Also lso so av ava a aila ilab able le i n S Sri Lanka, Lanka a, Ma allaysi a a, Singapore po , Thaila and, nd Taiwan, China & Ho ong Kong
EDITORIAL
White Revolution 2.0!
D
airy is one of the sectors where India not only has a big advantage now, but this trend can continue in the foreseeable future as well. The underlying presumption here is that the sector gets its act together both locally and globally. To put it in perspective, a study conducted by Associated Chambers of Commerce and Industry of India (ASSOCHAM) last year projects the Indian dairy sector to be worth ` 5 lakh crore by 2015 with milk output of 190 million tonne by then. At present, the sector, as the world’s largest milk producer, accounts for nearly one-fifth of global milk production with a double-digit growth rate per annum. That said, there lies significant scope for further growth of the Indian dairy sector considering the growing economic prosperity in the country as well as the recent regionspecific trends in global dairy trade towards cheese and milk powder. In fact, according to a recent research by Tetra Pak, there will be a need for 10 billion litre of more packaged milk globally during 2011 to 2014, thanks to the demand from the bottom of the pyramid populace. This itself calls for revisiiting all the for fodder aspects of the dairy value chain right from the land required fo to the right packaging options and retailing logistics of milk andd milkbased products. Besides, there is immense scope for broadening the milk-baased products basket in the time to come. The list includes varieties of cheese, milkshakes, sweets, milk and fruit-based beverages, amon ng others. Not to mention milk proteins that are seeing increasin ng demand for replacing animal and vegetable proteins in speciaa l bakery products and instant foods. Perhaps, the time for thee Second White Revolution in the country is now!
Editorial Advisory Board
While India on one hand has the distinction of producing the cheapest raw milk in the world, its dairy products figure on the diametrically other side of cost range! The reasons – quite predictably so – are fragmented scale of operation, high wastage, deficient cold chain, poor product mix and lack of adequate investment in research and development, etc. Hence, the writing is on the wall. There was never a more opportune time to fortify the dairy processing sector right from the farm gate to the food plate. It remains to be seen how soon the dream m of India becoming the dairy basket of the world can be realised..
Dr A S Abhiraman Former Executive Director - Research, Hindustan Lever Ltd
Prof M Y Kamat Former Head, Food Engg & Technology Dept, UICT, Mumbai
Manas R Bastia manas@infomedia18.in
June 2012 | Modern Food Processing
5 5
Insight & Outlook: Filling & Sealing Technology Filling & sealing equipmentt .............................................. 44 Novel sealing processes....................................................... 46 Caps and closures ............................................................... 48 Interface - Dr Guenther Burkhard, VP Sales - Business Unit Liquid Food, Bosch Packaging Technology.................. y 50 Interface - Kerstin Bernhart, Marketing Manager, Mettler-Toledo Garvens .................................................... 52
26 Cover illustration: Chaitanya Dinesh Surpur
Roundtable .......................................................................... 54 PET containerr .................................................................... 56
Special Focus: Dairy Processing
Automation Trends
Dairy processing ................................................................ 26
Dairy industry : Enriching production through operational excellence ........................................... 58
Dairy market....................................................................... t 28 Dairy packaging.................................................................. 32 Probiotic foods .................................................................... 34 Interface - Pradeep Chona, Managing Director, Havmor Ice Cream Ltd ...................................................... 36 Roundtable .......................................................................... 38
Energy Management Ultrasonic sealing: The green seal of energy efficiencyy ................................................................. 62
Policies & Regulations National Mission on Food Processing: A vision to prosperity through value-addition ................................. 64
Strategy Marketing communication: How to make a brand truly national? ........................................................ 66
In Conversation With
Tips & Tricks Dr Franco Gornati, Managing Director & CEO, 22 FNC SpA Group .................................
