 51818 | engexpo@infomedia18.in | +91-22-30034651

Brought to you by

Ahmedabad

Pune

its also about evolving.

CURTAIN RAISER

Offering an assortment of knowledge In the light of emerging opportunities in the food processing industry, India Foodex 2010 is being held in Bengaluru to give a competitive edge to the players in the industry. It will provide an effective platform for developing business, gaining insights on the technological advancements in the domain, besides other benefits. Read on to know more…

ith the total food production in India expected to double in the next few years, there will be a plethora of business and investment opportunities in food processing, packaging and allied sectors. The potential growth prospects are in the areas of canning, packaging, refrigeration for dairy, poultry, fisheries, meat, ready-to-eat products, cereals & grains, high protein foods, nutraceuticals, etc. In this backdrop, the second edition of India Foodex 2010 will be organised by Media Today Group from August 20-22, 2010, at Palace Grounds, Bengaluru.

The event India Foodex 2010 holds vast significance for the food processing and allied sectors. It will focus mainly on food products, spices, fresh foods, coffee & cocoa, food ingredients, food retailing & technologies and grains among others. A concurrent show, GrainTech India 2010, will also be held during the event. Both the events – Grain Tech and India Foodex – are closely interlinked and cover the entire gamut (from the grower to consumer) of the food business. India Foodex will display quality food, ready-to-eat products, and

Modern Food Processing | August 2010

provide insights on how promotion is done by retail outlets in India & abroad. GrainTech will be devoted to post-harvest management, processing and value-addition to grains. To impart more value to the event, a two-day international conference is being planned and the theme of the conference will be ‘Food security through technology’.

Participation & support The expo aims at facilitating farmers, machinery manufacturers, food product exporters & importers to gain a competitive edge by learning about the latest trends, best practices and upcoming technologies in the food processing industry. Exhibitors from India and abroad will participate in the event, which will be supported by the Union Ministry of Agriculture, the Ministry of Food Processing Industries (MoFPI) and Agricultural & Processed Food Products Export Development Authority (APEDA). Other organisations supporting the event include Indian Institute of Crop Processing Technology, Roller Flour Millers’ Federation of India, Indian Oilseeds and Produce Export Promotion Council, All India Food Processors’ Association, Indian Biscuits Manufacturers’ Association and Bharatiya Krishak Samaj, among others.

EVENTS CALENDAR

National

Pune

Ahmedabad

Indore

Chennai

Maharashtra

Gujarat

Madhya Pradesh

Tamil Nadu

Nov 19-22, 2010

Dec 10-13, 2010

Jan 7-10, 2011

Mar 11-13, 2011

India’s premier industrial trade fair on products and technologies from machine tools, fluid power, instrumentation & control, electrical & electronics, material handling, plastics, rubber, packaging, chemical, CAD/CAM, auto components, and general engineering.

For details contact:

Engineering Expo Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022-3003 4649, Fax: 022-3003 4499, Email: shamal@infomedia18.in

India Foodex 2010

Fi India 2010

An exhibition on food processing & packaging technology, and food & beverage products will be held concurrently with GrainTech India and AgriTech India; August 20-22, 2010; at Palace Ground, Bengaluru

An event that would feature companies showcasing ingredients for food & beverages, dietary supplements, functional/health foods, nutraceuticals, natural foods; October 22-23, 2010; at Bombay Exhibition Centre, Mumbai

For details contact: Media Today Group - Exhibition Division T-30, Khirki Extension, New Delhi 110 017 Tel: 011-2668 1671; Fax: 011-2668 2045 Email: indiafoodex@gmail.com

For details contact: UBM India Pvt Ltd Sagar Tech Plaza, SakiNaka Junction Andheri (E), Mumbai 400 072 Tel: 022-6612 2600, Fax: 022-6612 2626 Email: bipins@ubmindia.com

International Foodtec India 2010 An international exhibition and conference for food processing, packaging, ingredients, beverages, cooling & refrigeration; September 30-October 03, 2010; at Bombay Exhibition Centre, Mumbai

Food & Bev Tech 2010 An exhibition & conference for the food and beverage processing industry; October 29-31, 2010; at Bombay exhibition Centre, Mumbai

For details contact: Cidex Trade Fairs Pvt Ltd 1, Commercial Complex, New Delhi 110 076 Tel: 011-2697 1056; Fax: 011-2697 1746 Email: info@cidex-tradefairs.com

For details contact: Anil Padwal, CII (Western Region) 105, Kakad Chambers, Dr A B Road, Worli, Mumbai 400 018 Tel: 022-2493 1790, Fax: 022-2493 9463 Email: anil.padwal@cii.in

PROMACH 2010

International PackTech India

An exclusive exhibition for the process plant & machinery industry; October 01-04, 2010; at Bangalore International Exhibition Centre, Bengaluru For details contact: Bangalore International Exhibition Service 10th Mile, Tumkur Road, Bengaluru 562 123 Tel: 080-6583 3234 Email: dayanand@bies.co.in

An exhibition and conference for the packaging & processing industry that will be held along with drink technology India; November 18-20, 2010; at Bombay exhibition Centre, Mumbai For details contact: Messe Düsseldorf India Pvt Ltd 1, Commercial Complex 2nd Floor, Sarita Vihar, New Delhi 110 076

Modern Food Processing | August 2010

Tel: 011-2697 1745, Fax: 011-2697 1746 Email: info@md-india.com

Food Technology Show 2010 To be held concurrently with PackPlus 2010, this event will focus on technologies, equipment, materials & services for food production & processing, baking, freezing, refrigeration & climatic engineering, etc; December 03-06, 2010; at Pragati Maidan, New Delhi For details contact: Print-Packaging.com Pvt Ltd International Infotech Park Vashi, Navi Mumbai 400 705 Tel: 022-2781 2093, Fax: 022-2781 2578 Email: info@indiapackagingshow.com

