Modern Food Processing - December 2010 by Infomedia18

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Modern Food Processing

December 2010

An invite that rewards as well...

Dear Reader, ‘Modern Food Processing’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the food processing industry.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 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 of the world’s largest trade publishing houses with more than 200 special interest titles and offices in every major country), it ensures that advertisers are able to promote their products and services across the globe at no extra cost. So get going and rush your articles, write-ups, etc… Thanking you, Yours sincerely,

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EDITORIAL

Creamy prospects

iven India’s numero uno position in milk production, the processing part of it has a lot to achieve. However, the upward surge of value-added products in the overall packaged dairy products market in the country over the recent years, is quite heartening. New packaging formats that are smaller & convenient-to-carry, greater cross-cultural exposure to different food habits, etc seem to be amplifying this phenomenon. Globally, dairy products are witnessing a flood of health and wellness trends. These include consumers’ growing preference for food products vouching improved nutrition, fitness and general well-being; with probiotics, fibres, vitamins, calcium and omega-fortified products figuring among common fortifications in dairy products. The recent consumer trends suggest a transformation of the dairy sector from a traditional low-margin liquid milk practice to a branded value-added approach. However, to leverage these opportunities, one needs to fortify the capabilities in terms of product development, market distribution and brand building, among others. The question is how many of the existing dairy players in the country would be able to manage this transition successfully? Turn to the ‘Sector Watch’ and ‘Market Scope’ for more interesting insights into the dairy space.

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), Anwesh Koley (Delhi) Copy Desk: Marcilin Madathil Products Desk: A Mohankumar Chief Photographer: Mexy Xavier 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 CEO-Publishing: Sandeep Khosla 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

Now, let’s look at another sector, where India is keeping pace with the global peers. The confectionery market, in particular, where the new product development aspect is said to have seen the launch of more than 200 products in various categories last year! Along with rise in upscale retail outlets that have helped increase the acceptance of foreign chocolate brands and gourmet confectionery, interestingly the adult population is adding to the growth of this industry. The ‘Industry Update’ analyses the plethora of opportunities as well as challenges in the confectionery segment. Last but not the least, as the sunrise sector of Indian food processing continues its growth journey driven by market demand, it is important not to lose sight of constant innovation in products and services. Besides close collaboration between research institutions and industry in identifying joint business opportunities, public-private-partnership in boosting R&D can give India a strategic advantage. Take a look at the ‘Roundtable’ for various viewpoints on this.

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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December 2010 | Modern Food Processing

CONTENTS

LEADERS SPEAK 26

“Development of natural solutions to keep food safe and fresh is a trend around the globe” ...says Melanie Galloway, President, Kemin Food Technologies

ROUNDTABLE 28

R&D in food processing: Scopes for improvement

IN FOCUS 32

Haasia Packaging Pvt Ltd: Empowering the packaging segment

SECTOR WATCH 34

Dairy processing: En route another ‘white’ revolution Pankaj Gupta and Angshuman Bhattacharya, Tata Strategic Management Group

MARKET SCOPE 38

Dairy whiteners: Leveraging the ‘convenience trend’

INDUSTRY UPDATE 40

Confectionery industry: Mouthful of opportunities

MARKET INSIGHT - AUTOMATION PRODUCTS 45

Automated manufacturing: Means to enhance efficiency T R Jayaram, Head - Automation, Buhler (India) Pvt Ltd

MARKET INSIGHT - VISION SYSTEMS 50

Quality improvement: Eliminating defects & impurities with a clear vision Didier Lacroix, Senior VP - International Sales & Services, Cognex Inc

INDUSTRY INSIGHTS 54

Baby foods: The changing market paradigm Shushmul Maheshwari, CEO, RNCOS E-Services Pvt Ltd

FOOD SAFETY 58

Halal certification: For faithfully safe foods Subhash Vaidya, Proprietor, Dairytech Consultancy Services

SMART LOGISTICS 64

Backward linkages: Imperative for an efficient supply chain Abhijit Upadhye, Director, McDonald’s India

CURTAIN RAISER Frost & Sullivan 2010 India Excellence in Chemicals, Materials and Food Awards: Recognising exemplary achievements

REPORT Cover photo courtesy: Russell Finex

Fi India 2010: Giving a boost to ingredients

Food & Bev Tech 2010: Synergising success by stimulating growth

R EG U L A R S EC TI O N S Editorial .................................................... 11 National News ......................................... 14 National News - Report .......................... 20 World News............................................. 22 Events Calendar ....................................... 68 Product Update........................................ 72 Product Inquiry ........................................ 83 Advertisement Inquiry.............................. 85 Product Index........................................... 87 Advertisers’ List ....................................... 88

Highlights of Next Issue Sector Watch : Health Foods (Functional Foods / Nutraceuticals) Industry Update : Fish Processing Note: ` stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise

Modern Food Processing | December 2010

70 71

Details on page no. 43, 44, 61, 62

NATIONAL NEWS RESEARCH INITIATIVE

Novozymes inaugurates R&D centre

Novozymes, one of the leading producers of industrial enzymes, recently inaugurated its new R&D centre in Bengaluru. It will house the Indian operations, including global support services and the R&D centre. DOMESTIC MANUFACTURING

Cadbury to manufacture Tang in India Cadbury India recently announced plans of local manufacturing of parent Kraft Foods’ orange drink Tang, and capacity expansion plans for its confectionery products. “It is a legacy plant of Kraft in Hyderabad, which has not been utilised. We will start the manufacturing there,” said Anand Kripalu, Managing Director,

ALCOHOLIC BEVERAGES

NV Group announces capex and new product plans

Alcoholic beverages maker NV Group has announced investment plans worth nearly ` 450 crore in two facilities as it aims to nearly quadruple its current NEW FACILITY

FieldFresh inaugurates unit at Hosur FieldFresh Foods, a joint venture of Bharti Enterprises and Del Monte Pacific Ltd, has inaugurated its R&D and manufacturing facility at Hosur, Tamil Nadu. The facility is the first-of-its-kind in India with beverage and processed food being produced at the same place under the brand Del Monte. The

It was inaugurated by Steen Riisgaard, CEO, Novozymes and Per Falholt, Executive Vice President - R&D. “Our Indian management team has found a facility that can accommodate both the needs of Indian business in order to deliver on our growth promise and the growing demand for global shared services. We believe that this space creates a prominent landmark for Novozymes in India and is geared to accommodate the growth of

Novozymes in India in coming years,” said G S Krishnan, Regional President – India, Novozymes. Per Falholt said, “This centre will play an important role in our efforts toward discovering new applications and technologies globally and locally.” The R&D centre will undertake protein engineering work for Novozymes’ global requirements and will act as a resource base for the company’s discovery projects.

Cadbury India. He added that Tang, which has been imported from Thailand to serve the Indian market so far, will be produced at Kraft’s Hyderabad plant. Cadbury India came under the Kraft Foods fold after the US-based firm acquired British candy maker, Cadbury Plc for $ 19.6 billion in January this year. The integration process is on in terms of synergising distribution channels of Cadbury and Kraft in India. “Capacity is a

challenge for us, as we look to drive up volumes. We need to expand it and we will be doing it significantly,” he observed. Expansion plans will take place at the company’s existing six facilities in India.

capacity by 2012. The company, which has two distilleries and five bottling plants at the moment, currently has a production capacity of 200 kilolitre (kL) per day. It is in the process of establishing two more multi-grain distilleries in Assam and Andhra Pradesh. “We are investing nearly ` 450 crore in Assam and Andhra Pradesh for setting up two distilleries. With these becoming operational in 2012, our capacity will touch 750 kL,” said Ashok Jain, Chairman, NV Group.

The Delhi-based NV Group, which has 12 alcoholic brands, including Blue Moon Vodka and Party Special Whiskey, under its portfolio, is one of the biggest spirits makers in India. The company recently inked a sales and manufacturing agreement with Belvedere Group, France for launching its products in the country. Under the agreement, NV Group will manufacture Belvedere group’s famed Sobieski vodka in its Haryana-based distillery and then market it through its network.

facility, with an initial investment of ` 115 crore is spread across 21.4 acre and will produce fruit drinks. “Going forward, our vision is to make Del Monte one of the top 10 brands in the processed food and beverage industry over the next few years,” said Rakesh Bharti Mittal, Vice-Chairman and MD, Bharti Enterprises. Besides, the facility will process fruit drinks at the rate of 300 cans & 200 PET bottles per

minute and over four tonne per hour of culinary products. “India is one of the most exciting consumer markets to be in. I am excited about this new chapter of Del Monte’s journey and look forward to more milestones in our India story,” said Joselito D Campos, CEO, Del Monte Pacific Ltd.

Modern Food Processing | December 2010

NATIONAL NEWS ACQUISITION

Jain Irrigation acquires UK firm

Jain Irrigation Systems Ltd (JISL), one of India’s biggest fruit and vegetable processing companies, has acquired controlling stakes of 80 per cent in the UK-based food firm Sleaford Quality Food CONDIMENTS

McCormick buys 26 per cent in Eastern Condiments McCormick, one of the global leaders in the manufacturing & marketing of spices, herbs and seasonings, has bought 26 per cent stake in Eastern Condiments Pvt Ltd (ECPL), a major Indian spices and seasonings dealer, for $ 36 million. The partnership is believed to bring the latest technology in spice supply chain management and manufacturing NEW APPOINTMENT

AFPPA sets up new advisory council

The Aseptic Food Processing & Packaging Industry Association of India (AFPPA) recently announced the details of its newly constituted advisory RECOGNITION

McCain Foods India wins prestigious award McCain Foods India Pvt Ltd, a whollyowned subsidiary of McCain Foods Ltd, was recently honoured with the prestigious SIAL d’OR Country Award 2010, for the commercial success of its McCain Aloo Tikki product, at the Salon International de l’Alimentation (SIAL) Show in Paris, France. Aloo Tikki, scored the highest among participants in nine

Ltd for around £ 10 million. Sleaford is a noted supplier of food ingredients to food industry, both in the wholesale and retail space since 1968. The acquisition is perceived as bringing JISL one step closer to the market, with an opportunity to enter into the large ethnic food market in the UK and possibility of addition of new products in its food division product range. “Jain’s food business is worth around ` 520 crore. We believe

Sleaford affords us good returns and adds to our top-line. Through this deal, we will have direct access to the endusers of our products,” said Anil Jain, Managing Director, JISL. James Arnold, Managing Director, Sleaford Quality Foods, said, “JISL is the perfect partner for our business. In addition to their strong product supply support, they bring excellent agricultural and food processing expertise to help improve the success of the business.”

into India. McCormick will also help ECPL grow in the authentic Indian cuisine segment in the US and other Western markets. “McCormick’s global presence will bring authentic products to Indian consumers in international locations as well as introduce other consumers to Indian cuisine. This is a partnership of two like-minded companies devoted to quality and serving the customer,” said M E Meeran, Chairman, ECPL.

Alan Wilson, Chairman, President and CEO, McCormick, said, “This partnership is an important element of the firm’s strategy. EPCL has built a strong brand image and we look forward to working closely with them to drive differentiation and growth in India.”

council. This council includes: Rajiv Dhar, Secretary General; D P Tripathi, Senior Advisor - Corporate and Legal Affairs; Dr Sanjay Oak, Advisor - Nutrition and Health; Ranjana Saikia, Environment and Sustainability; Jaideep Gokhale, Industry Advisor; and Kamal K Khosla, Industry Advisor. It will be working towards achieving the objectives of the association, which deal with promotion of benefits of aseptic technology and

balanced nutrition; representing issues like VAT, GST, legislation & other aspects of the industry, among others. Commenting on the development, Dhar said, “AFPPA is the voice of the packaging industry and an essential link between the government and the industry. Its strong managerial leadership will focus on achieving the defined objectives based on food safety, consumer wellness & environment sustainability.”

categories, winning the ‘Country Award - India’. SIAL, one of the largest trade shows for food in the world, created the SIAL d’Or, which recognises innovative products for success in trading in their local markets. K S Narayanan, Managing Director, McCain Foods India Pvt Ltd said, “We are extremely honoured that the product has been recognised as the country’s best product among leading food processors. Aloo Tikki marks McCain Foods’ foray

into the ethnic snack foods category in India. Since its introduction, Aloo Tikki has been well-accepted not only by retail consumers but also in the food service segment and is now being exported to many countries.”

Modern Food Processing | December 2010

NATIONAL NEWS BEVERAGE LAUNCH

Lime flavour added to Smirnoff’s vodka range

Smirnoff, one of the leading vodka brands in the world, recently launched a new flavour, Smirnoff Lime. Abanti HEALTH FOOD

YBG launches Nutrinext range of sugar-free products Rebirth, the branded wellness stores of the Yash Birla Group (YBG) has introduced sugarless health and nutritious food products in contemporary formats. Rebirth claims to offer a healthy eating option without compromising on the taste with its sugarless cookies,

Sankaranarayanan, Director - Marketing and Innovation, Diageo India, said, “The latest innovation from the world’s number 1 vodka brand, Smirnoff Lime has been developed to appeal to consumers who are looking to add more variety to their current drinks repertoire and to complement the existing successful range of flavoured vodkas by Smirnoff. Smirnoff Lime’s versatility presents a wide and new spectrum of unique concoctions for the

consumers.” Smirnoff Lime is available for ` 720 for a 750 ml bottle and ` 180 for a 180 ml bottle. For over a century, Smirnoff has produced premium quality, triple-distilled vodka. Today, Smirnoff is one of the world’s leading premium vodka brands, with distribution in 130 countries and a number of popular products. Diageo offers a large collection of beverage alcohol brands across spirits, wines and beer categories.

chocolates, muffins and nutribars. These products allow quicker digestion and assimilation, thus enhancing body metabolism. “We at YBG always believe in enriching lifestyles and introducing products that are healthy. With Indians having a high propensity to turn diabetic and the fact that every fourth diabetic in the world is an Indian, propelled us to come up with an eating option that is tasty and would help prevent diabetes.

Since the products are sugarless, they can also be enjoyed by people who are already diabetic and need to control the urge,” said N Venkat, CEO & MD, Birla Wellness.

Modern Food Processing | December 2010

NATIONAL NEWS Report

Expansion plans

Buhler opens application centre and training academy in India Buhler Group has recently set up an application centre for grain processing industry and Buhler Academy in Bengaluru. The company is also targeting a turnover of ` 1,000 crore by 2014.

s a part of its 150th anniversary grain management in the Indian climatic celebration, Buhler India has conditions.” launched a state-of-the-art Stefan Scheiber, Head of Food Processing application centre in Bengaluru. Division, Buhler AG, said, “The expected growth With its technological expertise and thorough in global population in conjunction with knowledge of local needs, Buhler engineers increasing urbanisation and the related changes have been able to solve numerous problems of in dietary habits are steadily accelerating Indian grain processors over the years. Dipak demand for grain to cover the needs for meat & Mane, Managing Director, Buhler India, said, dairy products. At the same time, crop-growing “India contributes almost 15 per cent of world’s areas are limited or are even tending to grain output, but investment in this segment is decrease due to the change in climate and the less than 5 per cent. Also, utilisation of valuable crop today grain handling is acreage for other purposes. the biggest challenge. In this environment, Buhler The use of latest grain can make an important processing technology for contribution in the areas generating higher yields of food, raw materials, and integration of grain energy & the environment, processing units will help and will indeed assume this India overcome these responsibility.” challenges.” The company has also The application started Buhler Academy, centre has been set up L-R: Dipak Mane, Urs Buhler, Calvin Grieder with the objective of and Stefan Scheiber with an investment of creation of future talent ` 10 crore and is an for the organisation and ideal place for undertaking optimal design offer world-class training to Buhler customers. of modern product processing units. With Mane informed, “Buhler Academy currently a range of machines and automation & has four major programmes (Buhler Academy control systems, the plant also serves as an for Specialized Education or BASE), which will in-house platform for hands-on training. encourage entrepreneurial opportunities for the Urs Buhler, Chairman, Buhler AG, who was Indian youth in the food grain management present for the anniversary celebrations in sector, enabling a robust future for the sector.” India, said, “Looking back at our history, it has Buhler is one of the leading global been a meaningful journey. We are delightful to suppliers of process engineering solutions. celebrate 150 years of our existence, of which In India, Buhler is one of the leading system India is an integral part.” providers for rice, pulses & wheat processing Calvin Grieder, CEO, Buhler AG, expressed, industry. Its Bengaluru facility manufactures “We are working on providing India-specific the main rice and flour milling machines along needs. We are continously doing research with the control systems, aspiration equipment and development to provide solutions for & accessories.

Modern Food Processing | December 2010

WORLD NEWS NEW UNIT

MachinePoint establishes new subsidiary

Cesar Rodriguez

MachinePoint Group has established a subsidiary, MachinePoint Food Technologies, to offer complete plant & COLLABORATION

PETpoint and Brau Beviale to be held at same place drinktec, one of the world’s leading fairs for beverage and liquid food technology, and Brau Beviale, the European trade fair for beverage raw materials, technologies, logistics and marketing, will co-operate in future in the PET segment. The organisers of the two exhibitions, Messe München GmbH and Nürnberg Messe GmbH, have concluded a corresponding

DAIRY PROCESSING

Tetra Pak launches heater for direct UHT treatment

Tetra Pak has launched a new direct heating unit for ultra heat treatment (UHT) dairy production, which it claims can significantly cut both product loss CAPACITY EXPANSION

Giles Foods expands production capacity The UK-based specialty bread producer, Giles Foods, claims that the expansion of its production facilities with an investment of £ 4.5 million will allow it to meet a hike in demand for its premium and artisan range. David Marx, Director - Sales and Marketing, Giles Foods, said, “An additional 45,000 sq ft plant at its

process installation, and turnkey projects to processors in the agro food, beverage and dairy industries. The subsidiary offers the possibility of integrating used machinery into a new project offering. Born from a partnership between MachinePoint Group and Gemina, the new unit will cater to industries that are looking to expand, update or modify their production facilities. The possibility of incorporating used, along with new machinery, is a unique proposition.