Dehumidifier: Tips to maintain moisture during processing................................................................ g 68
Event Preview PackPlus South 2012: A knowledge platform to inspire innovative packaging solutions........................... 74
Event Report
Facility Visit: GCMMF Ltd Milking success through quality approach ........................ 40
Regular Sections Editoriall ............................................................................ 5 News, Views & Analysis .................................................. 10 Technology & Innovation ................................................ 18 Technology Transferr ........................................................ 21 Projects ............................................................................ 70 Event Listt ........................................................................ 72 Book Review.................................................................... w 76 Products .......................................................................... 78 List of Products .............................................................. 96 List of Advertisers .......................................................... 98
Food & Bev Tech 2012: A technology forum to exchange novel business ideas ............................................ 75
Highlights of Next Edition Special Focus: Plant Safety & Maintenance Insight & Outlook: Edible Oils & Fats
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Note: ` stands for Indian rupee, e, $ stands sta for US dollar and ÂŁ stands for UK pound, unless mentioned otherwise June 2012 | Modern Food Processing
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June 2012 | Modern Food Processing
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NEWS, VIEWS & ANALYSIS
FOOD SAFET Y POLICIES & REGULATIONS
MoFPI contemplates to transfer four schemes to state governments The Central Government is contemplating to transfer four schemes to state governments, which are hitherto under the purview of the Union Ministry of Food Processing Industries. The four schemes include promotion, human resource development, non-horticultural cold chain and technology upgradation. “We have not transferred formally yet any scheme but the proposals are there to transfer them. We have issued approval for the state government to undertake the preparatory steps,” said Rakesh Kacker, Secretary, MoFPI, Government of India. The government has a scheme for promotion, which is being done by way of education through seminars or conferences. According to him, there are several ways to undertake skill development or support people, which is the aim of the second scheme. “It can be done either through shortterm training courses or other types of study courses in the food processing technology,” Kacker said. The third and fourth schemes respectively are nonhorticulture cold chain and technology upgradation. “We have already stopped receiving applications and are asking people to submit their applications to the state government. But the final approval will come during July-August 2012,” Kacker revealed. Prasenjit Chakraborty
FSSC 22000 certification to give boost to BERICAP India The Food Safety System Certification soft drinks for the necks 1810 and 1881 22000 (FSSC 22000) recently received by (where the closure SuperShortyy is used) but also for hot-filled products with the BERICAP India will give further boost to grow its business in the food closure diameter of 28 mm and beverages segment. “Food and 38 mm. safety certification has become The performance of the mandatory for suppliers to the company in India during FMCG companies in India. the last years has been increasing steadily. “If further Being the early bird to get this investments into the beverage certification is an advantage and non-beverage market are for BERICAP India as it would be considered as the made, BERICAP India will Jeevahan Ebenezer grow into a company with a only packaging supplier now turnover of about Euro 10 million. Future with the certification. Others are preparing for the same,” opined Jeevahan Ebenezer, investments are all related to lightweighting Managing Director, BERICAP India the closures even more to achieve better tamper evidence solutions and to produce Pvt Ltd, which produces closures for the beverage industry and other industries more consumer-friendly closures. Special such as pharma, lube oil, chemical and developments for India have been made, which will be launched within the next edible oil industry. In the beverage market, year,” added Ebenezer. BERICAP India supplies closures not Rakesh Rao only for the application on carbonated CONVENIENCE FOODS
High-end technology behind ACT II popcorn launch AgroTech Foods Ltd has launched a new line of Ready-to-Eat y to-Eat (RTE) ACT III popcorn, which is air popped to ensuree quality, crispiness and freshness. The product also provides health benefits as it is high in dietary fibre. Asheesh Sharma, Head-Marketing, AgroTech Foods Ltd, said, “Wee want to offer consumers healthier and convenient choicess within our portfolio and ACT II RTE popcorn is a step in that at direction. Consumers are looking for convenient snacks without ut compromising on quality or taste. ACT III fills a void for popcorn lovers looking for delicious, premium and wholesome popcorn at n an affordable price point.” RTE ACT III popcorn is is available in four flavours and priced at ` 5 for 10-gm pack. Mahua Roy
FOOD TESTING
State-of-the-art laboratory for food research and analysis launched in Kolkata
Edward Food Research and Analysis Centre Ltd (EFRAC), a state-of-the-art laboratory having the most advanced and
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Modern Food Processing | June 2012
high precision instrumentation set-up to do multi-parameter & multi-product testing in compliance with national & international standards, has been set up in Barasat, Kolkata. It aims at supporting government’s mission of ensuring food safety. With an investment of ` 35 crore, the project was completed in roughly one year and six months. Dr Balwinder Bajwa, CEO, EFRAC, said, “With
state-of-the art customised equipment, manpower, essential competent accreditations and infrastructure, this laboratory will cater to the R&D and analytical needs of sectors like food processing, beverage & juices, packaged drinking water, milk and milk products, spices, canned and frozen food, poultry, meat, fruit & vegetables, etc.” Avani Jain
NEWS, VIEWS & ANALYSIS
CONFECTIONERY AGRI-BUSINESS
Portebello mushroom gaining popularity in India Portebello mushroom basically used in Italian cuisine is slowly becoming popular in India. “We are the first to launch Portebello mushroom in India around eight months ago. It has all the features (high in protein, fibre etc) like in regular mushrooms. The advantage of the mushroom is its size, which helps in stuffing,” said Ajeeta Shivdasani, Manager-Sales, Fresh Products, Weikfield Foods Pvt Ltd. Consumers are gradually showing interest for the product. Currently, Portebello mushroom is available in Maharashtra and Bengaluru. “We are getting good response from the customers. Currently, it has been retailed through few malls. Many five star hotels are buying the product from us,” said Shivdasani. Talking on the promotional exercise, she said that giving samples to reputed hotels and participating in exhibitions etc are the ways to promote it. “We are getting encouraging response from consumers and will expand the business to other states,” she said. At present the production of Portebello mushroom is 50 kilo per day and price of the product is ` 40 a packet. Prasenjit Chakraborty
Mad Over Donuts optimistic about Bites range Mad Over Donuts recently launched Bites, miniature donuts in multiple flavours assembled in a gift box. “We have always focussed on delivering the best product in taste, quality and experience. Our gourmet, eggless donuts are an affordable indulgence. As an extended version, we decided to evolvee the gifting concept witth a beautifully designed sleek and stylish box of 18 bite-sized donuts. They ey are an excellent option for gifting vis-à-vis the traditional sweets or chocolate boxes. The exciting combination of fruits, coffee, nuts and chocolate makes it all the more desirable,” said Tarak Bhattacharya, COO, Mad Over Donuts.