Hi-Tech Manufacturing To be held concurrently with ‘HiTech Automation’, the show is one of the largest advanced design and manufacturing events in India featuring machine tools, hydraulics & pneumatics, process machinery & equipment, packaging & auxiliaries, IT products, electrical & electronics with a special focus on automation & instrumentation and material handling; February 17-19, 2011; at Bombay Exhibition Center, NSE, Goregaon, Mumbai For details contact: Infomedia 18 Ltd Ruby House, A Wing, J K Sawant Marg, Dadar (W), Mumbai 400028 Tel: 022-3003 4649, Fax: 022-3003 4499 Email: engexpo@infomedia18.in

EVENTS CALENDAR

International Western Foodservice & Hospitality Expo 2010 A trade fair showcasing latest trends in food processing, catering and hospitality industries; August 14-16, 2010; at Los Angeles Convention Centre, Los Angeles For details contact: Reed Exhibitions USA 383 Main Avenue Norwalk CT 06851, USA Tel: +1 (203) 840-4800 Fax: +1 (203) 840-5805 Email: inquiry@reedexpo.com

INTERMEAT 2010 An exhibition for meat, cold meats and sausage; September 12-15, 2010; at Düsseldorf Exhibition Centre in Dusseldorf, Germany For details contact: Messe Düsseldorf GmbH Stockumer Kirchstrasse 61 D-40474 Düsseldorf, Germany Tel: +49 - 211 - 4560 900 Fax: +49 - 211 - 4560 668 Email: info@messe-duesseldorf.de

FI South America 2010 International food ingredients exhibition; September 21-23, 2010; at Transamérica Expo Center in Sao Paulo, Brazil For details contact: United Business Media Industrieweg 54, PO Box 200 3600 AE Maarssen, The Netherlands Tel: +31 34 65 59 444 Fax: +44 (0) 20 7921 8059 Email: jblack@cmpinformation.com

Saudi Agro-Food Industries 2010 A trade fair showcasing the latest in food products, processing and packaging technologies; October 04-07, 2010; at

Riyadh International Exhibition Centre in Riyadh, Saudi Arabia For details contact: Riyadh Exhibitions Co. Ltd Olaya Road Postfach, P O Box 56010 SA - 11554 Riyadh, Saudi Arabia Tel: +966 1 454 1448 Fax: +966 1 454 4846 Email: esales@recexpo.com

IPA 2010 International food processing and equipment week; October 17-21, 2010; at Paris Nord Villepinte in Paris, France For details contact: Comexposium Immeuble le Wilson 70, avenue du Général-de-Gaulle 92058 Paris-La Défense, France Tel: +33 (0) 1 7677 1111 Fax: +33 (0) 1 7677 1212 Email: infos@exposium.fr

SIFSE 2010 Shanghai International Fisheries & Seafood Expo; December 10-13, 2010; at Shanghai Everbright Convention & Exhibition Center, Shanghai For details contact: Shanghai Gehua Exhibition Service Co Ltd Rm.1206-1208 Xin’an Building No. 99 Tianzhou Rd Shanghai 200233, China Tel: +86-21-54451166 Fax: +86-21-54451968 Email: info@gehuaexpo.com

ISM International sweets and biscuits fair; January 30-February 02, 2011; at Exhibition Centre Cologne, Germany

Food Processing & Packaging Indonesia 2010 International exhibition on food processing & packaging machinery, equipment, materials & services; October 27-30, 2010; at Jakarta International Expo in Jakarta, Indonesia

For details contact: Koelnmesse GmbH Messeplatz 1, 50679 Köln, Germany Tel: +49 221 821-0 Fax: +49 221 821-2574 E-mail: info@koelnmesse.de

Gulfood Exhibition

For details contact: Krista Exhibitions Jln.Blandongan 28 DG Jakarta 11220, Indonesia Tel: +62-21 6345861 Fax: +62-21 6340140 Email: info@krista-exhibitions.com

A trade fair showcasing the latest developments in food & beverage, refrigeration & food service equipment, food processing machinery, bakery & confectionery products & equipment, and food packaging; February 20-23, 2011; at Dubai International Exhibition Centre, UAE

Ingredients Russia 2010 An event for food ingredients, additives and flavours; November 23-26, 2010; Crocus-Expo IEC, Moscow For details contact: ITE Group Plc 105 Salusbury Road

London, NW6 6RG, The UK Tel: +44 (0) 20 7596 5000 Fax: +44 (0) 20 7596 5111 Email: enquiry@ite-exhibitions.com

For details contact: Dubai World Trade Centre PO Box 9292, Dubai, UAE Tel: +971 (4) 332 1000 Fax: +971 (4) 3312173 Email: info@dwtc.com

The information published in this section is as per the details furnished by the respective organiser. In any case, it does not represent the views of Modern Food Processing

August 2010 | Modern Food Processing

PRODUCT UPDATE

Powder disperser

Control valve

Quadro Engineering Corp offers ‘Ytron® ZC’ powder disperser, which incorporates and disperses extremely difficult-towet gums into a liquid stream in a single-pass. The advanced design of its rotor/stator provides for intense shearing of the gums prior to hydration, to produce homogeneous dispersions that are completely free of lumps and ‘fish-eyes’. A near-perfect vacuum permits concentrations up to 25 per cent by weight to be generated with minimal air entrainment. Because the powder is completely hydrated, yield is maximised and over-processing and wastage are eliminated. It reduces batch times by 80 per cent, which result in average powder savings of 5-10 per cent. This powder disperser is available in three sanitary models and is designed to meet 3-A sanitary standards. It gives liquid throughputs from 3-20 gpm.

