Modern Food Processing - June 2011 by Infomedia18

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Modern Food Processing

June 2011

EDITORIAL

The impetus of automation

o you know that food and food products make the biggest consumption category in India? A recent survey pegs its market size at $181 billion and it is projected to touch $258 billion by 2015! With the nation’s population exceeding 1.1 billion and food forming a major part of the consumers’ wallet spending, this seems to be a realistic scenario. However, the challenge lies in facilitating this magnificent demand surge along with the requisite safety and quality norms. Help may be at hand in the form of process automation. Apart from ensuring safety and quality of food and beverages, it can play a key role in helping bridge the demand and supply gap in this sector as well as bringing down the wastage of food as compared to manual processing. There are ample scopes for automation systems in food processing units; right from washing, cleaning to sorting of the raw materials. The dairy segment in India can be cited as a good example of how automated food processing can achieve considerable success in terms of milk and value-added dairy products. On the flip side, the application of automation systems is yet to witness spread across food processing units - big and small.

Published in association with Editor: Manas R Bastia Assistant Editor: Rakesh Rao Senior Features Writer: Prasenjit Chakraborty Features Writer: Mahua Roy Correspondent: Avani Jain (Ahmedabad) Copy Editor: Marcilin Madathil Edit Associate - Products: Abha Mishra Assistant Art Director: Varuna Naik Chief Photographer: Mexy Xavier Photographer: Neha Mithbawkar, Joshua Navalkar Design: Mahendra Varpe Production: Pravin Koyande, Vikas Bobhate, 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 Circulation/Subscription: Sunil Nair, Distribution Head Email: sunil.nair@network18online.com, customercare@infomedia18.in Tel: 91-22-3003 4631/4633

With competitiveness in the global market fast becoming the benchmark, it should not take longer for those players on the fence to leverage its benefits. ‘Sector Watch’ offers a detailed perspective into the latest dynamics of process automation in food processing. On a different note, the food packaging segment has come a long way with some of its recent offerings being state-of-the-art futuristic solutions to meet the growing demands of food safety, traceability and environment-friendliness. Empowering consumers with accurate knowledge about the integrity of the product inside, the active and smart packaging technology for food and beverage is estimated to grow globally at a Compounded Annual Growth Rate (CAGR) of more than 8 per cent. Besides aiding food processors in reducing or eliminating preservatives in products, active/intelligent packaging holds promises as a tool to lessen food waste and the resources lost thereof. Turn to ‘Industry Update’ for further insights.

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

Manas R Bastia Editor manas@infomedia18.in

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

June 2011 | Modern Food Processing

CONTENTS

LEADERS SPEAK “Glocalisation is a way for international companies to enlarge their customer base and build customer loyalty in local markets” ...says Sanjay Coutinho, Chief Executive Officer, Barista Lavazza

ROUNDTABLE Alcoholic beverage packaging: Waging the battle for sustainability

FACILITY VISIT IDMC Ltd: Milking success through innovative solutions

SECTOR WATCH Process automation: ‘Arm’ing the industry with safety and quality systems

INDUSTRY UPDATE Active packaging: A smart solution for new-age challenges

MARKET SCOPE Inspection system: Plugging loopholes with a clear ‘vision’ Didier Lacroix, Senior VP - International Sales & Services, Cognex Inc

INDUSTRY INSIGHTS Food retailing: A value for money proposition Shushmul Maheshwari, CEO, RNCOS E-Services Pvt Ltd

FOOD SAFETY Spices industry: Retaining flavour and aroma safely Subhash Vaidya, Proprietor, Dairytech Consultancy Services

TREND ANALYSIS Indian confectionery market: Sweet prospects to savour Gaurav Marchanda, Analyst, Consumer Markets, Datamonitor

QUALITY MANTRA Food safety guidelines: Weeding out hot spots Courtesy: Coca-Cola Retailing Research Council Asia

CASE STUDY Cover illustration: Chaitanya Surpur

RE G GU ULAR SE EC C TI TIO ON NS S Editorial .................................................... 11 National News ......................................... 14 World News............................................. 22 Tech Updates ........................................... 28 Events Calendar ....................................... 70 Technology Transfer ................................. 72 Book Shelf ............................................... 74 Product Update........................................ 76 Product Index........................................... 86 Advertisers’ List ....................................... 88

Non-returnables line: Adding new dimension to bottling Andreas Reusche, Project Manager - Sales, Krones AG

Highlights of Next Edition Sector Watch : Industry Update : Market Insights :

Non-alcoholic Beverages Edible Oils/Fats Baby Foods

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

Modern Food Processing | June 2011

Details on page no. 39, 70

NATIONAL NEWS

HEALTH DRINKS

SOCIAL RESPONSIBILITY

BNatural offers new natural flavours

Bosch takes part in ‘Save Food’ initiative

Bengaluru-based Balan Natural Foods (Bnatural) has introduced two new flavours in its beverages range – Amla & Brahmi available in 100 ml tetrapak. BNatural produces juices, beverages, milk, yoghurt and processed food products. Introducing these two products, Arunachalam Nadaakumar, Chairman, BNatural, said, “Balan Natural

Food is nature’s courier – committed to delivering the natural taste in any fruit or vegetable to its customers. Human wellness is our purpose and our task is to deliver that nourishment in the original tastes and flavours that each fruit, vegetable, herb and grain offers with least possible distortion in processing and packaging.” The amla fruit is considered to boost immunity and scavenge free radicals from the body by detoxifying the blood and other tissues in the body. Brahmi has been used in Ayurveda to improve memory and concentration, as well as optimise the blood pressure.

Packaging Technology business unit of the Bosch Group, in order to help ensure that in the future, less food perishes on its way to the consumer, took part in the international ‘Save Food’ initiative, which was initiated by the United Nations’ Food and Agriculture Organization (FAO). At present, over a third of all food is wasted globally as it travels from the field to the plate. In emerging countries like India the amount is over three-quarters. The initiative wants to ensure more diligent handling of available foodstuffs and to look for solutions so that less food is wasted. “Only a joint effort will succeed in combating today’s massive waste of food,” said Friedbert Klefenz, President, Bosch Packaging Technology. One reason why food decays prematurely is the lack of appropriate packaging to protect the products from weather conditions or pests. This means that transportation and storage

is impossible without causing damage to the products. This illustrates the importance of packaging technology in our everyday lives. “Without packaging technology, there would also be much less variety on our dining tables,” Klefenz explained. As early as 2007, Bosch took action against the waste of food and resources in emerging countries. In India, truckmounted machines, customised to meet local needs, were used to convince local farmers and authorities about the benefits of packaged food products. Each year, an additional 100 machines come into operation. Their use could be even more widespread, if there was a distribution network to assure the transport of goods over longer distances. A widespread distribution of packaging machines is the goal in order to prevent on-site perishing of goods. Additionally, it is important to build distribution networks.

PRODUCT POSITIONING

Cadbury-Kraft introduces Tang for children With the onset of summer and many leading ready-to-mix drink players in the market battling for their own stance, Cadbury India, as part of the Kraft Foods Group, has introduced the Indian-made Tang. The drink is a combination of refreshing flavours of orange, lemon and mango that help in replenishing the essential vitamins A, B & C, and iron, which get depleted during the course of life, particularly in children. “Tang has been available in India as an imported product in select outlets for the last four years and it already has an established equity among a niche set of consumers. We are proud to introduce Tang, making it now easily accessible to Indian consumers through retail outlets across the country,” said Narayan Sundararaman, Director-Powdered Beverages, Gum and Candy, Cadbury India.

MINT CONFECTIONERY

Dabur India launches digestive mint candy under Hajmola brand Dabur India Ltd recently announced its entry into the mint candy market with the launch of Hajmola Mint Masti. The new offering, under the flagship digestive brand Hajmola, claims to offer consumers the freshness of mint along with the digestive properties of Hajmola.

“Conventional mint candies provide only fresh breath. Hajmola Mint Masti offers not just fresh breath but also helps in digestion of food,” said Rajeev John, DGM (Marketing) - Digestives, Dabur India Ltd. “The mint super category is currently valued at around ` 720 crore. We found that all the products were competing in the same brand space with little to no

Modern Food Processing | June 2011

differentiation in product attributes. It was our strategic decision to enter the category with a definitive USP of both fresh breath & digestion. Almost a third of all consumption of mint happens after meals to mask the malodour of last meal consumed. Hence Hajmola’s equity of digestion combined with fresh breath is an innovative & relevant offering,” added John.

NATIONAL NEWS

QSR UPDATE

ACQUISITION

McDonald’s announces future investments

HNG to acquire Germany-based Agenda Glas AG

McDonald’s has brought one of its most popular global products, McSpicy chicken burger to Indian customers, and has also launched McSpicy Paneer Burger, Big Spicy Chicken Wrap & Big Spicy Paneer Wrap. McDonald’s has invested close to two years and more than ` 3.5 crore in R&D to bring the McSpicy products to India. Amit Jatia, Vice Chairman, McDonald’s India (West and South), said, “With the McSpicy range, we extend the range to not only include an extremely popular global product, the McSpicy burger, but also innovated to add a punch of localisaton to the menu by introducing the Big Spicy Wraps, product ideated and developed

in India.” McDonald’s (South & West) has joined the global league of business franchisees with Hardcastle Restaurants Pvt Ltd now becoming a Development Licensee. Jatia said, “This is a great moment for us as we have matured to a point where we have been trusted with carrying forward the aggressive plans of McDonald’s for India. In the immediate future, we will be investing ` 500 crore and doubling our presence over the next three years in India. According to Peter Rodwell, Division President – Greater Asia & Middle East Division, “The recent change from Joint Venture to Development Licencee in India’s South West is based on the Corporation’s view that India’s economy will continue to grow rapidly and sustainably, creating significant present and future opportunities for the expansion of the McDonald’s brand.”

Hindusthan National Glass (HNG), one of the leading glass container manufacturers in India with 55 per cent marketshare in the domestic glass packaging segment, recently announced that it is all set

Mukul Somany

to acquire Agenda Glas AG, Germany, entailing an investment of about ` 321 crore over the next one year. The acquisition will act as a stepping stone to the company’s global growth plans and will drive HNG’s vision of becoming one of the top 15 global glass packaging companies. The acquired company is a new facility catering to the alcoholic beverages segment, with state-of-theart technology and has a production capacity of 320 tonne per day.

Mukul Somany, Vice Chairman and Managing Director, Hindusthan National Glass and Industries Ltd, said, “Through this acquisition, we plan to set our foot into the container glass manufacturing segment in the international market and we will also be following a high growth path in the next three years. In India, we have been looking at aggressive organic growth through greenfield and brownfield expansions with an investment of ` 2,500 crore. The inorganic growth in building manufacturing presence in the international market is also crucial to the company’s strategic global expansion plans and vision to becoming one of the top 15 global glass packaging companies.” Exports to over 23 countries in Europe, the US, UAE and Africa already contribute a portion of HNG’s ` 1,500 crore annual turnover. HNG offers the widest range of bottles ranging from 5 ml to 3200 ml with downstream applications in the liquor, beer, beverages, pharmaceuticals processes, foods and cosmetics industries.

OVERSEAS EXPANSION

Jubilant Foodworks to launch Domino’s in Sri Lanka Jubilant Foodworks Ltd (JFL) recently announced that it will launch the first Domino’s Pizza store in Sri Lanka in June as a part of its plan to expand presence outside India. JFL is also looking to tap fast food market in Bangladesh, besides enhancing reach within India by setting up 80 new stores this fiscal. “We will enter Sri Lanka through our subsidiary by launching first Domino’s store in June. In 2010-11, JFL opened 72 new stores with an investment of around ` 70 crore. This fiscal the company intends to open 75 to 80 Domino’s stores,” said Ajay Kaul, CEO, JFL. Besides increasing the number of outlets, JFL also plans to set up new commissaries at Mumbai, Kolkata and Chandigarh. Earlier this year, JFL had signed a master franchise agreement with USA’ leading baked food and coffee chain Dunkin’ Donuts to bring the brand in the country. “The first Dunkin’ Donuts store is likely to be set up this year-end or early next year. In the next five years, we plan to set up 80-100 such stores in India. JFL witnessed another strong quarter and a strong fiscal not only from profitability point of view, but also from a strategy point of view by way of tieup with Dunkin Donuts,” Kaul added.

Modern Food Processing | June 2011

ADVERTORIAL

ccording to a report published by market research firm RNCOS in April 2010 titled ‘Indian Food and Drinks Market: Emerging Opportunities’, the Indian food and beverages market is expanding rapidly and is projected to grow at a compound annual growth rate (CAGR) of about 7.5 per cent during 2009-13 and would touch US$ 330 billion by 2013. In order to further advance the food processing industry, the Ministry of Food Processing Industries (MOFPI) has formulated a Vision 2015 action plan which aims to treble the size of the food processing industry, raise the level of processing of perishables from 6 per cent to 20 per cent, increase value addition from 20 per cent to 35 per cent, and enhance India’s share in global food trade from 1.5 per cent to 3 per cent. It is evident from these figures that India’s Food Processing Industry is on the cusp of experiencing a significant growth trajectory. However, the Food Processing Industry is faced by some complex technology related challenges that need to be addressed if it is expected to continue along this growth curve. This is true not only of the Food Processing Industry in India but also across geographies where certain challenges faced by companies in this space are similar in nature. One such instance is that of Matrix Technologies, headquartered in the US which faced a challenge that resonates with companies in Food Processing in India as well.

The challenge Matrix Technologies Inc. is a leading provider of engineering services to Industries such as food and beverage, pharmaceutical, chemical, oil and gas, metals, glass and automotive. While catering to the food Industry, Matrix technologies faced a typical problem that is encountered by many in the canned food segment, across the world. Typically, producers of canned foods make a large volume of a particular product, such as tomato soup, and then store the cans in a warehouse without labels while waiting for orders from customers. The cans are labeled just before shipment, often with the customer’s private brand label. The cans go by at a speed of one every 60 milliseconds so conventional manual inspection is not possible. The only known effort at applying machine vision to this problem used a camera connected to a frame grabber board on a computer. Its weakness is that the specialized hardware is not designed for use in a factory environment. The cameras and frame grabber boards are susceptible to heat and dust. A considerable level of expertise is also required to set up and maintain this type of system, expertise that is typically hard to deploy in such a processing unit. A similar challenge is faced by Food Processing companies in India as well which further widens the gap between available facilities, technology and infrastructure and the desired output basis new quality-check guidelines being put in place.

the ability of the PatMax tool to recognize a pattern regardless of its location. Rather than reading individual characters the application is configured to simply look for an image that matches the three-digit product code. A new product code can be configured simply by putting a can with the new code in position to be viewed by the vision system and positioning a rectangular box around the product code. From that point, the vision system will detect that product code even if it is in a different position or at a different angle as long as it is in the field of view. This approach is much simpler, more robust and more economical than the machine vision technology used on this application in the past. Additionally, Matrix Technologies deployed bright stock labeling solution which also includes a laser scanner that reads the barcode on the label of each product. A fibre optic sensor identifies labels that have not been properly glued to the can by detecting a protruding flap. The combination of Cognex In-Sight® 5600 vision system and Matrix Technologies’ bright stock labelling have already proven their ability to provide accurate inspection results with virtually no downtime. Matching the images of the product codes has proven to be a much more reliable and robust solution than attempting to convert the images to characters allowing plant personnel to maintain the equipment and program them to read new product codes without any difficulty. Based on performance criteria, benchmark testing, and user acceptance, this solution delivers an attractive value for bright stock inspection in the food and beverage industry, taking into account the practical problems faced by the industry everywhere.

The solution To tackle the challenge, Matrix Technologies utilized recent advances in vision system technology to develop a better approach to brightfield automated inspection using Cognex In-Sight® 5600 vision system to inspect the product codes against the bright can background at a speed of 1000 products per minute. The Cognex PatMax® pattern matching tool inspects the product code. This application takes advantage of June 2011 | Modern Food Processing

NATIONAL NEWS

ITALIAN FLAVOURS

GOURMET RETAIL

Del Monte launches Italian range of products

Future Group enters elite gourmet retailing

Del Monte recently launched new authentic and easy to cook Italian range of products, which now include a wider portfolio of authentic Italian pastas, pasta sauces and olive oil. The brand, which already enjoys prominence in the market with innovative ketchups, sauces, packaged fruit and fruit drinks, now brings a wide range of Italian products to the Indian kitchen. Del Monte will now cater to burgeoning needs of a fast growing authentic Italian cuisine market, estimated to grow at 30-40 per cent. It claims to offer products that are high on taste and nutrition. The pasta range is made with 100 per cent durum wheat semolina and is completely vegetarian. Sanjay Nandrajog, CEO, FieldFresh Foods, said, “It is our constant endeavour to understand the developing trends in the processed food & beverages category and bring the finest products to the Indian customers under the brand Del Monte. The new launches under Del Monte’s Italian range in India are yet another step in this direction, which addresses the needs of the growing consumer class that wants authentic, healthy and easy to cook Italian products.” With the new launches, Del Monte pasta is now available in seven different shapes like farfalle, penne, chifferi, spaghetti, spirali, spirali tricolour and lasagne sheets. In addition there is a new whole-wheat version of the popular penne. The pasta sauces market is leaping ahead at close to 50 per cent year-on-year growth by value and the Del Monte range includes arrabiata, tomato & basil, veg bolognese & siciliana. Yogesh Bellani, Business Head, Del Monte Foods Business, FieldFresh Foods, explained “Authentic Italian cuisine is the next big thing. This is reflected in the proliferation of brands in this space both in FMCG as well as food service. There is definitely increased retail shelf space being dedicated to authentic Italian food products like the range from Del Monte. There is also a large segment of consumers who are used to buying domestic vermicelli & macaroni and they are seen to be upgrading to more authentic & easy-to-cook options. With the widest range in the Italian category, Del Monte is poised to dominate this market in the times to come.”

Kishore Biyani’s Future Group is going super elite for the first time with the launch of a gourmet food chain. The owner of Big Bazaar hypermarkets and Central destination malls opened the first all-new format of gourmet food store, Foodhall, in Mumbai’s most luxurious shopping mall Palladium. Foodhall is the fourth organised food retailing chain in Future Group’s portfolio. The three existing ones include mass retail store Food Bazaar, no-frills smallformat KB’s Fair Price stores and franchisee store FoodRite, which it acquired from South African grocery chain Shoprite.

Foodhall stores will serve high-margin fine foods and will completely steer clear of discounts & consumer promotions. It will offer a range of fresh & packaged assortment foods and will cover international & pan-Indian cuisines. The opportunity for gourmet food is estimated at about ` 4,000-5,000 crore, which is about 5 per cent of the overall food industry. The competition includes Godrej Nature’s Basket, which operates over 10 stores, and smaller chains such as Le Marche & Modern Bazaar. Besides, RPG’s Spencer’s Retail has a section on gourmet foods at some of its stores.

BUY OUT

Orkla Brands buys Pune-based spice company Orkla Brands has entered into an agreement to purchase Rasoi Magic Foods, an Indian manufacturer of spices and spice mixes, located in Pune. Under the agreement, Orkla Brands is acquiring 100 per cent of the shares through its Indian company MTR Foods. Rasoi Magic Foods’ product portfolio comprises spices, spice mixes and ready

mixes for the ready-to-cook segment. “This acquisition is part of our further investment in India, which we consider to be an attractive and growing market. Rasoi Magic Foods complements the products of our Indian branded company, MTR Foods. At the same time, we are expanding the market for our products. We see

Modern Food Processing | June 2011

considerable potential for synergies between the two companies,” said Paul Jordahl, CEO, Orkla Brands International. Orkla Brands acquired MTR Foods in Bengaluru in 2007. The company manufactures processed vegetarian foods, such as ready meals, ready mixes and spices.

NATIONAL NEWS IMAGE MAKEOVER PACKAGING TRADE SHOW

PackPlus South 2011 to be held in July Building on the success of last year’s India Packaging Show and Bulk Pack, the PackPlus South will now be held in Hyderabad as the total packaging, processing and supply chain event. Presenting a run-up of the development scenario in the southern sector, PackPlus South 2011 will commence on July 1-4, 2011. The four-day exhibition, organised at HITEX, Hyderabad, will showcase latest innovations in packaging, converting, processing and supply chain industry. The show will bring together the worldwide manufacturers and providers of machinery, materials and services for food, pharma and packaging industry from India and neighbouring countries. “The best names in the country are on board to exhibit in this edition. The show has been promoted extensively at the grass root level,” said Neetu Arora, Director, Print-Packaging.Com, the organisers of the event. Exhibitors coming from several segments including packaging machines, equipment, materials and services, will display latest innovations from the industry. The Converting Zone at PackPlus South will focus on the latest developments from the industry. Featuring India Converting Show, India Corrugated Show and India Flexo Show, this zone will have exhibitors from converting, pre-press, printing, coating, laminating, finishing, label printing, labelling, paper, film, foil, inks, anilox rollers, flexo presses, corrugating boxes, heating systems, boilers, adhesives and testing equipment for paper and packages industry. The Processing Zone will feature Food Technology Show, Pharma Technology Show and Automation 4 Packaging. Exhibitors in the zone will include manufacturers and providers of process automation, instrumentation and controls, robotics, motion drive automation, automation in machine tools, software & enterprise solutions, technologies, equipment, materials & services for food production, processing, brewing & distilling, baking, freezing, testing and measuring, pharmaceutical and parapharmaceutical product process & packaging machinery, quality control, environmental control, handling and storage system. Running concurrently with the main event will be PackAge 2011, the twoday conference focussing on the latest converting and pharma packaging technologies. The two-day conference will focus on ‘Cost-effective, innovative & sustainable packaging’.