Mad Over Donuts has created a niche for itself in the F&B segment, being the first concept of its kind to enter India from Singapore. “Our recipe has been developed by a team of world develo renoowned F&B specialists. Th he product development teeam has over 150 years oof combined bakery eexperience and has in nvested a significant am mount of time on trials for perfecting a tri recipe for the perfect eggless donut,” said Bhattacharya. The brand currently operates at 33 stores across the country. The year 2011 saw the maximum growth with 16 new stores. Mahua Roy
DAIRY PRODUCTS
BLOCKBUSTER range of ice creams by Havmor Havmor has launched BLOCKBUSTER range of ice cream candies. Made using world-class technology, these candies are available in four variants – Almond Mocha, Cookie Cream, Mango Magicc and Classic Vanilla. Made using specially imported plant and machinery, it has rich ice cream within a delicious crust. Further, the company has launched these ice cream candies in Gujarat, Maharashtra and Rajasthan. Pradeep Chona, Managing Director, Havmor Ice Cream Ltd, said “Our customers expect unique products from us and BLOCKBUSTER will truly exceed their expectations on every count – size, taste, consistency.” Avani Jain
FOOD PROCESSING MACHINERY
HRS Process’ new dicing machine enhances quality and hygiene HRS Process Systems Ltd (HRS PSL), part of HRS Group, UK, recently launched HRS ParaDice, designed specifically for value-added processing in the food sector. “We launched HRS ParaDicee processing solutions for processing products in a way, never been witnessed in India ever before,” claimed V Gokuldas, Managing Director, HRS Process Systems Ltd. In the last ten years, the food processing industry has witnessed many changes. “But if you look at value addition, it was not much in food. Now with this, processors have scope to add value. They can introduce a product
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Modern Food Processing | June 2012
according to the need of the market and that too in a more efficient way than ever before,” he said. Most hotels and catering companies now require dice products. They need to buy raw fruits, store and then get it cut into pieces, pack it and send it. In the whole process, they are not sure how long it lasts because everything is done in wrap-in condition. Touch by hand affects quality and hygiene aspects of the product. “This equipment totally processes without the use of hand right up to packaging and filling of product,” claimed Gokuldas. There are
many advantages of HRS ParaDice. In most of the cities and towns, waste disposal poses a problem, and this machine can solve the problem to a large extent. “This machine accumulates all the waste in one place due to which one can convert the waste into biodegradable products. Most of the vegetable waste can be converted into biogas. This offers added revenue to the factory,” he points out. HRS ParaDicee can process diced fruits, vegetables and similar food products to cater to their requirement in various application areas like fruit bases & toppings, fruit pulp drinks, ice creams, soups, jams, among others. Prasenjit Chakraborty
NEWS, VIEWS & ANALYSIS
SUSTAINABLE PACKAGING PACKAGED FOOD
McCain Foods unveils packaged South Indian cuisine McCain Foods India Pvt Ltd has launched a new product for the Indian market – McCain Idli Sambar Combo Pack. It offers twin benefits of convenience and nutrition. Made from rice and lentils, the product is free from preservatives and can be prepared in 3-5 minutes flat, claimed the company. With its multiple cooking options, McCain Idli Sambarr is microwaveable or can be cooked on a stove top. It will be sold in a 360-gm pack, which will be priced at ` 60 only. The product is available at leading frozen food retail outlets and modern kiranaa stores across Delhi-NCR and Mumbai. With this launch, the company aims to cater to the food basket of homemakers, working women and consumers who are on the lookout for convenient snacking solutions, without compromising on taste and nutrition. Ritu Mukherji, Marketing Manager, McCain Foods India, said, “The USP of McCain Idli Sambar Combo Pack is that for the first time rice idlis and sambar are available in one pack and the preparation time is only 3 minutes in the microwave. Untouched by human hands, the product is wholly indigenous and manufactured at our facility in Mehsana, Gujarat.” Avani Jain