Forbes Marshall offers ‘Ecotrol’, control valve, which is robust, compact and light in weight. It comes with a pneumatically operated, easy field reversible multi-spring diaphragm actuator and a sturdy, pipe-less and vibration-resistant mounted digital positioner. It is also available with handwheel (optional). Tubeless mounting, with the digital positioner and the option of bi-directional communication is the key feature of this control valve. The double use of auxiliary energy is by using pneumatic multi-spring diaphragm actuator with the option of permanent spring case ventilation. It is designed according to ANSI, with standardised trims. The prevention of leakage and bypass leakage is by a limited compressive load acting on both encapsulated gaskets. It is used in oil & gas, chemical & petrochemical, pharmaceuticals, distillery & food, fertiliser, steel and metal, power, industries etc.

Quadro Engineering Corp Waterloo – Canada Tel: 519-884 9660 Fax: 519-884-0253 Email: sales@quadro.com

Forbes Marshall Pvt Ltd Pune - Maharashtra Tel: 020-2714 5595, Fax: 020-2714 7413/7593 Email: vmktg@forbesmarshall.com

Turbine blowers/exhausters Acmevac Sales offers turbine blowers/exhausters, which is available from 0.5 HP to 15 HP. These are regenerative blowers and can be used for vacuum or pressure applications. The impeller is directly mounted on the motor shaft itself. There are no rubbing parts, and hence, these blowers are practically maintenance-free and absolutely oil-free. Noise levels are considerably reduced as silencers are provided. These blowers are used in areas where oilless, continuous non-pulsating air flow is required. These turbine blowers/exhausters are used in air tables, agitation/aeration, vacuum hold down & pick up, air blow-off, aquaculture, pneumatic conveying, etc. Acmevac Sales Pvt Ltd Mumbai - Maharashtra Tel: 022-2837 5837 Fax: 022-2836 4977 Mob: 092233 88105 Email: acmevac@vsnl.com

Modern Food Processing | August 2010

Waterjet cleaning machines Technical Trading & Services offers fully automatic centralised high-pressure waterjet cleaning machines, which are used for industrial applications. These systems are designed to meet the full cleaning and sanitising demand of the industry to their required level. Some of the advantages of the centralised systems are: no machine movements inside the processing hall, availability of pressurised water at required locations, reduce water consumption, cleaning time, effect of cleaning is high & with capacity to undertake many jobs, which are impossible by hand or any other cleaning methods. These machines are offered with time delayed stop system, ie, the units switch off totally within 30 seconds, if not used. This helps to reduce the wear & tear of the units. The waterjet cleaning machines are designed for large food processing, pharma, chemical, poultry, beverage and other processing industries. Technical Trading & Services Bengaluru - Karnataka Tel: 080-2580 5767, Mob: 098453 47977 Email: sales@tts.net.in

PRODUCT UPDATE

Peristaltic hose pump Moniba Anand Electricals offers industrial peristaltic hose pump. This pump comes with tubular element inside the casing, which is compressed by the rotary action of the rotor and its corresponding rollers or shoes. It recovers its initial shape creating a vacuum, thus suctioning the fluid into the hose. The fluid gets into the cavity formed by the rollers that press the tubes, and is gently pushed to the outlet by the following roller. This pump offers resistance to abrasion and corrosion. It is easy to clean & maintain, silent in operation and can handle liquid with solids. Features include reversible rotation, dry run without damage, suction list up to 9 m, etc. This pump is used in mills products, wines, sauces, jam, liquid eggs, molasses, meat products, fruit juices, oils, detergents, acids, peroxides, etc. It is available with geared motors with or without VFDs. Moniba Anand Electricals Pvt Ltd Mumbai - Maharashtra Tel: 022-2857 3156 Fax: 022-2857 3135 Email: mail@moniba.net

August 2010 | Modern Food Processing

PRODUCT UPDATE

Infrared lamps/heaters Alok International offers a complete range of infrared heaters and lamps manufactured by Victory Lighting (UK) Ltd. Infrared is an electromagnetic radiation whose wavelength is longer than visible light but shorter than microwave radiation. It is divided into short-wave, medium-wave and long-wave infrared. These infrared lamps/heaters are used in PET preform heating, drying water-based inks on printing presses, paint baking, powder-coating curing, curing inks on textiles, drying glue on paper, drying moisture in paper mills, paper coating drying, shrink wrapping, food warming, evaporation of water in humidifiers, soldering and in the semiconductor industry. The company also offers complete range of short-wave infrared lamps, ceramic infrared heaters and medium-wave quartz infrared heaters. Alok International New Delhi Tel: 011-2592 0408/0439; Fax: 011-4144 3563 Email: alok@alokinternational.in

Metal detector Technofour Electronics offers conveyorised metal detector for detection of metal contamination in food and pharmaceutical products. It is an Eddy current-based digital metal detection system, which also finds applications in chemical, cosmetic, garment, leather, rubber, and in many other industries. The metal detector consists of electronic unit, test coil, conveyor and rejection mechanism. The functions performed by the electronic unit are diagnostics, auto product compensation, set parameter retention on loss of power, buzzer and LED indication on detection of metal contamination, LCD bargraph/ numeric display to monitor noise and signal, etc. Rejection mechanisms offered by the company are conveyor stoppage, air nozzle, diverter arm, flap and pusher/puller. Technofour Electronics Pvt Ltd Pune - Maharashtra Tel: 020-2605 8063/4/5; Fax: 020-2605 8073 Email: sales@teplindia.com