Tata’s Tetley tea gets new look Tata Global Beverages is undertaking an image makeover of its flagship tea brand Tetley, as part of a strategy to reposition the product and bring about uniformity across global markets. The firm said Tetley will have single new logo with a tagline, ‘Free your mind...That’s Tetley!’ in contrast to its current strategy of developing the product on a local basis, presenting the brand differently around the world. The company said the brand is present in over 70 countries across the globe and has around 500 different varieties of tea available around the world. “We are thrilled to be introducing the refreshed Tetley brand to the consumers. Our new design will create a bolder Tetley presence on shelf and allow shoppers to explore our range of products with greater ease,” said Sushant Dash, Vice President (Marketing), Tata Global Beverages. FOOD RETAIL

HyperCITY inaugurates its 2nd store in Bengaluru HyperCITY launched its second store at the Royal Meenakshi Mall, Bengaluru. This is the second HyperCITY store in Bengaluru and the third in South. The

BREWERY BUSINESS

Appollo Distilleries to become a subsidiary of Empee Empee Distilleries has acquired Appollo Distilleries, an associate company, making it a subsidiary. Appollo Distilleries is setting up a 7.5 lakh cases a month greenfield brewery at Gummidipoondi to the North of Chennai. It is promoted by the promoter of the Chennai-based Empee Group. M P Purushothaman, Chairman, Empee Group, said the brewery set up at a cost of about ` 110 crore is set to commence production by August. The unit will come out with

two or three of its own beer brands named Max 7000 Mega Strong and Coolberg Premium Lager. It is also in discussions with leading beer brands for a bottling arrangement. With the launch of its own brands Empee, a leading player in the Indian made foreign liquor segment, is re-entering the beer range nearly a decade after it sold its brewery business. In 2002, it owned the then popular Marco Polo beer, when it sold its brewery business to the UB Group.

Modern Food Processing | June 2011

launch of this store marks the presence of 10 HyperCITY stores across India. Speaking on the occasion, Mark Ashman, CEO, HyperCITY Retail (India), said, “Bengaluru is an evolved market and has witnessed an amazing growth in the retail category. The cosmopolitan city has the right blend of customers that have accepted and believe in the organised retail format. HyperCITY customers will enjoy the convenience of international shopping from over 44,000 products at great value under one roof.”

WORLD NEWS

APPOINTMENT MEGA DEAL

General Mills signs Yoplait acquisition agreement General Mills has entered into definitive agreements to acquire a 51 per cent controlling interest in French yoghurt maker Yoplait and a 50 per cent stake in a related entity that holds the global Yoplait brands. General Mills, which has held the licence for the Yoplait brand in North America since 1977, won a bidding race with an offer of Euro 810 million in March, after private equity firm PAI had put its 50 per cent share in the company up for auction last summer – attracting bids from major food industry players, including Nestlé, Bel, Lactalis and The Bright Food Company. French dairy co-operative Sodiaal will hold the remaining ownership stakes in both entities. Completion of the transaction is subject to regulatory approval, but is expected in the first quarter of General Mills’ 2012 fiscal year. The business will be run by a supervisory board with representation from both General Mills and Sodiaal. Gerand Budin, President - International, Sodiaal, with Chris O’Leary, Executive VP & COO, General Mills, said in a joint statement, “We see tremendous opportunities to work together to become a major competitive force in the global yogurt market.”

American Beverage Association announces its Board of Directors The American Beverage Association (ABA) recently announced the election of two new members to its Board of Directors. The new members are Kirk Tyler, President, Atlantic Coca-Cola Bottling Company, and Matthew Dent, President & Chief Operating Officer, Buffalo Rock Company. “I am pleased to welcome these exceptional leaders in our industry to ABA’s Board of Directors. Our industry is known for its leadership in advancing solutions that work, and I look forward to the fresh perspectives of our new board members,” said Tom Bené, Chair, ABA’s Board of Directors. Members of ABA’s board of directors serve a four-year term and participate in semi-annual meetings that help shape association policy and initiatives. With the election of these members, there are now 28 members on ABA’s Board of Directors.

INVESTMENT

FOOD INGREDIENTS

European bank to invest in Russian cake maker

Tate & Lyle launches new sugar reduction concepts

The European Bank (EBRD) has bought Euro10 million stake in Russian cake and biscuit producer Hlebprom. A producer of flour-based confectionery and chilled cakes, Hlebprom has its main production site in Chelyabinsk (Urals), Russia. “We welcome EBRD as our new partner, helping us to finance improvements to our production facilities, which will allow us to upgrade our product offering to consumers all over the Russian Federation,” said Anton Gubkin, General Director, Hlebprom. According to Christian Kleboth, Banker, EBRD’s Agribusiness Team, although Hlebprom has gone a long way in growing its operations and building an impressive logistics network, it has now reached a stage where it needs a stable, reliable and long-term investor to improve corporate governance. The funding will mainly be used to upgrade Hlebprom’s manufacturing plants.

Tate & Lyle, a leading global provider of innovative food ingredients and solutions, has launched new beverage prototypes as part of its OPTIMIZE™ offer. Tate & Lyle’s global optimisation service, OPTIMIZE™, helps food manufacturers to formulate food and drinks recipes, which cost less but retain their original taste. One of the new additions to the offer is a pomegranate-grape juice drink. With this new reformulated product, the company has reduced the sugar content by up to 45 per cent, using a blend of sweeteners to retain the drink’s original taste and sweetness profile. Importantly, the prototype delivers significant sweetener cost savings, while also reducing calories by 45 per cent. This combination gives manufacturers the opportunity to replace traditional full-sugar drinks with a low-cost, low-calorie alternative. It has a complete portfolio of OPTIMIZE™ beverage concepts, which includes juice drinks and carbonated soft drinks with different flavours, as well as tea flavoured drinks and flavoured waters. These are examples of the potential benefits of recipe reformulation for both food manufacturers and their customers. Paul Cornillon, VP - Global Applications, Tate & Lyle Specialty Food Ingredients, explained, “With commodity prices soaring and consumers becoming increasingly cost- and health- conscious, manufacturers are finding it more challenging than ever before to maintain profitability. The pressure on margins is such that manufacturers need to step up their reformulation efforts - this new product shows what can be achieved.”

Modern Food Processing | June 2011

WORLD NEWS

STRATEGIC DECISION

ECO-FRIENDLY REFRIGERANTS

Beechdean buys Loseley Ice Cream

Frascold’s propane compressors making rapid strides

Beechdean Farmhouse Dairy Ice Cream has bought Loseley Dairy Ice Cream’s brands and revealed plans to double its own turnover to £ 20 million within two years. Andrew Howard, Managing Director and Co-founder, Beechdean, revealed that the food service and leisure supplier plans to produce a super premium Loseley retail product in near future. He further added, “We want to reposition the Loseley brand back as a super-premium product, moving it away from the very difficult and competitive own-label sector that it had gone into in recent years. We will be going back to a whole milk recipe from Jersey milk and using the finest possible ingredients.” Beechdean has two farm-based facilities, in southeast and northwest in England, where Loseley products would now be manufactured, Howard explained. He also said that the Loseley purchase had the potential to double Beechdean’s turnover from the current £ 10 million in the next two years, and that the deal was privately funded.

Frascold compressors are playing a key role in the pioneering hydrocarbon refrigeration platform being rolled out by Waitrose at stores across the UK. As one of the UK’s leading food retailers, Waitrose is committed to moving away from the use of HFC refrigerants due to their high global warming potential. It is also mindful of the uncertainty surrounding the long-term future of HFCs due to possible EU legislation. The retailer’s innovative approach is based on the use of integral refrigerated cases on the retail floor, running on the hydrocarbon propene (R1270), using chilled water/glycol as the condensing medium. This is supplied by roof-top-mounted Geoclima chillers based on Frascold compressors running on R290 propane. The high efficiency refrigeration system is fully integrated with a store’s building services, and uses various heat recovery/balance and cold air retrieval systems to capture rejected energy from the integral units and deliver it to where it is needed in store aisles, making the store environment more comfortable for customers and staff. The whole approach is designed to minimise energy waste, optimise plant performance and eliminate refrigerant leakage throughout the store. Use of hydrocarbon refrigerants improves the energy-efficiency of individual systems by 10 and 20 per cent, with further gains of around 10 per cent delivered as a result of heat recovery and storewide integration. When added to the 100 per cent containment of refrigerant, the CO2 reduction in stores to date is running at around 32 per cent. The system is Waitrose new standard refrigeration format. The retailer will be installing the new refrigeration solution in all new stores and undertaking major refurbishments of existing stores. COLLABORATION

FOOD SECURITY

Cargill and Wal-Mart favour open markets in Asia-Pacific for food security Food and retail giants Cargill and Wal-Mart recently said that they were looking for Asia-Pacific trade ministers to recommit to open markets as a way to boost food security. “Ministers need to take the use of food as a weapon off the screen,” said Emery Koenig, Senior Vice-President, Cargill. In a separate statement, a private sector advisory group urged Asia-Pacific Economic Co-operation (APEC) to renounce all export restrictions and end existing export restrictions on all food products. They also called for the establishment of a permanent public-private partnership within APEC to bolster food security, by working on issues such as

reducing waste and harmonising food safety standards. According to Koenig, export embargoes and other actions taken by 33 countries in 2007 & 2008 in response to drought & other weather problems that drove up prices had a marketdistorting effect that still lingers today. Scott Price, Chief Executive, Wal-Mart Asia, said the feeding of the world’s growing population in coming decades would require a far more integrated global food system. “Conflicting standards and testing requirements for food products around the world are inefficient and lead to higher prices for consumers,” he pointed out.

Modern Food Processing | June 2011

Domino Foods enters stevia market in collaboration with Sunwin and Wild Domino Foods, Wild Flavors and Sunwin International have entered a collaborative agreement to produce naturally-derived sweeteners and sweetening systems, the companies announced. Stevia supplier Sunwin International joined with flavours & ingredients firm Wild Flavors in February 2009 to produce proprietary sweetener blends based on its stevia for the food and beverage industry. This latest collaboration brings major sugar producer Domino Foods on board, allowing the triumvirate to offer a range of natural sweeteners and sweetening systems, which could be based on stevia blended with sugar, brown rice syrup, evaporated cane juice, malt, or molasses, among others.

WORLD NEWS

EXHIBITION

ASEPTIC PACKAGING

New Tetra Pak carton bottle takes on plastic in premium milk market Tetra Pak has unveiled the full details of its new aseptic carton bottle – a package designed to rival plastic bottles at the premium end of the ambient milk market. The new bottle – composed of a carton body and a plastic neck and top – is initially being launched only in 1 litre format, exclusively for ambient milk. And within that category, the new Tetra Evero Aseptic is initially being targeted at premium brands. “Currently, it is going more into premium but in time, interest is likely to spread down to other segments of the market,” said Charles Brand, Marketing Chief, Tetra Pak. The company claims that the new pack combines the easy pouring and handling of a bottle with the printability & cost advantages of carton. Tetra Pak conducted research in Germany, Spain, Italy and France to discover how consumers view the Tetra Evero Aseptic against rival bottles made from PET and HDPE. With a screw cap that can be opened in one step – developed with the Italian firm Sacmi – the research indicated that Tetra Evero Aseptic compares particularly well on ease of opening. EXPANSION PLAN

Nestlé Professional invests Euro 35 million in Germany Nestlé Professional is investing Euro 35 million to extend its premium frozen baked cakes and desserts factory in Erlenbacher, Germany. The extension is part of the factory site, which produces the company’s specialist brand Erlenbacher. The new addition aims to increase the

factory’s production capacity by 50 per cent, enhance production line performance, and extend operational, logistics & storage space. Furthermore, the extension includes new lines, which will produce frozen single portions, as a response to the demand for smaller individual-sized desserts such as mini tartlets, bites and cups.

Modern Food Processing | June 2011

Fi Asia China 2011 to be held in Shanghai Fi Asia China (FiAC), along with Health Ingredients China, Natural Ingredients China and Nutraceutical Products China, will be organised by Shanghai UBM Sinoexpo International Exhibition for the food and beverage sector at Shanghai New International Expo Centre, from June 21-23, 2011. The show would be attended by over 100 exhibitors, who would exhibit items in front of thousands of visitors from more than 130 nations. The event is focussed on providing a base for emerging opportunities in the food sector and would hopefully prove to be a hub for leading manufacturers, suppliers, exporters and importers this year. FiAC 2011 is considered to be an important meeting place for international and regional suppliers & buyers of ingredients. The expo will hold seminars and conferences so as to discuss the latest developments & trends in the market.

NEW DEVELOPMENT

Victrex® PEEK™ provides benefits to the food processing machinery Food manufacturers frequently face problems with metal and graphite sleeves in their canning machines, and hence look for a way to reduce system costs and parts performance. Taking due note, Victrex Polymer Solutions, a division of Victrex Plc, has introduced Victrex® PEEK™ polymer which provides a significant benefit to original equipment manufacturers who supply the food and beverage processing industry by enabling the construction & reproducible mass production of complex, injection moulded components that do not require further processing or machining after initial manufacturing. Victrex rollers can replace steel and graphite sleeves located inside the steel rollers. The key requirements of this process include high temperature resistance at 215°C for curing the can labels, resistance to sodium dioxide for cleaning and regular wear resistance due to regular use. The sleeves made of Victrex PEEK meet these requirements and last longer than original sleeves made of graphite & steel. Even though the cost of the new sleeves is higher, cost savings are substantial due to the longer operational life provided by these new sleeves, resulting in less downtime spent replacing machine parts such as bushings and rollers.

WORLD NEWS

INFORMATION RESOURCE

Ocean Spray ITG launches new website for food & beverage industry The UK-based Ocean Spray Ingredient Technology Group (ITG) has launched a new website called www.oceansprayitg.com. The website is an essential resource for food & beverage manufacturers and distributors worldwide and serves as a destination for all Ocean Spray marketing activity. Through the web site visitors will be able to easily access the latest news and announcements from Ocean Spray ITG, as well as view information on the extensive range of fruit ingredients and cranberry application ideas. Talking on the business prospect Marion Burton, Marketing Manager, Ocean Spray Ingredient Technology Group, said, “The new website is an essential resource for food and beverage manufacturers and distributors worldwide. It provides information on the extensive range of ingredients we offer, cranberry application ideas and information on the whole body benefits of cranberry.” Ocean Spray’s ingredient portfolio includes sweetened dried cranberries (SDCs) and BerryFusions® Fruits, which are suitable for a variety of product applications including bakery, dairy, confectionery and cereals. Not only that users will have the option to join the mailing list to receive regular business & product updates and find out more about Ocean Spray’s products or contact a local representative. Elaborating on the Indian market Burton said that Ocean Spray works with a local representative in India to provide food manufacturers with the extensive range of cranberry ingredients that can add value to a variety of consumer products. “We offer food and beverage manufacturers a stable fruit supply, and consistent product quality. Ocean Spray has recently achieved the highest attainable Safe Quality Food (SQF) standard for food manufacturing of sweetened dried cranberries in recognition of its comprehensive food and safety quality management systems.” Ocean Spray ITG is part of Ocean Spray, which currently ranks as one of the top 50 food and beverage companies in the US. In Europe, combined sales of branded products and ITG ingredients have topped $ 100 million. Ocean Spray ITG offers an extensive portfolio of fruit ingredients including sweetened dried cranberries, BerryFusions® Fruits, cranberry powders and purée – all available year round.

June 2011 | Modern Food Processing

TECH UPDATES

A cyclodextrin wrapper protects functional ingredients in F&B

Elliott Absorbents launches Berry-Sorb for fresh fruits

Often functional ingredients have bitter taste. Food companies are, thus, faced with a dilemma. On one hand, they want to provide their products with an additional health-promoting benefit, which is why they fortify soft drinks, for example, with green tea extract. But, on the other, by adding this functionality, they are incorporating the bitter aftertaste. True, the product does contain the desired health promoter, “but of course no consumer wants a thirst quencher that has a bitter taste,” explained Heiko Zipp, Head-Nutrition Business Team, Wacker Biosolutions, WACKER’s Life Sciences and Biotech Division. WACKER’s development team has devised an option: a wrapper made of cyclodextrins. These ring-shaped molecules – produced enzymatically from starch – are able to incorporate other molecules in their inner cavity. Cyclodextrin model: The The bitter substance in green tea ring-shaped molecules is bound in the cyclodextrin, so its are able to incorporate specific substances such taste is no longer perceived by the as vitamins, which are consumer. “Cyclodextrins offer an released by moisture attractive way of masking healthand discharged to promoting food ingredients that the surroundings in a would otherwise taste unpleasant,” controlled manner Courtesy: Wacker Chemie AG said Zipp.

After extensive field trials and over 12 months of market development, Elliott Absorbents has launched its fruit absorbent pad Berry-Sorb. Designed specifically to aid the long term freshness and appeal of soft fruits, such as raspberrys and blackberries, Berry-Sorb combines both cushioning, with a 150 gsm dual ply absorbent cellulose, applied to a totally absorbent, yet sealed topcoat. Fungal droplet moisture is totally absorbed by the new pad and locked away to avoid spoilage through fungal fruit rot. It offers advantages such as cushioning to avoid fruit bruising & damage, and bio-compostable pad. It is estimated that UK supermarket alone suffer 7 figure losses annually on wasted soft fruits. Berry-Sorb is expected to lead to major savings in pad usage by avoiding fruit rot waste. It is available in both pad and reel-fed formats from Elliott Absorbents. Established in 1982, Elliott Absorbents is the UK’s largest manufacturer and re-seller of food absorbent products. Operating from two sites, totalling 27,000 sq feet, in Rochdale, Lancashire, it has full accreditation to BRC/IOP standards of food hygiene and EC/FDA food contact compliance.

Novel technology promises speedier packaging of bar products

New on-machine seasoning system improves processing efficiency

Bosch has reportedly developed a new single, seamless packaging line for confectionery bar wrapping, which can increase production and changeover speed in addition to reducing operator errors. The station, accumulator, flow wrapper and cartoner, as well as all the interfaces are part of one system, rather than a chain of machines, said the packaging giant. The company officials said, “This makes operation of the entire line as simple as operating a single machine and reduces the risk of operator errors, which can cause lengthy and costly production stoppages.” Consisting of horizontal flow wrapping machine Sigpack HRM and the cartoner Sigpack TTM, the company claimed that this is the first system designed specifically for both the primary and secondary packaging of bars & bar-shaped products. The cartoner Sigpack TTM was developed for speeds of up to 150 cartons per minute, the firm said, adding that this enables an overall output of 1,000 bars or more per minute. Other benefits of the packaging line include a reduction in cleaning and format changeover times to a few minutes. As a result of optimal accessibility, toolless changeover and innovative changeover strategies, time savings are achieved. “Human errors are reduced through automated precision splicing at speeds of up to 150 metre per minute, hence operators can place new reels onto the splicer. The accuracy of the splicing process reduces waste and saves material costs,” said Bosch officials.

tna has launched innovative products, designed to improve performance while delivering simplicity and flexibility to food processing. It has developed new additions to the its intelliflav® OMS on-machine seasoning range – an extension to the tna intelli-flav® portfolio. Representing a breakthrough in on-machine seasoning (OMS) technology, the tna intelli-flav® OMS 3 now features a responsive variable mass seasoning system, with a dynamic vibratory weigher to control the flow of seasoning powder into the drum for improved coverage and flavour dispersion. The tna intelli-flav® 3 can be used for both wet and dry seasoning applications and linked to the tna conveyors for an integrated processing solution. The company has also introduced latest electromagneticallydriven vibratory motion conveyor. The tna roflo® VM 3 prevents and smoothes out any build up of free-flowing product, minimising waste and maximising efficiency. This machine can be combined with the tna roflo® HM 3 horizontal motion conveyor, a totally reversible system, which offers users complete control over product speed and direction, with almost instant response to control signals. tna is the only supplier to offer both horizontal and vibratory motion

Modern Food Processing | June 2011

TECH UPDATES

Pack strapping as the PET secondary packaging of the future

Ishida develops novel dual-line tray sealer

The shrink-pack is the most commonly used form of secondary packaging for PET containers. Shrink-film, however, requires fossil raw materials for its manufacture, and in the shrink-on process in the shrink tunnel, moreover, energy consumption is relatively high. Krones AG has been working on creating a resource-economical alternative to film-wrapped shrink-packs – a complete pack system including the packaging as such and the associated machinery. The company was able to tap into strapping technology already trialled and used with success in other sectors, thus creating a completely new packaging design for PET containers, called Krones LitePac. Users will also benefit from cost economies compared to shrink-films, with some estimates exceeding 50 per cent. The requisite technology is provided by the newly developed Evolite packer – comprising a container infeed module and a container strapping module. Fewer conveyors, reduced footprint, cost savings a simpler line layout, a smaller storage area, less pallet traffic – all these make the pack strapping technology a truly up-to-thefuture concept.

Ishida Europe has claimed to have developed the world’s first high-performance, split dual-line tray sealer for packing fresh food into trays. The QX-1100 SDL extends the company’s QX-1100 range and will greatly increase the versatility and responsiveness of any tray line that fills trays. “One can make floorspace more productive by using QX-1100 SDL high-performance split dual lane traysealer, which packs two traysealers into one. The user can run two different products at the same time, and the flexibility of this latest model in the QX-1100 series goes much further,” claimed Ishida officials. The sealer can simultaneously handle two different tray types and sizes, each packed to the specifications of a different brand or manufacturer. Each line can operate independently and to its own speed. Hence, one can run different tray sizes, pack weights and even separate products. The new tray sealer, which is capable of handling up to 250 packs a minute, is designed to handle ready meals, salads or meat and poultry products. The twin lane lines deliver roughly twice the throughput of single lanes but with a reduced footprint significantly saving factory space.

NFP’s bakery tray meets biodegradability standard

Bollore’s new ultra thin films can cut cost

Nicholl Food Packaging (NFP) has launched a light biodegradable ovenable bakery tray, aimed at industrial bakers looking to exploit the premium end of the market. NFP, whose core business is aluminium foil trays, said the container meets all requirements for direct food contact and adheres to the European standard on biodegradability EN13432. According to Chris Patten, Business Development Manager, NFP, paper tray, which is made from renewable wood pulp, is a response to customer demand for more varied packaging formats. It is manufactured from a single layer of grease-proof paper that absorbs moisture to ensure effective barrier functionality, he commented. “It is a sturdy container that withstands the rigours of high volume production and denests very well,” said Patten, who added that the containers would suit bakery manufacturers that rely on automated denesters and filling machines. The tray was produced by the French and Belgium division of NFP, Ecopla, and has been flagged up as the first in a new range of lighter weight and biodegradable packs from the group. For use in both convection and microwave ovens, Patten said that in terms of margins the tray is most applicable to the higher value end of the bakery market and might be used with products such as summer fruit tarts.