AIGMF conducts LCA on glass packaging With its aim to project the green image optimistic that our client organisations will have more clarity on the distinct of glass among user-industries including advantages of glass over other packaging food & beverages (F&B), the All India Glass Manufacturers’ mediums and will be in a Federation (AIGMF) better position in taking recently launched the first an informed decision as far ever ISO 14040/44 compliant as choosing a packaging medium is concerned,” stated and independently reviewed Mukul Somany, President, cradle-to-cradle Life Cycle AIGMF, and Vice Chairman Analysis (LCA) study on glass packaging in India. It and Managing Director, has been commissioned by Hindusthan National Glass. Mukul Somany The glass packaging AIGMF and executed by PE Sustainability India, subsidiary of PE industry, valued at about ` 6,000 crore, is driven primarily by user-industries International AG, Germany. “We have taken a collective decision such as liquor, F&B, pharmaceuticals, to refer to the insights of this study cosmetics and perfumery etc. The liquor and chart out our individual initiatives segment is the major consumer of glass packaging contributing up to 55 per towards implementing each of the recommendations made in order to cent of the total revenue of the overall promote the green aspect of glass among container glass industry in India. Rakesh Rao our clients, ie the user-industries. We are FROZEN FOODS
Vadilal launches Ice Trooperr range of frozen desserts Vadilal Industries Ltd, India’s leading ice cream and frozen dessert player, has come out with a completely new range of products r targeted at the kids’ category under the umbrella brand Ice Trooper, the mascot for this new segment. It has introduced five products with indigenous shapes and flavours, namely Double Strikee in choco cream flavour, Jelly Peell in banana & strawberry flavour, Smiley Launcherr in pineapple & tamarind flavour, Thunder Stickk in bubble gum & black currant flavour and White Knightt in white chocolate & strawberry flavour under this brand. The products that fall in the price range of ` 15 and ` 35mainly target kids in the age group of 7 to 13 years. Devanshu Gandhi, Managing Director, Vadilal Industries Ltd, noted, “We at Vadilal are constantly striving to delight our consumers with innovative products, and this product launch is an example of that. Further, we have created a mascot to add to the fun/cheer factor to the brand. Ice Trooper is likeable personality whom the kids would love to relate to.” Avani Jain
FOOD PACKAGING
ITW India launches labelling applicator ITW India Ltd recently launched labelling applicator machine for secondary packaging. According to Jayant D Bagel, Product Manager, Labelling Solution, ITW India Ltd, the food industry will benefit from this machine. “For the food industry, there is need for real-
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Modern Food Processing | June 2012
time data such as, when the product was manufactured and packed. This dynamic data is produced through this machine and applied to the product. With this, we can easily manage last in-first out and first in-first out kind of inventory pertaining to the food. Besides, this machine is helpful
to print the barcode and 2D barcode for tracking and tracing,” he said. The machine can be customised according to the need of customers. “Batch number, manufacturing and expiry dates can be printed online,” said Bagul. The cost of the machine is between ` 8-12 lakh depending on the application, he added. Prasenjit Chakraborty
NEWS, VIEWS & ANALYSIS
FOOD ANALYSIS EXOTIC FRUIT
Authentic kiwi from New Zealand now launched in India Zespri International (Asia) launched the Zespri Green Kiwifruit in India, which is claimed to be freshly harvested from orchards of New Zealand. The hi-fibre content kiwifruit will be available this season till November. As per the company, given the high water content of the kiwifruit, they make for an ideal ‘summer fruit’. Studies reveal that Zespri Green Kiwifruit is a powerful source of vitamin C having twice the content of vitamin C found in oranges. This is especially a boon for Indians during summers since Vitamin C helps prevent heat exhaustion and improves heat tolerance significantly. Judy Lee, Marketing Manager - Southeast/South Asia, Zespri, said, “We are happy to launch the New Zealand kiwifruit in India this May when the mercury levels are rising. These juicy fruits are now at their optimal ripeness and ready for consumption. Availability of the highly nutritious Zespri Green Kiwifruit is good news, especially for the health-conscious Indians who invest in health foods for their well-being.”