Modern Food Processing | August 2010

PRODUCT UPDATE

Table top coder Process Instrumentation & Controls offers table top coder. This batch coding machine is suitable for all manual & automatic coding on various packaging. This easy-to-operate coder is compact in design, which makes it easy to install, where space is limited. It operates on a microprocessor-based system and is equipped with motorised intermittent reciprocal contact coder. The coder can be used by manufacturers/packers of packaged goods to print batch no, date of manufacturing, expiry date, prices and other statutory information on various packaging, containers, labels, cartons, pouches, etc. It gives bigger printing area up to 50 mm and can easily have 4-6 lines of printing on various packed goods. Process Instrumentation & Controls Vadodara - Gujarat Tel: 0265-235 7228, 232 0756 Fax: 0265-235 5429 Email: batchprinting@yahoo.com

Ultrasonic sensor Banner Engineering offers ‘U-Gage® M25U’ ultrasonic sensor, which is purpose-built to deliver flawless operation in the harsh environment of food processing and other sanitary industries. It can withstand high-pressure washdown and severe temperatures. A rugged stainless steel housing makes this sensor an ideal solution for clean-in-place (CIP) procedures in food & beverages applications. It cleans easily with no threads, gaps or seams to trap debris and can withstand high temperature sprays of up to 80°C and 1,500 psi occurring every few hours. Constructed of FDA approved materials, it disinfects and cleans up with minimal effort. It is used for presence detection of clear or coloured container during sanitising, food processing monitoring, position monitoring, aseptic bottling in contained environment. Banner Engineering India Pvt Ltd Pune - Maharashtra Tel: 020-6640 5624 Fax: 020-6640 5623 Mob: 093223 39208 Email: salesindia@bannerengineering.com

August 2010 | Modern Food Processing

PRODUCT UPDATE

Reverse osmosis desalination system Parker Hannifin India offers reverse osmosis desalination system. It consists of ‘Aqua Pro® 3 or 5’ plunger high-pressure pump with titanium head for maximum corrosion resistance, balanced drive for low noise & pulsation and ceramic plungers as well as nylon valves for long service life. The SS-316 prefiltration housings deliver 200 sq ft of filtering area, and a boost pump provides up to 50 psi of boost pressure to the filtration system. It is provided with stainless steel, glycerin-filled pressure gauges, which accurately read pressure at filters, pump and product. The easy-to-operate SS-316 high-pressure bypass valve controls the operating mode from cleaning/rinsing to water production. Automatic diversion valve diverts water to discharge if water quality decreases below acceptable standards. Digital water quality monitor displays ppm TDS of product water output and also displays temperature and total hours for accurate service logs. Parker Hannifin India Pvt Ltd Navi Mumbai - Maharashtra Tel: 022-6513 7081-85, Fax: 022-2768 6841 Email: parkerind@parker.com

Food extruder Malik Engineers offers single-screw food extruders suitable for extruding pellets from wheat, potato or corn. The line consists of a ribbon blender for dry mixing. After mixing, screw conveyors propel the product to pre-conditioner chamber, which consists of a single rotating agitator shaft fitted with mixing paddles. The material is cooked by mechanical shear and heat supplied by heaters wrapped around the temperature controlled barrel. The cooked dough is extruded out of the cooker extruder in the form of a continuous ribbon and is chopped into small lengths by stationary blades fitted at the end of the barrel. These are pneumatically transferred to the driers, which further removes extra moisture present in the pellet. The pellets are then weighed and packed for future consumption by expansion in hot oil (frying). It is available in screw sizes of 50, 65, 75 and 100 mm to give throughput rates of 25, 50, 80 & 120 kg/hr, respectively. The company also offers a special model with screw diameter of 160 mm, which provides up to 800 kg/hr output of pellet product. Malik Engineers Thane - Maharashtra Tel: 0250-239 0839, Fax: 022-2883 0751 Email: info@malikengg.com

Modern Food Processing | August 2010

PRODUCT UPDATE

Food slicing machine Global Technology offers food slicing machine manufactured by Weber, Germany. It processes sausage, ham, meat and cheese. This slicing machine can be extended to form automatic processing line that includes feeding, scanning, cutting, portioning, weighing, sorting, buffering and automatic transport in packaging machine. It slices up to 2.5 tonne of sausage or cheese per hour, which is the equivalent of 8,000 slices per minute. The ‘Slicer 904 MCS’ with overlapper joins the portions cut next to each other and places them on top of each other. The portions are then fed into the packing machine on a fully automatic basis. The machine is equipped with the ‘Pac-Drives C400’ and ‘C600’ for all motion control, logic and technology functions in the slicer. Up to 17 frequency inverters, 100 digital inputs & 100 digital outputs, the check weigher and the optical weigher are networked via a CAN network over approximately 50-m length. It is provided with 20 seven-digit weight displays, which indicate the package weight and are located above the packaging machine, where the machine operator can check whether to add or take off slices. Global Technology Mumbai - Maharashtra Tel: 022-6699 5218, Fax: 022-2822 6570 Email: info@globaltechnology.org.in