The French firm Bollore has developed a new range of ultra-thin polyolefin shrink film, which can cut cost and reduce material requirement. In addition, it is puncture resistant and environment-friendly. The four new BTT films offer the same performance as conventional thicker film. Fabian Theuriet, Export Manager, Bollore, said, “Our range of BTT films are ultra thin but that are perfectly resistant and adapted to high-speed machines. For example, the 11-micron film can be used in applications where it was not possible before.” The materials achieve enhanced performance because of application of high-tech resins, including the latest generation of metallocenes, he added. Developed to seal and quickly at low temperatures, the films are suitable for a range of applications, including with fruit and vegetables and as shrink wrap secondary packaging. The BTT +90 is a multilayer film that boasts of ‘outstanding yield’ and can be used at high speed. The crosslinked BTTX 110 offers high impact strength, a broad sealing window and the same mechanical properties as a 15-micron film. The BTT+ 125 is a multilayer film that offers instant sealing, rigidity and high shrinkage at low temperature. Soft shrink, high elongation and tear resistance are characteristics of the BTTXF 130.

June 2011 | Modern Food Processing

LEADERS SPEAK

“Glocalisation is a way for international companies to enlarge their customer base and build customer loyalty in local markets” …says Sanjay Coutinho, Chief Executive Officer, Barista Lavazza. With an experience of 17 years in the retail and F&B industry, he is spearheading the aggressive growth of Barista Lavazza in India. In this exclusive interview with Mahua Roy, he talks about the branding measures of this company and its efforts towards tapping the growing café culture in the country. Brand positioning of Barista Lavazza Barista Lavazza is positioned as the pioneer of Indian café culture. We represent the true symbol of rich and finest Italian culture and espresso coffee. Our guests mainly comprise coffee lovers, in the age group of 25 years and above, who not just look for a cup of coffee but beyond. Our chain of Espresso bars delivers an original Italian coffee experience in a warm, friendly and relaxed environment. We aim to provide a comfortable place for people to unwind over interesting conversations and a cup of coffee.

Sustaining brand loyalty Our mission is to provide ‘A truly Italian coffee house experience’ to our guests and we do not chase any numbers or marketshare. We have our own niche and we are happy to maintain it. We believe in enhancing customer experiences, and hence develop customer engagement programmes on regular intervals such as, ‘Friendship Jam’, ‘Valentine’s Day celebrations’, ‘Masters of the menu’ and so on & so forth. Barista Lavazza has recently launched a new menu ‘Hawaiian Summer’ that has especially been created for summers. Keeping customer-centricity at core, it has recently introduced Bean‘O’holic, a loyalty and a gift card programme. Barista Lavazza is the first ever coffee chain to come

Modern Food Processing | June 2011

LEADERS SPEAK

up with such a loyalty programme for its customers. The slew of rewards and benefits on the Bean’O’holic card would certainly bring our guests closer to their favourite café chain and enhance the overall coffee drinking experience. Apart from the exquisite coffee experience at our cafés, we regularly come up with other interesting elements of engagements like providing guitars, scrabble, chess boards, etc, to our guests. We also continuously engage our guests with various in-store promotions in an endeavour to bring something new and fresh to our guests’ table.

Maintaining a steady growth rate The retail sector in India is witnessing a consolidation phase. The ` 650crore café business is growing at 30 per cent per annum and attracting huge investments from national & international café chains. The coffee chain market in India, at 6.5 per cent of the total coffee retail market, is valued at ` 400 crore, according to the retail consultancy KSA Technopak. The consumer trends are positive for the Indian retail industry, hence it will continue to grow in India for many years to come. It is a mix of the above factors coupled with increasing time spent out of home by people that has led to a growing retail culture, and the concept of ‘experiential shopping’ is leading consumer preferences towards organised retail industry.

Coffee culture has grown by leaps and bounds in the country and cafés have become a hotspot for the young and old, alike. The café culture that is spreading across the cities in the country is pushing up the domestic coffee consumption.

new levels. Barista Lavazza opened 45 stores last year and plans to continue the same momentum in the next two to three years. The focus is to enhance guest experience through consistency in quality, services and offerings. All store openings are done post-extensive consumer profile research and mapping.

case in point is our latest ‘Hawaiian Summer’ special menu, which is inspired by the Hawaiian island state. However, we have kept the Indian flavour at the core of the menu. The summer drinks have an aam panna base and sandwiches include paneer and chicken korma.

Growth opportunities and challenges for coffee chains

Tapping the health consciousness trend Consumers are increasingly focussing on their diets to stay in good health, and they believe healthy eating habits are the best way to manage illnesses & prevent health problems. Therefore, to keep our consumers delighted, we have introduced a range of healthy products like Slimmer’s Choice Veg Sandwich, Spinach & Corn Sandwich, etc. A range of nutritious and healthy salads such as Julienne Veggie Salad, Chicken Caesar Salad and Julienne Chicken Salad, make an apt choice for those who are health-conscious. Apart from these, there is always an option for our guests to pick from a choice of breads like whole wheat & oat breads to make their sandwiches more fulfilling, nourishing and healthy at the same time.

There has been a paradigm shift in consumer tastes and preferences over a period of time. And incorporating these changing trends has always helped us to grow by offering our guests with their choice of food. Modern retailing is all about directly having ‘first-hand experience’ with customers, giving them such a satiable experience that they would like to enjoy over and again. Providing great experience to customers can easily be said than done. Thus, challenges like retail differentiation, merchandising mix, supply chain management and competition from supplier’s brands are the talk of the day. In India, as we are moving to the next phase of retail development, each endeavour aims at offering an experience to the customer.

Aggressive expansion

‘Glocalisation’ of food products

Outlook for this industry

Our strategy is to leverage the Lavazza brand as the global brand. Coffee has made its way across the Indian landscape and rooted itself in the lifestyles of people, both young & old. At Barista Lavazza, our core promise is innovation and to keep the promise intact, the café chain serves a diverse range of coffee merchandise, keeping in mind the tastes of discerning customers. It has been our constant endeavour to serve the finest Italian coffee concoctions to our guests, thereby taking their coffee drinking experience to

Glocalisation is a way for international companies to enlarge their customer base and build customer loyalty in local markets. Glocalisation often involves a certain degree of trial and error. Our strategy is to listen more to local consumers and then act on it. There are two main conditions for international companies to localise successfully. First, they have to understand the local market they are trying to cater to. Second, they must find a good balance between their global and local brand dimensions. A

Coffee culture has grown by leaps and bounds in the country and cafés have become a hotspot for the young and old, alike. The growth rate of coffee consumption in the country has been steadily rising over the last few years. The café culture that is spreading across the cities in the country is pushing up the domestic coffee consumption. Coffee is fast becoming a preferred drink of the young and the ones on the go. It is emerging as a centre point around which a lot revolves for everyone.

June 2011 | Modern Food Processing

ROUNDTABLE

Alcoholic beverage packaging

Waging the battle for sustainability Packaging is considered an integral part of the alcoholic beverages industry. Using the appropriate packaging, marketing communication can be directed towards building and maintaining the brand image. With PET making gradual inroads into this industry, traditional glass packaging needs to sustain the competition by introducing product innovations. Mahua Roy speaks to some industry experts to get a holistic picture of where alcoholic beverage packaging is headed to.

Dr Benjamin Punchard, Head of Global Packaging Research, Euromonitor International Glass remains the main pack type used for alcoholic drinks, accounting for 68 per cent of all alcoholic drinks packaging globally (and over 90 per cent of all alcoholic drinks packaging in India, at 16.7 billion units for on-trade and off-trade combined). The properties of glass, being heavy, clear, inert and with a high gloss finish make it ideal for packaging premium products. However, glass has taken a beating in terms of alcoholic drinks as PET continues to make inroads into this domain. While PET is more typically used for economy alcoholic beverages, this material type is increasingly finding favour for more premium brands. For example, for sporting events or other outdoor events, organisers or legislation prefers the use of PET bottles over glass as they are unbreakable,

Modern Food Processing | June 2011

and so are seen as a safer alternative. PET also benefits from being a practical material â&#x20AC;&#x201C; lighter to carry, less likely to break and often easier to re-close. Consumers are increasingly looking for convenience, even in their alcoholic drinks packaging. Over the past five years, PET bottles have outperformed glass bottles in alcoholic drinks (both globally and in India). However, increased consumption has led to unit growth for all pack types overall, and glass remains set to be the dominant pack type for the foreseeable future. Both glass and PET can position themselves as being environmentfriendly. They are both recyclable, and though glass may be recyclable with no loss of quality, PET is catching up and can also claim to be more energy-efficient in production & transportation. As both have good environmental advantages, it is likely that price will be a crucial decider for the brand owner making the choice. Research towards attaining lightweight and reducing energy costs will be important for both glass and PET as producers will be looking for the pack type that can offer the lowest price.

ROUNDTABLE

David Williamson Public Affairs Manager, Government & Consumer Affairs, Scotch Whisky Association, The UK Scotch whisky is a luxury product and high quality packaging supports brand image & integrity in the international marketplace. It is seen as an essential ingredient towards brand recognition and protection globally. Glass continues to be favoured by producers because, primarily, it is a resource that can be recycled on a continuous basis. It is to be noted that, over the last decade, distillers have worked hard towards reducing the weights of glass bottles; investing in new lightweight

Lynn Bragg President, Glass Packaging Institute, The US Alcoholic beverages continue to be a large market segment for the glass packaging industry. In recent years, about 70 per cent of glass packaging produced in North America has been for beer, wine and distilled spirits. There has been little change in these percentages in recent years. Our research shows that consumers prefer glass packaging for alcoholic beverages because they feel glass best preserves taste and quality. The distilled spirits, beer and wine industries in North America continue to use glass as their primary packaging choice as a result of consumer attitudes, and because glass packaging denotes a level of prestige & quality that simply is not communicated with other forms of packaging.

Rohan Shah Associate VP - Winery Operations, Sula Vineyards When it comes to glass for wine packaging, besides the aesthetic value when compared to a PET bottle, it also has the advantage of being absolutely inert such that it does not impart any odours or off-flavours to the wine. It also has better barrier properties (with specific reference to oxygen uptake) than PET, so we can conclude that wine in glass packaging has a longer shelf-life. PET, on the other hand, has mainly two benefits: it is cheap and light in weight. The barrier properties (mainly with regard to oxygen uptake) are not as good in PET, so the shelf-life of the wine is comparatively lower in a PET bottle when compared to a glass bottle. In the current scenario,

technologies and minimising raw material & energy use. As a step towards sustainability, Scotch whisky companies have set ambitious industry targets to reduce and recycle packaging. For example, by 2020, the goal is to ensure that all product packaging will be reusable or recyclable, with at least 40 per cent of product packaging made from recycled materials.

Glass packaging is virtually inert, meaning that there is little interaction between the packaging material and the alcohol it contains. There is evidence that this may not be the case for other forms of packaging. Additionally, unlike other packaging materials, glass is endlessly recyclable, ie it can be used over and over again for packaging. We believe this makes glass a more environment-friendly packaging choice. The glass container industry continues to push the envelope of innovation and design to keep glass at the forefront of quality & sustainable packaging options.

PET bottles could have a limited application with entry level wines. There are developments in the glass industry to produce lightweight bottles with similar strength as the heavier bottles. This innovation will not only reduce the cost of the glass bottles but also lower freight costs. Similarly, there are developments in the area of PET bottles, in order to produce them with â&#x20AC;&#x2DC;oxygen scavengersâ&#x20AC;&#x2122; â&#x20AC;&#x201C; additives added to PET that help increase the shelf-life of wine in the bottle.

June 2011 | Modern Food Processing

ROUNDTABLE

Lee Williams Packaging Engineer, Bacardi Global Packaging Development The role of any packaging involves two parts, a technical function of containment, protection, preservation, measurement, storage and dispensing plus a marketing function of communication, display, information, promotion & selling the product. Glass covers these requirements extremely well for liquid packaging. It is also an inert substance. Optically, the material can be made transparent, translucent or opaque by varying colour or secondary surface treatments, and it can be formed into interesting and appealing shapes. Glass can be returned and reused, or completely recycled for reprocessing wherein appropriate collection facilities exist. The main advantages of PET include its low mass combined with ‘thin walls’ for containers produced using it. Resulting PET containers weigh significantly less than those manufactured in glass, which allows more product to be distributed per vehicle journey and improving the financial

Vimal Kedia Managing Director, Manjushree Technopack Ltd PET market for alcoholic beverages has seen a huge demand in India, primarily owing to its lightweight property and virtue of being unbreakable. PET bottles in the 90 and 180 ml category are already popular for the low-end segments; several states in India have given approvals for use of PET in the alcoholic beverages industry, and the rest should follow soon. According to certain reports, the Indian market for the 90 and 180 ml bottles is to the tune of 8 crore bottles per day. This is because PET is perhaps most chemically safe and inert material for packaging of food or alcoholbased products. Research has shown that at normal filling temperatures, it does not react with any food and is odourless. Moreover, PET is 100 per cent recyclable, and in fact the current situation in India is that we are facing a shortage of fast consumed recycled PET and it is currently

Modern Food Processing | June 2011

efficiency of distribution. Broken bottle losses through the total supply chain are a rare event too. Cost for PET containers can act as an important deciding factor but only if the economies of scale for PET are correct, as infrastructure investments, or CapEx for blowing PET containers tend to be high. In recent months, some global users of PET containers have unveiled a few bio-derived material options, thereby reducing their dependence on traditional fossil fuel sources. In certain sectors, PET has several uses, and in some countries/states its use is a regulatory requirement, where glass is banned on health & safety grounds. Also, it cannot be ignored that PET polymer is derived from a fossil fuel base like many plastics; this can be considered a disadvantage in a fossil fuel dependent world. Physically, PET containers have less vertical load resistance than glass. Storage of finished goods is usually less spaceefficient as palletised goods in warehouses cannot be stacked as high. In terms of product preservation, PET naturally is not a complete barrier to oxygen migration into liquids and also as barrier to any contained CO2, migrating out from the product. This property requirement is enhanced/improved by the inclusion of other materials in the form of additives, coatings or modification.

being imported to convert into polyester fibre for use in various forms. Also, PET is more consumer-friendly at the point of sale, provides better logistic functions and is far more energy-efficient (1 X PET bottle = 15 X glass bottles in terms of energy consumption). The only drawback with the PET bottle is that it is a ‘one-way’ pack. But it can also be viewed as a much better solution for the environment, wherein we recycle 100 per cent of this PET waste and still do not spend even half the energy used in producing a glass bottle. In absolute figures, a PET bottle will cost about ` 2 for a 90 ml pack and a glass bottle for the same volume will cost about ` 4. But glass can be recycled about 4-5 times before it breaks; thus the cost of glass may be taken at about ` 1 per cycle. One needs to make a conscious decision on whether in a country like India, wherein we do not have appropriate channels for recycling, is it safe to use cyclic glass bottle or use single-served hygienic PET bottles. In our opinion, more is to be invested in research pertaining to lightweighting of the PET bottle and improving shelf-life for some products packed in PET. In addition, a lot more has to be done to spread awareness among general public to use, reuse and dispose PET bottles responsibly.

ROUNDTABLE

Vinay Saran Senior Vice President Marketing, Hindusthan National Glass and Industries Ltd Global statistics suggests that glass is the safest mode of packaging, considering the consumers’ health and environmental aspects. It has been recognised as ‘GRAS’ or ‘generally regarded as safe’ by the USFDA. The usage of PET for alcobev industry is only seen in lower segments and not for premium or luxury segments. The choice of packaging mode is done by the manufacturers considering commercial aspects such as logistics and breakage cost. PET is not an alternative to glass; the premium image along with some essential properties of glass makes it the most apt form of packaging for alcobev industry. The alcobev segment is a lucrative market for glass packaging, especially in India with an annual growth rate of 12-13 per cent. Glass packaging reflects the premium

image of the packaged content. It is the most acceptable form of packaging medium for alcobev industry, as it does not react with the packed content. It is the only packaging medium, which is able to preserve the original taste of alcohol by acting as an excellent barrier to external gases. Some of the unassailable properties of glass such as inertness and impermeability leave no choice for the manufacturers of alcohol. The cradle-to-cradle property of glass packaging makes it the most popular form of packaging among consumers. Glass being completely recyclable resolves various health concerns and environmental issues. The requirement of the alcobev industry with regard to glass packaging is getting lighter containers and reducing the overall cost of logistics. In the recent times, the glass industry in India has started the use of Narrow Neck Press & Blow (NNPB) technology, which helps in equal distribution of glass in the manufacturing process. It helps in reducing the volume of material used, and at the same time, it saves a considerable amount of energy, raw materials and cost towards transportation. Going forward, glass manufacturers are aiming at making glass packaging more cost-effective and convenient for consumers.

June 2011 | Modern Food Processing

FACILITY VISIT

Way to the state-of-the-art facility

Spare machine parts at Unit-5

IDMC Ltd

Milking success through innovative solutions

Closed-type bulk milk coolers

Serving as an equipment manufacturing and project engineering company for more than three decades, IDMC Ltd provides unlimited solutions not only to the dairy industry but also to beverages, brewery and food processing sectors. Through its cost-effective technologies, the company enables food manufacturers to milk profits.

Avani Jain

he White Revolution made India not only the largest producer of milk and milk products, but also marked the beginning of new milk processing technologies, thanks to the endeavours of companies such as IDMC Ltd in this segment. Set up in 1979 as a wholly-owned subsidiary of National Dairy Development Board (NDDB) under Phase-I, and later incorporated as a limited company in 1992, IDMC is focussed on the welfare of the dairy farmers in India. Inaugurated by Dr Verghese Kurien, renowned as the Father of White Revolution, and the then Chairman of NDDB, the company offers customised solutions for dairy and other food processing industries. J P Gopal, Managing Director, IDMC Ltd, observes, “In India, even today, the machinery for the food and dairy industry is largely imported, which is expensive. Thus, our sole aim is to ensure that the farmers/milk producers

Modern Food Processing | June 2011

get value for money and technology at par with global standards. We concentrate on welfare & value proposition and it is for this reason that we act as a facilitator for Indian primary and secondary milk producers to achieve high quality standards.”

Manufacturing excellence The 30,000 sq m plant at Anand boasts of four manufacturing units, which are dedicated to produce dairy and food processing equipment. In addition, there is the fifth unit – a state-ofthe-art packaging film producing unit – Optifilm unit. The plant comprises the following: Fabrication shop: On a regular basis, it undertakes fabrication of storage tanks, process vessels, mixing vessels, reactors, fermenters, etc, that are mainly used in the dairy, beverage and brewery industry. The facility is equipped with state-of-the-art machinery and is considered to be the largest in the country with U-stamp. Machine shop: IDMC is equipped with fourteen state-of-the-art CNC machines and

FACILITY VISIT

backed by experienced & skilled manpower. The machine shop is ISO 9001 certified. Bulk Milk Cooler (BMC) unit: The company manufactures BMC, which is used to cool raw milk at the village level co-operative societies from the ambient temperature to 40C in conformity to specified ISO 5708 standard. Also, waste heat recovery systems and stateof-the-art milk analysis modules have been added in the product range. “We ensure that each BMC manufactured by us is better than the rest. If a normal BMC takes three hours for cooling the milk, our BMC takes only two-and-ahalf hour. These BMCs are optimally engineered and are best-in-class in terms of operational- and energy-efficiency. IDMC today holds 55 per cent of the marketshare,” claims Gopal. Plate Heat Exchanger (PHE) manufacturing shop: Full line of heat exchangers for refrigeration, dairy, brewery & beverages are also produced at IDMC. The PHE & fabrication shop is certified with ‘ASME U’ stamp providing highest possible standards in design, manufacturing and testing of PHE.

Storage tanks used in brewery & beverage industry

Plate heat exchangers ready for dispatch

The manufacturing marvel IDMC has developed many machines and provided solutions that are one-of-its-kind. R Milking parlour: IDMC with its Ireland-based solutions partner Dairy Masters has set up milking parlours, where 200-600 cows can be milked. Here, a complete history about the cows is maintained and through automated system, the best time for milking is determined. R Ice silos: These are huge ice storage systems, which are used in different parts of India. These are fully sanitised tanks, which can produce, store and dispense ice whenever required during the day. Through this IDMC has ensured 10-18 per cent energy saving in dairy processing industry across the country. R Paneer line for Amul: It is a plant commissioned in collaboration with Obram, Poland, which can produce 26 tonne of paneer per hour. Similar plant was developed for Sabar Dairy in Himmatnagar. R Cup & cone filling machine: This machine has the capacity of 6,000 cups/cones per hour. The machine is unique with single drive comprising various stations like cup/cone dispensing, chocolate spray, product filling and chocolate & nuts topping, lid application and ejection. R Plants for Carlsberg beer: IDMC has designed and executed two plants of Carlsberg beer in India and one in Nepal through technical collaboration with Krones, Germany.

Sectoral competencies The core competency of IDMC is in dairy equipment manufacturing and project engineering. Till date, it has completed over 200 turn-key projects in India. The company has developed milk-processing technologies for liquid milk, butter, ghee, cheese, paneer, icecream, curd and indigenous sweets. It also offers farm technologies for farm cooling, milking parlours, milking systems and milk transportation, among others. In addition, it manufactures equipment for fruit- and milk-based beverages, carbonated soft drinks (CSD), raw fruit handling and fruit pulp processing. The company has executed several process modules for manufacturing and processing beverages for both hot/cold-filled as well as aseptic applications. Specialised sugar-dissolving systems, sterilisers & pasteurisers and homogenisers made by the company cater to the needs of the beverage industry. When it comes to breweries, IDMC manufactures and supplies process equipment and modules in commercial & micro brewery segment such as complete brew house module using

Lauter Tun brewhouse energy recovery system, large capacity fermentation, storage modules, refrigeration systems, etc. In addition, it has set up complete breweries.

Novel packaging practices After successfully positioning itself in the dairy and food processing equipment manufacturing industry, the company has endeavoured to open up new markets in modern business. In order to meet the growing demand for high quality packaging materials, IDMC has set up a modern manufacturing facility, ie, the Optifilm unit where 50 per cent of packaging films (used for dairy products) are produced out of total packaging films portfolio. “IDMC offers packaging solutions to companies like Amul, besides beverage manufacturers. The state-of-the-art unit is supported with the cutting-edge flexible packaging technology and facilitates aseptic packaging solutions as well,” notes Gopal. The unit has three-layer fully automated blown film lines to produce high quality film with consistent thickness and minimum tolerance

June 2011 | Modern Food Processing

FACILITY VISIT

Our aim is to provide the best-in-class solution in terms of operational- and energy-efficiency. We are also continuously undertaking research activities to improve the solution profile. We have constituted the Centre of Excellence in Design & Application Development to come up with new and better products and processes.