MachinePoint Used Machinery, a sister company of MachinePoint Food Technologies, controls 80 per cent of the used equipment currently for sale in Europe; and has extensive logistics and engineering experience in transporting & integrating used equipment successfully into new plant layouts. “Establishing MachinePoint Food Technologies was a natural move in the continuous growth of MachinePoint Group,” said Cesar Rodriguez, CEO, MachinePoint Group.

agreement under which the PETpoint, the PET segment at drinktec, will also take place at Brau Beviale in Nürnberg in future, starting in November 2011. The PETpoint will take place for the first time at Brau Beviale in Nürnberg from November 9-11, 2011, after which an annual cycle is planned. The PETpoint presents mainly technologies and accessories for the manufacturing and recycling of drink bottles made of polyethylene

terephthalate (PET). Polylactide (PLA) and other plastics for beverage containers are also represented at the PETpoint. The PETpoint has been an integral part of drinktec.

and operating cost. Direct heating units, as opposed to indirect units, use steam injection to speed up the heating and cooling process so that the impact of heat on product quality is minimised. Run at higher operational cost than indirect units, such heating systems are designed to be used in the manufacturing of premium dairy and soy products. With its new, Tetra Therm Aseptic VTIS unit, Tetra Pak aims to reduce the cost and product loss associated with direct heating systems.

Compared to the previous generation of direct UHT heaters, the company claims that the Tetra Therm Aseptic VTIS reduces operating cost by 15 per cent. In addition, the Swedish firm said the direct heating unit cuts product loss by up to 40 per cent compared to current industry standards and boosts running time by up to 60 hours. To deliver such improvements in operating efficiency, Tetra Pak said it has introduced a number of design changes.

Milton Keynes site along with investment in automation and a three-deck tunnel oven from Mecatherm means it can achieve an increase of volume capacity of 40 to 50 per cent.” Migration to a fully automated facility from a previous rack and tray operation has also resulted in efficiency gains and, moreover, it has already seen a massive reduction in its carbon footprint. The gas and electricity metre readings at the

new manufacturing facility over the past two months indicate energy savings of 45 to 50 per cent. The automated facility also enables it to cut labour costs as it no longer has a requirement for temporary staff.

Modern Food Processing | December 2010

WORLD NEWS MARKET REPORT

Fitch predicts stable outlook for packaged food sector

While the US economy has struggled to shake off the effects of recession, making CONFECTIONERY MARKET

Baker Perkins launches high-value deposited soft confectionery Baker Perkins has developed a range of unique high-value soft confectionery products using a multi-headed ServoForm depositing system – toffee cups, complete with different fillings, toppings and/or inclusions. The two and threeheaded depositor technology employed INSTRUMENTATION

SensoTech’s inline beer analyser can cut water and energy costs

SensoTech has claimed that its new version of the LiquiSonic input beer analyser can SUPPLY CHAIN

System from Qadex can simplify traceability The supply chain solution provider Qadex has developed a product specification system that would enable manufacturers to provide a full description and history of food & drink ingredients and packaging in retailer-friendly formats. The new system can incorporate software, which Qadex had launched in 2009, that alerts

consumers cautious about their spending, demand for packaged food has remained relatively stable. However, the margins of packaged food companies have come under pressure as overhead costs for such products as commodities have increased. “Swiftly rising input costs have put packaged food companies in a situation where margins are being squeezed. It will take time for price increases implemented by the food companies to catch up with the commodity cost inflation they are

already incurring,” said Judi M Rossetti, Senior Director, Fitch Inc. But overall, there is good news for packaging manufacturers who supply material to leading companies such as Heinz, Campbell Soup, Kraft and ConAgra. According to the Fitch report, “Food remains an eternal necessity for consumers, and therefore the packaged food companies tend to have relatively stable operating results and credit metrics under various economic conditions.”

to make these indulgence products, combined with flexible rubber mould technology, can produce high quality luxury products more economically than many conventional processes. The first head deposits a toffee cup, the second a filling – fondant, praline, chocolate, jam and jelly are among the possibilities. A third head can add a topping such as chocolate, or inclusions including nut or fruit pieces.

The process utilises Baker Perkins’ ‘long-term’ layering technology. A dwell time between each deposit allows the first to partially set before the next one is deposited.

minimise water and energy processing costs. By measuring the product flow of a main pipe, the Liquisonic Plato 40 can analyse beer ‘directly and completely’ by using a combination of an ultrasonic sensor with a process refractometer. The analyser measures the alcohol content in addition to the resulting concentration of original gravity and the temperature. “It is the goal of breweries to realise quality control, efficiency and environmental protection by saving energy and water. The installation of a

‘modern and reliable’ measuring system is required to meet these demands, which is why we have developed the LiquiSonic Plato,” said SensoTech officials. The device can detect the extract content of the liquid during the lautering process, which means the sparge water point can be ‘determined exactly’. By equipping the system with an EXtrACTTotalizer, the current wort (liquid extracted from the mashing process during the brewing of beer or whisky) concentration with the wort flow can be calculated.

processors to the potential allergen risks their products run. But the new system goes further in detailing a comprehensive picture of all raw materials used, holding details of everything from nutritional information to country of origin. Processors would be able to migrate information currently held on their product databases onto the new Qadex system and it would convert it into the format required by any customer. “The

software will create the information in the format required by Tesco or Sainsbury, for example. If the information is on another system, we can migrate it over with a migration tool,” explained Stephen Whyte, Business Development Director, Qadex.

Modern Food Processing | December 2010

LEADERS SPEAK

â&#x20AC;&#x153;Development of natural solutions to keep food safe and fresh is a trend around the globeâ&#x20AC;? â&#x20AC;Śsays Melanie Galloway, President, Kemin Food Technologies, USA. With an educational background in chemical engineering and business management, she has been instrumental in driving the growth of Kemin Food Technologies since 2002. In an interaction with Mahua Roy, Galloway analyses the performance of the ingredients industry and highlights the importance of India as a growth driver for the company.

On the Indian market Kemin has been present in the Indian market since the mid 90s. We have local operations and a strong infrastructure. In general, India is one of the largest and fastest growing markets in the world. Food and beverage market in India is expanding rapidly and is projected to grow at a Compounded Annual Growth Rate (CAGR) of about 7.5 per cent during 2009-13 and we expect it to reach $ 330 billion by 2013. For Kemin, the Indian market is critical to achieve its worldwide vision of reaching half the populace of the world each day with its wide range of products and services. While the opportunity in this market is clear, there are challenges as well. For the food industry, the marketplace is fragmented, which makes it difficult to introduce new technologies and molecules. Also, there is a wide variation in the market demands. In the urban areas,

Modern Food Processing | December 2010

consumers are driving manufacturers toward more natural, label-friendly and healthy alternatives. However, the mass market is still cost-conscious, needing to provide nutrition to many at the lowest cost possible. As a supplier to this market, we need to offer solutions taking both the aspects into consideration.

Growth strategy in India In the food processing value chain, India is dominated by mass market, convenience, snacking and other primary processed foods. The country has a tremendous potential to move up in the value chain due to favourable market drivers like rising income levels, growing need for convenience due to urbanisation and a greater proportion of urban working women, growing organised retail & changing food habits. Our strategy for growth is similar to that in other regions of the world. We focus on

LEADERS SPEAK

understanding our customers’ current and future needs, developing products to meet their requirements, and providing these solutions with quality and responsiveness one can count on. The Indian and US consumers tend to be different. In the US, people eat more processed foods than Indian consumers. From my experience of travelling to India and visiting supermarkets, there are certain things that are the same. However, the amount of whole foods and unprocessed goods that are seen regularly in India is much higher than that in the US. Over a period, I feel that consumers from each region will influence each other more and become more harmonised in their habits & needs.

R&D initiatives

Optimising the supply chain

Interesting innovations at Kemin

Continuous improvement is the goal in all areas including costs, and we have a multiple approach model to minimise fluctuations in the price of our products. There are three areas that we focus on under this model. One, during our product development process our operations personnel work with the R&D team to best match a new product with existing processes/production capabilities or optimise the development of a new process/capability. Second, being basic in the production of raw materials is an important part of our total cost management system. An example is our rosemary extract, where Kemin developed its own proprietary cultivar of rosemary that maximises active compounds. Kemin grows, harvests, extracts and formulates based on its customers’ needs. If we cannot be basic, we work to develop partnerships with suppliers of key raw materials. Taking advantage of global requirements and consolidating purchases also increases our purchasing power and reduces overall costs. Last, we have local production capability around the world to maximise flexibility, meet customer lead-time demands and ensure consistent supply.

Continuous innovation is a key focus at Kemin. We utilise a stage-gate process developed within Kemin known as the Product Innovation Process (PIP). In PIP, many ideas are submitted and evaluated to move through the innovation funnel. One of the areas Kemin stresses is that these ideas can come from anyone, not just from the R&D team. As an example, this gives the sales force a chance to submit ideas coming straight from our customers. The other way Kemin Food Technologies develops new product applications is through our Customer Laboratory Services (CLS), in which we offer free evaluation of our products in a customer’s food matrix.

Our most exciting innovations right now come from Kemin’s Specialty Crop Improvement (SCI) group. This specialised team focusses on developing and growing botanicals that contain actives for food stability. The latest development from this group is a new natural, water-soluble antioxidant from a unique source. We are in the process of launching this product worldwide. The major enduser segment is beverages, although any primarily water-based matrix with small amounts of fat to oxidise, is ideal for this product. The low flavour profile makes this product’s feasibility in flavour sensitive applications attractive.

‘Natural’ is in Worldwide, we see the trend of consumers becoming more aware about reading labels of products they are considering and choosing, based on products having fewer synthetic ingredients. In addition, consumers are reading a lot online about what foods and ingredients are healthier for them and their families. One of the key trends in the natural market is a consumer reading ‘no additives’.

From an international perspective, the regulatory landscape can be challenging as it is changing continuously. While some of the changes are definitely necessary, others can actually delay the launch of new & innovative molecules and products in the market. Growth opportunities The development of natural solutions to keep food safe and fresh longer is a trend around the globe. Another is the development of ingredients or processes allowing food manufacturers to reduce the total amount of sodium in their products. From an international perspective, the regulatory landscape can be challenging as it is changing continuously. While some of the changes are definitely necessary, others can actually delay the launch of new & innovative molecules and products in the market.

Growth prospects As families, our lives seem to get busier by the day. With the continued push to get more accomplished during the same 24 hours of each day, technology and products that make everyday activities more convenient and efficient will grow. For the processed food industry, there is a great opportunity for growth not only in providing convenient foods, but also those that have labels more like our homemade meals. Consumers are searching for products that offer the same efficiency, while allowing them to feel confident in the quality and nutrition they are providing to their families. As a supplier to the food industry, our challenge is to provide solutions that make development of processed foods with label-friendly ingredients possible without compromising on freshness and safety.

December 2010 | Modern Food Processing

ROUNDTABLE

R&D in food processing

Scopes for improvement Although the food and beverage (F&B) industry in India has been focussing on R&D, there is scope for further improvement. To make significant strides in R&D, the research institutes and industry need to collaborate and identify joint business opportunities. Entry of new overseas players and increase in investments by MNCs are also giving impetus to R&D activities in India, finds out Shivani Mody. Courtesy: Pacific Northwest National Laboratory

Dr Arpita Mukherjee Professor, Indian Council for Research on International Economic Relations Indian consumers are different from their international counterparts & manufacturers should identify the local flavour & taste trends and reduce cost of processed food since Indian consumers are price-conscious. There is need for investment by F&B companies in environmentfriendly packaging technologies, which will increase the shelf-life of products. However, there has not been much investment in R&D in the F&B segment. This is because until recently, many multinational and foreign brands did not have presence in India. Besides, the growth of corporate retail in food and grocery segment is slow; FDI is not allowed in multibrand retail; the supply chain is fragmented, and last but not the least, large number of the F&B manufacturers

Modern Food Processing | December 2010

are in the SME segment thus not having enough funds for investment in R&D. In India, agriculture research is largely concentrated in government-funded universities and institutes. Private-public collaborations in R&D have been limited. But, this trend is gradually changing. The government is now offering tax incentives and exemptions to private sector for setting up R&D centres and for import of research equipment. There is a need to encourage publicprivate partnership in R&D. Private sector should be made a part of inter-government agreements. Allowing FDI in multi-brand retail will encourage foreign retailers and manufacturers to explore the Indian market and invest in R&D & manufacturing. Although investment in R&D by F&B companies had been low in India in the past, there has been an increase in R&D investment in recent times. For example, Nestle has announced plans to set up an R&D centre in Gurgaon; and FieldFresh, the 50:50 joint venture of Bharti Enterprises and Del Monte Pacific Ltd, is investing around ` 115 crore in an R&D & manufacturing facility in Hosur.

ROUNDTABLE

Dr B Sesikeran Director, National Institute of Nutrition Over the past couple of years, the F&B industry in India has seen considerable efforts towards R&D. Many industries have started investing significantly towards conducting research for development of new products as well as modifying the processes to meet the needs of customers and the country. In doing so, F&B manufacturers will have to keep in mind a number of issues while developing new food products. They will have to find ways to modify their existing product range in line with the growing problem of lifestyle disorders like obesity, diabetes, high blood pressure, cardiovascular diseases, etc. Companies will also have to develop new

Parveen Dang Director (Sales & R&D - South Asia), Orana India There is a need to invest in R&D to develop new products including process development and process validation, ensure technology improvement, enhance shelf-life of perishable fruits & vegetables, and set up state-of-the-art laboratories to develop innovative products to meet changing needs of customers. Several technological innovations have been made in India in areas like health foods, speciality foods, ready-to-serve foods, eco-friendly packaging materials, etc in recent times. But there is room for greater improvement in all segments. Keeping in mind the food security for the huge population of India, we must move towards increased processing and preservation of food. For this we need technology at affordable

M A Tejani Managing Director, Gits Food Products Pvt Ltd The growth and development of food processing industry in India has not kept pace with the rest of the world for well known reasons. The situation has not improved much over the years, despite all-round efforts. Majority of the manufacturing units are small-scale and there is not much emphasis on R&D. Hence, there is only negligible investment in research. The Ministry of Food Processing Industries is trying to establish mega food parks with R&D centres combined with quality assurance laboratories, but these are yet to get functional. The focus area for R&D in India for F&B companies and research institutes needs to be multi-pronged. First, the agri-horticultural yield per hectare needs to be raised to world

products having the muchneeded essential nutrients, which need to be modestly priced to meet the requirements of the underprivileged segment of our society. They will have to demonstrate the usefulness of products by conducting clinical studies. Research institutions need to have greater interactions with the industry and build capacity to ensure that the R&D done by the industry is scientifically valid.

price, which can be achieved through collaboration. The focus areas should be product as well as process development. This will ensure that the country develops high quality processed foods for domestic as well as export market. Investing in appropriate technology will give us the right products at competitive prices. There should be focus on value addition for processed foods in terms of shelf-life, preservation and nutrition. A well-focussed approach can make India the processed food factory of the world.

standards. Secondly, the varieties of fruits and vegetables should be changed to render them suitable for processing. At present, the agricultural produce in India is of table varieties rather than processing varieties. Obviously, more needs to be done to transform farming, which will ensure that the right raw material is available for the food processing industry. Simultaneously, modernisation of SME food processing industries is the need of the hour, if India is to become the food supplier of the world.

December 2010 | Modern Food Processing

ROUNDTABLE

P V Suryaprakasa Rao Technical Advisor & Director, Ushodaya Enterprises Pvt Ltd (Priya Foods Division) Unfortunately, we do not have authentic, well-publicised, freely available data on the magnitude of investments made on R&D by F&B industry in the country. However, it is a fact that the R&D investment levels are poor and totally inadequate, barring, perhaps, multinationals and some of the companies of repute.

P L Kaul Managing Director, Mariental India Pvt Ltd The F&B industry is definitely not doing enough in terms of R&D and there is scope for more investments. At present, the R&D activity has just started and has a long way to go. Majority of the funding by the government is directed towards research institutions and the industry does not have access to it. There is a major disconnect between the research laboratories and the industry. Currently, initiatives are

Srividyaranjani V Research Analyst, Chemicals, Materials and Foods, South Asia and Middle East, Frost & Sullivan Though the Indian government is taking initiatives in research, finance is insufficient. It requires investment from the private sector also. In addition to the bulk of Indiaâ&#x20AC;&#x2122;s investment resource, there is an important role to be played by the FDIs in R&D, which adds value, develops new technology, brings new management practices, opens up new markets and launches new products.

Modern Food Processing | December 2010

The ceaseless quest and efforts of any R&D unit is largely directed towards cutting costs and wastes, quality upgradation, adding product & brand value, enlarging product portfolio, enhancing consumer satisfaction, and constant troubleshooting. The most urgent and crucial need of both the research institutes and government is intensive and continual interaction with the industry. There has been no institutionalised standing mechanism to promote collaboration and co-operation between research institutes and industry in order to create and sustain the synergy derived or derivable from the efforts made on either side. Such an arrangement is a vital necessity of the industry.

directed towards developing an interface between research institutions and the industry for a more collaborative approach. This will also enable knowledge sharing and exchange of technical know-how that will help the industry for development of products & processes. There needs to be a paradigm shift in the mindset of the industry to reap benefits. Further, the industry feels that research institutions carry out academic-related, fundamental research, which is not applicable in the industry. Moreover, R&D is not well-developed in the country due to lack of finance and investments. One model that the industry can look at is the one that is followed in foreign countries. The lack of funds for research institutes globally is balanced with the industry funding research activities.