August 2010 | Modern Food Processing

PRODUCT UPDATE

Burner Eclipse Combustion offers ‘AH-MA’ burner, which produces a uniform odourless and smokeless flame ideal for heating fresh air in make-up and process air heating applications. Its design provides stable operation over a wide range of velocities, inputs and fuels. This burner is ETL listed, complies with ANSI Z21.2 design standards, and is used in systems, which meet emission standards for NOx and CO. This burner can be assembled from straight sections, tees and crosses to produce required configuration. The features of the burner include inputs of up to 12,00,000 Btu/hr/LF, up to 30:1 turndown, up to 450ºF/232ºC upstream air temperature, up to 850ºF/450ºC downstream air temperature, multifuel capability (natural gas, propane and butane), etc. Eclipse Combustion Pvt Ltd Pune - Maharashtra Tel: 020-3250 3630, 3234 7612, 3260 5979 Email: sdeo@eclipsenet.com

Cleaning nozzle Industrial Equipwash offers fully automatic turbo tank cleaning nozzle powered by cleaning fluid. It is designed for large volumetric tanks/agitators in pharma, food, distillery, beverage, chemical and other process industries. The heart of the turbojet cleaner is an internal hydraulic motor, which makes the nozzles automatically perform a geared rotation around the horizontal and vertical axes. The number of cycles required for proper cleaning usually depends on the cleaning distance, cleaning procedure and cleaning agent. To control the RPM of the machine the flow rate is controlled through nozzles of various orifice sizes. A choice of nozzles is available to suit tank geometry and cleaning requirements. Industrial Equipwash Inc Mumbai - Maharashtra Tel: 022-2679 7941, Fax: 022-2679 2936 Mob: 098692 31815 Email: iewi@vsnl.net

Modern Food Processing | August 2010

PRODUCT UPDATE

In-mould labelling system Neejtech India offers inmould labelling (IML) system manufactured by Hekuma GmbH. The advantages of the IML system include reduced costs, promotes hygienic production, increases decorative possibilities, offers resistance to heat & scratching, reduces in-house container inventory & overhead costs, better strain & squeeze resistance and improves sidewall strength & shelf-life. The application areas of the IML system are injection moulding IML for cups & containers and thermoforming IML, blow moulding IML & BDA (blister decorating applications) for thermoformed PET/PVC blister packaging. The company provides complete systems for insert and take-out automation of injection moulding processes with up and downstream automation. The downstream automation turns complex customersâ&#x20AC;&#x2122; requirements into simple, reliable and highly efficient solutions. Neejtech India Ahmedabad - Gujarat Tel: 079-2656 1312; Mob: 098250 40231 Email: sales@neejtech.com

Flexible screw conveyor Noida Fabcon Machines offers flexible screw conveyor for food, pharmaceuticals, chemicals, minerals, ceramics, plastic and rubber industry. It consists of electric motor driven spiral, which rotates within a food grade sealed tube. The material moves along the spiral within the tube. The unique action of the flexible spiral conveyor eliminates the risk of the product separation. The conveyor maximum length can be up to 15 metre for material bulk density of 0.6 kg/litre and may be increased or decreased inversely with bulk density. Feed hopper is available in standard size or according to customerâ&#x20AC;&#x2122;s specification. Its main features include dust free, easy to clean, high & low level control, safe & hygienic handling, accurate metering and high transfer capacity. The different sizes of conveyor are suitable for any capacity up to 15 tonne per hour and any length from 2 to 15 metre per conveyor. Distribution of product at more than 1 outlet is also possible. The flexible nature of conveyor allows bends to be incorporated while installing the conveyor & the same can be managed through walls & roofs with minimal problem to the existing layout. Noida Fabcon Machines Pvt Ltd New Delhi Mob: 098183 77111, 098112 09769 Email: nishantb@fabcon-india.com

Modern Food Processing | August 2010

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PRODUCT UPDATE

Powder mixing equipment Toshniwal System and Instruments offers powder mixing equipment to handle solid, powder, flaky materials, etc. Lowpower consumption and short time operation with reduced maintenance cost are the main advantages of this mixing equipment. Since it can handle solid, powder and flaky materials, it is widely used in applications like food, animal feed, construction, chemical, refractory industry, etc. Apart from homogenous mixing, it also helps in achieving the desired technical performance in the final product and its subsequent application. Other products of the company include measurement instruments, vacuum pumps, oil purification plants, turbo molecular pumps, etc. Toshniwal Systems & Instruments (P) Ltd Chennai - Tamil Nadu Tel: 044-2644 5626/8983 Fax: 044-2644 1820 Email: sales@toshniwal.net

August 2010 | Modern Food Processing

PRODUCT UPDATE

Emulsifier Tricon offers multi-purpose high-speed microcut emulsifiers for continuous process control and consistent size reduction. The easily removable carbide tipped cutting rotors have no metal-to-metal contacts and provides long tool life, easy cleaning and minimum product temperature rise. It does not require pre-run or adjustments. It is used for meat emulsions for sausages, kababs, etc, where protein swelling is better. This emulsifier is also used for making fish-head paste, flaking fish for re-fabrication into portions, grinding fish or chicken skin for fat recovery, sea moss, reduction for pet food, offal, etc. It is also used for making fine pastes of wet spices, which include onions, ginger, chilli, garlic and paste of peanuts, vegetables, fruits and confectionery. This machine has an output of 600-1,000 kg/hr. Tricon Pune - Maharashtra Tel: 020 -2565 2205/2451; Mob: 098901 92832 Email: trivedi@pn2.vsnl.net.in The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any case, it does not represent the views of

Modern Food Processing

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Dear Reader, ‘Modern Food Processing’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the food processing industry. You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 3000 words, while that of a product write-up should not exceed 200 words. The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format. The final decision regarding the selection and publication of the articles shall rest solely with ‘Modern Food Processing’. Authors whose articles are published will receive a

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complimentary copy of that particular issue and an honorarium cheque. Published by Infomedia 18 Limited, ‘Modern Food Processing’ is the leading monthly magazine exclusively meant for producers and user fraternities of the food processing industry. Well supported by a national readership of over 80,000 and our strong network of 26 branch offices across India, this magazine reaches out to key decision makers among the Indian manufacturers of food processing products, machinery and allied sectors. Brought out in association with Hong Kong-based Ringier Trade Publishing Ltd (one

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Modern Food Processing | August 2010

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Aerosol spray paint .................................... Deep freezer .............................................. In-mould labelling machine........................