J P Gopal Managing Director for use in various industries such as dairy, food & beverage, confectionery and edible oils. The 8-colour and 10-colour gearless high speed CI flexo printing machines are equipped with auto registration and viscosity control to offer crisp registration for perfect photographic images with no stretching of film, thereby avoiding distortion of the film. The modern flexographic printing uses toluene-free ink, rendering the packaging material suitable for food grade application. This modern facility is equipped with high-speed solvent-less & solventbased lamination machines and high-speed pouch-making machines. In order to further consolidate its position, IDMC has renewed its partnership with Stork Foods and Dairy

Plate heat exchangers

Systems BV, the Netherlands, to offer state-of-the-art solutions for sterilisers and aseptic packaging systems. Along with Stork Foods, IDMC will now provide customised and economic aseptic processing solutions including after-sales services for the milk, juice, beverage and various food industries in India.

Quality assurance & control IDMC believes in quality assurance and every system, be it software, hardware or manpower, all work in tandem to achieve the set goal of zero defects. “IDMC adheres to European Hygienic Engineering & Design Group (EHEDG) standards. All the machines are made error-proof and the system employed is fully backward integrated to check for any errors at any given point of time,” says Gopal. The quality control department is well-equipped with the latest in testing and inspection apparatus to adhere to industry standards. Prominent among them are surface roughness testers and comparators, ultrasonic thickness gauge, coordinate measuring machine, spectrometer, fibre scope up to depth of 6.5 m, ultrasonic crack detector, to name a few.

Research philosophy

Bulk milk cooler shop

The worldwide success of IDMC is backed by its strong R&D philosophy. “When it comes to research, IDMC believes in the principle of ‘Simple & Innovative’. Our aim is to provide the best-in-class solution in terms of operational- and energy-efficiency. We are also continuously undertaking research activities to improve the

Modern Food Processing | June 2011

solution profile. We have constituted the Centre of Excellence in Design & Application Development to come up with new and better products and processes,” says Gopal. He adds, “We have come up with an innovative milk and beverage dispensing machine that will revolutionise the Indian dairy market. We are in the process of testing and validating it.” At IDMC, the policy of ‘Fit & Forget’ is followed for enhanced safety, minimum maintenance and reduced operating costs. Moreover, capacity enhancements, performance benchmarking and innovation are the main mantras of the company.

Envisioning the future IDMC aims at living up to its tagline ‘Solutions Unlimited’ by providing latest technologies and complete indigenous solutions that are cost-effective to the Indian customers. This gives it a competitive edge in the marketplace. “The company with a human strength of 650 personnel is more labour-intensive. We also aim to move towards higher level of automation in the near future,” reveals Gopal. Although IDMC mainly concentrates on Indian farmers’ needs, it is globally known for providing high-quality solutions to the dairy, food, brewery and beverage sectors. “The company is not extensively concentrating on exports currently, but time and again, we have proved our worth at an international level. IDMC was the only company selected by General Mills, USA, to design its plant in China, Brazil and the US,” explains Gopal. This is just one of the many achievements. “The dairy industry is booming in India and a growth of 1520 per cent CAGR is envisaged soon. Since the demand for milk and milk products is increasing, the demand for dairy processing equipment will surely be witnessing a rise,” concludes Gopal. (Photo by: Aamir Kadri)

SECTOR WATCH

The untapped potential in the food processing sector coupled with rapid lifestyle changes calls for huge investments in automation. But, the process is not keeping pace with the requirements at this point of time mainly due to monetary constraints and lack of knowledge. However, on a positive note, the industry is now realising the significance of automation for addressing issues pertaining to hygiene, quality and mass production, to name a few.

Illustration by: Chaitanya Surpur

Modern Food Processing | June 2011

SECTOR WATCH

IT enables data processing and controls a lot easier. There can hardly be any industry not using IT in some form or the other. R&D involves a lot of experimenting and calls for flexibility. This is possible with IT. In many ways, modernisation is going on in the Indian food processing industry since the customer demands are ever-changing.

Prasenjit Chakraborty

ndia is one of the world’s largest producers as well as consumers of food products. Without doubt, the food processing sector is contributing enormously to the development of the economy. A recent survey conducted by FICCI reveals that with a market size of $ 181 billion, food is the biggest consumption category in India. The spending on food and food products in the country amounts to 21 per cent of the GDP and constitutes the largest portion of consumer spending – more than 31 per cent share of wallet. With a population of more than one billion and food constituting a major part of the consumers’ budget, this sector has naturally emerged as the most lucrative one. The survey also predicts that the Indian food market is expected to grow by nearly 40 per cent of the current market size by 2015, to touch $ 258 billion. To facilitate the growth, it is imperative to look at several factors, one being that of automation. The aspects of huge demand and hygiene can be addressed effectively, if the food processing industry adopts automation on a larger scale. However, as of now, the pace is slow.

Why to invest in automation? R Automation

provides greater assurance in terms of safety and quality of food to consumers It enhances competitiveness of food manufacturers in both domestic as well as international markets It helps to bridge the demand and supply gap in the food sector to a great extent Automation can enhance integration of the food processing infrastructure from farm to market It can help to bring down the wastage of food as compared to manual processing

S M Dangi Manager, Marketing, Festo Controls Pvt Ltd Pace of automation In India, food processing industry constitutes organised and unorganised sectors. The induction of automated system is limited to MNCs and a few reputed companies. Mass production and hygiene are the prime reasons that led these companies to invest in automation. “For these companies, every operation, right from the raw material stage to packaging of finished goods, is automated. Hygiene is among the main reasons for adopting automation,” opines S M Dangi, Manager, Marketing, Festo Controls Pvt Ltd. According to Ashok Gourish, Business Head, Bosch Packaging Technology India, the pace of induction of complete IT and automation in the Indian food processing industry is still limited to corporate sector. “Corporate companies and MNCs use IT & automation to the full extent,” he notes. However, SMEs dominate the Indian food processing sector. If SMEs do not opt for automation, then the industry will not be able to deliver the desired results. On the status of SMEs in this area, Gourish says, “The companies that fall in the middle category are moving towards automation with the focus on growth. Still their working capital management is slowing down the pace towards full automation, as the investment for fully-automated plants is on a higher side. Even the know-how on the automation is limited in these organisations.” When it comes to small companies, manually operated machines rule the roost. “There is a feeling that automation

is expensive to implement and also to maintain. Rather, it is easy to handle manual labour, which is also easily available,” observes Gourish. Every industry has been using IT, some way or the other. Food processing is also no exception. The question here is, can the food processing sector benefit more by using IT? “IT enables data processing and controls a lot easier. There can hardly be any industry not using IT in some form or the other. R&D involves a lot of experimenting and calls for flexibility. This is possible with IT. In many ways, modernisation is going on in the Indian food processing industry since the customer demands are everchanging,” points out Dangi.

Hygiene and safety Industry observers believe that many companies by virtue of their capacity

Print mark sensors for food packaging Courtesy: Pepperl+Fuchs India

June 2011 | Modern Food Processing

SECTOR WATCH

The companies that fall in the middle category are moving towards automation with the focus on growth. Still their working capital management is slowing down the pace towards full automation, as the investment for fullyautomated plants is on a higher side. Even the know-how on the automation is limited in these organisations.

Ashok Gourish Business Head, Bosch Packaging Technology India can opt for automation systems in their units right from the stage of washing, cleaning and sorting of the raw materials. “Hygiene demands that there should be no human contact at any point of time. The equipment must be easily washable to keep it bacteria free. Certain processes involve high temperature, for instance, baking or frying,” observes Dangi. The components should be able to withstand certain parameters like high temperature and corrosion. Automation enables built-in safety measures, and factors like overloading can be avoided. Human fatigue factor is one of the reasons for accidents and could be overcome with automation. “Automation will ease the process and reduce the manual handling of food products, which is one of the causes of contamination in food. But this does not imply that all automated plants are hygienic. A number of safety issues are addressed by way of IT and automation; still there are some other safety aspects that need to be taken into consideration,” says Gourish. If the Indian food processing industry has to achieve the projected growth and become globally competitive, it is imperative to address hygiene and safety aspects. “Avoiding human touch, humidity and temperature control are the key aspects for ensuring a hygienic food processing environment. And, automation is key to attain these,” asserts Ganesh Prabhu, General Manager, Factory & Automation, Pepperl+Fuchs India Pvt Ltd.

Innovative solutions In India, the food processing industry generally follows US and

European standards. This is because manufacturers from these countries employ state-of-the-art processing technologies. Food processing facilities call for easy, fast and safe cleaning of machinery. Requirements increase in terms of cleaning processes (often unknown & confidential detergents/cleaning cycles/cleaning period/temperature/foam cleaning/ steam cleaning, etc). Sensors for such areas/cleaning processes should be well sealed/tight; housing should be of high grade stainless steel and hygienically designed. Processing of any food products normally has major attributes for three different zones – product zone, splash zone and product-free zone. “In product zone, sensors must fulfil European Hygienic Engineering & Design Group (EHEDG), ECOLAB, FDA guidelines and should be IP69K. And housing materials should be of high grade steel and surface roughness should be Ra<0.8,” points out Prabhu. Similarly, in splash zone, sensors must fulfil ECOLAB guidelines and should be IP69K (tight ingress protection). For product zone, general purpose sensors could be used. Keeping such criteria in mind, various companies are offering products that suit the industry. It goes without saying that value-addition in products is an ongoing process. “We have good experience in developing and designing sensors for such applications keeping in mind the required attributes and zoning regulations. We have a wide range of products for such applications,” says Prabhu.

Modern Food Processing | June 2011

Similarly, Festo solutions are built in collaboration with the system integrators and end-users. “Every industry has a different need. Keeping this in mind, we provide solutions accordingly. Our solutions constitute the latest and state-of-the-art technology, offering higher performance leading to enhanced output, costeffectiveness due to optimum solution, reduction of the equipment size due to high performance, compact nature of components & durability due to high quality,” claims Dangi. For Bosch, it is different. It is not into the processing but into packaging. Packaging, especially in the processed food sector, plays an important role in many ways. Bosch machines are incorporated with safety interlocks so that any abusive handling of the machines brings them to a halt, thereby ensuring the safety of the machine and the operator. “We follow the hygiene standards through design concepts in our machines. Some food products with high protein contents have stringent hygiene requirements. For such products, we

Robotic technology used in confectionery sector Courtesy: Bosch Packaging

SECTOR WATCH

have special hygiene machine that are manufactured at our mother plants in Europe and the US,” says Gourish. He further adds, “Our machines have an operator-friendly Human Machine Interface (HMI), which displays and teaches the personnel on the operations as well as safety of the machine. The faults are also displayed on the HMI, so that the maintenance staff need not fiddle around with the other systems while resolving a problem.”

Raising quality standards The food processing sector in India has started drawing attention of the world since the last couple of years. The sector currently encounters many challenges. The first and foremost problem is acute shortage of skilled labourers. It is a known fact that the industry is leaving no stone unturned to increase quantity and quality of food processing, but as of now the results are not encouraging. The desired results to a great extent can be achieved with the support of proper technologies. So, modern technology with maximum automation is the solution. If food processors invest in automation and maintenance-free machinery, which works 24x7, they will not only be able to increase their output but also be able to bridge the demandsupply gap. There are many technology providers that can not only minimise the use of labour in the processing units but also increase the overall efficiency. This calls for a change in mindset and huge investments. “The food processing industry in the developed world is at an advanced stage. In India, we are

Automatic bottling line Courtesy: Festo Controls

trying to reach those levels. Further, the market dynamics and the approach of entrepreneurs as well as end-users are also different when it comes to developed countries and that in India. Moreover, the unorganised sector dominates the Indian market, hence the comparison at this stage is not correct,” explains Gourish. A closer look into the segment shows that many entrepreneurs are sitting on the fence due to cost factor. They are not sure whether investing in automation at this point of time is justified or not. “In India, the level of technology used in several industries is not at par with the developed world due to cost reasons. The efficiency of the process tends to remain at relatively lower levels. If the agricultural output is raised, then the demand for the packaged food exports may rise. In such a scenario, the technology levels will have to change. In the distant future, India may become a food supplier to the world, if we are able to

Avoiding human touch, humidity and temperature control are the key aspects for ensuring a hygienic food processing environment. And, automation is key to attain these. Milk and value-added dairy products are best examples of how automated food processing can do wonders.

Ganesh Prabhu General Manager, Factory & Automation, Pepperl+Fuchs India Pvt Ltd

produce more as well as increase the export levels,” opines Dangi. If the progress of automation is tracked in a sector-specific manner, then dairy segment in India has witnessed significant advancements. “We should take cue from co-operative milk societies, which made us proud by creating worldclass milk processing plants. Milk and value-added dairy products are best examples of how automated food processing can do wonders. We are able to enjoy packed butter, ghee, butter milk/ curd. Similarly, we get fruit juices during off-season too because of longer shelflife. This has become a possibility due to advanced packaging technology and automated process,” asserts Prabhu. Over the years, the demands of consumers are changing, and to keep in line with these trends, the industry is also changing. The industry has realised that automation, to a large extent, will determine the future of the food processing segment. Now the question remains as to how fast the industry can implement it. There are some positive signs – due to changes in lifestyles, the demand for packaged food and restaurants has increased significantly. This has generated demand for automation in food processing as well as packaging. Taking everything into consideration, it is just a matter of time that the industry will soon witness significant investments in automation.

June 2011 | Modern Food Processing

INDUSTRY UPDATE

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How about a more intelligent option for proving the ‘best before’ date? Or confirming a spoilt package even before opening it? Or, using a packaging material you can eat! The food packaging industry has definitely come of age, offering incredible solutions to suit the growing demands of food safety, traceability and environment-friendliness.

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Courtesy: Cryovac Food Packaging

Mahua Roy

n this age of rapidly-transforming consumer dynamics and choice, packaging is no longer taken for granted. It has grown beyond branding initiatives. Food processing companies, in tandem with packaging companies, are investing more and more into research, thereby coming up with futuristic packaging solutions aimed at empowering consumers with accurate knowledge about the integrity of the product being sold to them. This is the reason why the global market for active and smart packaging technology for food and beverage is expected to grow from $ 15.798 million in 2010 to $ 23.474 million in 2015, at an estimated CAGR of 8.2 per cent. Modified Atmosphere Packaging (MAP) holds the largest share of the overall active and smart packaging technology in terms of value, while smart and intelligent packaging technology is witnessing the fastest growth at an estimated CAGR of 12.1 per cent. In active packaging,

Modern Food Processing | June 2011

oxygen scavengers and moisture absorbers form the two largest product segments. Both are estimated to grow at a CAGR of 8 per cent and 11.9 per cent respectively. “There has been considerable interest in active/ intelligent packaging to help protect product quality particularly as processors look to reduce or eliminate preservatives in products, offer organically sourced or all-natural products, and/ or incorporate more healthy fats/oils (omega 3, trans fat-free & reduced saturated fats). Active/ intelligent packaging also is a tool that can be used to reduce food waste and the resources lost when food is discarded rather than consumed,” says Scott Beckwith, Marketing Manager, Sealed Air’s Cryovac Food Packaging.

Packaging comes of age The talks of sustainability have reached the peak, with consumers and processors striving towards the common goal of greener solutions. Sustainable packaging solutions need to be developed in such a way that all three dimensions

INDUSTRY UPDATE

of sustainability, ie people (social), profit (economy) and planet (environment) are positively responded to. In other words, the ‘perfect’ packaging solution should be, most importantly, cost-efficient, provide value to generate revenue and it should also be user-friendly (easy to handle and provide information). Also, goes without saying that it needs to be lean on resources, recoverable and prevent its contents from being spoilt. Lifestyle trends today are impacting upon consumer purchasing decisions. For the packaging and processed food industry, many of these trends are positive, encouraging innovation. Consumers are becoming increasingly demanding and short of time, seeking solutions that offer traditional and functional benefits, but at the same

There has been considerable interest in active/intelligent packaging to help protect product quality particularly as processors look to reduce or eliminate preservatives in products, offer organically sourced or all-natural products, and/or incorporate more healthy fats/oils (omega 3, trans fat-free & reduced saturated fats).

Scott Beckwith Marketing Manager, Sealed Air’s Cryovac Food Packaging time are convenient. Also, issues of food quality and safety are rising and growing awareness of health present new challenges to food processing and packaging companies & retailers alike. Taking into account the needs of the consumers, packaging technologies are in a dynamic state of research,

Intelligent packaging technologies R Ethylene scavengers: Ethylene induces fruit ripening thus accelerating

spoilage. In response to this, packaging technologies that aim to ‘scavenge’ or absorb ethylene from packaged food have now been developed. Most commonly used application is one based on a sachet that contains either potassium permanganate or activated carbon with a metal catalyst. R Oxygen scavengers: Oxygen in packaged food might accelerate oxidative

reactions, or growth of moulds, resulting in food deterioration. Oxygen scavengers come in different forms such as sachets, labels, or may be directly incorporated into package material and/or closures. Some most common oxygen scavengers are ferrous oxide, ascorbic acid, sulfites, catechol and photosensitive dyes. R Carbon dioxide absorbers & emitters: Carbon dioxide acts in a positive

manner when added to certain products like baked goods, fresh meat, poultry, cheese, etc, by suppressing microbial growth. Apart from this, it is also used to decrease the respiration rate of fresh produce, to overcome package collapse or partial vacuum caused by oxygen scavengers. Carbon dioxide can be added in different forms, like moisture-activated bicarbonate chemicals in sachets and absorbent pads. R Moisture control agents: Evidently enough, excess moisture in foods

can have unpleasant results, especially in crispy, powdered, hygroscopic products. Adding moisture control agents is an effective way of ensuring product integrity. The use of humidity-control technology controls condensation inside packages of respiring and other high-water content foods & eliminates water films on the food without further drying it. R Modified atmosphere packaging: As the name suggests, this preservation

technology changes the air surrounding the food in the package to another composition. Instead of preserving foods using extreme temperatures of heat (sterilisation) or cold (freezing), this method utilises ‘minimal processing’ – preserving food with the least amount of damage to quality, texture, taste and nutrition. Some of the most common MAP systems available are micro perforation of PE packaging film and incorporation of inorganic particles along with micro perforated PE film.

thus providing the most friendly and convenient solutions.

Self-heating and self-chilling packaging Who doesn’t appreciate valueaddition? Most new technologies are created keeping in mind the lifestyles of consumers. Self-heating packages, for soup or coffee, and self-cooling containers for beer have been under development for more than a decade. “One trend that we have acted on is the growing demand among producers of home heated meals for functional packaging,” says Nick Greco, Business Development Manager (BDM), Avery Dennison Designed and Engineered Solutions. The Avery Dennison Flexis™ Steam valve technology facilitates the measured escape of steam from food packaging during cooking. The result: home-heated packaged foods cook with greater consistency, more thoroughly and faster than foods in conventional steam release packages. “Such functional and specialised packaging also offers a safety benefit. The selfventing valves eliminate needs for consumers to cut packages or interact with a valve to release steam. The valves also guard against the entry of contaminants by remaining hermetically sealed until the food product is cooked. Functional packaging of this type equips food processors to bring greater value to the consumer, and so they find it particularly attractive,” he adds. To add to this innovation, if one provides a self-heating or selfcooling container a sensor to inform

June 2011 | Modern Food Processing

INDUSTRY UPDATE

Materials for edible packaging Polysaccharides and derivatives: Methylcellulose (MC) & hydroxypropyl methylcellulose (HPMC) have the ability to form thermally induced gelatinous coating.

R Cellulose

R Chitin and

chitosan: According to recent research findings, films from chitosan were rather stable and their mechanical & barrier properties changed only slightly during storage. Chitosan coatings are usually used on fruit and vegetable products such as strawberries, cucumbers, bell peppers as antimicrobial coating, and on apples, pears, peaches & plums as gas barrier.

Lipid films

Proteins

R Waxes and paraffin: Paraffin

R Zein: Zein coating have shown

wax is permitted for use on raw fruits, vegetables and cheese. Waxes are used as barrier films to gas and moisture (skin on fresh fruits) and to improve the surface appearance of various foods (eg, the sheen on sweet). R Acetoglyceride: Acetylated monoglyceride coatings have been used on poultry and meat cuts to retard moisture loss during storage. R Shellac resins: Resin and its derivatives are widely used in coating for citrus and other fruits.

an ability to reduce moisture and firmness loss & delay colour change (reduce oxygen & carbon dioxide transmission) in fresh tomatoes. R Gelatin films: Gelatin is used to encapsulate low moisture or oil phase food ingredients and pharmaceuticals. Such encapsulation provides protection against oxygen and light, as well as defining ingredient amount or drug dosage. In addition, gelatin films have been formed as coatings on meats to reduce oxygen, moisture and oil transport. Source: ICT, Mumbai

the consumer about the correct temperature, the package becomes ‘smart’. Most commonly used technology incorporates the use of a thermochromic ink dot to indicate the correct serving temperature following refrigeration or microwave heating.

Incr‘edible’ packaging Learning from nature to solve engineering problems is not new. “Edible films and coatings have received considerable attention in recent years because of their advantages over synthetic films. The main advantage of edible films over synthetic films is that they can be consumed with the packaged products. The edible package can enhance the nutritive and organoleptic properties of packaged foods provided they contain various

components (flavourings, colourings, sweeteners),” says Dr Smita Lele, Head - Food Engineering & Technology Dept, Institute of Chemical Technology (ICT), Mumbai. Another possible application for edible films could be their use in multilayer food packaging materials together with non-edible films. In this case, edible films would be the internal layers in direct contact with food materials. Consumer interest in health, nutrition and food safety combined with environmental concerns has renewed efforts in edible coating research. In addition to being a source of nutrition, the edible packages are also environmentally safe. “The development of new edible coatings with improved functionality and performance for fresh and minimally processed fruits is one

Slight premium attached with specialised packaging is outweighed by business advantages associated with an improved food product. When you consider that the consumer will experience smart packaging as an integral part of the overall product offering, it becomes a critical ingredient to the meal’s success in the marketplace.