Mettler Toledo and Konica Minolta form a strategic partnership Mettler Toledo and Konica Minolta Sensing Europe BV have decided to join forces with a strategic partnership by adding colour measurement solutions to density, refractive index and pH measurement to offer a dedicated automatic multiparameter analysis system for the food and flavours & fragrances industry. The partnership will bundle the CM-55 or CR-5 spectrophotometer from Konica Minolta with the density, refractive index and pH instruments from Mettler Toledo to provide a complete system for automatic quality monitoring of raw materials and finished goods. “Benefit of this partnership includes efficient quality control of several parameters such as incoming goods
Mettler Toledo and Konica Minolta partnership to offer a dedicated automatic multi-parameter analysis system
inspection of food ingredients (flavours, colours and simultaneous measurement of specific gravity, refractive index and colour) and QC of transparent & liquid food (such as clear juices, vegetable oil etc) are required,” said a Mettler Toledo spokesperson.
CSR EFFORTS
Tata Chemicals organises free blood pressure check-up camps On the occasion of World Hypertension Day, Tata Chemicals, the maker of Tata Salt, organised a ‘hypertension awareness’ drive in various parts of the country wherein more than 4,000 people actively participated. In Mumbai, the company conducted free blood pressure check-up camps and recreational activities to bring the urban community’s attention towards hypertension. Ashwini Hiran, COO – Consumer Product Business, Tata Chemicals, said “In these stressful times, it is highly recommended to sensitise families about the problems pertaining to lifestyle diseases like hypertension, diabetes etc. Tata Salt Litee is aimed at families, which seek preventive measures to manage blood pressure through a low sodium intake in their diet.”
RTC FOODS
BIOTECHNOLOGY
Godrej Real Good Yummiez launches Chicken Kabab Platter
Chr. Hansen launches cultures for yoghurt
Godrej Tyson announced the launch of Chickenn Kabab Platterr under its fastest growingg brand Real Good Yummiez. The platter has been launched in three flavours – Lucknowi Seekh Kabab, Punjabi Tikka and Awadhi Shami Kabab, in packs of 200 gm. Sushil Sawant, Associate Vice President – India Operations, Godrej Tyson Foods Ltd, said, “Food is always at the centre of all our joy. In this fast-paced life today, people look forward to spending quality time together and Godrej Yummiez enables our consumers to flip up a perfect recipe anytime.” Priced at ` 299 for 600-gm pack, the Chicken Kabab Platterr is available at all leading stores across the country.
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Modern Food Processing | June 2012
Chr. Hansen recently launched probiotic cultures for yoghurts. Going with the global trend wherein the international appetite for Greek style yoghurt has exploded, these cultures have been launched strategically. The success of this variant is so pronounced that the market research company Zenith International believes it will increase global yoghurt consumption by 4.5 per cent in 2012. Well in line with the booming popularity, Chr. Hansen has introduced a new series ® and probiotic nu-trish® ® cultures perfectly of powerful YoFlex® suited for Greek style yoghurt. The new portfolio of seven cultures – three of them with the well-documented BB-12® ® probiotic strains for improved gut health – enables dairies worldwide to deliver on four mega consumer trends at the same time: exquisite taste, healthy, 100 per cent natural and Greek.
TECHNOLOGY & INNOVATION
CK Checkweigher enhances flexibility and user interface Mettler-Toledo Garvens has equipped its CK Checkweigherr with new software and a new Human Machine Interface (HMI) to simplify operator use and provide greater flexibility for food and beverage manufacturing lines in Asia. The new HMI is easier to navigate for production line operators and facilitates product changeovers for enhanced efficiency. Ideal for heavy loads after final packaging, the CK Checkweigher’s r sensitive weighing capabilities and high throughput speeds enable small to medium size manufacturers to automate food & beverage production while
New powder blending technology provides flexibility and safety Blendhub has introduced powder blending technology that provides a dedicated portable, flexible, safe, turnkey and modular solution adapted to specific need. The solution enables easy project execution and implementation, both during the project and also during installation & commissioning. The powder blending technology unit has been designed for real-time optimisation allowing one to benefit from a vision that already has considered most of the opportunities and challenges in handling of powders. Entering business decisions requires careful planning in all aspects such as financial, operational as well as strategic. The powder blending technology solution benchmarks business drivers, applies process and technology in a modern and efficient way to ensure food safety in all aspects. Whether a businessman is revising actual business strategy, making new investment proposals, evaluating entrance into new markets or products, trying to solve custom tariff barriers, optimising financial model and tax payments or simply reviewing ways of improving general profitability, it will meet his requirements. Project management and execution has the objective to merge customer expectations with supplier promises. This scope requires a true understanding and commitment to ensure a win-win situation for both parties during the entire process. Otherwise project is delayed or at worst, does not meet the standards, which are agreed upon. The problems of unclear scope and responsibility often lead to difficult customer-supplier relationships. The powder blending technology has combined innovative engineering to ensure a competitive, complete and ready to plug & produce solution to match time-tomarket requirements.