Aging vat................................................... Dehumidifiers............................................. Invertor/variable frequency drives ............... Air chiller ................................................... Dehydration equipment ............................. Lab spray dryer .......................................... Air cooler................................................... Doors......................................................... Laminar flow workstations ......................... Air handling units ...................................... Drawer magnet.......................................... Level controllers ......................................... Air showers................................................ Drives ........................................................ Liquid filling unit........................................ Air tents for operation theatre ................... Dust control door ...................................... Lobe pumps............................................... Animal feed technology ............................. Easy open beverage can............................. Low RH AHUâ&#x20AC;&#x2122;s ........................................... AODD pumps ............................................ Eccentric disc pump ................................... Magnetic equipment..................................

B2B magazines .......................................... Electronic balance ...................................... Magnetic traps...........................................

Bearings..................................................... Emulsifier................................................... Metal detector ........................................... Blast chiller ................................................ Encoders.................................................... Metallic & non-metallic pump ....................

First Fold Here

Blast freezer ............................................... Evaporating units for cold rooms ............... Metering pumps ........................................ Boilers........................................................ Exhibition - Annapoorna India.................... Milk chiller ................................................. Brain chiller................................................ Exhibition - Engineering Expo..................... Mixing machine ......................................... Brewing units............................................. Exhibition - Food Ingredients India 2010 .... Moisture analyser....................................... Brine chillers .............................................. Exhibition - Promach 2010......................... Motion controls ......................................... Bucket conveyors ....................................... Extruded products...................................... Multi-fuel fired IBR steam boiler ................. Bulk milk chiller.......................................... Fire tube type package IBR steam boiler ..... Multi-level car parks ................................... Burner ....................................................... Flexible screw conveyor .............................. Oil milling unit ...........................................

Fax.: +91-22-3003 4499 Email: b2b@infomedia18.in

Batching system......................................... Emulsification solutions.............................. Measuring & monitoring relay ...................

Cable carriers ............................................. Flexible transparent PVC strip door............. Oil/coolant coolers ..................................... Cable connectors ....................................... Flour milling unit ....................................... On-line check weigher ............................... Carpet cleaning machines .......................... Fluid mixing dispersion system ................... Pallet scale ................................................. Centrifugal pumps ..................................... Food extruder ............................................ Panel air-conditioners ................................. Chains ....................................................... Food processing lines ................................. Pasta making machine ............................... Chest freezer.............................................. Food slicing machine ................................. Peeling unit................................................ Chocolate/cocoa making machine .............. Food testing programmes .......................... Peristaltic hose pump .................................

Circumferential piston pumps .................... Forced convection unit air cooler................ Photo electric sensors.................................

Tel.: +91-22-3003 4685

Clean room equipment .............................. Fruits/vegetables processing equipment...... Piston pumps............................................. Clean room projects................................... Gears ......................................................... Plastic & steel chain belts ...........................

Second Fold Here

Clean room validations & services............... Grain handling system ............................... Plastic pellets ............................................. Cleaning nozzle ......................................... Grill magnet............................................... Polycarbonate sheets.................................. Cleaning section equipment ....................... Grinding & dispersion unit ......................... Powder disperser........................................ Cold form C & Z purlins ............................. Gyratory screen .......................................... Powder filling machine............................... Cold room door ......................................... Heat resistant door .................................... Pre-engineered steel buildings.................... Cold room PUF panel ................................. Heavy industrial steel buildings................... Pre-fab shelters .......................................... Colour measuring instruments ................... High pressure cleaners ............................... Processing solutions for fruit juices & urees Colour sorting unit..................................... Hopper magnet ......................................... Programmable logic controllers .................. Connectors ................................................ Hot air & water generator unit................... Programmable terminals ............................

Please tick against the box of product(s) you are interested in: Mention specific product/service you need, Complete all the details on this form. Tear the form & mail it to us. (It is a prepaid mail)

Automatic scrubber driers .......................... Electromagnetic feeder .............................. Magnetic plate...........................................

Contamination controller ........................... HVAC clean room ...................................... Proximity sensors ....................................... Control valve.............................................. Ice candy machine ..................................... PVC strip door ........................................... Conveying systems ..................................... Industrial control & sensing devices............ Rare earth tubes ........................................ Conveyors .................................................. Industrial cooling systems .......................... Ready-to-eat retort pouches ...................... Cooling & boiler water treatment programmes ...... Industrial door ........................................... Refrigeration unit ....................................... Corrugated tube heat exchangers .............. Industrial inkjet printers ............................. Residential steel houses..............................

Send your inquiries at: Tel: +91-22-3003 4685 Fax: +91-22-3003 4499 Email: b2b@infomedia18.in

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Aerosol can................................................ Cutters/slicer .............................................. Infrared lamps/heaters ...............................

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Aero-mechanical conveyor ......................... Counters & power supplies ........................ Industrial-type unit air cooler .....................