Nick Greco BDM, Avery Dennison Designed and Engineered Solutions

Modern Food Processing | June 2011

of the challenges for the post-harvest industry. In the past few years, research efforts have focussed on the design of new eco-friendly coatings based on biodegradable polymers, which not only reduce the requirements of packaging but also lead to the conversion of by-products of the food industry into value added film-forming components,” adds Dr Lele. An ongoing project on edible packaging at ICT is being carried out, which involves making of a novel edible coat using ash gourd peel wax for extension of shelf-life of easily perishable fruits. Using this wax, the shelf-life of strawberry was extended from three days to one week with respect to texture, colour, weight loss, titrable acidity and microbial attributes. This technology can also be applied to other easily perishable fruits. “The goal of edible packaging is a step further to healthy eating. The hope is to bring the concept of ‘eating without opening’ into the society,” says Dr Lele.

Extensive research When it comes in the area of packaging, cost area of focus.

to further research active or intelligent management is the “The raw material

INDUSTRY UPDATE

In the past few years, research efforts have focussed on the design of new eco-friendly coatings based on biodegradable polymers, which not only reduce the requirements of packaging but also lead to the conversion of by-products of the food industry into value added film-forming components.

Dr Smita Lele Head - Food Engineering & Technology Dept, ICT cost is often higher for specialty polymers but this cost is offset by improved product quality, shelf-life or flexibility with product formulations. It also can help reduce food wastage,” says Beckwith. Similar views are shared by Greco who says, “There is a slight premium attached with specialised packaging. But this is outweighed by business advantages associated with an improved food product, safer handling and overall customer satisfaction. When you consider that the consumer

will experience smart packaging as an integral part of the food producer’s overall product offering, it becomes a critical ingredient to the home-cooked meal’s success in the marketplace. Ultimately, it delivers a powerful competitive advantage compared with traditional steam release methods.” But this area is bound to see a lot of positive push because packaged food is the future. From product innovations and value-additions, every effort is being driven towards the enhancement

Courtesy: Avery Dennison

of packaged food. “Improvements in food safety, shelf-life, product quality and reduction in product and packaging wastage will continue to drive advances in the active/intelligent packaging area. It will also stimulate research of existing technologies to provide alternative formats and further optimisation,” concludes Beckwith.

June 2011 | Modern Food Processing

MARKET SCOPE

Inspection system

Plugging loopholes with a clear ‘vision’ Product packaging has come a long way. From just being traditional food packages designed to keep products safe, today their role also includes food preservation as well as monitoring and communicating information about food quality. In future, machine vision systems are likely to play major role in the production process as food manufacturers adopt high levels of automation.

Didier Lacroix

ver the last couple of years, the F&B packaging industry in India has witnessed robust growth. Rising brand awareness coupled with various other socio-economic factors such as steady industrial growth, increase in consumer spending and adaptation to western culture are some of the reasons, which have provided a greater thrust to the ` 70,000-crore packaging industry in India. According to a report published by market research firm RNCOS in April 2010 titled ‘Indian food and drinks market: Emerging opportunities’, the Indian food and beverages market is expanding rapidly and is projected to grow at a compound annual growth rate (CAGR) of about 7.5 per cent during 2009-13 and would touch $ 330 billion by 2013. This growth in the food & drink market will directly help boost the packaging industry which has also seen a change in the concept of product packaging. Today, packaging in India is not only about delivering the product but

Modern Food Processing | June 2011

Courtesy: Cognex Inc

companies are using innovative packaging solutions as a way to attract buyers and change their perception of the product quality, reliability as well as value. As far as innovative packaging is concerned, the F&B industry has witnessed a huge change as compared to products in other industries. Traditional food packages were only designed to keep products safe and protect them from the harmful effects of the environment. But now one can see product packaging playing an active role not only in food preservation but also in monitoring and communicating information about food quality. Innovative food packages today have indicators on the outside of the package, which changes colours indicating the quality of contents inside. Pushing the technology to another level, packages today can also control various aspects of the product such as moisture content, ripeness as well as the pressure to keep contents fresh for longer periods of time. However, as India steadily adapts itself to implementing these innovative packaging methods, it still relies on the countries

MARKET SCOPE

such as Europe and the US for technology & machinery that can accomplish international hygiene and quality norms. In addition, trained professionals are required to operate these state-of-the-art machines.

Machine vision in packaging Apart from innovation, basic packing and handling of processed food also pose a major challenge to the industry. Dairy food products, for example, have higher density and fat content, which makes it difficult for the product to flow, thereby leading to inaccuracy in weight and appearance when the final product is packed. Sensing the right quantity and quality of food being packed, tracking packaging errors and maintaining high standards of quality control are imperative for an industry as sensitive like F&B. As the F&B packaging industry aligns itself to high levels of automation, thanks to the new governmental regulations and a need to meet international standards, machine vision systems will play an important role in tracking operations on the production line. These vision systems are capable of not only inspecting the product but also identifying minor defects that are not visible

to the naked eye. Machine vision system is an important ingredient in the factory automation process as it addresses three critical areas in the manufacturing process which include guidance, inspection and identification. Each of these processes has a huge impact on the quality control aspect of food packaging. As more and more food processing units are becoming fully automatic,

As India gears up to follow international packaging standards, companies will have to invest in R&D and deploy state-of-the-art machine vision systems. vision system now aid robotic arms in picking up food items from a conveyor belt and placing them into containers. They also help in inspecting product dimension as well as track and trace products along the entire production cycle.

Automation-driven

growth

Growth in the F&B packaging directly depends on the developments in the processed food sector. India is a major power house of food production in the world today and there is huge growth opportunity in the food processing sector, which is expected to reach $ 330 billion by 2014-15, according to a report by the Ministry of Food Processing Courtesy: Cognex Inc Industries (MoFPI).

However, the processed food industry is currently in its infancy with only 2.2 per cent of the total fruits and vegetables being currently processed across the country. In the case of milk, the portion that is processed is higher at 35 per cent but still low as compared to other western countries such as the UK where nearly 88 per cent of fruits, vegetables and milk are processed and 45 per cent in a developing country like the Philippines. In order to further give a boost to the food processing industry, the MoFPI has formulated a Vision 2015 action plan, which aims to treble the size of the food processing industry, raise the level of processing of perishables from 6 to 20 per cent, increase value addition from 20 to 35 per cent, and enhance Indiaâ&#x20AC;&#x2122;s share in global food trade from 1.5 to 3 per cent. It is evident from these figures that Indiaâ&#x20AC;&#x2122;s food processing industry is on the cusp of experiencing a significant growth trajectory. Rising cost of key raw materials such as paper and international prices of crude oil, machinery and technology to develop innovative packaging solutions and low levels of food processing are some of the challenges that the F&B packaging industry will have to tide over. Also as India gears up to follow international packaging standards companies will have to invest in R&D and deploy state-of-the-art machine vision systems to streamline their production process as well as improve quality control procedures. Despite all these challenges, there are hopeful signs that the packing industry will well cross the ` 1,00,000-crore mark in the years to come. Didier Lacroix is the Senior Vice President - International Sales & Services at Cognex Inc. For details, contact on email: sales.in@cognex.com

June 2011 | Modern Food Processing

INDUSTRY INSIGHTS

Food retailing

A value for money proposition India is one of the most striking destinations for retailers. The country’s food and grocery industry secures the sixth position in the world. Having one of the highest growing populations in the world, India exhibits tremendous potential to further strengthen its position in the global retail market.

Shushmul Maheshwari

urrently, the Indian food retail industry stands at a mammoth size of $ 70 billion, with about 95 per cent of the industry dominated by unorganised sector. Food & grocery form the largest segment of the country’s retail sector accounting for about two-third of the total retail sales in India. The country’s rising middle-income consumers, changing lifestyles of consumers, rapidly growing disposable income, innovative food processing capacity, emergence of organised retail, and change in consumption patterns are driving the growth of food retail sector. In addition, more than 50 per cent of the Indian population is young (under the age of 25 years), who favours buying or eating quality and processed foods, which is yet another motivating force for the food retail market in the country. As far as retail formats are concerned, the Indian food retail market consists of several co-existing types of formats namely: road-side hawkers and mobile retailers, fair price shops, traditional retailers, co-operatives, such as janatha bazaars, Military canteens’ margin-free shops, and modern retailers. As per RNCOS analysis, the penetration of organised food retail in the country is low as majority of Indian consumers prefer to buy from corner grocery shops or modern outlets. Even the buying pattern of Indian consumers varies

Modern Food Processing | June 2011

from the international consumers who tend to store weekly or sometimes monthly grocery requirements. Therefore, the segment holds huge potential for new entrants, particularly in untapped markets like rural and semi-rural areas.

Demand & supply scenario India secures the second position as the largest producer of food in the world. During FY 2011, the country’s total food production stood at around 235 million tonne, an increase of around 8 per cent from the previous fiscal. The food industry in the country has been witnessing a marked change in consumption pattern on the back of increasing disposable income. Currently, India’s food industry is valued at $ 180 billion. RNCOS’ study on the market indicates that the demand of the commodity is more than its supply, implying that there will be a deficit of the commodity in future. The gap between supply and demand is narrowing down over the years for all the food items. As per RNCOS analysis, the demand will surpass supply in future due to rapid growth in population and rising per capita income of consumers. Besides, it can be observed that the demand for cereals will slow down and consumers will prefer other items, such as pulses, edible oil and sugar. Taking into consideration the supply side factors, production of food items is expected to be affected by low-yield growths, especially in cereals and sugarcane. In the short and medium

INDUSTRY INSIGHTS

term, there might be excess of cereals in the country, but this outlook is likely to diminish in the years to come. Moreover, the picture will be even more alarming for edible oil, sugarcane and pulses. Therefore, with the increment of food requirement in the country, it would either need to increase agricultural production, or depend more on imports. These constraints would also push farmers and retail companies for making increased efforts in food supply.

Competitive scaling Comprising a large number of players, Indian food retail market is extremely fragmented and unorganised. The market is dominated by mom & pop stores (kirana shops), while the organised retailing merely forms 5 per cent of the total food retail sales in the country. The total number of trade food stores in the country reached around 1,72,341 at the end of 2009, an increase of around 1 per cent from the previous year. The major domestic food retailers in the country include Food World, Spencer’s Retail, Food Bazaar, Trumart, Nilgiri’s, Arambag Foodmart, Namdhari’s Fresh, Reliance Fresh, Big Apple Supermarkets, and so on. At the state level, the market was dominated by the regional players such as Trinethra in Andhra Pradesh, and Margin Free Markets in Kerala, but with the opening up of the market for foreign players like Wal-Mart, Carrefour, etc new scope for retail business has emerged. On the strategic front, the companies are focussing on various expansion measures like opening of new retail outlets across the country and signing agreements with other companies. For instance, recently Spar International, a global food retail chain, has signed a licensing agreement with Dubai-based Landmark Group’s Max Hypermarkets to expand its operations in northern and western India. Reliance Retail has announced opening up of 150 new stores in India, adding to its 1,050-store network. Besides, the food retail sector in India offers huge potential for

expansion of foreign retailers. As per RNCOS analysis, India is ranked as the most attractive country for food retailing, among 30 emerging markets across the world. As the economic conditions in developed markets are improving at a much slower pace, the emerging markets are becoming much more important sources of growth for global retailers. Additionally, due to the increasing number of affluent and brand-conscious consumers, the modern retailing formats are gradually gaining popularity in the country. The sector represents a huge opportunity for multinational brands as well as input suppliers to enable them to increase their exports, facilitate technology shift, sign new joint ventures, and create valuable investments in India.

Government initiatives

70. 1

66. 1

2009

2010

Source: RNCOS

Figure 1: Food retail sales (in $ billion), 2009 & 2010

products, condensed milk, ice cream and meat production have been entirely exempted from excise duty. The government has decided to invest in retail supply chain to improve infrastructure of cold chains and storages. As an initiative, National Horticultural Mission of India has approved 24 storage projects with a capacity of 14,00,000 tonne. In addition to the Horticultural Mission’s projects, 107 cold storage projects of 5,00,000 tonne capacity have also been approved. Clearly, the increase in warehousing space will further increase the supply of fresh foodstuff to consumers while enabling retailers to reduce prices.

As far as the role of government is concerned, the current FDI regulations in the country are making it difficult for foreign food retailers to enter India. Presently, FDI in multi-brand retail is banned, but the government allows 51 per cent FDI in single brand retailing and 100 per cent in wholesale trade. But, as per latest industry developments, the government is considering to allow Industry shortfalls 100 per cent FDI in multi-brand retailing, In recent years, India has demonstrated which if implemented, will surely have a remarkable growth in its food retailing positive impact on the modern retail sector. Although, due to rapidly growing sector in India. Moreover, the FDI in population and changing lifestyles, the multi-brand retailing will also help local country offers lucrative opportunities enterprises to upgrade their technology to new entrants. However, there are and practices to face competition from some roadblocks, which may hamper the exponential growth trajectory of this the MNCs. Besides, initiatives like opening industry in future. Following are some up of 15 mega food Table 1: Forecast for food demand-supply gap parks and reduction of (million metric tonne), 2011 & 2021 excise duties will also Food item 2011 2021 have a major impact on Rice (1.26) (8.98) the market. Recently, (21.21) (27.33) Wheat the government has Total cereals (21.19) 2.94 reduced the excise duty Pulses 8.05 24.92 on ready-to-eat packaged Edible oil 6.66 17.68 foods and instant food Sugar 4.31 39.67 mixes from 16 to 8 per Source: Indian Council for Research on International Economic Relations cent. Fruits & vegetables

June 2011 | Modern Food Processing

INDUSTRY INSIGHTS

of the factors that have the potential to severely affect the industry’s growth rhythm. R Poor supply chain management: The supply chain management is highly inefficient leading to significant wastages in storage and poor handling. Too many intermediaries are involved throughout the value chain at the collection level, which act as a major constraint for the industry. Due to large number of intermediaries at collection level, the quality of food suffers. R Channel conflicts: Ideally, a retailer should maintain a direct relationship with their suppliers. But, due to the complex tax structure and geographic extension of the country, most of the companies are developing a regional distribution and re-distribution network, leading to channel conflicts. R High rental costs: Another challenge for all retailers is to find a right location with reasonable rental for their stores. As rent forms a large portion of the total expenditure, retailers have to be cautious before buying/hiring a place for stores. R Changing tastes & preferences and buying habits: A typical Indian consumer prefers more of fresh fruits and vegetables over packaged foods; therefore, this issue needs to be taken care of if the sector vies for further growth. R Sourcing quality agricultural base: Due to highly fragmented supply base in the Indian agricultural system, and lack of proper legal framework, it is becoming more complicated for retailers and food processors to acquire quality product at competitive costs directly from farmers. R Lack of basic infrastructure: Lack of adequate infrastructure with respect to roads, electricity, and ports has also hampered the development of food retail in India.

Tips to boost food retailing The industry regulators need to take care of the following suggestive measures to present an impressive position of India in the global food retail industry: R The opening of a new store requires a lot of licenses. Therefore, the government should grant all the licenses under one roof in order to speed up the process. R To support the growth of the sector, in-house and collaborative R&D programmes should be encouraged & supported by the government. R Build up a strong back-end support, particularly for perishable products, to help reduce wastages and boost investment in developing new storage facilities. R In order to minimise channel conflicts, the retailers should work closely with the suppliers and shorten the supply chain network resulting in saving time & money. R To avoid paying high rents, the retailers should first evaluate the option of setting up a property development/management arm that will source/ develop stores at lower rentals.

Road ahead The immense population of India calls for a huge potential for the food retail industry in the coming years. It is anticipated that the country’s food retail industry will reach around $ 150 billion by 2025. Innovation in products and marketing strategies is the need of the hour for most of the companies operating in the Indian food retail market. Further, 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. Although the demand from rural and semi-urban regions will grow at a fast pace, it will put an immense strain on the margins of retailers because of high competition. Moreover, the increasing rural and semi-urban income levels, along with massive advertisement by retailers via electronic media, will spread awareness in these regions and, therefore, the companies will introduce affordable products for them. Moreover, the set-up of retail formats in India is evolving with the changing food consumption patterns and consumers requirement for ease & complete value for money. The consumers nowadays, visit about 5-7 retail outlets to buy varied food items, which make up the daily consumption

Modern Food Processing | June 2011

basket. These outlets comprise fruit & vegetable outlets, bakeries, kirana stores and dairy booths that are quite timeconsuming. As a result, the convenience in food shopping is accelerating the growth of other retail formats that can provide ‘value for time’ besides ‘value for money’ to the consumers. Additionally, the private label business is small in India, making a small value subset of the business enjoyed by the organised retail industry. The private labels enable retailers to offer products at a lower price, thus, attracting more number of customers to the store. This in turn, will not only enable better margins by eliminating middlemen but also enhance retailers’ bargaining power with supplier. Thus, the penetration of private labels is expected to witness high growth in India. 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

FOOD SAFETY

Spices industry

Retaining flavour and aroma safely From time immemorial, India has been known as the land of spices and has made a mark in global spices trade. With the world consumption of spices growing steadily every year, the export potential has increased. Hence, it is pivotal to improve quality and adhere to global standards, especially when it comes to food safety, for retaining the global marketshare in the spices segment.

Subhash Vaidya

ndia has been famous for its spices and herbs since ancient times. It is perhaps the largest producer and consumer of spices in the world today. In recent years, the spices industry is booming in terms of the export markets. In the global spices trade, India accounts for nearly 45 per cent and 30 per cent in terms of volume and value, respectively. The booming world spices market also provides opportunity for the Indian industry to sell and market quality spices at competitive prices. However, India faces stiff competition from countries like China, Malaysia and Pakistan in terms of product pricing. Therefore, product quality and safety will play an important role while exporting to countries like the US, EU, Japan, among others. Manufacturers, therefore, should ensure consistency in supply, product quality and marketing strategy to augment their share in the export market. Some of the major spices under

Modern Food Processing | June 2011

the export category include chillies, seed spices, turmeric, spice oil, pepper, cardamom, ginger fennel, fenugreek, tamarind, nutmeg and mace. The Government of India has taken the initiative to help farmers, growers and processors of spices to handle & process these in a hygienic manner. Right from fresh produce to ready-toeat food, in the entire food chain, be it ingredients, raw materials, additives or packing materials, the consumers demand safe food. There are several methods and laws available to prevent food adulteration and ensure safety. To manage safety-related hazards, one of the most powerful sequential techniques is the Hazard Analysis Critical Control Point (HACCP), which is a part of ISO 22000-2005 Food Safety Management System.

Pre-requisite programmes Like in every other food category, the spices industry is also required to adopt the Pre-requisite Programmes (PRS). The implementation of food safety system calls for programmes like food

FOOD SAFETY

hygiene, Good Manufacturing Practices (GMP), Standard Operating Procedures (SOPs), without which the food safety management systems cannot be implemented. Some of the key focus areas for the same include: Premises: The building and surroundings should be designed & constructed in such a way that it enables prevention of food contamination. Land should be free from debris and should not be located close to polluted areas. Sanitary and hand wash facilities: Washrooms should be available and situated separately from changing rooms. Hand washing facilities, equipped with sanitisers and air driers, should be provided at each entry point in the production, storage & dispatch area. Plumbing & sewage disposal: There should be proper drainage facilities and provision for disposal of sewage without any stagnant water. Waste generated & collected in the plant should be moved, stored and disposed to avoid foul odour & prevent pests.

Receiving of raw material

r Storage of raw material

r Manual cleaning of raw material

r Heat treatment

r Magnetic detection

r Weighing & packing

r Labelling

r Storage of finished goods

r Dispatch of finished goods Figure 1: Flow diagram for spice processing

Equipment cleaning: Proper cleaning of equipment and utensils should be undertaken, as it plays an important part in maintaining food hygiene. Water, ice & steam quality: Ice, water and steam used during the processing activities should be free from bacteriological contamination and regular testing programmes should be established for ensuring the same. Transportation and storage: The establishment should ensure that raw materials, packing materials and finished products are transported and handled hygienically to prevent any chances of contamination. Preventive maintenance: There should be will documented preventive maintenance programme in place. Pest control programme: The establishment should adopt adequate pest control programmes to avoid food contamination on account of rodents and other pests. Recall programme: The recall procedure should ensure that potentially unsafe food is effectively removed from the point of use or point of sale.

Spices processing Generally, in the spices industry, there are different types of activities that can be classified into the following: R Whole spices R Seed spices in whole form R Spices in powdered & crushed form R Seed spices in powder form R Powdered spices R Blended spices in whole form Here, let us consider food safety issues for whole spices as well as spices in powdered and crushed forms. This will present a fair picture of how hazards usually occur and also the ways to overcome them. For rest of the other products, the processes will mainly remain the same, more or less.

Whole spices The whole spices category mainly includes whole chillies, turmeric fingers, black & green cardamom and cloves, among others.

There are three types of hazards associated with any food industry. These are bacteriological, chemical & physical. Therefore, we are identifying the hazards as per the steps in the process flow chart (Figure 1). Receiving of whole spices: There are chances of bacteriological hazards, for instance, the presence of pathogens. This can be controlled by inspection at the incoming stage in the factory, and further it can be prevented at the time of heat treatment. Stones, metals, insects and dirt, among others are the major physical hazards found in the incoming spices. In order to control and prevent these, the management has to be strict regarding raw material specification and must also have some inbuilt preventive steps for dealing with worst-case scenarios. Storage: After the receipt of raw materials at the factory, it is stored in the godown and there are chances of pathogens & insect infestation. This can be controlled & prevented by way of fumigation of godown. Manual cleaning: During the manual work, many-a-time, the personal hygiene of employees handling these items is not maintained and there are chances of contamination by way of pathogens through human touch. Hence, personal hygiene is essential. There are chances of physical hazards due to foreign objects such as grease, plastic, paper, etc, getting mixed with the spices, and at times the employees may not be aware of this. Hence, employee training will help control these hazards. Heating: In this step, there are chances of survival of pathogens, which can be prevented by ensuring proper time and temperature control during heat treatment. Magnets: The raw materials are passed through magnets and the iron particles, which remain stuck on the magnets can get mixed with the products again. It is, therefore, essential to clean the magnets as per the requirements of process from time to time.