Arla Foods’ functional milk proteins can cut salt in cheese by 65 per cent
enhancing regulatory compliance. The machine’s new HMI terminal features a bright, multi-line Vacuum Fluorescent Display (VFD), making it easier to read. The upgraded terminal now offers five soft keys to simplify use of the software; each key can be programmed as a shortcut to one of 25 product memories. The addition of enhanced three-level password protection and configurable error logging provide added security and facilitate due diligence. The advanced CK Checkweigher can accurately weigh up to 80 packs per minute with a maximum load of 100 kg. Compact footprint makes the CK Checkweigher easy to install and use for operations with limited space.
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Modern Food Processing | June 2012
Arla Foods Ingredients has developed a range of functional milk proteins that make it possible for food manufacturers to slash the salt content in their processed cheese products by up to 65 per cent. The Nutrilac® ® proteins offer excellent emulsification properties, which mean they can replace the emulsifying salts normally used to achieve a stable texture in spreadable, block and sliceable processed cheese, as well as cheese sauce products. This results in a dramatic reduction of sodium levels in the end-product – to the tune of anything between 50 per cent and 65 per cent. The proteins also eliminate the need for creaming – speeding up processing times by as much as an hour. In addition, they offer fat simulation properties, helping manufacturers to produce high-quality processed cheese products that are not just lower in salt but in fat, too. The range comprises Nutrilac® CH-65400 for spreadable processed cheese and cheese sauces; and Nutrilac® CH-66088 for block and sliceable products. Claus Andersen, Application Group Manager - Cheese, Arla Foods Ingredients, said, “Nutrilac® functional milk proteins are the perfect solution for any processed cheese maker that is looking to improve the nutritional profile of their products by reducing salt without impacting negatively on consumer acceptability. Coupled with the potential to reduce fat levels, they offer a superb opportunity to create better-for-you processed cheese products that do not compromise on taste.”
TECHNOLOGY & INNOVATION
BERICAP offers lightweight neck closure for packaged water Blue Waters, a reputed packaged water player in Trinidad, has adopted BERICAP’s DoubleSeal SuperShorty® ® closure. By adopting BERICAP ’s products, weight of closure in water bottle could be reduced to 40 per cent. As the market in general moves to the PCO 1881 neck, Blue Waters also followed this trend and converted to the lightweight neck using closures from BERICAP for the sizes above 0.65l. It used the DoubleSeal SuperShorty® Still, l saving up to 40 per cent of weight compared to the previous closure types and necks. BERICAP’s new 28 mm pushpull closure for PCO 1881 allowed to lightweight the smaller packages for on-the-go as well, still providing the same consumer convenience and safety as before. For their 6l and 8l containers, Blue Waters is using BERICAP’s SK 38/15 S 3T MO closure for sealing, but still providing consumer-friendly opening torques. Lately, Blue Waters became Pepsi co-packer for Trinidad and Barbados in association with Cabcorp, the anchor Pepsi bottler in Central America, Ecuador, Puerto Rico and Jamaica. Again, Blue Waters selected BERICAP DoubleSeal SuperShorty® CSD closures for its carbonated beverage range after a successful test at a Pepsico-appointed independent lab in Mexico. Also, the new lightweight closures from BERICAP support Blue Waters’ efforts to produce on a reduced cost base in their 20,000 sq m bottling plant in Trinidad.
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Modern Food Processing | June 2012
DCN can crushers can fit six times more cans The air operated can crusher from D C Norris & Company Ltd (DCN) reduces the size of cans by up to 85 per cent enabling customers to fit six times more cans in their recycling bins. Increasing the quantity and weight of the waste provides customers with a means to sell the scrap metal instead of facing increased costs to have it disposed. The latest model to join the DCN product range is suitable for a wide variety of can sizes, both large and small including the ubiquitous A10 size. The high performance crusher can get through up to ten cans per minute resulting in great savings in time and costs. The empty can is placed in the chamber before the lid is closed, an operator then presses the button; the can is crushed and falls into the waste bin. Thus, the entire process is simplified. This precision machined crusher offers great features for operators, reducing health and safety risks with a chamber cover, which must be closed prior to activation. The stainless steel design sits on a tabletop or counter, and can be wiped down easily after use. The Model 990 0 can crusher is manufactured in the UK and ideal for any food production environment.