The research institutes and government organisations should provide support to entrepreneurs and exporters in India to export home-grown food items effectively. But the collaboration between the institutes and industries is limited. The shortage of quality R&D specialists is one of the major blocks preventing new product development in the industry. This can be reduced by educational and training institutions offering advanced courses in the areas of food science and technology. The food processing companies can collaborate with research institutes for upgradation of high-end skills, product improvement and should support the institutes to take up consultancy work for the industry.

IN FOCUS

Hassia Packaging Pvt Ltd

Empowering the packaging segment In a short span of time, Hassia Packaging has established a strong foothold in the market. The cornerstone of its success is its customer-centric solutions along with focus on issues like operational ease, packing speed, high accuracy, optimal film usage, etc. The machines manufactured by the company have been installed in the dairy, food, agrochemical and detergent plants in several countries.

Prasenjit Chakraborty

he journey of Hassia Packaging Pvt Ltd started in 1999 with the setting up of a manufacturing unit at Sanaswadi, Pune. It is part of a Euro 450-million German process and packaging group, OYSTAR Holding GmbH. Currently, the company has one unit comprising an office area of 3,439 sq ft and 15,677 sq ft manufacturing unit. It includes a demo room, where analysis and testing are carried out to offer the best filling systems. The unit also has different departments like design and R&D, machine assembly & sub-assembly, machine testing set-up, quality control, etc. All the departments are well-synchronised to ensure optimised production. Hassia Packaging offers a wide range of solutions like vertical form fill seal (VFFS) machines, high speed VFFS machines (for packing products up to a speed of 250 packs/ min), jar indexers (for any product to be filled in jars/cans/tins), fillers, stand-alone weighers (for filling product in preformed bags), universal rotary fillers (for packing products in cups, tubs and cones) and complete solutions (combination of any filler with bagger or jars). The range of products that are filled by Hassia (in the weight range of 3 gm to 25 kg) include dairy products (milk powder, dairy whitener, shredded cheese, yoghurt, ice cream), food (snack foods, atta, rice,

Modern Food Processing | December 2010

lentils, tea/coffee, salt, sugar, frozen foods, spices, etc), agro products (agrochemical, seeds), home and personal care products (detergents, white cement, scouring powder, etc).

Manufacturing standards Hassia believes that conducive work environment always results in better productivity. Hence, all processes are clearly defined, documented and controlled. Moreover, critical processes are validated to ensure consistency and compliance with specifications. All instructions and procedures are followed as well as instructions are given clearly. The assembly team is trained to carry out document procedures. “If there is any complaint regarding a product, the causes of defects are investigated, and appropriate measures are taken to rectify them & prevent recurrence of such defects,” says K Ravi, Managing Director, Hassia Packaging Pvt Ltd. Its quality control starts right from the drawings, selecting the appropriate machine parts, test certificate for special materials, vendor evaluation policy, to design review, performance test, pre-dispatch inspection report, etc. “All these attempts aim at improving and stabilising production, to avoid or minimise issues that lead to the defects in the first place,” asserts Ravi. This helps the company to deliver best machinery that help customers to achieve the targeted production capacity.

IN FOCUS

To ensure safety at the workplace, the company provides employees basic training and imparts knowledge on materials & processes employed in production, which leads to the scientific & methodological approach towards the control of work & environment. “The company conducts worker training on regular basis and also inspects facilities, machinery & safety equipment in order to identify and correct potential hazards. This ensures safety regulation compliance,” says Ravi.

Productivity enhancement programme Training of employees is a continuous process at Hassia, which ultimately helps in improving productivity. ”The company also sends its employees to participate in seminars, exhibitions, training programmes, to acquire knowledge on the latest trends in the industry, informs Ravi. Besides, the company sends its design engineers to its main office in Germany to keep them abreast about the latest developments & technologies, so that they can implement it in India. “A good work culture, equal opportunities for all, among other things help our employees to achieve maximum success in their professional and personal life,” claims Ravi. Hassia has unique management systems to measure its growth, which is dubbed as ‘Performance Management System.’ The system depends on meticulous planning for the company, department and individual

performance. “The aim of this system is to enable different departments seek support from other departments to reach its (department) objectives. Department heads conduct one-toone discussions with their reportees to set individual goals,” reveals Ravi. This particular method ensures that the work performed by the employees accomplishes the expectation of the organisation and they (employees) have a clear understanding of the quality and quantity of work expected from them. In this system, employees also receive information about how effectively they are performing vis-à-vis expectations. In turn, it helps the employees to grow.

R&D initiatives In order to achieve enhanced speed with maximum accuracy, the company has pioneered various innovations in the industry. “Our latest addition in this direction is 180TC (twin bagger), 110TC (to pack small size pouches at a high speed & with high accuracy),” reveals Ravi. Hassia has a wide range of weighers (application focus), fillers – both volumetric and load cell based like easy-dose cup filler, accu screw auger filler, twin auger, linear vibratory weigher, linear micro vibratory weigher, net scale, belt weigher, screw weigher, etc. All these products are part of its R&D initiatives and based on modular engineering concept. “We conduct tests & trials on our products in our test room and suggest a weigher and filler according to the product. We also have a strong

Production in progress on the shop-floor

K Ravi Managing Director

The company conducts worker training on regular basis and also inspects facilities, machinery & safety equipment in order to identify and correct potential hazards. This ensures safety regulation compliance. R&D team, which is ready to cater to any new innovation or idea as per customers’ need to turn it into reality,” says Ravi.

Spreading wings Hassia had sold its first packaging machine to a dairy company in 2000. Since then it has sold over 350 machines and has become the preferred supplier for Unilever India, Indonesia, The Phillippines, Morocco, Pakistan, Bangladesh, Sri Lanka, and several other multinationals worldwide. Its client list includes the who’s who of the dairy, food and agrochemicals industry. “Machines manufactured at our Pune plant are installed in New Zealand, Malaysia, Indonesia, Bangladesh, Sri Lanka, Pakistan, UAE, Saudi Arabia, Oman, Egypt, Kenya, Sudan, Swaziland, Nigeria and Uganda,” says Ravi. Speaking on India’s packaging industry, he says that the industry is growing at around 15 per cent. “However, leading companies in the Indian packaging industry are registering 30 per cent growth annually,” he adds. Hassia is also attaining a growth rate of 25 per cent year on year. In its endeavour to infuse further growth, plans are afoot to augment the production capacity. In this direction, Hassia is increasing the size of its office and plant. “We have already started to upgrade our material handling systems, and are also adding new equipment to achieve superior finishing of products,” concludes Ravi.

December 2010 | Modern Food Processing

SECTOR WATCH

Dairy sector is one of the key industries in India as the country is the leading producer and consumer of milk & milk-based products in the world. Although the level of milk processing is low currently, it is likely to increase in the near future with rise in demand for dairy products. The value-added dairy products market in India is expected to treble to ` 12,000 crore by 2014 from ` 4,000 crore in 2009. To tap this opportunity, packaged food players will have to focus on product development, distribution and marketing.

Courtesy: Russell Finex

Modern Food Processing | December 2010

SECTOR WATCH

Pankaj Gupta and Angshuman Bhattacharya

he share of value added products in the overall packaged dairy products market in India has increased from 27 per cent to 36 per cent between 2005 and 2009, while the share of milk has decreased from 73 to 64 per cent during this period (Figure 1). The trend is expected to continue in the future, making this an attractive market over the next five years. According to a research by Tata Strategic Management Group (TSMG), there are five consumer mega-trends driving this transformation: R Increased food safety and hygiene consciousness R Need for convenience R On-the-go consumption R Palate diversification R Growing health and wellness consciousness

Shift from ‘made-at-home’ consumption to ‘brought-to-home’ consumption: The Indian urban consumer today is willing to pay a premium for products that provide convenience and save time. This phenomenon is evident from the growth of categories like set/pouch curd at 20 per cent between 2005 and 2008. Products like curd and lassi, which have traditionally been made at home are increasingly being ‘brought to home’. Increasing preference for longer shelf-life products: After an initial consumer reluctance to adopt non-fresh dairy products, ultra heat treatment (UHT) packing is finding widespread acceptance across dairy beverages. UHT enhances the shelf-life of the product, thereby offering usage convenience. Strong growth of UHT milk at 32 per cent per annum between 2003 and 2008 is an indicator of this trend (Figure 3).

Improving incomes and increasing hygiene consciousness are driving conversion from unpackaged to packaged products across food categories. Higher awareness towards health & hygiene, food safety and adulteration concerns are resulting in consumers converting from unorganised sources in traditionally unpackaged segments like paneer, curd, chaas & lassi to packaged/branded sources. The increased share of packaged dairy products from 32.6 per cent in 2005 to 39.4 per cent in 2009, demonstrates this shift (Figure 2).

Need for convenience Busy lifestyles and increasing nuclear families are leading to paucity of time for various domestic chores. The Indian household is looking for more efficient and convenient options around food products, leading to the following sub-trends:

2005

64%

2009

Source: TSMG

Figure 1: Share of milk in packaged dairy products

33%

2005

39%

2009 Source: TSMG

Figure 2: Share of packaged dairy products in overall dairy products

420

105

‘On-the-go’ consumption Increased food safety & hygiene

73%

Diversification away from carbonated soft drinks to healthier categories like dairy products and juices is fuelling on-the-go consumption in these categories. New packaging formats that are smaller and convenient-to-carry products like flavoured milk and chaas are being introduced.

2003

2008

Source: TSMG

Figure 3: UHT milk consumption in India (` crore)

177138 92000

Palate diversification With increasing globalisation, cross regional migration and greater cross cultural exposure to different food habits, the Indian consumer has started experimenting with various dairy products. This is increasingly leading to palate diversification of two kinds – regional blending of tastes and acceptance of western products. Products like paneer and lassi are increasingly finding their way into South Indian homes. On similar lines, cheese, a Western product, has witnessed a steady growth between 2005 and 2009. Products like yoghurt & yoghurtbased drinks, smoothies and various

2009

2014

Source: TSMG

Figure 4: Potential market for packaged food products (` crore)

4000

12000

2009

2014 Source: TSMG

Figure 5: Potential market for value-added dairy products (` crore)

December 2010 | Modern Food Processing

SECTOR WATCH

Product development: Constant innovation in manufacturing and packaging will be required by manufacturers to offer consumers a wider range of value-added products. Innovations have to address the price premium, shelf-life and taste expectations of consumers. Industry players will need to Courtesy: West Coast Event continuously invest in R&D varieties of cheese are witnessing new and product development to ensure product introductions in the market. that their portfolio is in line with Going ahead, this trend is likely to prevailing consumer needs. Dairy products, be further amplified, as consumption R Distribution: dominated by liquid milk, have habits converge to incorporate a blend traditionally been distributed through of cultures. milk booths. The emergence of Health and wellness new consumption occasions and consciousness points-of-sale implies the need for a Dairy products globally have seen a channel-shift away from milk booths variety of health and wellness variants. towards traditional and modern Multinationals like Danone have built grocery outlets. Incumbents would multi-billion dollar brands on this have to create alternative channels platform. Changing lifestyle related serving grocery outlets to meet disorders like obesity, high blood this demand. pressure, heart disorders and diabetes R Marketing and brand creation: With increased number of choices are significantly gaining prominence. On for consumers, creation of brand an average, 33 per cent of SEC A and pull would be of utmost importance B (the ‘high’ socio-economic classes) in the value-added dairy products consumers in India suffer from lifestyle sector. Like in other packaged foods diseases. To address these concerns, and beverages, dairy products will consumers are increasingly adopting food need to build aspirational brands. products for improved nutrition, fitness and general well being. While probiotics, fibres, vitamin, calcium and omega- Opportunity for food players fortified products are among common TSMG analysis reveals that about fortifications in dairy products; low fat ` 4,000 crore value-added dairy and sugar-free versions are dominating products (excluding liquid milk, powder milk and stable traditional categories the ‘better for you’ category. like butter) could potentially treble, at a Implications CAGR of 25 per cent, to approximately The consumer trends currently ` 12,000 crore over the next five years. witnessed indicate a transformation of This compares attractively with an the dairy sector from a traditional low anticipated growth of 14 per cent in the margin liquid milk play to a branded packaged food market over the same value-added play. To capitalise on period (Figure 4). these trends, dairy players will have The current industry structure is to significantly enhance capabilities in largely dominated by dairy co-operatives. three business areas: These players have traditionally focussed

Modern Food Processing | December 2010

on serving liquid milk demand first, producing value-added products only to absorb surpluses. Consequently, the business model of most co-operatives has laid higher emphasis on procurement and manufacturing efficiencies, leaving a huge capability gap in management of value-added dairy products. These players have a weak distribution presence in the grocery channel. In contrast, large food companies in India have significant expertise in developing & managing valueadded products and brands. These players have traditionally viewed the dairy market with caution, due to challenges of milk procurement and distribution. However, growing demand for value-added products opens up a highly attractive market opportunity for these players.

Milky way of success The dairy sector in India is fast transforming from a commoditised-lowmargin liquid milk business to a branded value-added play. Driven by changing consumer preferences, the current ` 4,000 crore value-added dairy products market in India is expected to treble to ` 12,000 crore by 2014. Unlocking this opportunity will require a thrust on product development, distribution and marketing. Many existing dairy players in India may not be able to manage this transition successfully opening the floodgates for packaged food players to enter the attractive value-added dairy products sector. Pankaj Gupta is the Practice Head - Consumer & Retail at Tata Strategic Management Group (TSMG). He has over 14 years experience in industry & consulting, and his areas of specialisation include entry, growth and turnaround strategy formulation & performance improvement in the retail, FMCG and consumer durables sectors. Email: pankaj.gupta@tsmg.com Angshuman Bhattacharya is the Engagement Manager with the Consumer and Retail practice of TSMG

MARKET SCOPE

Dairy whiteners

Leveraging the ‘convenience’ trend Though nascent today, the dairy whitener market has a huge potential to surge upwards because it holds the ‘convenience’ tag, which is in vogue today. Armed with a plethora of benefits over loose milk, dairy whiteners are on an expansion-spree in the market, with exciting product launches.

Mahua Roy

ndia is one of the leading global producers of milk accounting for about 15 per cent of the world’s output and 40 per cent in Asia. The country has also been witnessing a 4 per cent growth per annum in this segment, which is far above the global average of 1-2 per cent, in recent years. Currently, more than half of India’s total milk production is consumed in urban areas, where the population is projected to cross the 400-million mark by 2011. In spite of being one of the leading producers of milk, only 15 per cent of the total milk output is processed in the organised dairy. By 2011, it is predicted that the value of the dairy industry would be about ` 5,20,780 crore, which will include ` 1,59,600 crore from liquid milk, and dairy whitener constituting about ` 9,100 crore.

Market scenario In India, some of the leading players in the dairy whitener segment are Nestle (Everyday), Britannia (Milkman) and Amul (Amulya). With abundant milk supply in the country, milk powders have low market penetration, as consumers perceive loose milk as fresh, and hence give preference to it. “Traditionally, basic milk powder/dairy whitener has been found to be popular and relevant in those areas of India where access to fresh milk is inadequate. Most companies also focussed their efforts in these limited geographies and consequently, this

Modern Food Processing | December 2010

category saw a rather low penetration at the national level. The regional skew tends to be for the East & South,” says Kumaran Nowuram, General Manager - Dairy, Nestle India. With vigorous marketing for consumers concentrated only in a few areas, dairy whiteners were largely perceived as a stand-by option in this milk-surplus country. Also, one of the negative factors here is the price constraint, with dairy whiteners being slightly premium-priced. “In the consumer segment, dairy whiteners are essentially used for making tea, coffee, homemade sweets, etc. In the institutional segment, it is being used in myriad forms like vending premix, ice creams; sweetmarts, etc,” opines Vinod Menon, Head – Dairy Business, Britannia Industries Ltd. The whiteners find a high level of institutional acceptance, especially by railways, hotels & restaurants, airlines, hospitals and corporate offices. Since India is a major consumer of tea and coffee, it has the potential to become a big market for dairy whiteners. In addition, companies can look at the export opportunities, especially to neighbouring countries & the countries in the Middle East, the Gulf and Africa.

MARKET SCOPE

Meeting consumer needs The global trend, however, is slightly different. Fortification is the buzzword in the food processing industry today, and the dairy industry is not an exception. Taste plays a vital role in the choice & loyalty of the consumer towards a particular brand, and hence companies are looking to offer products in a variety of flavours. “Globally, the market has segmented itself by unique formulations like dairy whiteners, which is specific for making coffee, or through fortification, offering benefits like extra calcium for kids or low fat for the health-conscious. The consumer dairy whitener business in India today is largely undifferentiated,” opines Menon. This premise can translate itself into a profitable opportunity in India. Nestle’s Coffee Mate (Canada) is one such innovative product, which is aimed at coffee-drinkers. Offered in favourite flavours like hazelnut, vanilla, etc, this dairy whitener has made the most in this untapped market. Also, just like agri-products, the dairy products are also entering the organic bandwagon, which is gaining momentum across the world. With changing perspectives of the consumers who are laying a lot of stress on health, the organic dairy segment seems to be on an ascent. Organic dairy whitener is free from the bovine hormones that

Kumaran Nowuram General Manager Dairy, Nestle India

Traditionally, basic milk powder/ dairy whitener has been more popular and relevant in those areas of India where access to fresh milk is poor. Most companies also focussed their efforts in these limited geographies and consequently, this category saw a rather low penetration at the national level.

come with regular milk. Organic dairy farmers claim that dairy whitener so prepared from organic milk helps boost the immune and digestive systems of the body.