June 2011 | Modern Food Processing

FOOD SAFETY

Weighing, packing & labelling: At the time of weighing and packing, there are chances of product contamination due to the human element. Care has to be taken to follow personal hygiene, SOPs, besides providing proper training to employees for strict visual inspection, which will prevent and control the hazards at this stage. Labelling: Sometimes, wrong labelling poses a challenge in the process. Stringent measures need to be taken to eliminate this error. Storage of finished goods: Stringent measures are called for in order to keep spices safe after all the processing is done and the product is ready to reach the end-consumer. Fumigation: Pest infestation should be prevented by using authorised pest control measures and batchwise inspection. Dispatch: There are chances of existence of pathogens despite all the care taken during the process. In order to avoid such situations, the quality control lab should check and maintain each batch & dispatch records for ensuring that there are no pathogens or insects present at the final stage.

Whole spices in powdered & crushed form Another category of spices includes those that come in powdered or crushed forms such as chilli/turmeric/ ginger/cloves/nutmeg powder, kibbled turmeric, shrivelled nutmeg, crushed chillies, green & black cardamom & cinnamon powder, among others. Receiving of whole spices, storage & cleaning: In these areas, the steps are similar as mentioned earlier for whole spices. Drying: In this process, moisture content can cause a physical hazard, which can be avoided by control measures pertaining to time and temperature.

With food safety concerns looming large in India and worldwide, spice manufacturers will have to adopt high food safety standards in their units to gain a global foothold.

monitored and documented in order to control it. This generally constitutes the Critical Control Point (CCP) in the process. Moisture content in the product also must be controlled through proper time and temperature monitoring systems. Second hammer milling & grinding: During this step, iron particles get mixed up with products resulting in contamination. In order to prevent and control this hazard, cleaning of magnets frequently is advisable. Weighing & packing: All SOP regarding packing should be strictly adhered to besides following hygiene standards during this stage. Labelling: Wrong labelling needs to be controlled by undertaking supervision and training. Storage of finished goods: Storage at finished goods stage poses issues pertaining to pest infestation, which can be prevented by SOP installed for the process. Fumigation & dispatch: For these two processes, the procedures remain the same as discussed earlier for the whole spices.

Keeping aroma intact Magnets: Sometimes, residue of iron particle remains on the magnet, which can get mixed with the powdered spices. This issue can be avoided by cleaning the magnet frequently, as required by the process at that time. First hammer milling and grinding: Often, metal particles get mixed up with products. It is, therefore, recommended that screens be cleaned before production. Sieving: There can be possibility of oversized particles in the spices, which can be controlled by checking screens prior to production. Heat treatment: Due to improper time and temperature control, there is a likelihood of the presence of pathogenic organisms, which needs to be verified,

Modern Food Processing | June 2011

The Spices Board of India, which is responsible for post-harvest handling and R&D, has initiated its own quality programmes. India has a tradition of producing different spices and has a capacity to grow almost all spices in the world. The Indian spices industry has transformed itself into a global player during the recent years. With food safety concerns looming large in India and worldwide, spice manufacturers will have to adopt high food safety standards in their units to gain a global foothold. 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

TREND ANALYSIS

Indian confectionery market

Sweet prospects to savour

A growing propensity to consume premium chocolates and healthy cereal bars will drive strong growth in the Indian confectionery market. On a sweet note, this market is all set to savour the opportunities and make the most out of them.

Gaurav Marchanda

n 2009, the Indian confectionery market was valued around $ 1.27 billion, and the market size is growing rapidly. During 2004-09, the industry grew at a compounded annual growth rate (CAGR) of 10.5 per cent, placing it among the fastest growing confectionery markets globally, far ahead of larger confectionery markets such as China and the US, which grew at a CAGR of around 5.07 per cent and 2.63 per cent, respectively, during the same period. Rapid economic growth and rising per capita income in India, along with the large untapped rural market, make the Indian confectionery market one of the most promising in the times to come. In the near future, this rate is expected to increase further. It is estimated that the Indian confectionery market will grow at a CAGR of 12.4 per cent during 2009-14 (making it the second-fastest growing market in terms of CAGR during the period). This rapid growth should augment its global rank from 25th in 2009 in value terms, to 19th by 2014.

â&#x20AC;&#x2DC;Chocolateyâ&#x20AC;&#x2122; prospects Chocolates constitute the dominant category in the Indian confectionery market in value terms. It was also the second-fastest growing category during 2004-09. Sugar confectionery is also a large category; however, it has historically been a slow growing category, and can be expected

Modern Food Processing | June 2011

to continue this way in the coming years as well. Furthermore, the gum category is expected to exhibit a healthy growth, with oral hygiene becoming a bigger priority for consumers. Cereal bars is the smallest but fastest-growing category in the Indian confectionery market, and is expected to perform well on the back of the growing health trends in the country. Gifting chocolates during traditional Indian festivals like Diwali and Raksha Bandhan also continue to gain popularity. Such products have a longer shelf-life than traditionally available sweets, and are also accompanied by well-targeted marketing campaigns & product positioning. This is leading to a shift from gifting dried fruits and sweets to chocolates. Also, as most of these products are targeted at middle-aged consumers, who have greater disposable income compared to children, such product concepts are also contributing to the fast-increasing value in the chocolate category. The manufacturers, especially in the chocolate category, realise that there is an increasing opportunity in targeting the older age groups, as they have higher disposable incomes. This is why the demand for premium chocolates is increasing, as is the number of premiumpositioned chocolates. One of the key strategies to target the older-age segments is positioning the chocolate products as an indulgence, something that a manufacturer like Cadbury is doing well through its new launches.

TREND ANALYSIS

Impediments on the way Despite these significant growth prospects, the per capita expenditure in the Indian confectionery market is still extremely low. Comparatively, the per capita expenditure in other growing markets like Brazil and South Africa is about 25 times that of India. Furthermore, there are several obstacles that will impede growth in the Indian market. Added strains on household budgets due to high food inflation in India will indirectly put pressure on the confectionery market, as discretionary spending on comfort food items diminishes. In addition, the price of both sugar and cocoa beans (the main ingredients in chocolate) is on the rise, which is likely to exert pressure on the profit margins of manufacturers. Higher sugar prices directly impact the input costs of low-value sugar confectionery products, which in India tend to have lower price elasticity.

Healthy trends Over 30 per cent of the Indian population is in the 0-14 age group, which is the primary target segment for confectionery manufacturers. Consumers in this segment will be the prime movers for growth in the confectionery market in India. As the Indian confectionery market continues to evolve, strong trends have come to the fore that will shape the future of the market and categories within it. Health-consciousness is one trend that has certainly caught the attention of manufacturers. Chronic obesity

and lifestyle-related problems like diabetes are increasingly plaguing Indian consumers, which are making consumers, particularly those in urban cities, increasingly conscious about what they consume, and its impact on their health. Consequently, new product launches are increasingly moving towards a healthier positioning. The health-consciousness trend majorly impacts the sales of cereal bars, which offer a healthy snacking option. This explains why cereal bars are currently the fastest-growing category in the domestic confectionery market. Thus, the relatively older-age segments are also expected to increasingly contribute

The Indian confectionery market is expected to continue growing at a rapid rate, driven by premium chocolates and the fast-growing cereal bars category. to the Indian confectionery market. With the premiumisation trend on the rise, this age segment is driving value growth in a number of categories, like chocolate and cereal bars. In terms of new product launches, the sugar confectionery category continues to dominate the Indian market. The chocolate category is also a large contributor to new launches, as rapid value growth and changing consumer preferences for premium chocolates are driving new launches in the category. ‘Vegetarian’ is an extremely important claim for new launches, as it allows the product to access most of the population in the country. Almost half of all new confectionery launches in the country claimed to be vegetarian. ‘Recyclable’ packaging and ‘no sugar’ were other important claims, which indicate the

growing environment- and healthconsciousness in the society.

Future scope The Indian confectionery market is highly consolidated. The top five manufacturers in the market – Cadbury (Kraft), Perfetti Van Melle, Nestlé, Mars, and Parle – together account for a major share of the market. International manufacturers are particularly dominant in the market, and also lead the way in terms of new product launches. For example, Cadbury accounted for almost 20 per cent of new product launches in the Indian confectionery market during 2010. An analysis of the leading manufacturers in terms of growth suggests that companies like Cadbury and Nestlé, with a higher focus on chocolate products, are performing better than other confectionery manufacturers. The untapped rural Indian markets present an opportunity for confectionery manufacturers, as over 70 per cent of the country’s population resides in rural India. As economic prosperity gradually trickles down to the rural population and disposable incomes rise, tier 2 and tier 3 cities will grow in priority for manufacturers. Furthermore, the highly competitive nature of the market within cities has seen rural regions grow in prominence as an attractive consumer segment. Going forward, the Indian confectionery market is expected to continue growing at a rapid rate, driven by premium chocolates and the fast-growing cereal bars category. Sugar confectionery, which is still a ‘high volume, low value’ category, is expected to exhibit the slowest growth in the coming years. Gaurav Marchanda is an Analyst, Consumer Markets at Datamonitor. For more details, contact Aartee Sundheep on email:asundheep@datamonitor.com

June 2011 | Modern Food Processing

QUALITY MANTRA

Food safety guidelines

Weeding out hot spots Retailers act as the trigger for shaping market evolution, influencing industry participants, and establishing an improved foundation for food safety across Asia, revealed a survey on the region. Both individually and collectively, the best practices adopted by them would help eliminate all the hot spots concerning the aspects of freshness, quality and safety of food products.

etail leaders can drive rapid improvement in the areas of freshness and food safety by prioritising and addressing the biggest risks, which is referred to as ‘hot spots’. At each stage of development of food products, different failure points generate the greatest food safety risks. Retailers in different countries – be it emerging markets, developing or developed – need to adopt, revise and implement the practices of leading retailers such as Wal-Mart, Wellcome, Aeon, CR Vanguard, among others. This is because these retail leaders are instilling a new mindset & culture around food safety in their stores and throughout their supply chains.

The food safety ‘hot spots’ Through a food safety survey, some of the major hot spots faced by retailers in various countries were identified. For emerging countries, an invariable hot spot is producer usage of harmful chemicals; while developing countries need to focus on the issue of quality standards followed by producers & suppliers; and developed countries need to prioritise end-to-end traceability.

Emerging markets Overall, the top priority for emerging markets is to stop the use of harmful chemicals, especially in the

Modern Food Processing | June 2011

fish/seafood and vegetable/fruit categories, where issues related to residual chemicals are prevalent. For meat/poultry, the focus must be on ensuring temperature control during transportation to prevent microbe contamination and spoilage. Meat/poultry: The meat/poultry category in emerging markets is rife with microbe contamination and spoilage issues. The core challenge is to sustain chill temperatures across the supply chain. Refrigeration and freezing facilities are often too costly for suppliers or, if installed, are turned off to save money. In China’s tier 2 cities, for instance, refitted trucks are often used instead of purpose-built refrigerated vehicles. Doing so can cut vehicle price by 20 per cent, but at a cost of reduced capacity and temperature control. Suppliers with refrigeration facilities but weak usage standards might look to Wal-Mart’s approach in tier 2 cities of China. Wal-Mart enforces its supplier guidelines by conducting temperature tests right at the receiving gate. While refusing product that fails the testing, Wal-Mart understands that it risks temporary stock-outs, but believes that having the highest quality standards will pay off in the long run. The improved consistency in quality has already led to fewer consumer complaints and lower product shrinkage for the retailer.

QUALITY MANTRA

Product mishandling is another major culprit when it comes to microbe contamination and spoilage. Retailers should look at swiftly eliminating the problem by introducing fundamental hygiene standards, following the lead of retailers who have already instituted product handling procedures as well as taken the initiative of educating staff. Fish/seafood: Producers in this category often use dangerous chemicals, such as growth stimulants, antibiotics and antiseptics at fish farms. Fish and seafood products are vulnerable to chemicals in general, but farmers tend to use harmful chemicals, which are inexpensive, easily acquired, and more potent than safe chemicals. Although use of these chemicals is already prohibited by law in most countries, standards are often not sufficiently enforced to prevent their usage. Product testing is costly and time-consuming, and tracing product back to source is nearly impossible. The template for addressing the problem exists, however. Tesco Lotus, a leading retailer in Thailand, directly sources fish products to ensure traceability. However, given the sheer number of producers and limited quantity & variety that each provides, direct sourcing is not a comprehensive option. As a supplemental solution, the Thailand FDA has equipped retailers with â&#x20AC;&#x2DC;quick testâ&#x20AC;&#x2122; toolkits, which determine the presence of residual chemicals within two hours, helping retailers to conduct faster and less expensive tests. Fruits/vegetables: Farmers in emerging markets often operate at subsistence levels, with limited knowledge about modern pesticide practices. As such, they tend to use harmful pesticides, fertilisers and post-harvest chemicals, which are less expensive. Pesticides account for a large part of production cost, and farmers are eager to cut expenditure. Use of such chemicals is already prohibited in China and India, but the

Category

Meat/poultry

Fish/seafood

Table 1: Hot spots in the emerging markets Proven practices by Major hot spots leading retailers R Conduct temperature testing R Poor temperature at receiving gate and reject control during sub-standard deliveries transportation R Enforce global infrastructure and R Poor staff and customer procedures to ensure hygiene hygiene in stores standards R Poor breeding R Use large slaughterhouses that environment at source from partner farms and producers offer traceability & testing R Source directly from producers and conduct on-site audits R Use of harmful drugs by R Use crushed ice for product producers at fish farms displays and have productR Poor handling processes in place. in-store Keep live fish fresh by investing in temperature control advanced equipment and staff hygiene R Poor temperature R Use advanced chilled vehicles control during and temperature control systems transportation to ensure seamless cold chain in transport

Fruits/vegetables R Producer use of harmful pesticides

Partner with production bases to maintain higher standards and conduct regular audits Source: McKinsey market visits and interviews

fragmented producer landscape makes standards hard to enforce. However, Wal-Mart and CR Vanguard in Chinaâ&#x20AC;&#x2122;s tier 2 cities apply a direct sourcing approach to address this issue. They build partnerships with contaminant-free production bases, provide extensive guidance and training on quality standards, and also conduct testing for residual chemicals either in stores or at distribution centres (DCs).

Developing markets As cold chain development; producer & supplier sophistication; and standards enforcement measures come to fruition in developing markets, food safety problems will become less severe than those in emerging markets. Central issues remain with producers and suppliers failing to meet standards. Meat/poultry: In developing markets, cold chain facilities are available, but suppliers often fail to meet required temperature control standards.

Insufficient producer control of breeding environments is another problem in developing markets. Many producers raise pigs and chickens in pens with low-quality feed and limited epidemic prevention, resulting in high vulnerability to disease. A large number of farmers are unaware of advanced breeding standards, or do not have the means to afford them. Several slaughterhouses still source pigs from such farmers, driven by the cost advantage, but it renders traceability and producer monitoring impossible. In contrast, some slaughterhouses have shifted to best practices and source only from large, certified production farms that produce 10,000 pigs annually. Fish/seafood: Hot spots in fish/ seafood are often caused by the inability to move product from storage to sales floors to displays in the order it arrived. Without a proper first in, first out (FIFO) system, some products will be left to spoil in the stockroom or on sales floors.

June 2011 | Modern Food Processing

QUALITY MANTRA

Table 2: Hot spots in developing markets Major hot spots Proven practices by leading retailers R Work with multinational R Poor suppliers to ensure temperature sufficient temperature control and control during conduct quality & temperature testing transportation R Poor at DC receiving gate breeding Meat/poultry environment at R Ensure that main suppliers source only from large certified farms; establish producers R Poor traceability and conduct daily product supplier testing hygiene and process R Establish a QA team that conducts management product testing at packing houses R Poor retailer shelfR Develop a comprehensive set of life control or guidelines and manuals to ensure Fish/seafood adherence to FIFO that staff handle products strictly system according to FIFO R Overuse of pesticides R Use direct sourcing for all products, by producers or Fruits/vegetables and conduct extensive training to raise short incubation standards periods Category

Source: McKinsey market visits and interviews

Aeon, a leading retailer in Japan, has comprehensive guidelines and manuals to ensure that staff adhere to a strict FIFO system in handling products. Specifically, all fish and seafood products are tagged at the time of processing. Each product has a deadline and is checked regularly. For instance, when the time since processing exceeds four hours, certain products are marked down. After six hours, they are disposed of. Whole fish displayed on ice is sliced or cut into sashimi (bite-sized cuts of raw fish) to avoid deterioration. Retailers adopting these practices can maintain shelves filled with fresher products throughout the day. Fruits/vegetables: Residual chemical problems remain severe for developing markets, but for a different reason than in emerging markets. Farmers in developing markets tend to overuse pesticides or cultivate products without maintaining a sufficient incubation period. This is observed especially in monsoon regions and crops exposed to heavy pest damage. In such markets, farmers break standards to increase crop volumes. Many developing countries and markets, such as Hong Kong,

Singapore and Taiwan, rely heavily on imports from neighbouring emerging countries, and retailers are constantly concerned that farmers in these countries apply low chemical control standards.

Developed markets As developed markets meet most foundational requirements and follow best practices, hot spots are less severe than for markets at earlier stages. Concerns about fish/seafood and fruits/vegetables are higher for Japan and Korea, however, where raw fish and vegetable products are commonly consumed. Overall, the highest priority should be on improving end-to-end traceability and in-store temperature & hygiene for fish/seafood products. Meat/poultry: Some producers in developed markets still have poor breeding environment controls, which can result in animal disease. To deal with this problem, Aeon in Japan selects producers & packers using its own standards; conducts regular audits for all producers and follows Hazard Analysis and Critical Control Points (HACCP) steps to ensure safety.

Modern Food Processing | June 2011

Fish/seafood: Residual chemical problems remain a major concern for developed markets. Despite the lower general risk, when incidents occur, tracing problems back through the supply chain remains difficult. Many farmed fish producers keep spotty product information, and the fragmented producer landscape makes tracing difficult. Another concern is microbe contamination and spoilage. As in developing markets, the issue lies in retail environments, where equipment, temperature, and handling controls can be poor due to lax habits and poor awareness. Aeon has installed product shelves on the shop floor that regulate and record temperature. In processing and storage rooms, each fresh category is kept separately to avoid cross-contamination. Fruits/vegetables: Residual chemical concerns persist among developed market retailers, as some products, including imports, still contain higher levels of residual pesticides. Consumer awareness on the issue is increasing, which has created another set of problems. Many consumers stretch the interpretation of restrictions to mean that amounts exceeding the standard pose an immediate health hazard. Retailers are understandably worried that such misinterpretation could lead to unnecessary regulatory pressure. Aeon has dealt with this issue by sourcing domestic product from certified producers, and for others it asks wholesalers to work with producers who adhere to high food safety standards. For imported products, Aeon either asks major food companies to provide information or conducts self-audits after product goes through quarantine. For private brands, its own strict certification standards, including no child labour, high hygiene level, sanitary working environment, and self-monitoring systems, are followed.

QUALITY MANTRA

Quick incident response ‘Prevention’ is certainly the watchword for Asian retailers to address the hot spots, but they must also be ready to react quickly when an incident occurs. It is up to retailers, as the ‘last line of defense’, to avoid the spread of incidents. Retailers following best practices have clear incident response measures. Aeon, for instance, has made great strides in preventing food safety incidents, but it also takes a pragmatic approach in responding to potential risks and developing post-incident manuals. For severe incidents, it directs staff to identify victims, report to area office, inform manufacturers, review measures to prevent further spreading, and determine media communication approach and message – all within one hour of the incident. Standardised procedures, information-sharing processes and a contact sheet are provided to producers to enable independent review of their own operations to assess potential risks. Lastly, in the aftermath of an incident, Aeon conducts thorough safety restoration. In one incident where a needle was found in a product, all remaining items were scanned with a portable metal detector to ensure safety. The magnitude of difference retailers can make by fostering a ‘prevent’ mentality is clear when considering recent incidents such as the 2008 tainted infant formula scandal in China. Leading retailers such as CR Vanguard and Wal-Mart immediately withdrew both identified and at-risk dairy products even before the first government announcement. Such positive examples demonstrate that retailers can make a difference by reacting to incidents immediately after they occur, whether in-store or across their supply chains.

It is about leadership, not deep pockets The proven practices introduced by retailers at each stage of market development have proved effective and feasible within current market contexts. Clearly, adoption of best practices would call for some level of equipment or capital expenditure. But cash outlay is a minor part of the effort required from retailers. Far more critical is the managerial commitment and drive. Courtesy: Coca-Cola Retailing Research Council Asia (CCRRCA) This article is based on a study commissioned by retail industry think tank CCRRCA and conducted by McKinsey & Company to encourage retailers to focus more on improving food safety standards. CCRRCA is a research body dedicated to in-depth investigation of food retailing issues in a cooperative, non-competitive environment. For details, email: gwalsha@apac.ko.com

June 2011 | Modern Food Processing

CASE STUDY

Non-returnables line

Adding new dimension to bottling

According to SAB, this was one of the most successful line commissioning jobs ever performed for the company

Andreas Reusche

lcohol-based mixed drinks are gaining immense popularity in South Africa. SAB, a subsidiary of the SABMiller Group, operates seven breweries and five soft drinks plants in South Africa. Its principal beer brands include Carling Black Label, Hansa Pilsner, Castle Lager and Castle Light. While the South African beer market exhibited strong growth in the 1990s, growth rates slowly declined over the past decade. In 2009, beer consumption witnessed a fall for the first time, the result of the global economic crisis during that period. This scenario also gave way to fierce competition. Hence, SAB diversified its product portfolio in good time, to include mixed drinks with an alcohol content. As far as beer is concerned, South Africa still retains a preference for returnables, which make up more than twothirds of the total. SAB’s Chamdor brewery, located in Krugersdorp to the west of Johannesburg, has an output of around 3.5 million hectolitre – it is the fifth-largest SAB brewery in South Africa. SAB purchased it from Intercontinental Breweries in 1979. It is almost 40 years old and has been refurbished in several phases. The most recent step in the refurbishment project was the construction of a new, well-dimensioned bottling

Modern Food Processing | June 2011

With increasing demand for flavoured alcoholic beverages (FABs), The South African Breweries Ltd (SAB), South Africa’s leading beverage producer, commissioned a non-returnables line from Krones dedicated exclusively to bottling these drinks. For this purpose, it offers various options for end-ofthe-line packaging, coupled with intelligent process control for high line availability levels.

hall with a footprint of 4,000 sq m for what is called ‘Line 7’, which is at present used exclusively for filling flavoured alcoholic beverages (FABs) into 275-ml, 330-ml and 340-ml non-returnable bottles. Chamdor manufactures a variety of FABs. Chamdor makes the Sarita brand in two variants, with 5.5 per cent volume of alcohol; the fruitbased alcoholic drink Brutal Fruit available in six flavours, and the Skelter’s Straight brand.