Bosch’s flexible pouches provide application from retail to food service SurePOUCH H (reclosable, flexible pouches), developed by Bosch Packaging Technology, has a wide range of applications from retail to food service. The packs are filled on the new SurePOUCH H clean-fill machine series (SPC), roll-fed vertical form, fill and seal (VFFS) machines with a small footprint of six sq m. The pouch formats ‘retail’ for retail sales and ‘food service’ range in filling volume sizes from 100 ml to 5 litre. The SPC can produce four different pouch formats. The formats EZPouch, EZGable and EZSquare offer flexible applications for retail. For food service, the EZPillow can hold up to 20 litre, allowing for easy and quick refilling. All formats are produced, filled and sealed with the same machine. This enhances flexibility for the manufacturer since it allows the user to expand the product portfolio without fundamentally converting the production line. Clean-filled applications for the SurePOUCH H include non-carbonated beverages and water, dairy products, concentrates, soups, sauces and dressings. The SurePOUCH H system is capable of filling viscous liquids up to 25,000 centipoises as well as particulates up to 25 mm in diameter while protecting particulate integrity. The machine can also handle dry bulk goods, such as flakes, powders, rice or coffee. The new vertical form, fill and seal machine is capable of filling a variety of products, achieving hygiene standards up to ultra clean-fill. SurePOUCH packs are also fitted with reclosable spouts, which are ultrasonically welded to the exterior of the pouch and can be positioned in various locations. They provide an enhanced hygienic feature as the product is filled directly into the pouch and not through the spout. The closure only comes in contact with the product when the consumer opens the package. The spouts are available in sizes of 10, 20 and 30 mm. Bosch also provides customised options for food service. Alternatively, drinking straws or simple tear-notches can be added to the SurePOUCH H pack styles. For the food service sector, adjusting extra handles to the upper seam simplifies lifting and dosing when pouring.
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 ‘three-in-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
technology to manufacture chitin and chitosan - important byproducts from the shell of shellfishes. Chitin is the most important organic constituent of the exoskeletal material of invertebrates and the important economical source of this material is the shrimp processing industry. Areas of application Industries such as food processing, biotechnology, pharmacy and medicine Forms of transfer Consultancy, technology licensing
Chitin and chitosan
Retort pouch technology
An
Indian
company
is
offering
An
India-based
company
offers
technology for ready-to-serve fish curry in retortable pouch. The technology provides a method for preparing the ready-to-serve fish curry in retortable pouch with excellent storage stability and quality with a shelflife of more than one year at ambient temperature. The thermal processing conditions have been standardised for this product in order to make it safe for consumers. Areas of application Food, meat, fish processing Forms of transfer Consultancy, technical services, technology licensing
TECHNOLOGY REQUESTED Coconut milk beverage 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
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
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.
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. Areas of application Food processing 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.
Share and Solicit Technology The mission of Modern Food Processingg is to spread the technology culture. Here is an opportunity to be a part of this endeavour by sending your technology on offer or technology requirements. If you belong to any of these two categories, you are invited to furnish the techno-commercial details for publication. The write-up needs to be as per the format of this section with information about the particular technology offered or requested, its areas of application and forms of transfer. Contact us: 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 l Fax: 022-3003 4499 l Email: spedit@infomedia18.in
June 2012 | Modern Food Processing
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IN CONVERSATION WITH Dr Franco Gornati
With the g growth of processed p food segment, g how is the demand for fill and seal machinery in India? With the type of growth curves that Indian food processing sector is witnessing, it is clear that there will be a good demand for high-quality packaging machines, which can add greater value to packed products. In the last decade, we saw the Indian market graduating from basic packaging machinery requirements
talking about niche packaging machinery requirements. Now, the Indian customers would like to have the popular formats of the developed countries like Modified Atmospheric Packaging (MAP), vacuum packaging, etc. Such special packaging formats have a direct co-relation to the product’s shelf-life, aesthetic look of the final pack etc. Niche packaging will play a special role in the retail space, since there is tremendous competition among the branded products.
So far, in yyour jjourneyy in India, what was the most challenging g g task? How did you overcome it? No doubt, the Indian market is huge, but there are many challenges to overcome. Fragmented market is a huge challenge. We find existence of different markets in one segment; market is price–sensitive; and foreign technology today is still looked with suspicion, among others. But to overcome these challenges, we are gearing up and staying as close as possible to the markets &
We are highly bullish on Indian market for future growth … says Dr Franco Gornati, Managing Director & CEO, FNC SpA Group. He has more than 40 years of expertise in niche thermoform fill seal machinery technology domain. Prasenjit Chakraborty caught up with Dr Gornati during his recent visit to India to learn about the opportunities Indian market offers; and the solutions offered by FNC Veripack to the food and beverage sector. to value-added niche packaging. Today, India has the eyes and ears of all the major packaging companies in the world who are willing to understand the intricacies of the product and specific packaging process required. It is the endeavour of our Indian subsidiary Veripack Solutions India to be close to the customers and understand their needs completely and provide the right solution accordingly.