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Reverse osmosis detection system .............. Sweepers ................................................... Vertical non-IBR oil fired steam boiler......... RFID .......................................................... Switching relays ......................................... Vibration motor ......................................... Rice milling equipment............................... Table top coder .......................................... Viscometer................................................. Roof vent ................................................... Tank weighing unit .................................... Vision sensors ............................................ Roofing & cladding sheets ......................... Temperature controllers.............................. Wastewater treatment & recycle plant........ Rotary lobe pumps..................................... Thermal processes...................................... Water chillers ............................................. Safety door ................................................ Thermic fluid heater................................... Water cooler .............................................. Safety light curtains ................................... Timers........................................................ Water purification systems ......................... Self adhesive tapes..................................... Tin/can....................................................... Water treatment plant ............................... Shaped can................................................ Total water management ........................... Water wall membrane panel IBR steam boiler ... Single disc machines .................................. Turbine blowers/exhausters......................... Waterjet cleaning machines ....................... Slip lid can ................................................. Ultrasonic sensor........................................ Weigh bridge............................................. Special refrigeration equipment.................. Under counter refrigeration ....................... Weigh scales .............................................. Spout can .................................................. Universal-type unit air coller ....................... Wood fire four pass thermic fluid heater .... Sprockets ................................................... Vacuum cleaners........................................ Wood fire thermic fluid heater ................... Steam boilers ............................................. Ventilators ................................................. X-ray inspection system .............................. Structural floor decking sheets ................... Vertical freezer/chiller .................................

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Alfa Laval India Ltd .....................................................................

Igus India Pvt Ltd ........................................................................

Arctic India Sales.........................................................................

Ion Exchange Pvt Ltd...................................................................

Balkrishna Boilers Pvt Ltd.............................................................

Jay Instruments & Systems Pvt Ltd...............................................

Bangalore International Exhibition...............................................

Jaykrishna Magnetics Pvt Ltd .......................................................

First Fold Here

Bonfiglioli Transmissions (Pvt) Ltd ................................................

Millipore India Pvt Ltd .................................................................

Bry Air (Asia) Pvt Ltd ...................................................................

Modern Food Processing.............................................................

Buhler (India) Pvt Ltd...................................................................

Noida Fabcon Machines Pvt Ltd ..................................................

Diversey India Pvt Ltd ..................................................................

Omron Automation Pvt Ltd .........................................................

Engineering Expo ........................................................................

Paharpur - 3P..............................................................................

FICCI ...........................................................................................

Plast World .................................................................................

Fluid Energy Controls Inc.............................................................

Shah Brothers .............................................................................

FX Multitech Pvt Ltd....................................................................

Sreelakshmi Traders.....................................................................

Giantwell Machinery Co., Ltd. .....................................................

Steri Clean Air Technologies (I) Pvt Ltd.........................................

Hindustan Tin Work Ltd ..............................................................

UBM India Private Limited ...........................................................

HRS Process Systems Pvt Ltd........................................................

Ultraplast Chainbelts Pvt Ltd........................................................

IC Ice Make Refrigeration Pvt Ltd.................................................

United Steel & Structurals Pvt Ltd................................................

IDEX India Pvt Ltd .......................................................................

Werner Finley Pvt Ltd ..................................................................

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Special Projects

INFOMEDIA 18 LIMITED Ruby House, ‘A’ Wing, J.K. Sawant Marg, Dadar (W), Mumbai 400 028, INDIA.

PRODUCT INDEX Product

Pg No

Aero-mechanical conveyor......................... 69 Aerosol can ..................................................... 29 Aerosol spray paint .......................................... 71 Aging vat......................................................... 57 Air chiller ......................................................... 57 Air cooler........................................................... 5 Air handling units ............................................ 15 Air showers...................................................... 15 Air tents for operation theatre......................... 15 Animal feed technology..................................... 9 AODD pumps .................................................. 13 Automatic scrubber driers................................ 33 B2B magazines ........................................... 53 Batching system.............................................. FIC Bearings............................................................. 4 Blast chiller ...................................................... 57 Blast freezer..................................................... 57 Boilers.............................................................. 79 Brain chiller...................................................... 57 Brewing units .................................................... 9 Brine chillers .................................................... 69 Bucket conveyors ............................................. 69 Bulk milk chiller ............................................... 57 Burner .......................................................74, 79 Cable carriers ............................................... 4 Cable connectors ............................................... 4 Carpet cleaning machines ................................ 33 Centrifugal pumps ........................................... 13 Chains ............................................................... 4 Chest freezer.................................................... 57 Chocolate/cocoa making machine...................... 9 Circumferential piston pumps .......................... 13 Clean room equipment .................................... 15 Clean room projects......................................... 15 Clean room validations & services .................... 15 Cleaning nozzle ............................................... 74 Cleaning section equipment............................... 9 Cold form C & Z purlins................................... 19 Cold room door............................................... 57 Cold room PUF panel....................................... 57 Colour measuring instruments ........................ FIC Colour sorting unit ............................................ 9 Connectors ........................................................ 4 Contamination controller ................................. 15 Control valve.................................................... 68 Conveying systems ........................................... 72 Conveyors ........................................................ 69 Cooling & boiler water treatment programmes.... 39 Corrugated tube heat exchangers .................... 11 Counters & power supplies ................................ 3 Cutters/slicer .................................................... 72 Deep freezer............................................... 57 Dehumidifiers.............................................49, 73 Dehydration equipment ................................... 72 Doors............................................................... 71 Drawer magnet................................................ 74 Drives .............................................................. BC Dust control door ............................................ 71 Easy open beverage can ............................ 29 Eccentric disc pump......................................... 24 Electromagnetic feeder .................................... 74 Electronic balance........................................... FIC Emulsification solutions.................................... 13 Emulsifier......................................................... 80 Encoders............................................................ 3 Evaporating units for cold rooms....................... 5