Marketing and branding “With increasing consumer affluence and improved awareness of health & wellness, the scenario is beginning to change a little. In addition, most players in the industry are also putting efforts to increase the distribution reach and consumer awareness. These initiatives will certainly accelerate growth for the value-added milk powder categories,” voices Nowuram. The market penetration of dairy whiteners in the consumer segment is low in the country. The marketing strategies need to focus on the benefits that dairy whiteners have to offer. Similar to the manner in which the packaged juices promote the obvious nutritional information (vitamin C, minerals, etc), dairy whiteners too can adopt this marketing ideology. Dairy whiteners are a source of high-quality protein, with the amino acids readily digestible and completely bioavailable. Whey protein, which represents 20 per cent of the protein in dairy whiteners, is valued for its many health-enhancing properties. Dairy whiteners have a high content of soluble vitamins & minerals, including calcium, phosphorus and magnesium. According to nutritional reports, 100 gm of skimmed dairy whitener contains 1,300 mg calcium. Dairy whiteners contribute to a healthy image and a clean ingredient label. The other major benefit of dairy whiteners is the increased shelf-life. By removing the majority water content, fluid milk is transformed into a shelfstable dry powder with a shelf-life of up to 18 months, as compared to fluid milk’s comparatively lower shelf-life. Being a powder, the storage conditions are simpler, requiring no refrigeration. “There is a constant effort to invest in back-end processing capabilities

Vinod Menon Head – Dairy Business, Britannia Industries Ltd

There is a constant effort to invest in back-end processing capabilities and front-end infrastructure. The way forward lies in building a consumer franchise for differentiated products like dairy whiteners and investing in technology to bring in more value-added products in this nascent category. and front-end infrastructure. The way forward lies in building a consumer franchise for differentiated products like dairy whiteners and investing in technology to bring in more valueadded products in this nascent category,” says Menon.

Specialised products in demand Research in the field of processed dairy products is booming because the industry is realising the worth of the opportunities this sector has to provide. “We have the R&D strength and nutritional expertise to develop and introduce specialised products for different needs from creaming to nutritionally fortified products for children & adults, and that can address a wider target consumer base across India,” claims Nowuram. Fortification to develop specialised dairy whiteners aimed at women or geriatrics or even children will increase the consumer base. Apart from fortification, research also needs to be driven towards introduction of new flavours. Such new product development will ensure better market penetration. “However, the challenge will be the ability to reach this wide consumer base efficiently & economically, and educate them about the benefits of these specialised products,” he concludes.

December 2010 | Modern Food Processing

INDUSTRY UPDATE

Confectionery industry

Mouthful of opportunities Confectioneries live up to their promise of bringing joy & lifting one’s spirits and sustaining it as well. An all-time favourite delicacy and a raving topic for market analysis & scientific R&D, there is a continuous momentum being provided to this sector, in order to make this mature product remain exciting forever.

Mahua Roy

he Indian confectionery market is mainly segmented into chocolate-based, sugarboiled and mints & chewing gums. Sugar-boiled confectionery is categorised into hard-boiled candy, toffees and other sugarbased candies. “The entire Indian confectionery market is estimated at ` 4,400 crore for the year 2009, and is growing phenomenally with a growth rate of 13 per cent year on year. The market is characterised by increased volumes, high expenses on advertising, low margins for the products and price sensitivity,” informs Srividyaranjani V, Research Analyst (South Asia & Middle East - Chemicals, Materials and Foods), Frost & Sullivan (F&S). Some of the key confectionery majors include Cadbury, Nestle, Lotte, Perfetti, Candico, Parrys, Nutrine, Godrej Hersheys and so on.

Market fragmentation As per the figures provided by F&S, the Indian chocolate confectionery market is growing at a rapid pace. It shows an impressive double-digit growth rate of 20 per cent, year on year. The market is at present valued at ` 2,360 crore

Modern Food Processing | December 2010

(2009), which has grown at 18 per cent from 2008. On the other hand, the Indian sugar confectionery market is currently valued at about ` 2,052 crore (2009). The market has witnessed a moderate growth rate of 8 per cent from 2008. The unorganised sugar confectionery market is quite big in India and it is currently witnessing a trim in its growth rate.

Growth propellers Such notable figures are the outcome of the market drivers recognised by the manufacturers. The major and eternal growth driver is the labelling of confectionery, especially chocolate, as an ‘affordable indulgence’. Cashing in on this evident trend, manufacturers are looking at several ways to ensure better market penetration and reach of their products. Half of the new products launched in the Indian confectionery market in 2009 were priced below ` 20. “Some of the more recent and successful launches at Nestle include Milkybar Choco Choo at ` 5, Milkybar Crispy at ` 5, Munch Guru pack at ` 10 and KitKat single finger at ` 5,” says B Kannan, General Manager - Chocolate & Confectionery, Nestle India. Introducing the favourite brands in mini-packs, the manufacturers are building

INDUSTRY UPDATE

a customer connect by encouraging them to try out the new products, and thereby build brand loyalty in the long run. Rise in upscale retail outlets has increased the acceptance of foreign brands of chocolates, as well as gourmet confectionery. “The development of supermarkets, hypermarkets and convenience stores, along with higher allowances to children is providing a large consumer base for such products. This is driving the growth of the Indian confectionery market. The Indian retail market development has created a favourable environment for the imported designer chocolates,” opines Srividyaranjani. Also, confectionery manufacturers have realised that concentrating their marketing strategies only on children will simply lead to saturation of their marketshares. The adult population is proving to be a prominent growth driver of this industry. As a result, one has seen immense increase in new product development (NPD) catering to the adult population. To appeal to the consumers, advertising of confectioneries has always been creative. “To make the confectionery variants reach the consumers, innovative advertising strategies are required. The increased investment on advertising and

Srividyaranjani V Research Analyst, South Asia & Middle East Chemicals, Materials and Foods, Frost & Sullivan

The development of supermarkets, hypermarkets and convenience stores, along with higher allowances to children is providing a large consumer base for foreign brands and gourmet confectionery. This is driving the growth of the Indian confectionery market.

marketing are propelling the growth of the confectionery market,” explains Srividyaranjani.

B Kannan GM - Chocolate & Confectionery, Nestle India

Bitter challenges Cocoa and sugar being the major raw materials, any change in their prices will ultimately have an impact on the confectionery industry. “The most prominent challenges being faced by the chocolate-based confectionery products are those related to raw material prices. Among the major challenges being recognised by Lindt & Sprüngli AG are the volatile cocoa prices, which is a major concern for the global confectionery industry,” informs Urs Liechti, Maître Chocolatier, Lindt & Sprüngli AG (Switzerland). The reduction in the global cocoa production is a major cause of worry across the world. When it comes to manufacturing and logistics of confectionery products, the climatic and infrastructural challenges of our country pose a substantial amount of hurdles. “We need to develop products that are not only tasty, but are amenable to being sold in sub-optimal climatic conditions and in a retail environment that is quite bare in terms of infrastructure to maintain shelf-life. Distribution thus becomes an obstacle,” opines Kannan. The most prominent trend being capitalised upon by the entire length and breadth of the food processing industry is that of ‘health and wellness’. This trend is also making its presence felt across the Indian consumer. “However, most of the confectioneries are presumed to spoil the oral heath, is a perception harboured traditionally by the consumers. This perception of the Indian consumer can hamper the growth of the confectionery market,” observes Srividyaranjani. Chocolate was originally an impulsedriven brand. Transforming it into a planned purchase was a challenge. But in the recent times, Cadbury has made attempts towards this, steered by the Shubh Aarambh campaign. “Brands

We need to develop products that are not only tasty, but are amenable to being sold in sub-optimal climatic conditions and in a retail environment that is quite bare in terms of infrastructure to maintain shelf-life. Distribution thus becomes an obstacle. like Cadbury Celebrations, which has specifically been made for the Indian market has become a major gifting option for festivals. It is also becoming popular as a corporate gifting brand. This is one of our attempts at making chocolates Chocolate confectionery market

10%

50%

40%

Cadbury

Nestle

Others

Sugar confectionery market

15%

20% 65%

Nutrine

Perfetti Van Mille

Others

Source: Frost & Sullivan

Figure 1: Marketshares of chocolate and sugar confectionery

December 2010 | Modern Food Processing

INDUSTRY UPDATE

a planned purchase,” a Cadbury’s spokesperson states. Elaborating on other challenges, he adds, “India is a price sensitive market, and thus managing price points is an important challenge, given the high input costs.”

Exciting offerings A review of the international NPDs provides an insight as to how the manufacturers are translating the growth drivers into success stories by means of their product offerings. Some of the evident trends are that of flavour enhancement and new flavour development. Consumers are showing high acceptability and adaptability of exotic fruit flavours being introduced. Jolly Rancher Awesome Twosome Chews from The Hershey Co combined two bold, intense flavours featuring sweet watermelon surrounded by sour green apple, and juicy cherry filled with contrastingly sour orange. This surprising mix of flavours was a huge success as reported by Hershey. When it comes to chewing gums, providing functional benefits like whitening & strengthening teeth and overall oral hygiene have been complemented now with enhanced products like antioxidant fortification and tasty variants. Another trend is of a range of fruit and flavour granules that create an

Urs Liechti Maître Chocolatier, Lindt & Sprüngli AG

The most prominent challenges being faced by the chocolatebased confectionery products are those related to raw material prices. Among the major challenges being recognised by Lindt & Sprüngli AG are the volatile cocoa prices, which is a major concern for the global confectionery industry.

exciting sensory and visual experience. These granules give the product a fresh, fruity taste while also creating a striking visual effect and a crispy texture. These small granules draw consumers’ attention by differentiating it from competitive products. Chocolates are now offering beauty benefits as well. Though the trend is very much in its infancy, it has attracted some attention from established names in the food industry, including Mars. Mars’ Dove Beautiful Milk Chocolate claims to have skin nourishing ingredients such as vitamin C and E along with biotin, zinc and cocoa flavanols. This by far has been the most innovative marketing strategy in this segment. Experts also forecast that the potential health benefits of chocolate will continue to be evidenced. Consumers can expect to see more research into the potential health benefits of milk and dark chocolate, including exploration of naturally occurring cocoa compounds and positive effects on mood & blood pressure levels. Nuts are hailed as nutritional powerhouses, which is why they are utilised more in new product launches. Moreover, in the nuts category, almonds are the top ingredient in new chocolate confectionery products around the globe, according to Mintel’s Global New Products Database. Snack bars, in fact, are increasingly advertising the nut ingredients. Seeds too are getting their due on the health front in the confectionery segment, including flax, sunflower and pumpkin seeds. “Although chocolate is the ultimate comfort food, consumers want more permissibility and are interested in healthier alternatives to standard chocolates. They are choosing products that are free from allergens or have ‘cleaner labels’ – like free from gluten, lactose, artificial colours,” says Raphael Wermuth, External Communications Manager, Barry Callebaut AG (Switzerland).

Modern Food Processing | December 2010

Raphael Wermuth External Communications Manager, Barry Callebaut AG

Although chocolate is the ultimate comfort food, consumers want more permissibility and are interested in healthier alternatives to standard chocolates. They are choosing products that are free from allergens or have ‘cleaner labels’ – like free from gluten, lactose, artificial colours. Premium confectionery is also an emerging trend being adopted by the market players, with these sweets affecting palates and wallets alike. The most talked about NPD in the Indian market was the launch of Cadbury’s Silk. Also, Kraft Foods’ Toblerone Fruit & Nut bar combined Swiss milk chocolate with honey and almond nougat with raisins.

A long way to go India is not far behind when it comes to NPDs in confectionery industry. The Indian confectionery market witnessed the launch of over 200 products in various categories last year, thus ranking it among the top 20, in terms of global new product launches in 2009, according to Datamonitor. Sugar confectionery NPD amounted to 47 per cent of all NPD in the Indian confectionery market in 2009, followed by chocolate, which accounted for 29 per cent. Cereal bars contributed 8 per cent. However, this industry in India has a long way to go in order to match the consumption levels abroad. The annual consumption of chocolates by an Indian is just 60 gm against 11 kg in UK and 6-7 kg in the US. But the industry is optimistic, as confectioneries can never go out of fashion. As Cadbury very rightly put it in its slogan, ‘Not just for kids, but for the kid in everyone’.

MFP_Dec _2010_ Engg Expo_Tab-1_PG_43

MFP_Dec _2010_ Engg Expo_Tab-1_PG_44

Automation Products MARKET INSIGHT

Automated manufacturing

Means to enhance efficiency In the last few years, the food processing industry has undergone several changes. There is a general shift in demand for quality food and to maintain this, it is imperative to process food in a highly sophisticated environment. This underlines the need for automation. Of late, entrepreneurs have taken initiatives to modernise the milling sector as employing skilled labour is becoming expensive. Courtesy: Buhler India

T R Jayaram

he demand for high-quality products, the flexibility to use equipment for manufacturing several products and other factors have moved the food industry towards increased automation. Control system developers and the plant control system designers have responded to these needs by providing appropriate hardware & modular software capability so that the process engineer can concentrate on the process control rather than the control system design. Moreover, the quality norms for food processing has picked up drastically, thanks to the export of processed food from India. It has now become necessary to process food in a highly sophisticated environment; if one needs to export them to other countries. With power becoming scarce these days, the latest trend is to reduce energy consumption during processing. Production planning & control, process control, food safety and consistent finished products will fetch premium returns on the final product, while reduced labour, energy saving etc have become

essential in order to be competitive in the market. Equally, the norms of pollution control, safety of men and machines have also become very important. Hence, the focus is now on automating the plants so that most of the needs as mentioned above can be achieved.

Challenges in meeting the demands Today, food and beverage companies have to face following challenges: R To control the business, shape the future: The market is as dynamic as never before. Globalisation is a part of everyday lives, price pressures are escalating, and legal requirements are increasing. To be successful in such an environment, it is imperative to have clearly defined goals and promising strategies for the future. One must be able to rely on production plants that offer maximum uptime and optimal performance. R Modernisation of the milling sector: Entrepreneurs, businessmen and corporates are looking to invest in milling industries/ food processing plants in India and also abroad. As the industry is growing, the

December 2010 | Modern Food Processing

MARKET INSIGHT Automation Products

need of reducing the manpower for plant operations is also increasing. This is basically because of the want of specific skills, as labour is becoming expensive.

Technology-induced efficiency Automating production and improving process efficiency are two major objectives of the food industry worldwide. The benefits associated with increased control of raw materials, manufacturing, warehousing and dispatch are wide ranging and can have a significant impact on the profitability of food processing industries. Food manufacturing is a complex process. Maintaining the quality of a finished product by monitoring incoming raw material and regulating the production process effectively & efficiently are key to the success of a brand, and thus ultimately the business. In the last 10 years, the food processing industry has turned increasingly to the process control technology used in other parts of the world. In many respects, the industries are similar, all demanding high yields from raw materials as well as a consistent quality of finished products. While the regulations covering the manufacture of food are not yet as strict as those laid down in pharma and other industries, they are not far behind. Traceability, conformity and the procedure reproducibility from batch to batch not only have legal implications but they also directly affect the consumerâ&#x20AC;&#x2122;s acceptance of a product.

Business systems : PPS, ERP, etc

Interface production to planning

Plant level

Process level

Process and field level

Visualisation, operating, job management, analysis, alarm management, reporting, quality assurance PLCs, sensors, actuators, motors, etc Source: Buhler India

Figure 1: Pyramid of automation

As a result of the need for increased quality control and improvements in reproducible production, many food producers are now investing heavily in automated process control. This type of automation can take many forms, from the fairly simple control of a discrete process, to the complete automation of an entire factory, or, as one leading supplier of electronic process systems calls it, totally integrated automation. The suppliers are now offering wide range of control systems, which improve the product quality, safety, traceability, energy-efficiency, profitability, yield, plant life-time, etc. It is even more important to provide a quick service to the customers, in case of a failure. In fact, some of the control system providers are now offering remote support services. Few of the control system designers are offering system capable of transferring the production data to various Management Information Systems (MIS).

Digitalised growth

Courtesy: Buhler India

Modern Food Processing | December 2010

Forward-thinking food manufacturers have already made huge investments in automation. Most of the companies, which design & supply the processing plants & machinery for food

processing and the control system designers & manufacturers, provide both hardware and software solutions (viz SCADA, DCS system, application of frequency drives and soft starters). These provide the solution for product quality & safety, traceability, energy saving, high yield, profitability, plant safety, etc. It is important to note that the people with the process knowledge are in a better position to offer complete solutions. It is now possible for a customer to obtain information directly on the status of critical areas during processing, with the linking of production system to business systems. This integrated approach will play an important role in the food industry in the near future. T R Jayaram is the Head of Automation in Buhler (India) Pvt Ltd. He is responsible to build, set up and manage the electrical & automation team, project and facilities to deliver control systems for all the Buhler plants sold in the South Asian region. He has a wide range of experience in process industries and has an overall experience of almost 25 years in the field of electrical engineering and automation, overall project management, design & development, etc. For details, contact Gautam Putcha on email: gautam.putcha@buhlergroup.com

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MARKET INSIGHT Vision Systems

Quality improvement

Eliminating defects & impurities with a clear vision In recent years, there has been an increase in cases of product recall due to food safety issues. In addition, food & beverage (F&B) manufacturers have to consider issues pertaining to cost control, quality management, traceability, compliance, etc. As a result, many companies have invested in automation and advanced equipment to improve safety & quality of products. This article looks at the latest developments in F&B manufacturing and how vision systems help address various problem areas. Courtesy: Cognex

Didier Lacroix

ith the large wave of product recalls in Asia last year, there came a proportionally huge surge of criticism from consumer groups and tight scrutiny from media around the world. The affected products, which included everything from cough syrup to pet food, have brought up the question of food safety and quality control processes. As the frequency of product recalls continues to rise, a lot of attention is being paid to the regulatory front with increased global regulations. For example, in the US, the food industry faces the US Food Allergen Labeling and Consumer Protection Act (FALCPA), the Bioterrorism Act, and new Country of Origin Labeling requirements.