High demand Ever since these brands had been launched, demand has always been in the high doublefigure range, reaching 1.3 million hectolitre during 2008-2009 period. “These demand levels were behind the decision to buy a new non-returnables line,” stated Wally Tollemache, Senior Project Manager, SAB. “At the same time, we have created more capacity for beer filling on the other non-returnables line,” he added. The Brutal Fruit variants are filled in individually designed, 275-ml Applied Colour Label (ACL) bottles. Overall, the line has to handle eight different types of bottles.

Intelligent IT solutions There are several options for putting the drinks into sales packages: 6-bottle wrap-around cartons on a 24-bottle full-depth tray, 6-bottle shrink-packs on a 24-bottle full-depth tray or

CASE STUDY

in wrap-around cartons, or 24 loose bottles on a tray. For these tasks, the line has been equipped with three different packers to handle the disparate endof-the-line packaging variants, and also with innovatively intelligent IT solutions for optimum capacity utilisation & smart line control at product changeovers. In view of the multiplicity of different products being filled, this is of utmost importance. For this purpose, a line documentation system (LDS) for data acquisition and a line management system (LMS) for order handling have been installed. The LDS basically records all the relevant machine data and consumption figures, and outputs these in combined reports. The LMS, by contrast, provides support to the operators & line managers in handling the orders involved, making the necessary adjustments in the machines, providing appropriately co-ordinated procedures as well as concomitant notes and specifications at the machine touch-screen. Bulk glass is passed onto the line by a sweep-off depalletiser in robot design. And it is here that intelligent line control with the Krones LMS starts to come into play. This is because the number of pallets holding non-returnable bottles fed in at the depalletiser reflect the availability of the product at the filler. In simple words, when there is not much product left, the bulk glass supply should be decelerated down to a stop, under co-ordinated control, so that the end of filling can be matched to the number of

bottles still required. The LMS knows the order quantities in relation to the size of bottle being filled. By continuously checking the order and the filler’s buffer tanks, it is able to compute the number of bottles still required as the smallest unit accurately down to one bottle layer, and then stop the layer sweep-off function appropriately.

individualised temperature profiles. At the discharge, the LMS, in conjunction with the pasteuriser’s control system, makes sure that the order leaving the machine coincides with the order at the downstream machine, or – if it does not – interrupts product discharge.

The pasteurising zones

A lengthy section of conveyor follows the pasteuriser, which likewise serves as a buffer and leads to two multimodule labellers, each with four Autocol stations for pressure-sensitive labels and two stations for cold-glue neck-around labels. “SAB has traditionally used two labellers in lines of this rating, because labelling quality and performance are important production attributes,” said Tollemache. There are two labellers, which can run either in parallel or separately, depending on the order concerned. Their use for any specific order is dynamically determined by the LMS, both when the order is started and while it is being processed. On their way from the pasteuriser to the labellers, the bottles pass through a distribution gate, which enables any conceivable combination of labeller to be utilised. One of the possible variants, for example, is to finish a particular order with only one labeller, while simultaneously changing the other one over to the next order, so as to achieve a maximally smooth transition without any standstills between one order and the next. This is supported

Once depalletised, after an Accutable buffer, the containers are passed via a bottle spacing unit to the BLOCsynchronised Variojet rinser and the Sensometic VP-VI filler. After they have been inspected for the proper fill level in a Checkmat, they travel along a buffering section that takes them to the Sander Hansen pasteuriser. Depending on the pasteurisation unit stipulated, it can take up to 1.5 hours for the product to pass through this machine. This means, the pasteuriser may harbour a production quantity equivalent to 90 minutes worth of filler output. All the downstream processes can thus continue to work with these bottles after a corresponding time delay. To prevent the necessity of running the pasteuriser completely empty when a new order is started and to avoid any intermingling, a procedure between the LMS and the pasteuriser has been developed that requires a pause of only two pasteuriser zones. This corresponds to roughly ten minutes for reliably separating any two orders and permitting the pasteuriser to run

After passing an Accutable buffer and a spacing unit, the depalletised bottles reach the monobloc configuration, comprising a Variojet rinser and a Sensometic VP-VI filler

Smooth transition due to two labellers

For the different end-of-the-line packaging variants, the line is equipped with three different packers, including a Variopac and a Wrapapac

June 2011 | Modern Food Processing

CASE STUDY

by the LMS, which connects or disconnects a machine in the current route plan, on the basis of appropriate plausibility checks. If, for example, a particular order has come to its end in the pasteuriser, separated from the next by the two zones as mentioned earlier, the pasteuriser will send an appropriate signal to the labellers, which in turn will display the message ‘set guide rail’ for the operator, who then inserts the guide rail manually, concludes production at the labeller no longer active and can change the label reel while the second labeller is handling final completion of this nearly finished order. As soon as the next order leaves the pasteuriser, after the time delay of two separating zones, the first labeller is ready for duty again – provided that the LMS confirms the route as correct.

is derived from the material list for the goods to be produced, and monitored appropriately by the LMS. Based on the packs to be produced, the LMS creates a route incorporating the machines required, which is then monitored for availability. If a particular route has not been correspondingly set at the distribution gates, the upstream and downstream machines cannot be started up, and the operator is prompted by an appropriate message. Since the distribution gates have to be set mainly by hand in Chamdor, the operator is responsible for adjusting them, who receives the support of LMS routing function in this part of line operation.

Three different packers

Downstream of the Wrapapac, a spiral conveyor takes the packs up to a height of around six metre. For constructionrelated reasons, this is followed by a pack conveyor section that is roughly 250 metre long, leading to the palletiser. Here, like everywhere else in the entire line, SAB Chamdor uses energy-economical motors featuring the Krones eco-gear-unit. Moreover, both the pack and the container conveyors have been equipped with a sleep control feature, meaning they switch off automatically when there are no more containers or packs to be transported. “These two measures cut total energy consumption by 35 per cent compared to traditional motor and controls on conveyor systems,” said Tollemache. In addition, each machine is fitted with consumption meters. The final station is the Robobox with Robot 2A palletisers, which have been installed in the palletising zone that is shared by all filling lines and connects up to the warehouse.

After having been inspected for correct label position in another Checkmat, the bottles are passed to the end-ofthe-line packaging zone. For this, SAB Chamdor has installed a packer for six-pack cartons (third-party machine), a Variopac non-returnables packer and a Wrapapac non-returnables packer. Distribution gates enable these packers to be run either together in a series configuration, or only with a concatenated Variopac and Wrapapac one behind the other, or just with the Wrapapac directly. The decision as to which operating mode is appropriate

The final station is the Robobox with Robot 2A palletisers, which have been installed in the palletising zone that is shared by all filling lines and connects up to the warehouse

Ecologically enhanced gear unit and sleep control

Successful line commissioning By means of material data management, route plausibility

Modern Food Processing | June 2011

checks, monitoring routines for the individual machines and orderreferenced approach, the LMS supports line downtime minimisation. Thanks to the line management system, flying product changeovers are possible with a theoretical stop of about ten minutes at each machine. The line was acceptance-tested in a five-day test, with an efficiency level of more than 90 per cent. According to SAB, this was one of the most successful line commissioning jobs ever performed for the company.

Diversification of product mix The line’s operating efficiency has been planned at 75 per cent; the target for factory efficiency is – depending on the product mix involved – between 64 and 72 per cent. “This has been reliably achieved,” asserted Andries Le Roux, Project Engineer, SAB. Tollemache emphasised on the mutually supportive co-operation between project & production team of SAB and Krones. He added, “This was the only way to ensure that line installation went as smoothly as it did, with all the deadlines met in full. Another advantage was, of course, that this line was supplied by Krones on a turnkey basis. That made things a whole lot easier, which is why we preferred this approach across the board.” In the shape of this new nonreturnables line from Krones, SAB has put in place the technical preconditions for an important step towards diversification of its product mix, away from the beer business. This is because South Africa’s beverage market continues to exhibit huge potential, despite the global economic situation putting it slightly under pressure. Andreas Reusche is the Project Manager - Sales Department at Krones AG, Neutraubling. Email: andreas.reusche@krones.com

EVENTS CALENDAR

National RUDRAPUR: Uttarakhand, Sept 23-26, 2011, Gandhi Park AHMEDABAD: Gujarat, Nov 14-17, 2011, Gujarat University Exhibition Hall PUNE: Maharashtra, Nov 18-21, 2011, Auto Cluster Exhibition Centre CHENNAI : Tamil Nadu, Dec 8-11, 2011, Chennai Trade Centre INDORE: Madhya Pradesh, Jan 6-9, 2012, Poddar Plaza, Nr Gandhi Hall AURANGABAD: Maharashtra, Feb 17-20, 2012, Garware Stadium 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

For details contact: Trade Fair Secretariat, FICCI Federation House, Tansen Marg New Delhi 110 001 Tel: 011-2373 8760-70, Fax: 011-3091 0411 Email: ficciexhibition@ficci.com

India Converting Show 2011 Exhibition aimed at package converters, will showcase latest trends in packaging technologies; November 23-26, 2011; at Bombay Exhibition Centre, Mumbai

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

FF&B 2011 The second annual Functional Food & Beverages (FF&B) India show for health and wellness products; June 28-30, 2011; at ITC Maratha, Mumbai For details contact: Oby George Programme Manager - Fi Conferences 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: conferences-india@ubm.com

PackPlus South 2011 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 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

Food & Technology Expo 2011 An international exhibition focussing on food processing & packaging machines & technologies; July 29-31, 2011; at Pragati Maidan, New Delhi For details contact: Anil Rana NNS Events & Exhibitions Pvt Ltd Meri Delhi House, 25/10, East Punjabi Bagh New Delhi 110 026, Mob: 098102 13597 Email: anilrana_ars@yahoo.co.in

India Foodex 2011 An exhibition on food processing & packaging technology, and food & beverage products to be held

concurrently with DairyTech India, GrainTech and AgriTech India; September 09-11, 2011; at Gayathri Vihar, Palace Ground, Bengaluru For details contact: Media Today Group (Exhibition Div) T-30, 1st Floor, Khirki Extension Malviya Nagar, New Delhi 110 017 Tel: 011-6565 6553/2668 2045 Fax: 011-2668 1671 Email: dti@dairytechindia.in

Summit on Food Processing, Agribusiness & Dairy An event for processed food, agro and dairy market; September 14, 2011; at Hotel Le-Meridien, New Delhi For details contact: Dr O S Tyagi, Director ASSOCHAM Corporate House, 1 Community Centre Zamrudpur, New Delhi 110 048 Tel: 011-4655 0555, Fax: 011-4655 0596 Email: ombeer.tyagi@assocham.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

Annapoorna - World of Food India 2011 An international exhibition and conference for the food and beverage industry; November 16-18, 2011; at Bombay Exhibition Centre, Mumbai

Modern Food Processing | June 2011

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

IFDE India 2011 A food & drink international exhibition; December 01-03, 2011; at Pragati Maidan, New Delhi For details contact: Tarsus Group Plc Metro Building, 1 Butterwick London, W6 8DL, The UK Tel: +44 (0) 20 8846 2700 Fax: +44 (0) 20 8846 2801 Email: info@tarsus.co.uk

Sweet & SnackTec India 2011 A specialised event for sweet, snack and confectionery processing industry will be held concurrently with Dairy Universe India (an expo for the dairy industry); December 06-08, 2011; at Bombay Exhibition Centre, Mumbai For details contact: Koelnmesse YA Tradefair Pvt Ltd 501/502, Kemp Plaza, Mind Space Chincholi Bunder Ext, Off. Link Road Malad (W), Mumbai 400 064 Tel: 022-4210 7801-11, Fax: 022-4003 4433 Email: info@koelnmesse-india.com

India Packaging Show 2011 The show aims to bring together the worldwide manufacturers and providers of machinery, materials and services for food, pharma and packaging industry from India and neighbouring countries; December 07-10, 2011; at NSIC Exhibition Centre, Okhla Industrial Estate, Delhi For details contact: Print-Packaging.com Pvt Ltd International Infotech Park Vashi, Navi Mumbai 400 705 Tel: 022-2781 2093, Fax: 022-2781 2578 Email: info@indiapackagingshow.com

EVENTS CALENDAR

International PROPAK ASIA 2011

Food & Hotel Thailand 2011

SIMEI 2011

A trade show for food processing and packaging technology; June 15-18, 2011; at BITEC, Bangkok, Thailand

Exhibition for food & drink, hotel, restaurant, bakery and foodservice; August 31 - September 03, 2011; at Royal Paragon Hall Exhibition & Convention Centre, Bangkok, Thailand

An enological and bottling equipment exhibition; November 22-26, 2011; at Fiera Milano City, Milan, Italy

For details contact: Bangkok Exhibition Services Ltd 62 Rama VI Soi 30 Rama VI Road, Samsennai Phiyathai, Bangkok 10400 Thailand Tel: +66 (02) 617 1475 Fax: +66 (02) 617 1406 Email: info@besmontnet.com

FI ASIA-CHINA 2011 An international food ingredients exhibition; June 21-23, 2011; at Shanghai New International Expo Centre, China For details contact: CMP Information P O Box 200, 3600 AE Maarssen The Netherlands Tel: +31 346 559444 Fax: +31 346 573811 Email: fi@cmpinformation.com

DDTE 2011

DISF 2011 The Dubai International Seafood Expo (DISF) 2011; September 27-29, 2011; at Jumeirah International, Dubai

For details contact: Dmg World Media (UK) Ltd Westgate House 120/130 Station Road Redhill, Surrey RH1 1ET The UK Tel: +44 (0)1737 855000 Fax: +44 (0)1737 855475 Email: webmaster@ca.dmgworldmedia.com

For details contact: Index (Conferences and Exhibitions Organisation Est) P O Box 13636 Dubai, The UAE Tel: +971 4 3624717 Fax: +971 4 3624718 Email: index@emirates.net.ae

ANUGA 2011

SIFSE 2011

One of the leading exhibitions for processed foods and technology; October 08-12, 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 Email: info@koelnmesse.de

China Foodtech 2011 HI South America Summit 2011

The Dubai Drink Technology Expo (DDTE) will showcase latest processing & packaging systems, light machinery, equipment and technology for beverages; November 29 - December 01, 2011; at Dubai International Exhibition Centre, UAE

For details contact: Orange Fairs & Events P O Box 111164, Dubai, UAE Tel: +971 4 2988144 Fax: +971 4 2987886 Email: orangex@emirates.net.ae

FOODPRO 2011 A trade fair showcasing latest trend and technology in food manufacturing; July 10-13, 2011; at Sydney Convention & Exhibition Centre, Australia

For details contact: Ente Mostre Enologiche (EME) Via San Vittore al Teatro 3 20123 Milano, Italy Tel: +39 02 7222281 Fax: +39 02 866226 Email: info@simei.it

Conference and exhibition on Health Ingredients (HI); August 09-10, 2011; at Expo Center Norte, São Paulo, Brazil

Exhibition for the food processing and packaging machinery; November 02-04, 2011; at China International Exhibition Centre (CIEC), Beijing

For details contact: CMP Information P O Box 200 3600 AE Maarssen The Netherlands Tel: +31 346 559444 Fax: +31 346 573811 Email: fi@cmpinformation.com

For details contact: CIEC 6 East Beisanhuan Road Chaoyang District Beijing, 100028, China Tel: +86 10 8460 0335 Fax: +86 10 8460 0325 Email: wangbaoliang@ciec.com.cn

The Shanghai International Fisheries & Seafood Expo (SIFSE) for fish processing industry; December 08-10, 2011; at Shanghai Everbright Convention & Exhibition Center, China For details contact: Shanghai Gehua Exhibition Service Rm.1206-1208 Xin’an Building No. 99 Tianzhou Rd Shanghai, 200233, China Tel: +86-21-54451166 Fax: +86-21-54451968 Email: info@gehuaexpo.com

ISM International sweets and biscuits fair; January 29 - February 01, 2012; 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 Email: info@koelnmesse.de

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

June 2011 | Modern Food Processing

TECHNOLOGY TRANSFER

Technology Offered As part of our endeavour to spread the technology culture, this section provides a means to promote and facilitate exchange of select technologies. We strive to bring together suppliers of such technologies with suitable users for negotiations and industrial collaboration.

Beverage maker An Indian firm is offering ‘threein-one’ beverage maker, which is a portable kit that allows the user to simultaneously make three functional beverages as per requirement. Using this, the consumer can set up three different types of fermentation simultaneously at one particular temperature. Areas of application Beverage industry Forms of transfer Technology licensing

Chocolate manufacturing technology An India firm provides chocolate manufacturing and snack extrusion technology with machinery. The firm supplies chocolate machines like chocolate conches, chocolate enrobers with cooling tunnel, one shot chocolate moulding machines, chocolate storage tanks, etc. The machines are manufactured using European technology. Areas of application Chocolate manufacturing Forms of transfer Consultancy, technical services and equipment supply

Food-paste moulding machine A Thailand-based firm offers a food-paste moulding machine

that produces cylindrical-shaped food paste with both ends sealed. This machine enables faster production of food-paste with consistent size and hygiene, which increase business potential in bigger markets both locally and abroad. Areas of application It is useful in food processing industries where the food products of cylindrical shape are required Forms of transfer Technology licensing

Food processing machinery An Indian firm offers all machinery for processing fruits, vegetables, poultry, meat and fish. Manufactured in Europe, the machinery is very easyto-use and makes high quality food products. It also offers ice making machines. Areas of application Food processing, agro-based industries Forms of transfer Consultancy, Equipment Supply, Turnkey

Sugarcane juice powder (dried) An Indian firm offers technology for making sugarcane juice powder using spray drying technique. It is a natural, healthy, safe and nutritious product from sugarcane.

Areas of application Food & beverages sector Forms of transfer Consultancy, technology licensing

Technology for milk, fruit and cereal-based products An Indian firm offers technology for processing milk products, fruit & vegetable products and ready-to-eat & ready-to-cook food products Areas of application Food processing industries Forms of transfer Consultancy, subcontracting, joint venture, technical services, capacity building, technology licensing, equipment supply, turnkey, others

Vacuum sealer and gas injection machine A Thailand-based company is providing technology for preserving and extending shelf life of food products. Proper packaging is critical for avoiding food spoilage. The vacuum sealing and gas injection technique prevents contaminating microbes to enter the container, thereby increasing the shelf life of the product. Areas of application Food processing industry, agro-based industry Forms of transfer Technology licensing

Share Your Technology Propositions The mission of Modern Food Processing is to spread the technology culture. We offer you an opportunity to participate in this endeavour by publishing the best technology ideas. Technology developers/sellers are invited to furnish the techno-commercial details (with environmental benefits, if any) for publication in the Technology Transfer column of Modern Food Processing. R&D organisations, technical consultancy organisations and individuals assisting small and medium enterprises may send the relevant literature, indicating the scope & services and the areas of specification. Contact: Modern Food Processing Infomedia 18 Limited, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022-3024 5000, 3003 4672 z Fax: 022-3003 4499 z Email: spedit@infomedia18.in

Modern Food Processing | June 2011

TECHNOLOGY TRANSFER

Technology Requested Coconut milk beverage

Food preservation

An Indian entrepreneur is interested in acquiring the technology for producing & processing coconut milk beverage. Areas of application Food processing industry Forms of transfer Consultancy

A Thailand-based food and fruit preserved trading firm is looking for efficient technology to extend the shelf-life and preserve food and fruit. Areas of application Food processing industry, confectionary industry, pastry industry Forms of transfer Others

Corn processing An Indian company is looking for a complete proposal/project report to set up a dry milling corn processing plant in Andhra Pradesh. Targeted finished product is tinned corn, pop corn, corn flakes etc. It is also interested to import similar kind of plant & machinery to set up the same in India. Areas of application Corn processing industry Forms of transfer Others

Extruder pilot plant An Indian company is seeking the extruder pilot plant for manufacturing processed cereal-based weaning food. Areas of Application Infant food, supplementary food, weaning food Forms of transfer Others

Food processing equipment An Indian company is seeking technology and equipment for processing of fruits, vegetables and other related products. Area of application Food processing industry Forms of transfer Others

Fruit drinks-doy pack A firm from UAE is interested in acquiring the technology for manufacturing fruit juices and drinks using optimum formulation technology. The firm needs technology providers, consultants and price quotes for the project based on turnkey & know-how. Areas of applications Food processing industry Forms of transfer Others

Juice and food processing A company based in the UAE proposes to establish a food processing plant that would help process fruit juices, jam/jelly, juice concentrates & pulp. Through this plant, the company also wishes to obtain valuable by-products like cattle feed, fertiliser and raw materials for plywood. Areas of application Food processing industry Forms of transfer Others

Rice husk ash to silica precipitates An Indian company is seeking the technology to convert rice husk ash

into some useful matter like silica precipitate, as the rice husk is rich in silica content. Areas of application Agro-based mills, which burn rice husk for internal purposes Forms of transfer Others

Spice grinding and processing plant An Indian firm is seeking to set up a spice plant and requires turnkey project consultants for the same. Areas of application Food processing industry Forms of transfer Others

Virgin coconut oil production A Thai entrepreneur is interested in acquiring the technology for production of virgin coconut oil. He has an abundant supply of coconuts and plans to set up a coconut oil production line with technical cooperation from technology providers. Areas of application Food processing industry Forms of transfer Others

Xylitol technology A company based in Thailand is seeking the technology for producing gum by utilising maize-waste. Areas of application Food industry Forms of transfer Others

Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, United Nations - Asian and Pacific Centre for Transfer of Technology (APCTT), APCTT Building , C-2, Qutab Institutional Area, New Delhi 110 016 Tel: 011 - 2696 6509, Fax: 011 - 2685 6274, Email: krishnan@apctt.org, Website: www.apctt.org For more information on technology offers and requests, please log on to www.technology4sme.net and register with your contact details. This is a free of cost platform provided by APCTT for facilitating interaction between buyers and seekers of technologies across the globe. After submitting technology offer or request to this website, you are requested to wait for at least two weeks for receiving a response from a prospective buyer / seeker through this website, before contacting APCTT for further assistance.