Product

Pg No

Exhibition - Annapoorna India ......................... 65 Exhibition - Engineering Expo .......................... 63 Exhibition - Food Ingredients India 2010 ........... 6 Exhibition - Promach 2010 .............................. 75 Extruded products ............................................. 9 Fire tube type package IBR steam boiler.. 79 Flexible screw conveyor..............................69, 76 Flexible transparent PVC strip door .................. 71 Flour milling unit ............................................... 9 Fluid mixing dispersion system......................... 13 Food extruder .................................................. 72 Food processing lines....................................... 72 Food slicing machine ....................................... 73 Food testing programmes............................... BIC Forced convection unit air cooler ....................... 5 Fruits/vegetables processing equipment ........... 72 Gears .......................................................... 79 Grain handling system ....................................... 9 Grill magnet .................................................... 74 Grinding & dispersion unit................................. 9 Gyratory screen................................................ 74 Heat resistant door .................................... 71 Heavy industrial steel buildings ........................ 19 High pressure cleaners ..................................... 33 Hopper magnet ............................................... 74 Hot air & water generator unit ........................ 79 HVAC clean room ............................................ 15 Ice candy machine ..................................... 57 Industrial control & sensing devices ................... 3 Industrial cooling systems ................................ 69 Industrial door ................................................. 71 Industrial inkjet printers .................................. FIC Industrial-type unit air cooler ............................. 5 Infrared lamps/heaters ..................................... 70 In-mould labelling machine ............................. 76 Invertor/variable frequency drives ....................... 3 Lab spray dryer ......................................... FIC Laminar flow workstations............................... 15 Level controllers ................................................. 3 Liquid filling unit ............................................ FIC Lobe pumps..................................................... 24 Low RH AHUâ&#x20AC;&#x2122;s ................................................. 15 Magnetic equipment ................................. 74 Magnetic plate ................................................ 74 Magnetic traps ................................................ 74 Measuring & monitoring relay .......................... 3 Metal detector .......................................... FIC, 70 Metallic & non-metallic pump.......................... 24 Metering pumps .............................................. 13 Milk chiller ....................................................... 57 Mixing machine ............................................... 72 Moisture analyser............................................ FIC Motion controls ................................................. 3 Multi-fuel fired IBR steam boiler ...................... 79 Multi-level car parks......................................... 19 Oil milling unit ............................................. 9 Oil/coolant coolers ........................................... 69 On-line check weigher .................................... FIC Pallet scale ................................................ FIC Panel air-conditioners ...................................... 69 Pasta making machine ....................................... 9 Peeling unit ..................................................... 72 Peristaltic hose pump....................................... 69 Photo electric sensors ........................................ 3 Piston pumps................................................... 11 Plastic & steel chain belts................................. 79

Product

Pg No

Plastic pellets ..................................................... 9 Polycarbonate sheets ....................................... 19 Powder disperser ............................................. 68 Powder filling machine .................................... 79 Pre-engineered steel buildings ......................... 19 Pre-fab shelters ................................................ 19 Processing solutions for fruit juices & purees ... 37 Programmable logic controllers.......................... 3 Programmable terminals .................................... 3 Proximity sensors ............................................... 3 PVC strip door ................................................. 71 Rare earth tubes ........................................ 74 Ready-to-eat retort pouches ........................... 25 Refrigeration unit............................................. 57 Residential steel houses ................................... 19 Reverse osmosis detection system .................... 72 RFID................................................................... 3 Rice milling equipment ...................................... 9 Roof vent......................................................... 19 Roofing & cladding sheets ............................... 19 Rotary lobe pumps .......................................... 13 Safety door ................................................ 71 Safety light curtains ........................................... 3 Self adhesive tapes .......................................... 71 Shaped can...................................................... 29 Single disc machines........................................ 33 Slip lid can....................................................... 29 Special refrigeration equipment ....................... 69 Spout can ........................................................ 29 Sprockets ......................................................... 79 Steam boilers................................................... 79 Structural floor decking sheets......................... 19 Sweepers ......................................................... 33 Switching relays ................................................. 3 Table top coder.......................................... 71 Tank weighing unit......................................... FIC Temperature controllers ..................................... 3 Thermal processes.............................................. 9 Thermic fluid heater......................................... 79 Timers................................................................ 3 Tin/can............................................................. 29 Total water management................................. 39 Turbine blowers/exhausters .............................. 68 Ultrasonic sensor........................................ 71 Under counter refrigeration ............................. 57 Universal-type unit air coller .............................. 5 Vacuum cleaners ........................................ 33 Ventilators ....................................................... 71 Vertical freezer/chiller....................................... 57 Vertical non-IBR oil fired steam boiler .............. 79 Vibration motor ............................................... 74 Viscometer...................................................... FIC Vision sensors .................................................... 3 Wastewater treatment & recycle plant ..... 39 Water chillers.............................................57, 69 Water cooler.................................................... 57 Water purification systems............................... 45 Water treatment plant ..................................... 39 Water wall membrane panel IBR steam boiler ..... 79 Waterjet cleaning machines ............................. 68 Weigh bridge.................................................. FIC Weigh scales................................................... FIC Wood fire four pass thermic fluid heater ......... 79 Wood fire thermic fluid heater ........................ 79 X-ray inspection system............................ FIC

BC - Back Cover, BIC - Back Inside Cover, FIC - Front Inside Cover

SOURCE LIGHT & MEDIUM ENGINEERING PRODUCTS @ www.engg-expo.com

August 2010 | Modern Food Processing

ADVERTISERS’ LIST

Advertisers’ Name & Contact Details

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Advertisers’ Name & Contact Details

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Advertisers’ Name & Contact Details

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FIC

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Modern Food Processing | August 2010

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