Safety measures With the exception of Japan, the F&B manufacturing industry in Asia is just beginning to adapt to global F&B industry constraints. Higher quality and safety expectations of local consumers also drive the industry to better control their processes. However, substantial improvements still need to be made in order

Modern Food Processing | December 2010

to satisfy all levels of the local and international market. In order to be seen as a quality international supplier, the Asian F&B industry will have to invest heavily in quality control (QC) processes, while maintaining costs at a reasonable level to not affect prices at point of sales. Hence, in recent years, more Asian F&B companies have been taking measures by examining various ways to improve the safety and quality of their products. One such measure that is gaining popularity in the industry is the implementation of machine vision systems. Machine vision systems are equipped to see & spot defects and other problems in manufactured products, packages or assemblies. Vision systems look for manufacturing flaws using a combination of microprocessor technology & image analysis software to interpret images and generate information about them. The vision systems then report this information to other equipment, such as Programmable Logic Controller Systems (PLCs), robots, Human Machine Interface Software Integration (HMI/SCADA) devices or other machines along the production line. Machine vision can be used in four general types of applications:

Vision Systems MARKET INSIGHT

Gauging: To measure a product or examine its critical dimensions R Inspection: To indicate if a product is good or bad, based on its physical characteristics R Guidance: To accurately locate or place products R Identification: To determine whether the right product is present by inspecting its physical characteristics, reading characters or a marked code

Addressing challenges Specifically, hereâ&#x20AC;&#x2122;s how Asian F&B manufacturers can utilise machine vision systems to address the important issue of cost control, quality management, traceability, compliance, and manufacturing flexibility that they currently confront. Cost control: With respect to cost control, using vision systems for gauging, inspection, guidance and identification helps F&B manufacturers to reduce costs in their processing and packaging operations. By reducing waste and detecting process errors early, before thousands of products have to be scrapped, F&B manufacturers can isolate the source and extent of safety or QC problems to minimise production & distribution of unsafe or poor-quality products that may have to be recalled. This reduces the cost of recalls, potential cost of any related liability, and the cost of bad publicity, which can damage brand reputation. Quality management: While inspection at the end-of-the-line is great

for final product checking; waiting until after a product has undergone numerous value-add stages of production, often results in costly waste and timeconsuming rework. Plus, defects not caught at the source generate little information about the cause. Therefore, many F&B manufacturers deploy modular, standalone vision systems at multiple points along their production lines where significant value is added. By deploying vision systems at key process points where there is significant value addition, manufacturers can achieve tighter process control to ensure errorproof production. Machine vision provides production information that can be used for continuous process control to optimise productivity and overall equipment utilisation, which is important for continuous process optimisation, and thus is vital for firms to maximise output & profits. Traceability issue: Implementing two dimensional (2D) barcodes and image-based ID readers for traceability enables F&B manufacturers to better track inventory and work-in-process. Increased efficiency can be ensured, as all product component positions are known at any given time, and traceability ensures that processes are always performed on the correct components at the right time. Besides, bottlenecks can be immediately diagnosed and process improvements can be made. Traceability also enables packagers confirm label and product match to lower the risk of recalls due to mislabelling. In addition, they

help track lots, batches and individual products through the supply chain to reduce the cost of recalls due to product contamination. The better and more precise the tracing system, the faster a producer can identify & resolve product safety or quality problems. For example, a manufacturer may uniquely code each lot or batch to identify time & location of production to make recalls more efficient and less costly. This can be a huge benefit for manufacturers in an intensely competitive retail structure with narrow profit margins, such as the food industry, where reducing these costs can be the difference between successful and failed firms. Better compliance: Increasingly, F&B manufacturers, packagers and their equipment & materials suppliers consider vision system as a key technology that enable them to achieve compliance in an increasingly strict regulatory environment. Many of these firms implement vision systems, 2D barcodes and image-based ID readers and verifiers to comply with F&B safety initiatives. The result of compliance with these new mandates is improved F&B safety, product integrity and supply chain security. However, beyond compliance, F&B manufacturers have discovered value in being able to stop counterfeiting, prevent parallel trade through unauthorised channels and achieve greater visibility into how products are made, distributed & used. Manufacturing flexibility: Traditionally, vision systems have been

In-sight vision system inspecting cap & label (A) and Checker 3G1 vision sensor checking the carton orientation (B) in a beverage plant Courtesy: Cognex

December 2010 | Modern Food Processing

MARKET INSIGHT Vision Systems

used to indicate if a product is good or bad, but with networking, more vision systems are being used for control functions, including QC, process control, machine control, or robot control. Networking vision systems provides a number of important benefits. First, it enables vision systems to communicate with PCs, PLCs, robots and other factory automation devices. Second, it allows data & images to be archived for trend analysis and continuous process improvement. And finally, networking allows vision systems to increase manufacturing agility by automating procedures such as changeover for mixed-model processing. As mentioned above, virtually every product that is manufactured in high volume, or at high accuracy, or that has to be made at very low cost, can be made better, faster and cheaper using machine vision. Hence, investments in greater automation

and the implementation of vision systems & ID readers in processing & packaging operations will be beneficial to Asiaâ&#x20AC;&#x2122;s F&B manufacturing sector.

Sustaining growth Globally, the Asian F&B industry has seen sustained growth and this also applies for vision systems. This trend seems to have accelerated in 2009 despite the economic downturn. A shift in the attitude of Asian consumers when it comes to quality, safety & social trends such as health & wellness have pressed the F&B industry to be more in tune with customer expectations and thus, this has favourably impacted automation, processing equipment & machine vision sales. Currently, the level of automation varies greatly from company to company. Typically, large-scale manufacturers invest in more automation, advanced equipment and good process management

Modern Food Processing | December 2010

technologies, whereas medium- or small-sized companies tend to adopt new technologies at a slower rate. Regardless of size, once a company solves a critical manufacturing problem with a vision system and becomes comfortable working with the technology, it quickly identifies additional applications where vision technology can improve its operations. The increase has been continuous since the last couple of years. The indicators tend to show that the Asian F&B industry will pursue and increase its investments since this will enable it to boost its local & international marketshare. Didier Lacroix is the Senior Vice President - International Sales & Services at Cognex Inc. For details, contact on email: sales.in@cognex.com

INDUSTRY INSIGHTS

Baby foods

The changing market paradigm In a country, where motherâ&#x20AC;&#x2122;s milk is considered best for infants, the baby food industry has sustained to maintain its pragmatic lead for decades. Known to fulfill the nutritional needs of infants in a single scoop, baby food has reached millions of homes in the country. Courtesy: Global Package Gallery

Shushmul Maheshwari

larming levels of malnutrition and underweight children in the country signifies the importance of complementary baby food in the country. A crucial factor that has been contributing to early childhood malnutrition is the marginalised status of women in India. Malnutrition among Indian women is a manifestation of inequality within the society and as high as 83 per cent of women are anaemic. Such conditions in the country intensify the usage of complementary baby food for the child, in addition to motherâ&#x20AC;&#x2122;s milk. Moreover, changing socio-demographics and lifestyles of the urban Indian population are contributing to the growth of this market. Uniformity in the pattern regarding women employment and womenâ&#x20AC;&#x2122;s views about raising the family across the country has provided similar market conditions for the baby food market. Besides, Indian parents have developed a lot of interest in feeding their babies by relying more on formula and fortified cereals. Currently, priority of convenience and quality are the main agendas of consideration for a baby food purchaser in the country.

Market strength Coming over to market penetration, baby food accounts for the second-biggest chunk

Modern Food Processing | December 2010

(32 per cent) of the Indian milk product sales mix after the milk powder segment. Rising proportion of the service-class population supporting the baby food market has led the market to be worth around ` 1,500 crore in 2009. Cereals, snacks, bottled & frozen foods and soups comprise the major segments of the baby food market in India. Moreover, emerging micromarkets of baby food market include puree, juice, milk products, biscuits, puff and frozen fruits. As the market is advancing gradually, it has been observed that for different age-groups such as new born, infants, toddlers, and preschoolers, specially prepared food are available in the market. It is evident from the current trends that organic baby food is the fastest growing segment of the Indian baby food market and is quickly making a stronghold in the overall baby food market. A few years back, the organic baby food segment operated as a niche market but now, it is fast acquiring major marketshare. Increasing health consciousness among the public and demand for healthy & safe food has driven the sales of organic baby food. Considering the baby food merchandise, the baby food imports scaled up to around 901 metric tonne in financial year (FY) 2009, on account of increasing demand and limited domestic supply during the past few years. This trend is most likely to continue in the

INDUSTRY INSIGHTS

coming years because of growing branded baby food demand. However, stringent exports regulations and higher tariffs have been limiting the considerable exports of the baby food from the country.

Regional discrepancy Talking about regional break-up of the industry, the baby food market boasts of a huge marketshare in urban India. In fact, the baby food market is geographically balanced with the eastern and north-eastern states leading the trends. The consumption pattern is concentrated in Assam, Meghalaya, Mizoram and some other eastern states. Moreover, in the western region, states like Maharashtra and Gujarat are contributing majority shares to the baby food market. However, owing to its vast size and demand base, the Indian rural market presents great opportunities for the baby care companies. Nearly, 70 per cent of consumers reside in rural areas and almost 50 per cent of the national income is generated here. Further, the consumer base for baby care products in rural areas was estimated at 98 million in 2005. This figure is anticipated to reach around 104 million by 2010 and 109 million by 2015. Such a vast prospective population will provide enough market entry and growth opportunities to new & existing players, thus positioning India as one of the worldâ&#x20AC;&#x2122;s biggest & fastest growing baby food markets. Though it is true that the rural market offers opportunities to the companies,

it is difficult for any organisation to enter this market and walk away with a sizeable share. Various problems faced by companies while entering the rural market include physical distribution & channel management, promotion & marketing communication problems, and rural marketing, which involves more intensive personal selling efforts compared to urban marketing. Moreover, rural consumers are not as brand-conscious as their urban counterparts. With declining prices of baby food products and rising awareness among rural consumers, the preference for branded products over the unbranded products is anticipated to experience a stupendous upsurge.

As the profit margins on baby food products tend to be higher than those for many other food products, companies are focussing on introducing new products in the future. Competitive scaling The competitive landscape of the baby food market includes both national as well as international companies. Nestle, with its well-established brands Cerelac, Nestum, and Nestogen, holds over 85 per cent marketshare. The other major players in the industry include H.J. Heinz Company and Wockhardt Ltd. A few brands available in the market are Farex, Lactogen, Lactodex, Nan, etc, priced between ` 180 to ` 250. Imported formulas like Similac, Enfamil, etc are also available, but by and large there is not much difference in their constitution other than may be the newly added DHA, which again is available in Courtesy: Nestle the Indian brands.

901 799

FY 2008

FY 2009

Note: FY 2009 data is for April-February period Source: Global Trade Information Services Database

Figure 1: Indian imports of milk powder and baby food (in metric tonne) for FY 2008 & FY 2009

The baby food companies are focussing mainly on developing easily digestible fortified baby food at competitive prices. With the evolving food technologies, they are introducing varieties of baby food products such as, baby soup and frozen baby foods. Promotional activities are also banned for baby food in the country, and hence manufacturers now state that â&#x20AC;&#x2DC;breastfeeding is bestâ&#x20AC;&#x2122; on all infant formula product packaging and teach healthcare professionals about the benefits & advantages of breastfeeding for the first six months of life. As part of their larger responsibilities, manufacturers widely distribute the International Code and have instituted strong measures to improve their own marketing practices. Further, the companies are also supporting huge research for introducing new baby food products in India as against abroad. It is anticipated that the companies at present, are introducing products depending on the taste preference, keeping the price point in mind. They are focussing on products that have all the essential ingredients and nutritional value, which is needed for the specific segment. Thus, consumer buying behaviour and food habits play a key role in deciding the lines of introducing products/entering the baby food market. For instance, Nestle has launched Nido to cater to children over two years old. The parent company has brands like

December 2010 | Modern Food Processing

INDUSTRY INSIGHTS

22%

25%

33%

20%

East & Northeast North South West

Source: RNCOS

Figure 2: Indian baby food market by region in 2009

Gerber, Mucilon and Naturnes, which can be launched in India. International companies like Heinz are looking for baby-food acquisitions in emerging markets like India as the demand for baby food and infant formula is growing. As the profit margins on baby food products tend to be higher than those for many other food products, companies are focussing on introducing new products in the future.

Government’s policy To ensure safety, all infant foods are manufactured under strict hygienic & quality management procedures and in accordance with the National Legislation or Codex standards. The industry supports efforts by the governments and communities to increase public awareness on recommended infant feeding practices, including, when necessary, the appropriate preparation, handling & storage of breast-milk substitutes. The government’s regulations make India a tough market to operate in for infant foods and nutrition. India’s guidelines regarding the formula for infant foods are stricter than some of its neighbours. Moreover, advertising in this category is banned. However, if viewed from a different angle, the country has an excellent law in the form of The Infant Milk Substitute, Feeding Bottles and Infant Food (Regulation of Production, Supply and Distribution) Act, 1992. The Act, while not banning the products under its scope regulates marketing

of breast milk substitutes, which the Act calls infant milk substitutes, to children under the age of two, clearly in consonance with the World Health Organization recommendation of breastfeeding till 2 years. The specific labelling requirements for infant milk substitutes and infant foods are that, every container of infant milk substitute or infant food or any label affixed thereto shall indicate in a clear, conspicuous manner a statement ‘Mother’s milk is best for your baby’ in capital letters. In addition, a statement that infant milk substitute or infant food should be used only on the advice of a health worker as to the need for its use and a warning that infant milk substitute or infant food in not the sole source

It is anticipated that the companies at present are introducing products depending on the taste preference, keeping the price point in mind. of nourishment for an infant is also indispensible, while labelling the baby food products. As far as imports of baby food are concerned, the government has set up the following regulations: R ‘Milk food for babies’ is in the ‘Free’ list of milk products, ie, it can be freely imported to India. There is no requirement of any special import permit R As of July 7, 2009, the import duty on ‘milk food for babies’ is 68.95 per cent R This notification from the Department of Animal Husbandry and Dairying, Government of India, outlines sanitary

Modern Food Processing | December 2010

requirements of all milk products imported to India. It also provides the post-import requirements for the imported milk products R All manufacturers and exporters, whose products are sold in India, are required to register with the Bureau of Indian Standards to comply with the mandatory Indian quality standards

Industry shortfalls In recent years, India has demonstrated remarkable growth in the consumption of baby food. The country is viewed as a major potential to become one of the world’s leading baby food consumers, owing to its large population base. However, there still exist some roadblocks, which may hamper the exponential growth trajectory of this industry in future. Following are some of the factors that have the potential to severely affect the industry’s growth rhythm: R The Indian baby care market is mainly restricted to the urban areas, which are still to be fully penetrated when compared to other developed and developing markets in the Western countries. Thus, under-penetration needs to be overcome by the country R Competition from cheaper substitutes and home-made complementary food remains the biggest threat R Cultural aspects and regulations on ‘Infant Food Promotion’ play a key

Courtesy: Dinatorj

INDUSTRY INSIGHTS

role in hindering the growth of this potential market in the country Although, the government has not been much supportive to provide some corrective measures, industry players should take some initiatives to uplift the industryâ&#x20AC;&#x2122;s outlook. In fact, the country has a long way to go to sustain and improve the attractiveness & profitability of the baby food industry. Following corrective measures have been identified, which if implemented, can potentially improve the overall industry outlook: R Players should carefully determine the product segment they want to cater to R Careful identification of regions, states should be covered to maximise the product reach R Willingness to work with multiple channel partners R Enhanced investment in the development of channel and sales teams In addition, to support the development of this sector, in-house and collaborative R&D programmes should be encouraged & supported by the government.

Way ahead The multi-billion population of India proposes a huge potential for the baby food industry in the coming years. Innovation in products and marketing strategies is the need of the hour for most of the companies operating in this segment. It can also be expected that in future, penetrating deep into the urban market in conjunction with the rural market will provide exciting growth opportunities to the potential industry players. Baby food and nutrition, as a category in India, will grow around 10-12 per cent in the coming years as the usage of these products is limited to children aged between three months and two years. The tier-I, tier-II cities will account for the majority of the market because infant-formula milk powder will become affordable for a large number of people. Indiaâ&#x20AC;&#x2122;s GDP has been growing 8-9 per cent annually, and as the economy grows, the household income will also grow, so the affordability of households to buy infant-formula milk powder will grow. In the next decade or two, all the households in the local cities will catch up with the increasing baby food trend. 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 & discussions organised by business & trade-related associations. Email: shushmul@rncos.com

December 2010 | Modern Food Processing

FOOD SAFETY

Halal certification

For faithfully safe foods The word ‘Halal’ is usually associated with meat and poultry products. But, originally Halal, an Arabic word meaning lawful or legal, is a term designating any object (including food & drinks) or an action, which is permissible to use or engage in, according to Islamic law. In this context, the demand for Halal foods is increasing among Muslim as well as non-Muslim consumers as these types of foods are considered safe and hygienic. Courtesy: Glendal Foods

Subhash Vaidya

slam is one of the widely followed religions and represents a large section of the world population. Muslim population is estimated at 1.5 billion in the world today, of which 60 per cent reside in Asia. In India too, it represents a large segment. For the past 40 years, many Islamic countries are witnessing rapid economic development and there is a huge demand for food products, if they are Halal certified. Besides Muslims, other consumers also nowadays prefer to buy Halal certified food because of additional safety and sanitation features. It is estimated that the global Halal food market is valued around $ 600 billion per year. Therefore, there is a tremendous scope for Indian food manufacturers to get their products Halal certified in order to export to countries where Halal foods are preferred and expand their markets. Halal food source comprise fish (except those that are poisonous or hazardous to health); meat and poultry (except certain animal species not slaughtered as per Islamic Shariat law); all types of beverages (except those which are hazardous to health and those mixed with alcohol); and plants (for instance, vegetables).