June 2011 | Modern Food Processing

BOOK SHELF

Confectionery and chocolate engineering: Principles and applications Author : Ferenc Mohos Price : ` 12,450

This book elaborates the unit operations involved in confectionery manufacturing. The large diversity in both, raw materials and end- products in the confectionery industry, makes it necessary for this topic to be dealt in a more theoretical manner. Keeping this in mind, the following topics have been covered extensively in the book â&#x20AC;&#x201C; basic principles of food engineering, characterisation of substances used in the food industry, rheology of foods & sweets, physical properties like gelling, stabilisation, crystallisation, etc. The appendix is useful and provides ready information on fluid models, fractals and structure theory. This book provides insights on increasing efficiency of operations, use of new materials and applications for traditional raw materials. It can be used as reference material by food engineers, scientists, R&D technologists and students in related fields.

Offering an engineering perspective and the latest information on application of the rapidly expanding technique of extrusion-cooking, this book focusses on technology, engineering, materials and products as well as economic & ecological. In addition to theory, it also cites case studies that can be emulated across the industry. Each step in the process of extrusion-cooking is discussed with respect to its sustainability. The book encompasses various aspects in the extrusion-cooking of breakfast cereals, snack pellets, crispbread, bread crumbs, baby foods, precooked pasta, soyabeans, textured vegetable proteins, pet foods, confectionery, etc. The unique feature of this book is the inclusion of a section dedicated to the role of extrusion-cooking in waste management and thermoplastic starch. It can be used by food chemists, process engineers, chemists, agricultural scientists and chemical engineers.

Extrusion-cooking techniques: Applications, theory and sustainability Editor Price

: Leszek Moscicki : ` 3,850

Wisdom Book Distributors, Hornby Building, 1st floor, 174, D N Road, Mumbai 400 001 Tel: 022-2207 4484/6631 8958, Telefax: 022-2203 4058, Email: thadam@vsnl.com

Modern Food Processing | June 2011

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,

Manas R Bastia Editor Infomedia 18 Limited ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W) Mumbai 400 028 India

D +91 22 3003 4669 T +91 22 3024 5000 F +91 22 3003 4499 E manas@infomedia18.in W www.infomedia18.in

PRODUCT UPDATE

Chocolate suction pad

Vacuum packing machine

Schmalz India offers the SPG suction pad. It has an extremely thin and supple sealing lip that provides an optimal seal for both smooth, glazed chocolate bonbons and structured surfaces. The tapered suction pad geometry ensures that round and square chocolates are completely enclosed and securely held under maximum dynamic pressure. Even chocolates with fillings are moved at high process speeds without being broken. The bell shape securely encloses the chocolate while low vacuum values of -100 mbar prevent the fluid that is underneath the chocolate shell from leaking. The high nominal flow of the suction pad ensures that the required operating vacuum is quickly formed and the leaks that occur when moving highly-structured chocolates are optimally compensated. Manufactured from FDA-compliant silicone, the SPG is authorised for direct contact with food. It complies with applicable hygiene regulations because it can be replaced without causing contamination. A mounting aid that is integrated in the shaft enables one to mount or remove the suction pad without touching the sealing lip. This can also be steam sterilised and cleaned using industry-standard cleaning agents.

Monarch Appliances offers vacuum packing machine which is used to pack food products. The key advantage of this machine is that it increases the shelf-life of the products. It vacuums the product through machine. The advantage of chamber machine is that even the space surrounding the product outside the package also vacuums. Vacuum chamber machines can also be used to package products with a modified atmosphere. Very low residual oxygen figures can be obtained by first pulling a vacuum before the injection of gas. The vacuum machine is used for packing cheese, meat, fish, flower bulbs, coffee beans, pillows, PCBs, food products, khakhara, roti, groundnuts, namkeen, spices, instant food, bakery products, chemicals, electric components, pharmaceutical, dairy products, dry fruits, sea foods, etc.

Schmalz India Pvt Ltd Pune - Maharashtra Tel: 020-4072 5500, Fax: 020-4072 5588 Email: schmalz@pn3.vsnl.net.in

Monarch Appliances Rajkot - Gujarat Tel: 0281-2461 826, 301 7420, Fax: 0281-301 9788 Mob: 098252 15733 , 093767 77277 Email: monarchrajkot@gmail.com

Continuous food emulsifier

Wu-Hsing Electronics offers mini non-nozzle vacuum sealer. This sealer is made up of stainless construction, which keeps fish longer without freezer burn and stores clothing scent-free. This can preserve food fivesix times longer than traditional methods and is easy to use. The bright Light Emitting Diode (LED) lights help to monitor the stages of sealing. This is equipped with see-through acrylic vacuum lid for perfect bag alignment while sealing and is also equipped with a cooling fan. This sealer is ideal for solid goods vacuum & packing. It is also suitable for vacuum channel bags, nylon gusset bags and aluminium gusset bags (same as tea leaves and coffee bean bag).

Tricon offers multi-purpose high speed microcut emulsifiers (MC 15, MCH 20K) from Stephan Germany. This is useful for continuous process, controlled and consistent size reduction. The easily removable, carbide tipped cutting rotors having no metal-to-metal contacts provide long tool life, easy cleaning, and minimum product temperature rise. No pre-run or adjustments are required as the machine is almost maintenance-free. This is ideal for fine pastes â&#x20AC;&#x201C; wet spices (onions, ginger, chilly, garlic) peanuts, vegetables, fruit and confect, meat emulsions for sausages, kebabs, etc, where protein swelling is better. Also useful for fishhead paste, flaking fish for refabrication into portions, grinding fish or chicken skin for fat recovery, sea moss, reduction for pet food, offal, feather for feed.

Wu-Hsing Electronics Co Ltd Taichung - Taiwan Tel: +886 4 2271 1498, Fax: +886 4 2271 2806 Email: sealer@wuhsing.com.tw

Tricon Pune - Maharashtra Tel: 020 -2565 2205/2451, Mob: 098901 92832 Email: triconfood@gmail.com

Mini non-nozzle vacuum sealer

Modern Food Processing | June 2011

PRODUCT UPDATE

Digital colour mark sensor Lubi Electronics offers â&#x20AC;&#x2DC;Sunx LX-100â&#x20AC;&#x2122; series digital colour mark sensor. This can detect any marking because the sensor is equipped with red, green and blue Light Emitting Diode (LED) element. Furthermore, to expand the functionality the sensor comes with dual mode, ie, mark mode (ultra high-speed response) & colour mode (highprecision mark colour discrimination) to suit any application. This sensor comes with Mode Navi technology for enhancing features and easy to use. It is provided with 4-digit digital display, 12-bit A/D converter, D-code, key lock, timer, NPN or PNP outputs, IP67 protection, etc. It is used in many applications/industries, especially in packaging, food, pharmaceuticals, textile, plastic & many more. Lubi Electronics Ahmedabad - Gujarat Tel: 079-2220 5471, Fax: 079-2220 0660 Mob: 093274 97006 Email: info@lubielectronics.com

June 2011 | Modern Food Processing

PRODUCT UPDATE

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

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

Modern Food Processing | June 2011

PRODUCT UPDATE

On-line digital printing technology M&M Technologies offers online digital printing technology. It provides the printers with high-resolution Piezo inkjet technology, thereby offering the packaging industry the most efficient and state-of-art-technology in terms of hardware, software, accessories, consumables. In terms of application, it is the most cost-effective modern technology, used for marking, printing and traceability. It is a user-friendly, robust and compact technology. The simplified operation at each level of production process is versatility in application software to design the logos, text, barcodes, variable and fixed data field, option for multi-colour printing, standalone or network printing. Low maintenance and easy operability makes the system more userfriendly. The printing can be done on coated or uncoated corrugated boxes, aluminium foil, glass, metal for address printing, pharmaceutical primary, secondary package printing as well as on pallets. This system can also be linked into multi-plant and multi-location with Wi-Fi and Internet connection. M&M Technologies Pvt Ltd Navi Mumbai - Maharashtra Tel: 022-2778 1580 Email: mp@mmtechnologiesindia.com

June 2011 | Modern Food Processing

PRODUCT UPDATE

Three-deck pre-cleaner

Pulveriser

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.

Jas Enterprises offers impact pulveriser. It is a versatile grinding unit of heavy and rugged construction and built for continuous operation day after day. The unit is especially designed for the medium fine, and fine size reduction. It meets most capacity requirements and enables a wide degree of adjustments with fineness of the finished product ranging from about 60 mesh to bulk passing through 325 mesh, depending on a considerable extent to the particular material being handled. The impact pulveriser combines grinding, classifying and conveying all in one single unit. It consists of an encased rotor carrying swing hammers, whizzer classifier for fineness regulation, and blower fan mounted on a solid shaft. Raw material to be pulverised enters the crushing chamber through the hopper and automatic rotary feeder. The impact of the hammer on the feed material against the liner plates reduces it into fine powder. The ground material is carried towards the whizzer classifier for classification and the oversize particles are rejected by the classifier and returns to the crushing chamber for further grinding. The classified material is then conveyed into the cyclone for collection and bagging. A dust collector is provided in the system for ensuring dust-free operation and no loss of ground powder.

Sifter International Faridabad - Haryana Tel: 0129-406 0039, 223 4540 Fax: 0129-223 0039 Email: sifter@ndb.vsnl.net.in

Jas Enterprises Ahmedabad - Gujarat Tel: 079-2274 3454, Fax: 079-2274 5062 Mob: 094274 17384 Email: info@jasenterprise.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 enhancing product shelf-life. It has an 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

Modern Food Processing | June 2011

PRODUCT UPDATE

Lined carton machine

Belt coater

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 ± 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.

Chang Yang Machinery offers a revolutionised modern panning system – the belt coater. Its ease of use and great savings in space, labour and overall cost compared to traditional revolving pans, make it perfect for the small producers. These belt coaters are available in either a larger size 60” in 750 lbs capacity or a smaller type 24” and 48”. These uniformly coat all type of centres, including nuts, dried fruit, chocolate, coffee beans, cereals, etc. The self-contained unit includes a large, accessible coating chamber, air distribution system, and chocolate dispensing & automatic product unloading system. Optional digital-readout load cells monitor and control the coating process, allowing one to have consistent control over the loading of centres, chocolate coating process, and final batch weight. The optional Programmable Logic Controller (PLC) control offers full automation of the process, with programmable control of belt speed and direction, air flow and chocolate dispension, all through a user-friendly touch-screen control panel with multiplerecipe storage. The unit is all stainless steel constructed with high density plastic side panels and smooth polypropylene belting.

Rollatainers Ltd Faridabad - Haryana Tel: 0129-409 8800, Mob: 098115 66112 Email: info@rolapak.com

Chang Yang Machinery Co Ltd Taichung - Taiwan Tel: +886-4-2407 1185, Fax: +886-4-2407 1073 Email: ching890@giga.net.tw

June 2011 | Modern Food Processing

PRODUCT UPDATE

Water purification system

Automatic 6H seamer

Millipore (India) offers â&#x20AC;&#x2DC;Direct-Q3â&#x20AC;&#x2122; water purification system. It is designed for simple and intuitive operation. The system guarantees the production of high-quality ultrapure water (Type I), providing a superior alternative to bottled water or DI water. In addition, the system produces pure (Type III) water that is stored in an integrated reservoir and can be used for basic applications. It saves on electricity, water consumption, maintenance and time. The system allows delivery of a fixed volume of Type I water and automatically shuts off once the selected volume has been delivered. For applications requiring low organic contaminant levels, it incorporates a dual wavelength UV lamp to produce water with <5 ppb TOC, making it suitable for HPLC, GC, ILC and TOC analyses. It is available with a built-in 185 and 254 nm UV lamp for production of low TOC water required by organic-sensitive applications. The maintenance is reduced to a simple cartridge change once or twice a year. It is ideal for laboratories that do not have easy access to pre-treated water and need between 1 and 10 L of ultrapure water per day.

Shini-I Machinery Works offers automatic 6H seamer. S-B45 automatic 6H seamer is specially designed for round, empty or food can closing. Flanged (or filled) can is fed forward through a timing screw and a chain to enter seaming station equipped with 6 sets of seaming spindle. Two seaming rollers undertake seaming operation at each spindle. Cam driven knockout pad releases the seamed can from chuck and seamed can is carried out by a turret. Seam quality meets international standard. The capacity of a can is up to 500 cans/min for canning. Under cover gassing system can be incorporated for steam or CO2. Its simple structure and multiple safety devices leads to easy operation and maintenance.

Millipore India Bengaluru - Karnataka Tel: 080- 3922 4000, 3922 4001, Fax: 080- 2839 6345 Email: bioscience_info@milliporeindia.com

Shini-I Machinery Works Co Ltd Taichung - Taiwan Tel: +886-4-2623 8181 Fax: +884-4-2623 2129 Email: shinican@ms15.hinet.ne

Ice cream making plant Pal Engineers offers ice cream making plant. It comprises ageing vat, batch freezer, homogeniser and pasteuriser. The ageing vat machine is compact, has a rectangular mix tank for proper mixing of ice cream mix, all product contact parts made of SS-304 & is equipped with castors for easy movements. The glycol jacketed construction & stirrer gives even cooling and maintains temperature during power failure. Its features include less power consumption due to efficient refrigeration system and PUF insulation, bottom drive stirrer are easily removable for complete cleaning. All product contact parts of batch freezer are made of SS-304 or food grade material. The homogeniser is provided with specially designed pressure valve, which gives high-performance even at working time and diaphragm-type pressure gauge to maintain perfect hygienic conditions. All parts in direct contact with ice cream mix is made of either stainless steel or food grade material. The homogeniser is quick & easy to dismantle for perfect cleaning. The pasteuriser is robust and of sturdy construction. Pal Engineers Ahmedabad - Gujarat Tel: 079-2274 8877, 2277 2575 Email: info@palengineers.com

Modern Food Processing | June 2011

PRODUCT UPDATE

Nano crushing machine Full-Win Technology offers nano crushing machine. The high efficiency eddy flow crushing machine marks the beginning of a new era in nano crushing technology. It functions powerfully in crushing the minerals, plants, herbs fibres into sub-micron particles of 0.1~1μm, averagely at 0.5μm which the regular crushing machine cannot attain. Grinding chamber temperature are controlled at 30~40 to avoid raw materials’ characters from getting affected and assures very high purity of particles without contamination. The process can be done in one single operation. Its non-mesh design, almost no wastage of the raw materials, and no pollution, keeps the working environment always clean and hygienic. Full-Win Technology Co Ltd Changhua Hsien - Taiwan Tel: +886-4-895 2051, Fax: +886-4-895 2061 Email: tracyyen@fullwin.org, info@fullwin.org 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

June 2011 | Modern Food Processing

PRODUCT INDEX Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

Product

Pg. No.

AC servo system..................................... 7 Accelerated ageing test ............................. 65 Air cooler .................................................... 5 Air-conditioner .......................................... 23 Air-cooled sealer........................................ 47 Ammonia liquid chiller .............................. 10 Animal feed technology ............................ 13 APFC panel................................................ 23 AS-interface system ................................... 25 Auto-control accessories.............................. 7 Automatic 6H seamer................................ 84 Automatic scrubber drier........................... 19 Automation................................................. 7 Automation & storage system ................... 25 Banking services................................... 27 Batteries .................................................... 87 Belt coater................................................. 83 Biodiesel .................................................... 65 Blender and mixer ..................................... 85 Boiling/stirring machine ............................. 85 Brake pads ................................................ 87 Brewing..................................................... 13 Bulk milk cooler......................................... 10 Butterfly valve............................................ 10 Cables ................................................... 25 Cables handling & processing system ........ 25 Capacitive and magnetic sensor ................ 25 Carpet cleaning machine ........................... 19 Centrifugal monoblock system................... 85 Chocolate suction pad............................... 76 Chocolate/cocoa machine.......................... 13 Cleaning section equipment ...................... 13 Clutch plates & cover assemblies ............... 87 Colour masterbatch ................................... 35 Colour sorting system................................ 13 Compositional & trace metal analysis ........ 65 Computer numerical control system ............ 7 Confectionery machine .............................. 83 Connector accessories................................ 25 Continuous food emulsifier ....................... 76 Conveyor belt ............................................ 77 Counters & power supplies.......................... 3 Crimp contact & tools ............................... 25 Custom-made cable................................... 25 Cutter/slicer ............................................... 85 Dairy machinery ................................... 10 Data cable................................................. 25 Dehydration equipment............................. 85 Detector ...................................................... 7 Diesel-fuel ................................................. 65 Digital colour mark sensor......................... 77 Distribution transformer ............................ 23 Door.......................................................... 82 Drawer magnet ......................................... 78 Drum sieve machine .................................. 84 Dust control door...................................... 82 Electromagnetic feeder........................ 78 Encoder....................................................... 3 Energy-saving product.............................. BIC Evaporating units ........................................ 5 Exhibition - ASSOCHAMâ&#x20AC;&#x2122;s International ........ Exhibition - Engineering Expo.................... 39 Exhibition - FI India 2011 ............................ 8 Exhibition - FoodPro 2011......................... 53 Exhibition - India Foodex 2011.................. 69 Extruded product ...................................... 13 Factory automation ............................ FIC Failure analysis .......................................... 65 Filler compositional analysis....................... 65 Filter....................................................... 6,81

Sl. No. 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140

Product

Pg. No.

Filters ........................................................ 87 Filtration net.............................................. 81 Filtration separation solution ....................... 6 Filtration system ........................................ 81 Financial services ....................................... 27 Fish processing system .............................. 85 Flexible transparent PVC strip door............ 82 Flour milling system .................................. 13 Food forming machine .............................. 85 Food processing line.................................. 85 Food Summit ............................................ 57 Forced convection unit air cooler ................ 5 Fruit ripening machine .............................. 21 Gas chromatographer mass spectrometer ..... 15 Gases ........................................................ 65 Gasoline systems ....................................... 87 Gear oil ..................................................... 65 Gear pumps .............................................. 87 Grain handling system............................... 13 Grill magnet .............................................. 78 Grinding & dispersion system .................... 13 Gyratory screen ......................................... 78 Ham processing machine..................... 85 Heat resistant door.................................... 82 High pressure cleaner ................................ 19 Homogeniser ............................................. 78 Hopper magnet......................................... 78 Horns ........................................................ 87 Ice cream making plant ....................... 84 Identification system.................................. 25 Induction sealing....................................... 47 Inductive sensor ........................................ 25 Industrial auctioneers & valuers ................. 77 Industrial business solution........................ BC Industrial connector................................... 25 Industrial control & sensing devices............. 3 Industrial door........................................... 82 Ink adhesion.............................................. 47 Instrumentation made cable...................... 25 Invertor/variable frequency drives................. 3 Isolation transformer ................................. 23 Label adhesion ..................................... 47 Level controller ............................................ 3 Lighting..................................................... 87 Lined carton machine ................................ 83 Lubes (engine oil) ...................................... 65 Lubricants.................................................. 87 Magnetic equipment ........................... 78 Magnetic plate .......................................... 78 Magnetic trap ........................................... 78 Material identificaton ................................ 65 Measuring & monitoring relay .................... 3 Meat ball forming machine ....................... 85 Meat processing machine.......................... 85 Metallography ........................................... 65 Mini non-nozzle vacuum sealer ................. 76 Mixing processing equipment.................... 85 Motion control ............................................ 3 Nano crushing machine ....................... 85 Oil milling............................................. 13 Online B2B marketplace ........................ 9, 86 On-line digital printing technology ............ 81 Pasta making machine......................... 13 Petrol & fuel oil ......................................... 65 Photo electric sensor ............................. 3, 25 Piston pump................................................ 4 Plastic pellet .............................................. 13 Plate heat exchanger ................................. 10 Plug valve.................................................. 10 Pneumatic valve......................................... 10

Sl. No. 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208

Product

Pg. No.

Polymer characterisation............................ 65 Polynet ...................................................... 81 Power saver system ................................... 23 Process tank .............................................. 10 Programmable logic controller..................... 3 Programmable terminal ............................... 3 Protective-conduit system .......................... 25 Proximity sensor .......................................... 3 Pulveriser ................................................... 82 Pump .......................................................... 7 PVC strip door........................................... 82 Rail tanker ............................................ 10 Rare earth tube ......................................... 78 Refrigerant pump ...................................... 10 Refrigeration.............................................. 10 RFID ............................................................ 3 Rice milling equipment.............................. 13 Rotary encoder .......................................... 25 Rotary gear................................................ 85 Rotary lobe pump ..................................... 85 Safety door .......................................... 82 Safety light curtain ...................................... 3 Sanitary centrifugal system ........................ 85 Sauanng making machine ......................... 85 Screw compressor ..................................... 10 Screw pump.............................................. 85 Sealer ........................................................ 47 Self-adhesive tapes .................................... 81 Self-priming monoblock ............................ 85 Sensor ....................................................... 25 Servo stabiliser ......................................... 23 Single disc machine................................... 19 SME finance .............................................. 27 Spark plug................................................. 87 Spiral cable................................................ 25 Starter motor ............................................ 87 Submersible system ................................... 85 Surface treatment system .......................... 47 Sweeper .................................................... 19 Switching relay ............................................ 3 Tanks & silos ........................................ 10 Telecom system ......................................... 23 Temperature controller ................................ 3 Testing ...................................................... 65 Thermal processes ..................................... 13 Three-deck pre-cleaner .............................. 82 Timer........................................................... 3 TPU masterbatch ....................................... 35 Trade show organiser ................................ 78 Transmission fluid...................................... 65 Triplex plunger .......................................... 85 Tube heat exchanger ................................... 4 Turnkey project ......................................... 23 Ultrasonic sensor.................................. 25 Unit air cooler ............................................. 5 Universal type unit air cooler....................... 5 UPS ........................................................... 23 Vacuum cleaner ................................... 19 Vacuum packing machine ......................... 76 Ventilator .................................................. 81 Vertical inline pump .................................. 85 Vibration motor......................................... 78 Vision sensor ............................................... 3 Vision sensor and industrial ID reader ....... 17 Vision software ......................................... 17 Vision system ............................................ 17 Volumetric cup feeder system ................... 82 Water purification system ................... 84

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

Modern Food Processing | June 2011

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A.M.P. Rose

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FX Multitech Pvt Ltd

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Misumi India Pvt Ltd 19

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CII

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Modern Food Processing | June 2011

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