Modern Food Processing | December 2010

All Halal products sold, displayed and stored need to be labelled accordingly.

Processing and handling The processed food is considered Halal if all the ingredients used meet the requirements mentioned above as per the Shariat law. It should not contain anything in small or big quantities that are considered as najis (ritually unclean) according to this law. Sanitation and hygiene play an important role with special emphasis on personal hygiene, clothes, utensils and working place for processing & manufacturing of food. All foods should be prepared, processed, packed, stored and delivered to stores in such a manner that they comply with the local sanitation & hygiene requirements as well as the Shariat law. To Muslim consumers, products carrying Halal logo have more meaning and are more acceptable than those carrying ISO or similar certification mark. To them, Halal is more ‘wholesome’. When it involves cleaning, it is not only a standard cleaning procedure but has to be ritually cleaned as well. With the globalisation of trade, advancement in science & technology and continuous changes in product formulation & initiatives to simplify manufacturing processes, it is essential that the Halal concept is fully understood, especially

FOOD SAFETY

by the marketers of consumer goods (for food as well as non-food product categories). This is important because as the consumers become more religious or Halal-conscious, they will look for products that not only satisfy their needs but also give them peace of mind.

General guidelines Halal certificate for food is a document issued by a Muslim organisation certifying that it meets Islamic guidelines. If the companies use ingredients or processes that do not meet the requirements for Halal certification, then such foods are considered to be normal products. Hence, it is important for food processors to know the source of commonly used ingredients. Food additives, colours, flavours, stabilisers, packaging materials are most commonly used ingredients and care should be taken to eliminate the contamination.

Issuing authority Any individual Muslim, Islamic organisation or agency can issue a Halal certificate, but the acceptability of the certificate depends upon the country of import or the Muslim community served through such certification. For example, in order to issue a Halal certificate for the products exported to Malaysia and Indonesia, the issuing body of the Halal certificate must be listed on each countryâ&#x20AC;&#x2122;s approved list. Malaysia and Indonesia are the only countries that have a formal

Products qualified for certification The products generally certified are: R Meat and poultry products whether

fresh, frozen or processed R

Dairy products

Packaged food products

Pharmaceuticals

Nutritional products

Packaging material

Ingredients for dairy, meat and poultry

programme to Application approve Halal-certifying organisations. Other Pre requisite programme Preliminary audit Sanitation process countries, like Saudi of the unit Halal programme in Arabia, Singapore, plant audit Kuwait, United Arab Management Ingredient changes/ Process Emirates (UAE), Egypt review meeting modification change and Bahrain, may also Approval approve organisations of the unit for specific reasons. The process of Halal Production certification commences by choosing an Process Records Final audit verifications verifications organisation that meets market needs, be it local, neighbouring Batch certificate Yearly certificate countries, or global. Figure 1: Flow chart of Halal certificate process If the market area is global, then an internationally-accepted organisation has assurance about the product, the to be chosen. certificate is issued. There are two types It is necessary to understand the of certificates â&#x20AC;&#x201C; one is batch certificate products to be certified, production and another for total process for which process and the location where the regular audit takes place at planned intervals. Overall, the process for Halal certificate is not complicated.

Halal certificate enhances the marketability of food products in the Islamic regions, that too at a relatively small investment.

products are to be sold. Moreover, it is essential to collect the information about the food ingredients. It is, therefore important to set up a preassessment audit of the facility. One can negotiate the cost involved for the certification. During the pre-assessment of the audit, the organisation may ask manufacturers to replace the ingredients that are not acceptable. There are also recommendations made in this process. After the review meeting, the facility is approved. Once the production process is established, the actual audit takes place where all the records for incoming ingredients, raw materials, packaging materials and process steps involved are checked and verified. After the complete

Modern Food Processing | December 2010

Halal logo When the product is certified as Halal, a symbol is normally printed on the package for providing information to consumers. Different countries use varied symbols. However, a product will be better acceptable by the Muslim consumer, if the logo is from local authority and from a reputable Halal certifying agency.

Making its mark felt The Halal logo is a testimony to support Halal food chains. There is a huge opportunities to tap the global Halal food market that cater to 1.5 billion people. Hence, Halal certificate enhances the marketability of food products in the Islamic regions, that too at a relatively small investment. 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

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SMART LOGISTICS

Backward linkages

Imperative for an efficient supply chain Though India has the second-largest arable area in the world, the country is far behind in terms of agriculture and food processing. Over the past couple of decades, there has been limited or no focus at farm level to improve quality and productivity. However, as proven by companies like PepsiCo, strong backward linkages in the food value chain hold the key, be it in the area of agriculture, production or logistics. Courtesy: Mobius

Abhijit Upadhye

ndia has incredible opportunities in the field of food and agriculture because of various factors. It has the second-largest arable land in the world and has diverse agro-climatic zones. This makes India unique for producing several kinds of horticultural and agro products. Apart from this, India, with a population of 1.08 billion, growing at 1.6 per cent per annum, has a favourable demographic profile making it one of the largest consumption hubs. Indiaâ&#x20AC;&#x2122;s strong GDP growth and all the above mentioned factors have attracted many food & beverage companies to the Indian market. However, because of the underdeveloped and inefficient farm-to-fork food value chain, tapping into this huge potential is not an easy task. In 1989, PepsiCo launched its agro-business in India with a special focus on exporting specially packed tomato puree and paste. With a substantial investment, the company created a state-of-the-art tomato processing plant but was soon faced with the following challenges: Poor quality: Historically, tomatoes were never cultivated in India for their solid content or for other processing characteristics like colour, viscosity, water binding, etc. This meant that PepsiCo had

Modern Food Processing | December 2010

to work on developing new varieties that helped improve quality for processing tomatoes. Lower yield: There was never a focus at the farm level on yields, which also resulted in high input costs. A sound R&D programme backed by technology transfer was the intrinsic strength of PepsiCo. Post PepsiCoâ&#x20AC;&#x2122;s entry, tomato yield has increased from 14-16 tonne per hectare to almost 52 tonne per hectare. Inadequate quantity: The available tomato crop in Punjab was around 28,000 tonne over a 25-28 day period, while the company required at least 40,000 tonne over a minimum 55-day period. Others: Little effort was made to create a database on performance of different varieties. There were no modern farming practices and the existing procurement model for fruits & vegetables in the country was inefficient.

Tackling the challenge PepsiCo took this challenge head-on and devised an innovative approach towards agriculture, production and logistics. This led to the birth of PepsiCoâ&#x20AC;&#x2122;s famous backward-linkage with the farmers of Punjab. It also had a strategic partnership with local agricultural universities and government bodies. And the rest as they say

SMART LOGISTICS

is history. Encouraged by its sweeping success of contract farming of tomatoes, PepsiCo has successfully emulated the model in foodgrains, spices, oil seeds, and potatoes. Today, PepsiCo India is the largest corporate involved in potato contract farming dealing with 12,000 farmers, sourcing 1,50,000 tonne of potatoes every year. There are several other similar successful examples from companies like Amul, Nestle, McCain, McDonald’s, etc. Now, the question that arises is why did PepsiCo decide to create strong backward linkages and should all companies follow this approach in order to create a longterm sustainable competitive advantage in India. Here are the reasons: R India is the second-largest producer of fruits and vegetables. But nearly ` 70,000 crore of post-harvest produce is wasted because of a farm-to-fork supply chain system. Only 2.2 per cent of the total produce is processed R India is the third-largest producer of potatoes but less than 5 per cent can be processed R It is the world’s largest producer of milk, but the average yield per lactation cycle is 10 per cent of the US R The country is the world’s largest producer, consumer and importer of pulses, but our yields per acre in 2010 are the same as in 1951

Moving ahead through backward linkages Until now, there has been only few examples where companies have led from the front to overcome challenges faced in sourcing agricultural raw materials and even fewer examples where such initiatives have received government support. To establish an agrarian economy that ensures raw material for its expanding food processing sector; surplus for exports; food availability for its billion plus population; and improve the livelihood of farming community, strong backward linkage is clearly a viable alternative that needs to be encouraged. Several Indian and multinational companies have already begun such initiatives in India and have demonstrated repeated success. Unless there is a serious approach from the government towards initiating public-private partnership, these successful cases should inspire the rest of the producing and the consuming organisations to emulate them and reap benefits. Abhijit Upadhye is the Director of Supply Chain, Menu Management & New Business Channels at McDonald’s India and has an extensive experience of over 14 years. He has done his management studies (in marketing) from NMIMS, Mumbai and BE in Mechanical Engineering from VJTI, Mumbai. Email: abhijit.upadhye@mcdonaldsindia.com

December 2010 | Modern Food Processing

CURTAIN RAISER

Frost & Sullivan 2010 India Excellence in Chemicals, Materials and Food Awards

Recognising exemplary achievements Frost & Sullivan will honour top achievers in the chemicals, materials and food ingredients sector at the soon-to-be-held 2010 India Excellence in Chemicals, Materials and Food Awards. These awards will acknowledge prominent companies for their significant contributions in the areas of products and services.

he Indian Chemicals, Materials and Food (CMF) industry is witnessing rapid growth, with companies demonstrating best practices in different regional and global markets. To recognise superior planning and the execution of product launches, strategic alliances, distribution strategies, technological innovations, customer services, etc, Frost & Sullivan is organising the 2010 India Excellence in Chemicals, Materials and Food Awards on December 6, 2010, at Hyatt Regency, Mumbai.

and Food Practice, South Asia and Middle East, Frost & Sullivan, says, “Our research on the best practices went beyond the top 10 players in the industry and the MNCs to identify midsized domestic players, which have achieved operational and functional excellence in their own specific fields of business. We came across companies, which have demonstrated product leadership positions across the world, some of which are driven by first generation entrepreneurs.”

Award categories The selection process The excellence awards will identify and recognise prominent companies in the chemicals, materials and food ingredients sectors for their significant contributions in the areas of products and services. These awards will recognise the distinction of products and services with respect to customer value, competence, features & functionality, customer focus, etc with a host of other crucial factors such as leadership, strategy, growth, innovation, integration and reliability. The nominees and award recipients have been identified through a diligent process, taking into consideration the perspectives of customers, experts and thought-leaders within the industry along with Frost & Sullivan’s knowledge base. Speaking on the CMF industry, Mamta Wadhwa, Senior Director - Chemicals, Materials

Modern Food Processing | December 2010

The Voice of Customer Award Series involves a multi-tier process wherein excellence in industry is gauged through ratings provided by end-user companies. The initial stage involves the identification of key suppliers; end-users of suppliers’ products are then interviewed focussing on a sample that accounts for the majority of the total marketshare. The next stage of analysis includes a statistical and analytical model wherein a panel of in-house Frost & Sullivan CMF experts examine and compute critical parameters determining product innovation/quality/ customer service for each product category. A rating on these parameters is gathered from respondents on the importance and relevance in the purchasing and decisionmaking process. The final ratings are averaged across respondents to arrive at a mean score. Suppliers with the highest scores are

CURTAIN RAISER

Mamta Wadhwa Senior Director-Chemicals, Materials and Foods, South Asia and Middle East, Frost & Sullivan

Rationale behind organising the event… The rapid growth in the chemicals, materials and foods market in India has made the key companies in the industry to evolve beyond the conventional practices. Globalisation has resulted in increasing competition from developing economies and over the next decade, we could see a significant number of chemical companies from Middle East (ME)/Asia Pacific (APAC) region in the global top 10. The current platform is to give recognition to companies that have demonstrated excellence in terms of various aspects of business like product launches, strategic alliances, distribution strategies, technological innovations, customer services, etc.

What’s next? Awards are an unbiased, third party recognition that can provide a profound impact in enhancing the brand value, and thereby accelerating the recipient’s growth. Our positioning in the market and unique approach enables us to determine how best-in-class companies worldwide manage growth, innovation & leadership. Hence, we plan to regularly conduct such events to recognise best practices in the industry.

then nominated for the award and analysed further to determine the winner. The jury-based awards are based on the premise of nominations from industry experts from various sectors of the chemicals, materials and food ingredients industry. Further, Frost & Sullivan analysts track company revenues, growth, dynamics, marketshare, etc for the nominated companies. Specific criteria are used to ascertain the final competitor ranking in each industry. Post this, final analysis is viewed and then the jury of industry experts determines awardees. “Frost & Sullivan Best Practices Awards identify exemplary achievements within a multitude of industries and functional disciplines. The analysis on best practices identifies excellent performances of executives, companies, products and processes. This research is an invaluable source to companies for new ideas to improve strategies and processes, which ultimately drive corporate growth,” adds Wadhwa.

December 2010 | Modern Food Processing

EVENTS CALENDAR

National MUMBAI Concurrent Shows

AHMEDABAD

INDORE

CHENNAI

Gujarat Dec 10-13, 2010

Madhya Pradesh Jan 7-10, 2011

Tamil Nadu Mar 11-13, 2011

Gujarat University Exhibition Hall

Maharaja Shivajirao School Grd, Chimanbaug

Chennai Trade Centre

India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumatics, Process Machinery & Equipment, Automation & Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.

For details Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022 3003 4651 Fax: 022 3003 4499 • Email: engexpo@infomedia18.in

Corrupack Summit 2010 The annual conference of Federation of Corrugated Box Manufacturers (FCBM) of India will be held concurrently with I-Pack exhibition showcasing latest advances in the packaging industry; December 10-12, 2010; at HICC, Hyderabad For details contact: Andhra Pradesh Corrugated Box Manufacturers’ Association # 401, Vaibhav Kunj Apartments 1-2-605, Lower Tank Bund Road Hyderabad 500 080 Telefax: 040-2766 8908 Email: info@apcma.in

International Horti Expo 2011 A horticulture and food technology exhibition providing a platform to the entire sector, right from producers to retailers; January 07-09, 2011; at Pragati Maidan, New Delhi For details contact: Media Today Group T-30, Ist Floor, Khirki Extn Malviya Nagar, New Delhi 110 017 Tel : 011-2668 2045 / 81671 Fax: 011-2668 1671 Email: hortiexpo@gmail.com

TASTE 2011 A trade fair for wine, spirits, food & hospitality; January 27-29, 2011; at Bombay Exhibition Centre, Mumbai For details contact: Informa India A202 Business Square Solitaire Corporate Park

Andheri-Kurla Road Chakala, Andheri (E) Mumbai 400 093 Tel: 022-4020 3355 Fax: 022-4026 4000 Email: nece@informa.in

Aahar 2011 An international trade fair for food processing, machinery and technology; March 10-14, 2011; at Pragati Maidan, New Delhi For details contact: India Trade Promotion Organisation (ITPO) Pragati Maidan, New Delhi 110 001 Tel: 011-2337 1725 Fax: 011-2337 8464 Email: rkmaggo@itpo-online.com

Food Forum India 2011 This two-day conference and exhibition will focus on various areas of food business like retailing, design, technology & processing, logistics, etc; March 28-29, 2011; in Mumbai For details contact: Images Multimedia Pvt Ltd S-21, Okhla Phase II New Delhi 110 020 Tel: 011-4052 5000, 4050 2500 Fax: 011-4052 5001 Email: info@imagesgroup.in

India Packaging Show The event will focus on latest trends in food packaging and emerging opportunities in the fast industrialising markets of South India; July 1-4, 2011; at HITEX, Hyderabad

Modern Food Processing | December 2010

Maharashtra February 17-19, 2011 NSE Ground, Goregaon

One of the largest advanced design and manufacturing events in India featuring Machine Tools, Hydraulics & Pneumatics, Process Machinery & Equipment, Automation & Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.

For details Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022 3003 4650 Fax: 022 3003 4499 • Email: hitech@infomedia18.in

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

Fi India 2011 An event featuring new and innovative food ingredients from India and abroad; October 3-4, 2011; at Bombay Exhibition Centre, Mumbai For details contact: Bipin Sinha UBM India Pvt Ltd 611-617, Sagar Tech Plaza - A Saki Naka, Andheri-Kurla Road Andheri (East), Mumbai 400 072 Tel: 022-6612 2600 Fax: 022-6612 2626 Email: bipin.sinha@ubm.com

SUGARASIA 2011 An event dedicated to sugar processing, co-generation, ethanol and cane harvesting; November 21-25, 2011; in New Delhi For details contact: Nexgen Exhibitions Pvt Ltd 1201/1206 Pragati Tower 26, Rajendra Place, New Delhi 110 008 Tel: 011-4008 1051/1000 Fax: 011-4008 1099 Email: sugarasia@nexgengroup.in

EVENTS CALENDAR

International 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

DDTE 2010 An event for beverage companies to present their latest technologies and system solutions for the entire production chain (manufacturing, filling, packaging, distribution, wholesales/retailing, trading and marketing) of carbonated, fruit juices, milk & dairy products; December 13-15, 2010; at Dubai Convention & Exhibition Centre, Dubai For details contact: INDEX Conferences & Exhibitions Zabeel Hall, Dubai Tel: +971 4 362 4717, Ext:112 Fax: +971 4 362 4718 Email: drinkexpo@index.ae

FBK 2011 An exhibition for the baking and confectionery industries; January 23-27, 2011; at BEA Bern Expo, Switzerland For details contact: BEA Bern Expo Mingerstrasse 6, Case Postale 3000 Bern 22, Switzerland Tel: +41 (0) 31 340 12 34 Email: info@beaexpo.ch

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

IFFIP PACKFAIR International forum for food industry and packaging; February 02-04,

2011; at KievExpoPlaza Exhibition Center, Ukraine

2011; at Dubai International Exhibition Centre, UAE

For details contact: IFWexpo Heidelberg GmbH Landfriedstraße 1a 69117 Heidelberg, Germany Tel: +49 (0) 62 21 - 13 57-0 Fax: +49 (0) 62 21 - 13 57 - 23 Email: info@ifw-expo.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

Foodtechmash 2011

PRODEXPO 2011 An international fair of foodstuffs and food raw materials; February 07-11, 2011; at Expocentr’ Krasnaya Presnya Fairgrounds in Moscow, Russia 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

Fruit Logistica 2011 An international trade fair for fruit and vegetable marketing; February 09-11, 2011; at Messegelände Berlin, Germany

Exhibition of equipment and technologies for food industry; February 23-25, 2011; at KievExpoPlaza Exhibition Center, Ukraine For details contact: Kyiv International Contract Fair, JSC PO Box B-13, Kyiv, 01001, Ukraine Tel: +380 (44) 461-93-40 Fax: +380 (44) 461 93-40 Email: info@kmkya.kiev.ua

China Drinktec 2011 Exhibition on beverage, brewery and wine technology; March 09-11, 2011; at China Import and Export Fair Pazhou Complex, China For details contact: Adsale Exhibition Services Ltd 321 Java Road, North Point, Hong Kong Tel: +852 2811 8897, Fax: +852 2516 5024 Email: exhibition@adsale.com.hk

For details contact: Messe Berlin GmbH Messedamm 22 14055 Berlin, Germany Tel: +49 (0)30 3038 Fax: +49 (0)30 3038 2325 Email: central@messe-berlin.de

Seafood Processing America 2011

Mobac Show 2011 A specialised exhibition for the bakery and confectionery industries showcasing the latest trends in machinery, equipment, tools and raw materials; February 16-19, 2011; at Intex Osaka, Japan For details contact: JBCM No 3 Azuma-Bldg, 1, Kanda-Hirakawa-cho Chiyoda-ku, Tokyo 101-0027, Japan Tel: 03-3862-8478 Fax: 03-3862-8470 Email: mobac@jbcm.co.jp

Gulfood Exhibition 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,

Trade show for seafood and food processing industry; March 20-22, 2011; at Boston Convention & Exhibition Center, the US For details contact: Diversified Business Communications 121 Free Street Portland, Maine 04112-7437, USA Tel: +1 (207) 842-5500, Fax: +1 (207) 842-5503 Email: shows@divexhibitions.com.au

Interfood Sweden 2011 A food industry exhibition & congress; April 14-16, 2011; at Swedish Exhibition & Congress Centre For details contact: Svenska Mässan Box 5222, 40224 Gothenburg, Sweden Tel: +46 31 708 80 00 Fax: +46 31 16 03 30 Email: info@swefair.se

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

December 2010 | Modern Food Processing

REPORT

Delegates at Fi India conference

Giving a boost to ingredients

Specialised trade events for the food processing industry in India are on the rise owing to the impetus provided to this sector by the Indian government and international players alike. Fi India was reportedly successful owing to the niche segment it catered to. With ingredients propelling new product development across the food processing industry, this exhibition had a lot to offer. Visitors interacting with exhibitors

he food ingredients segment in India is gaining more prominence, with people becoming extremely health conscious and showing concern about what they consume. Today, the consumers want to know the ingredients that go into the making of any food product. In this backdrop, UBM India organised the fifth edition of Fi India 2010 from October 22-23, 2010, at the Bombay Exhibition Centre, Mumbai.

Offering a successful recipe The exhibition created opportunities for those associated with the food industry to tap new suppliers & customers, expand their brands, and display as well as explore latest technologies. This year, the event saw participation from established international players from countries like Belgium, France, Singapore and Malaysia. China alone had over 20 companies present at the exhibition to capture this emerging segment in India. More than 103 exhibitors participated this year as compared to 74 in Fi India 2009. “Fi India 2010 received an overwhelming response with participation from international players like those from Belgium, China, France, Singapore and Malaysia. There has also been an increase in the number of exhibitors from the domestic market as well. From a visitor count of 600 when Fi India was launched, the number has reached around 4,800 this year,” added Vincent Brain, Event Director, UBM Live.

Modern Food Processing | December 2010

Conference series Fi India 2010 also hosted a concurrent high-level modular conference. Speakers from organisations such as Hindustan Unilever, ITC, Britannia, Godrej Hershey, Nestle, Cadbury and Frost & Sullivan expressed their views on diverse topics such as food industry regulations and innovations in ingredients, bakery, confectionery, beverages, dairy, cold chain and packaging. The conference series helped in fostering ties among industry professionals apart from being a source of exchange and discussion of ideas, innovations and success stories. The exhibition brought together thousands of buyers and sellers right from food manufacturers, processing specialists, service providers and food industry consultants. Visitors had the opportunity to update themselves on the regulatory framework governing food safety and health claims in India. They were also able to discover the latest consumer trends in order to translate them into India-specific product innovations. “Companies from India and abroad exhibited their products and solutions at this event for an ascending growth in their business. This trade show was not just beneficial to the exhibitors but also benefited the visitors as well by providing them with opportunities to generate business with miscellaneous food ingredient & processing companies under one roof. Events like Fi India act as a platform to encourage business and accelerate market growth,” said Bipin Sinha, Project Director, Fi India.

REPORT

Synergising success by stimulating growth Dubbed as one of the significant exhibitions for the food and allied sectors, Food & Bev Tech 2010 received good response from the industry. The third edition of the event focussed on technologies that hold potential to address some of the key issues facing this industry. A report…

Subodh Kant Sahai addressing the summit

Sahai interacting with an exhibitor

ith an aim to explore the new avenues of growth as well as capitalise on the existing strengths in the food and beverage (F&B) sector, the Confederation of Indian Industry (CII) organised the third edition of Food & Bev Tech 2010 from October 29-31, 2010, at Bombay Exhibition Centre, Mumbai. In his inaugural address, Subodh Kant Sahai, Union Minister for Food Processing Industries, highlighted the potential of the industry, and also stressed on the importance of technology in making India the ‘food basket of the world’.

Event highlights The focus of the third edition was on technology & innovation in the F&B sector. It aimed at spreading awareness on how technology can enable to drive food production and give a boost to the packaging segment as well. The objective of the event was quite relevant as food worth ` 50,000 crore gets wasted in India every year. Lack of technology, to a great extent, is responsible for this huge loss. “If technology is adopted in appropriate areas, it would enable farmers to opt for market-driven farming. This culturised farming will also produce raw materials for different industries,” exhorted Sahai. The event showcased the latest production machinery, raw materials, packaging equipment, auxiliary equipment & accessories required by F&B manufacturers. It witnessed participation of

Visitors examine technologies displayed

120 national and global companies from the F&B sector. Some of the leading companies present at the exhibition included Blue Star, HRS Process, Ingersoll Rand, Domino Printech, Ion Exchange, Parle Agro, Siemens Ltd, etc. It also had a country pavilion from Taiwan.

Discussion forum The concurrent summit also threw light on many contemporary issues pertaining to the industry. Piruz Khambatta, Chairman, CII Food & Bev Tech 2010, and Chairman, Rasna Pvt Ltd, said, “The world looks at India for meeting their food requirements. Technology is a means to make India a food factory for the world.” He also stressed on the need for corporate involvement in farming. One of the issues discussed in the summit covered the theme titled ‘Is there any need to change policy to fuel the growth?’ Throwing light on it, Venkatesh Valluri, President, Ingersoll Rand International (India) Ltd, said, “It was not policy change that led to the growth of the BPO and IT industries. If we do not build technology where the end-farmer gains the benefit, growth and sustenance will become difficult.” Overall, the event was a grand success as the organisers were able to bring in national and international food & beverage processing companies together under one roof, which displayed a wide range of latest technologies and offered a platform for boosting trade ties.

December 2010 | Modern Food Processing

PRODUCT UPDATE

Homogeniser

Controlled particle size reduction unit

Goma Engineering offers high pressure homogeniser in capacities ranging from 20 to 20,000 lph. Its lubrication and air cooling system ensure optimum temperature for continuous duties. This homogeniser is equipped with hydraulically operated two stage homogenising head, specially designed homogenising valves,

Urschel Laboratories offers Comitrol Processor Model 1700 controlled particle size reduction unit. It accommodates all three types of reduction heads, which enable a broad spectrum of product processing capabilities. It is recommended for freeflowing dry and semi-dry product applications including textured vegetable protein, peanut butter, chicken slurries, baby food, dehydrated potato flakes, fruit & vegetable pastes, horseradish & dressings, extruded products, biscuits & cookies, nuts, fruit pulp, various spices, hard cheese and a variety of gels, ointments & creams. The standard operations include comminuting, granulating, milling, flaking, slicing, liquefying, dispersing and pureeing. The sealed enclosure deters escape of dust, vapour and liquid when the reduction unit is installed in conjunction with a collection system. The stainless steel construction ensures maximum durability and sanitation. The machine features continuous operation for uninterrupted production and simplified design for easy cleanup & maintenance.

plunger made of special steel with wear-resistant coating, special surface treatment, specially designed ball/poppet valves of stellite/ ceramic for viscous products, etc. The one piece forged cylinder block is ultrasonically tested for long life. It comes with plunger cooling system with low water consumption, easily replaceable plunger seals, SS-316 imported diaphragm type glycerin filled pressure gauge. The machinery is designed according to 3A standard & CE marked. Goma Engineering Pvt Ltd Thane - Maharashtra Tel: 022-2173 1801-02, 4161 4161 Fax: 022-2173 1803, 4161 4162 Email: goma@vsnl.com

Urschel Laboratories Inc Indiana - USA Tel: +1-219 464 4811, Fax: +1-219 462 3879 Email: info@urschel.com

Roll wrap machine A M P Rose offers roll wrap machine for wrapping of circular product in stick packs of varying lengths and number of candies. It comes with electronic vibratory system for the feeder. The wrap machine is provided with mechanical vibratory feed system, which enables the feeder to be turned to suit individual products. The key feature of this machine is the short pack and no-pack no paper system, which utilise infrared detectors. The paper feed can be simplified by utilising a servo drive and registration system. It can be fitted with various types of coders and printers. Its features include: improved hot melt and cold glue systems, improved wrapping head design to eliminate wear on wrapper jaw teeth, belt spindles, etc. A M P Rose (P) Ltd Bengaluru - Karnataka Tel: 080-2847 3611-14, Fax: 080-2847 3615 Email: sales@amprose.co.in

Modern Food Processing | December 2010

Laser scanner Omron Automation offers user-friendly and versatile OS32C safety laser scanner, which is able to cater to safety applications. Its low profile allows installation in small spaces making it ideal for collision avoidance of automated guided vehicles (AGVs). For complex AGV applications, up to 70 combinations - each with one safety zone and two warning zones can be set. The key feature of this scanner is that replacing a damaged sensor is faster & easier and re-programming is not required as the configuration, which is stored in the I/O block, can be detached from the sensor block. Omron Automation Pvt Ltd Bengaluru - Karnataka Tel: 080-4072 6400, Fax: 080-4146 6403 Mob: 099809 43045 Email: in_enquiry@ap.omron.com

PRODUCT UPDATE

Three-deck pre-cleaner Sifter International offers three-deck pre-cleaner. It is suitable for cleaning of cereals, grain, legumes and fine seeds. The deck pre-cleaner machine is used for separating oversized, under-sized and light impurities from the feed. It is available with two-aspiration systems; one for the feeding material and second for the cleaned material. The pre-cleaner machine is equipped with a feeder, which is driven by an independent gear motor. Fine dust and light impurities are separated out before putting the material in the first sieve with the help of an aspiration system. A blower is provided on the top of machine. The companyâ&#x20AC;&#x2122;s drum-sieve machine, a pre-cleaner machine, is used to separate coarse impurities, such as straw particles, string, paper, pieces of wood, maize, leaves and cobs. Sifter International Faridabad - Haryana Tel: 029-406 0039, 223 4540 Fax: 0129-223 0039 Email: sifter@ndb.vsnl.net.in

December 2010 | Modern Food Processing

PRODUCT UPDATE

Potato processing & frying machine Flavorite PPM Technologies offers potato processing & frying machine. It is available in capacities ranging from 100 kg/hr - 1,000 kg/hr. The machine consists of a peeler, slice washer, blancher/cooker, fryer, flavour applicator and flavour drum. The abrasive coated continuous peeler & batchtype peeler for continuous operations comes with variable speed rollers and consumes less water. The slice washer facilitates removal of slivers & nubbins and reduction of free starch. The SS blancher/cooker enhances product appearance. The stainless-steel fryer is available for all types of snacks. Its features include low oil hold-up, faster oil turnover rates, continuous fines removal system, custom-made solution, adjustable frying time, choice of heating method, etc. The flavour applicator has lump breaker in hopper, variable feed rates and gives uniform application flavour. The flavour drum is available in different profiles as per product demands. Flavorite PPM Technologies Pvt Ltd Indore - Madhya Pradesh Tel: 0731-257 5258, 404 6509, Fax: 0731-404 0953 Email: sales@flavoritefoods.com

Modern Food Processing | December 2010

PRODUCT UPDATE

Lined carton machine Rollatainers offers model RT-12 fully automatic lined carton machine. It is a specially-designed filling machine to handle liquids, powder, granules for both food and nonfood products. The machine is offered with 14 stations and all operations are driven mechanically. An easily accessible magazine holds approximately 150 cartons ensuring 12 minutes of running time. The machine is ergonomically designed to reduce fatigue for the operator. Its features include easy & quick changeover for carton size with same cross-section preset exchange parts, centralised lubrication and main drive with safety clutch, etc. It has a fill accuracy of Âą 1 per cent for 1 ltr/gm. A number of safety switches supervise faulty operation and prevent breakdown. It is designed to ensure hygienic filling and easy access for cleaning & servicing. Rollatainers Ltd Faridabad - Haryana Tel: 0129-409 8800, Mob: 098115 66112 Email: info@rolapak.com

December 2010 | Modern Food Processing

PRODUCT UPDATE

Screening machines Allgaier offers tumbler and vibration screening machines according to GMP and FDA-regulations for applications in pharmacy, food and fine chemicals. These specialised machines are used for the treatment of valuable powders, pellets and granules. The hygienic design includes solutions for WIP-cleaning devices and ATEX certification. The tumbler screening machines are high-performance screening devices for fractionating, protective screening and dedusting. The threedimensional tumbling movement creates exceptional fine cuts for the bulk solids. The modular design allows the production of additional fractions through additional screening desks in one machine. For simple applications, vibration screening machines, type VTS or Vibrall, are economic alternatives. Allgaier Werke GmbH Uhingen - Germany Tel: +49-7161-301353 Fax: +49-7161-34268 Email: siebtechnik@allgaier.de

Modern Food Processing | December 2010

PRODUCT UPDATE

Sigma mixer Paresh Engineering Co offers heavy-duty sigma mixer, which is designed to offer uniform mixing and kneading high viscosity materials. It is applicable to many products such as different kinds of doughs, stiff pastes, adhesives, polyester compounds, flush colours, brake lining compounds, soaps, PVC coatings, rubber compounds, food dough, etc. The mixing trough and blades are fabricated from mild steel/various grades of stainless steel. The product contacting parts are ground, buffed or smooth. The blades are designed to obtain thorough mixing of high viscosity materials and are machined on a leading edge to keep minimum equal gap between through walls & blades. It is provided with heavyduty gears, which are fitted to the blades. Shaft sealing into the stuffing boxes is provided by teflon chevron rings/PTFE breaded gland rope to prevent leakages from blade ends. Guards/grills and interlocking are provided for maximum safety. Paresh Engineering Co Mumbai - Maharashtra Tel: 022-2850 1794, Fax: 022-2850 9193 Email: pecmarol@vsnl.com

Volumetric cup feeder system Simple Packolutions offers volumetric cup feeder system for packaging homogenous granular products like avla, supari, whole spices, food grains, etc. It is provided with auto strip cutting system and does not require compress air for machine operations. All contact parts are in SS-304, 316 and is available with complete powder coated base frame structure. The system is equipped with castor wheel for ease of cleaning beneath the machine and for relocating. The auto-detect type photo-cell ensures no change of gear for change in pouch length. It is also available with stamp type contact coding system and nitrogen gas flushing attachment for enhance product shelf life. It has a output capacity of 15-100 ppm, depending upon product, weight per pouch and pouch size. Simple Packolutions Pvt Ltd Mumbai - Maharashtra Mob: 099690 00116, 098206 43731 Email: packolutions@gmail.com

December 2010 | Modern Food Processing

PRODUCT UPDATE

Bulk cooler module IDMC offers complete bulk milk collection centre module comprising automated milk receiving & weighing, milk testing, analysing & payment system, bulk milk cooler, DG sets, solar/electrical hot water system, CTP and purification system. The open and closed direct expansion bulk milk cooler modules are available up to 5 kL capacity with accessories. Bulk coolers up to 16 kL capacity in standard version and other configuration like vertical silos, mobile units, etc can be designed and manufactured on request. These coolers conform to ISO 5708 standards for 2/3/4 milking and are fitted with air-cooler condensing units working on R22, R134A and R407C refrigerant. The company also offers automated CIP, refrigeration chiller packages for specialised applications, waste heat recovery system and milk analysis module. IDMC Ltd Vithal Udyognagar - Gujarat Tel: 02692-236 375/229 917 Fax: 02692-234 397/236 164 Email: idmc@idmc.coop

Modern Food Processing | December 2010

` `

PRODUCT UPDATE

Semi automatic weigh feeder Sensograph Packaging offers semi automatic weigh feeder. This feeder is provided with load cell based 32-bit advanced controller. The controller has user-friendly operator interface where one can set different weights as per different batches and even different products. The feeder is available in single head, twin head and multi head versions. The manual sealer can be used to seal ready bags. This machine is ideally suited for products like farsan, pulses. wafers, dry fruits, tea powder, grocery items, vermicelli, candies, etc It is equipped with smart controller, 200 mm x 100 mm display, HMIs compatible with all Indian regional languages, etc. Since this controller uses pneumatic control system and not magnetic, its operation is noise free. Sensograph Packaging Technology Pvt Ltd Mumbai - Maharashtra Tel: 022-4142 0002 Fax: 022-2767 1931 Mob: 099202 32025 Email: mgt@sensograph.in

December 2010 | Modern Food Processing

PRODUCT UPDATE

Vision sensor Omron Automation offers Omron FQ vision sensor, which has been designed to simultaneously meet inspection reliability, ease of use, and cost performance requirements. With one-touch control via user-friendly, icon-driven menu, crystal-clear image quality, real colour processing (16 million colours) and a one-touch control via PC or the intuitive touch finder console, the user can access all functions and settings quickly and easily. Furthermore, with its advanced processing tools, excellent image quality is achieved from even the most challenging surfaces. Omron Automation Pvt Ltd Bengaluru - Karnataka Tel: 080-4072 6400, Fax: 080-4146 6403 Mob: 099809 43045 Email: in_enquiry@ap.omron.com 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

Modern Food Processing | December 2010

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Distilled water......................................... Metallography ........................................

Air purifier ..............................................

Doors...................................................... Metering pumps .....................................

Ammonia liquid chillers...........................

Drives ..................................................... Milk processing unit................................

Animal feed technology ..........................

Dry vacuum pumps ................................. Mixers.....................................................

AODD pumps .........................................

Dust control door ................................... Monoblock high vacuum pump ..............

Automatic bag splitter ............................

Emulsification solutions........................... Motion controls ......................................

Automatic filling machine .......................

Encoders................................................. Multi fuel fired IBR steam boiler ..............

Automatic scrubber driers .......................

Engine oils (lubes) ................................... Multi level car park .................................

Automation & robotic .............................

Evaporating units for cold rooms ............ Multi-head combination weigher machine

Banking services......................................

Exhausters............................................... Nozzles ...................................................

Bearings..................................................

Exhibition - Engineering Expo.................. Oil milling unit ........................................

Beverage canning system ........................

Exhibition - hiTech manufacturing show.. Oil seal high vacuum pump ....................

Beverage packaging machine ..................

Extruded products................................... Oil/coolant coolers ..................................

Beverage processing (fruit-based) ............

Failure analyser ....................................... Packaging machine .................................

Beverage processing (mineral) .................

Filler compositional analyser.................... Packing machines....................................

Biodiesel .................................................

Financial services..................................... Panel air-conditioners ..............................

Blowers...................................................

First Fold type Here package IBR steam boiler .. Fire tube

Boilers.....................................................

Flexible transparent PVC strip door.......... Pasteurising machine...............................

Box sealing machine ...............................

Flour milling unit .................................... Petrol & fuel oils......................................

Brewing unit ...........................................

Food testing equipment ......................... Photoelectric sensors...............................

Brine chillers ...........................................

Forced convection unit air cooler............. Piston pumps..........................................

Bulk container discharger ........................

Freezing equipment ................................ Plastic pellets ..........................................

Bulk cooler mixer ....................................

Fruits/vegetables processing plant ........... Plate heat exchanger...............................

Bulk milk cooler ......................................

Fuels- diesel ............................................ Plug valve ...............................................

Burners ...................................................

Gas conditioning and fire protection system.... Pneumatic actutators ..............................

Butterfly valve .........................................

Gases...................................................... Pneumatic hammers ...............................

Cable carriers ..........................................

Gear oils ................................................. Pneumatic valve ......................................

Cable connectors ....................................

Grain handling machine.......................... Poker vibrators ........................................

Capping & packaging unit ......................

Grinding & dispersion unit ...................... Polycarbonate sheets...............................

Carpet cleaning machines .......................

Heat resistant door ................................. Polymer characterisation .........................

Centrifugal pumps ..................................

Heavy industrial steel building ................. Potato processsing & frying machine.......

Chains ....................................................

High pressure cleaners ............................ Power & energy management .................

Chocolate/cocoa making machine ...........

Homogeniser .......................................... Pre-engineered steel building ..................

Circumferential piston pumps .................

Hot air & water generator ....................... Pre-fab shelter.........................................

Cleaning section equipment ....................

Industrial control & sensing devices......... Process tanks ..........................................

Cold form C & Z purlins ..........................

Industrial cooling systems ....................... Product handling equipment...................

Colour sorting units ................................

Industrial door ........................................ Production line........................................

Second Fold Here pumps ..................................... Industrial

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Dehumidifiers.......................................... Metal separation unit..............................

Air cooler................................................

Pasta making machine ............................

Compositional & trace metal analyser......

Programmable controllers .......................

Condition sensing switches and controls .

Industrial-type unit air cooler .................. Programmable logic controllers ...............

Confectionery machines ..........................

Invertor/variable frequency drives ............ Programmable terminals .........................

Connectors .............................................

Laser scanner .......................................... Proximity sensors ....................................

Controlled particle size reduction unit .....

Level controllers ...................................... Pump......................................................

Conveyor systems....................................

Lined carton machine.............................. Pump/valve .............................................

Corrugated tube heat exchangers ...........

Lipid food packaging unit ....................... PVC strip door ........................................

Counters & power supplies .....................

Liquid filler machine................................ Rail tankers .............................................

Couplings ...............................................

Liquid fillers ........................................... Receptacles .............................................

Cup filler machine...................................

Loading arms .......................................... Refrigerant pumps ..................................

Dairy enzymes.........................................

Material identificaton unit....................... Refrigeration ...........................................

Dairy machinery ......................................

Measuring & monitoring relay ................ Relays .....................................................

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Dairy plant .............................................. Mechanical vacuum boosters ..................

Advance fluid mixing dispersion unit .......

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Accelerated ageing test...........................

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Residential steel house ............................

Single stage monoblock vacuum pump...

Timers.....................................................

RFID .......................................................

Single stage vacuum pump .....................

Tin .......................................................

Rice milling equipment............................

SME finance............................................

Transmission fluids ..................................

Roll wrap machine ..................................

Special refrigeration equipment...............

Tri-lobe roots blowers..............................

Roof vent ................................................

Spray analyser .........................................

Turnkey systems for dust suppression ......

Roofing & cladding sheet ........................

Spray controller.......................................

Roots blower ..........................................

Spray fabrication.....................................

Roots vacuum pumps .............................

Spray nozzles and accessories .................

Rotary lobe pumps..................................

Stainless steel equipment and fitting .......

Rotary pumps .........................................

Steam boilers ..........................................

Safety door .............................................

Steriliser ..................................................

Safety light curtains ................................

Structural floor decking sheet .................

Screening machines ................................

Sweepers ................................................

Screw compressor ...................................

Switching relays ......................................

Seasoning system....................................

Swivels....................................................

Security systems ......................................

Tanks & silos ...........................................

Semi-automatic weigh feeder..................

Temperature controllers...........................

Water ring vacuum pumps......................

Separating magnetic & non-magnetic metals .

Testing equipment ..................................

Water wall membrane panel IBR steam boiler....

Sight flow meters....................................

Thermal processes...................................

Web 18 software services........................

Sigma mixer............................................

Thermic fluid heater................................

Wood fire four pass thermic fluid heater .

Single disc machines ...............................

Three-deck pre-cleaner ............................

Wood fire thermic fluid heater ................

Twin lobe roots blower............................ Two stage vacuum pump ........................ Universal-type unit air coller .................... USS univent ............................................ Vaccum cleaners ..................................... Vacuum pumps....................................... Vertical non IBR oil fired steam boiler...... Viscous paste filler machine .................... Vision sensors ......................................... Volumetric cup feeder system ................. Water chillers .......................................... Water purifier .........................................

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A.M.P. Rose.................................................................................

Jieh Hong Machinery Co., Ltd. ....................................................

Acme Air Equipment Co Pvt Ltd. .................................................

Joyam Engineers & Consultants Pvt Ltd. ......................................

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

Nichrome India Ltd. ....................................................................

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

Novozymes South Asia Pvt Ltd. ...................................................

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

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

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

P.P.I. Pumps Pvt Ltd. ....................................................................

CNZH Technology Share Co., Ltd. ................................................

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

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

Rockwell Automation .................................................................

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

S+S Separation And Sorting Technology Gmbh ..........................

Eureka Forbes Limited. ................................................................

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

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

Shiva Analyticals (India) Limited...................................................

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

Spraying Systems (India) Pvt Ltd. .................................................

Gudel India Pvt Ltd. ....................................................................

SSP Pvt Limited. ..........................................................................

Heat And Control........................................................................

Standard Chartered Bank ............................................................

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

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

HiTech Manufacturing Show .......................................................

WAM India Pvt Ltd......................................................................

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

Web 18 Software Services Ltd. ....................................................

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

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

IDMC Limited..............................................................................

Wraptech Machines Pvt Ltd.........................................................

IGUS India Pvt Ltd. ......................................................................

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PRODUCT INDEX Product

Pg No

Accelerated ageing test .......................... 74 Advance fluid mixing dispersion unit .............. 3 Air cooler........................................................ 7 Air purifier .................................................... 19 Ammonia liquid chillers ................................ 10 Animal feed technology................................ 13 AODD pumps ................................................. 3 Automatic bag splitter .................................. 57 Automatic filling machine............................. 77 Automatic scrubber driers............................. 47 Automation & robotic................................... 21 Banking services...................................... 67 Bearings.......................................................... 4 Beverage canning system ......................... 17,77 Beverage packaging machine..................17, 77 Beverage processing (fruit-based).................. 77 Beverage processing (mineral)....................... 77 Biodiesel ....................................................... 74 Blowers......................................................... 18 Boilers........................................................... 76 Box sealing machine ..................................... 77 Brewing unit................................................. 13 Brine chillers ................................................. 73 Bulk container discharger.............................. 57 Bulk cooler mixer .......................................... 78 Bulk milk cooler ............................................ 10 Burners ......................................................... 76 Butterfly valve ............................................... 10 Cable carriers ............................................ 4 Cable connectors ............................................ 4 Capping & packaging unit ............................ 77 Carpet cleaning machines ............................. 47 Centrifugal pumps .......................................... 3 Chains ............................................................ 4 Chocolate/cocoa making machine................. 13 Circumferential piston pumps ......................... 3 Cleaning section equipment.......................... 13 Cold form C & Z purlins.................................. 5 Colour sorting units ...................................... 13 Compositional & trace metal analyser ........... 74 Condition sensing switches and controls ...... 53 Confectionery machines ................................ 81 Connectors ..................................................... 4 Controlled particle size reduction unit........... 72 Conveyor systems.......................................... 65 Corrugated tube heat exchangers ................ BIC Counters & power supplies .......................... FIC Couplings ..................................................... 73 Cup filler machine......................................... 59 Dairy enzymes ........................................... 9 Dairy machinery ............................................ 10 Dairy plant.................................................... 37 Dehumidifiers................................................ 75 Distilled water............................................... 77 Doors............................................................ 81 Drives ........................................................... BC Dry vacuum pumps....................................... 75 Dust control door ......................................... 81 Emulsification solutions............................ 3 Encoders...................................................... FIC Engine oils (lubes)......................................... 74 Evaporating units for cold rooms.................... 7 Exhausters..................................................... 18 Exhibition - Engineering Expo .................. 43,61 Exhibition - hiTech manufacturing show .... 48,49 Extruded products ........................................ 13 Failure analyser ....................................... 74 Filler compositional analyser ......................... 74 Financial services........................................... 67 Fire tube type package IBR steam boiler ....... 76 Flexible transparent PVC strip door ............... 81 Flour milling unit .......................................... 13 Food testing equipment .............................. 63

Product

Pg No

Forced convection unit air cooler .................... 7 Freezing equipment ...................................... 77 Fruits/vegetables processing plant ................. 77 Fuels- diesel .................................................. 74 Gas conditioning and fire protection system.... 15 Gases............................................................ 74 Gear oils ....................................................... 74 Grain handling machine ............................... 13 Grinding & dispersion unit............................ 13 Heat resistant door ................................. 81 Heavy industrial steel building ........................ 5 High pressure cleaners .................................. 47 Homogeniser ................................................ 72 Hot air & water generator ............................ 76 Industrial control & sensing devices ..... FIC Industrial cooling systems ............................. 73 Industrial door .............................................. 81 Industrial pumps........................................... 73 Industrial-type unit air cooler .......................... 7 Invertor/variable frequency drives ................. FIC Laser scanner .......................................... 72 Level controllers ........................................... FIC Lined carton machine ................................... 75 Lipid food packaging unit............................. 77 Liquid filler machine ..................................... 59 Liquid fillers ................................................. 77 Loading arms................................................ 73 Material identificaton unit ..................... 74 Measuring & monitoring relay .................... FIC Mechanical vacuum boosters ........................ 18 Metal separation unit ................................... 25 Metallography .............................................. 74 Metering pumps ............................................. 3 Milk processing unit ..................................... 17 Mixers........................................................... 57 Monoblock high vacuum pump.................... 75 Motion controls ........................................... FIC Multi fuel fired IBR steam boiler ................... 76 Multi level car park ......................................... 5 Multi-head combination weigher machine.... 59 Nozzles .................................................... 73 Oil milling unit ........................................ 13 Oil seal high vacuum pump.......................... 75 Oil/coolant coolers ........................................ 73 Packaging machine ................................. 31 Packing machines ......................................... 77 Panel air-conditioners ................................... 73 Pasta making machine .................................. 13 Pasteurising machine .................................... 17 Petrol & fuel oils ........................................... 74 Photoelectric sensors.................................... FIC Piston pumps............................................... BIC Plastic pellets ................................................ 13 Plate heat exchanger .................................... 10 Plug valve ..................................................... 10 Pneumatic actutators .................................... 57 Pneumatic hammers ..................................... 57 Pneumatic valve ............................................ 10 Poker vibrators.............................................. 57 Polycarbonate sheets ...................................... 5 Polymer characterisation ............................... 74 Potato processsing & frying machine ............ 74 Power & energy management....................... 53 Pre-engineered steel building .......................... 5 Pre-fab shelter ................................................ 5 Process tanks ................................................ 10 Product handling equipment ........................ 65 Production line ............................................. 77 Programmable controllers ............................. 53 Programmable logic controllers.................... FIC Programmable terminals .............................. FIC Proximity sensors ......................................... FIC Pump....................................................... 52,75

Product

Pg No

Pump/valve ................................................... 17 PVC strip door .............................................. 81 Rail tankers ............................................. 10 Receptacles ................................................... 73 Refrigerant pumps ........................................ 10 Refrigeration ................................................. 10 Relays ........................................................... 53 Residential steel house.................................... 5 RFID............................................................. FIC Rice milling equipment ................................. 13 Roll wrap machine........................................ 72 Roof vent........................................................ 5 Roofing & cladding sheet ............................... 5 Roots blower ................................................ 52 Roots vacuum pumps ................................... 75 Rotary lobe pumps ......................................... 3 Rotary pumps ............................................... 75 Safety door ............................................. 81 Safety light curtains ..................................... FIC Screening machines ...................................... 76 Screw compressor......................................... 10 Seasoning system.......................................... 65 Security systems............................................ 19 Semi-automatic weigh feeder ....................... 81 Separating magnetic & non-magnetic metals ....... 25 Sight flow meters ......................................... 73 Sigma mixer.................................................. 77 Single disc machines..................................... 47 Single stage monoblock vacuum pump ........ 75 Single stage vacuum pump........................... 75 SME finance ................................................. 67 Special refrigeration equipment .................... 73 Spray analyser............................................... 15 Spray controller ............................................ 15 Spray fabrication........................................... 15 Spray nozzles and accessories ....................... 15 Stainless steel equipment and fitting ............ 17 Steam boilers................................................ 76 Steriliser ........................................................ 17 Structural floor decking sheet ......................... 5 Sweepers ...................................................... 47 Switching relays ........................................... FIC Swivels.......................................................... 73 Tanks & silos ........................................... 10 Temperature controllers ......................... FIC, 53 Testing equipment ........................................ 74 Thermal processes......................................... 13 Thermic fluid heater...................................... 76 Three-deck pre-cleaner.................................. 73 Timers.................................................... FIC, 53 Tin ................................................................ 23 Transmission fluids........................................ 74 Tri-lobe roots blowers ................................... 18 Turnkey systems for dust suppression ........... 15 Twin lobe roots blower...........................18, 52 Two stage vacuum pump .......................52, 75 Universal-type unit air coller .................... 7 USS univent .................................................... 5 Vaccum cleaners ...............................19, 47 Vacuum pumps ............................................ 75 Vertical non IBR oil fired steam boiler........... 76 Viscous paste filler machine .......................... 59 Vision sensors ........................................ FIC, 82 Volumetric cup feeder system ....................... 77 Water chillers .......................................... 73 Water purifier ............................................... 19 Water ring vacuum pumps ........................... 52 Water wall membrane panel IBR steam boiler ...... 76 Web 18 software services ............................... 8 Wood fire four pass thermic fluid heater ...... 76 Wood fire thermic fluid heater ..................... 76

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