What are the important p changes g yyou observed in fillingg and sealingg arena (mainlyy in Indian food processing sector)? As mentioned earlier, now India is on its highest growth curve in terms of the food processing sector. This is rightly indicated by the rise of the processed food sector from raw food exports, dubbing India as the ‘Food Factory of Asia’; the availability of educated working class in this industry, etc. Against this backdrop, the sector will obviously move from basic packaging to more mature packaging. We are now
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Modern Food Processing | June 2012
How has been the jjourneyy of FNC Veripack in Asia so far? The journey has been exciting and we are on the learning curve, understanding the markets, the ethnic products and processes. But in hindsight, the market has its complexities too and there are difficulties experienced by us. Understanding the requirements, processes, basic product characteristics has been a great learning for sure.
Which are the most exciting packaging p g g & processing p g technologies g you y introduced in the Indian market? Our Veripack Roll-stock Thermoform Fill Seal machines are catering to segments like frozen foods, ready meals and Indian ethnic snack foods. These machines as well as Veripack Tray Sealers will help Indian customers to stay at the top and have delightful customers in the supply chain end. Besides enhanced product shelf-life, they offer product integrity, high convenience factor, aesthetic appeal, best quality, valueadded packaging.
customers. We would like to be with them, understand them, and learn with them. By doing so, we will be able to provide right solutions that they require.
How important p is India in the overall business and your future plans here? We have started our Indian operations late last year with the opening of our 100 per cent subsidiary office Veripack Solutions India. Besides, we plan to set up couple of branch offices at key strategic centres in India to be inline with our mantra to be closer to customers. We have definite plans to start Veripack Technical Centre for demonstration of our machine throughout the year. This will be available for our customers to take trials and fully understand the technology. The Indian market is important for future growth of our group and we will continue to focus on this market. The markets in Europe and USA, which used to be big markets earlier for us, are now seeing a downfall phase. For future growth, we are highly bullish on Indian market. Email: prasenjit.chakraborty@infomedia18.in
Dr Franco Gornati
What is your success mantra? Customer focus, which is helping us move closer to our Indian customers.
How do you deal with tough situations? During tough times, we try to find the root cause of problems and work on this. Being an engineer myself, we are keen to have our bearings and fundamentals right.
Which is your favourite book?
The Remains of the Day by Kazuo Ishiguro. It portrays discipline and trust under extreme trying circumstances.
Your message for aspiring professionals... Be disciplined; never break trust; be honest to your self and the company where you work; admit mistakes; learn & move ahead.
Photo: Nikhil H Patel
Ju JJun June un u une ne 2 2012 01 012 0 12 | Modern 12 Mod Mo M od o d der errn ern e rn F Fo Food oo ood od dP Pr Pro Processing rro oces ce ce esssin ssin sing
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SPECIAL FOCUS
DAIRY PROCESSING DAIRY PROCESSING Packed with promising prospects .................................................. 26 DAIRY MARKET A new growth avenue for MNCs ................................................. 28 DAIRY PACKAGING Consumer-centric innovations for better acceptance .................... 32 PROBIOTIC FOODS Essential nutritional supplement for well-being........................... g 34 INTERFACE - Pradeep Chona, MD, Havmor Ice Cream Ltd “The market is leaning towards scoops with fusion and unusual flavours”..................................................................... 36 ROUNDTABLE Will National Dairy Plan help increase productivity? .................. 38
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Illustration: Chaitanya Dinesh Surpur
SPECIAL FOCUS Dairy processing
With the increasing demand for dairy products, it is time for the dairy sector to switch over to sophisticated technologies that address many issues right from volume, quality, wastage reduction to environmental concerns. Such technologies also help recover and reuse health beneficiary components from milk. Prasenjit Chakraborty
T
he Indian dairy sector has witnessed several changes be it in terms of milk production or dairy processing. The production of milk has increased manifold in the last few decades. In 1951, the production of milk in India was 17 million tonne (MT). Today, the figure stands at 115 million tonne. “It is estimated that in 2035, milk production will touch 230 million tonne. Currently, India’s share is 15 per cent of the total
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global milk production. The decade-wise rate of growth in milk production in India (3.6 per cent) is substantially higher than the world average of 1.5 per cent,” says Tapas Chatterjee, Managing Director, SSP Pvt Ltd. Certainly, these statistical figures highlight the future flow of milk in India to meet the demand of domestic as well as global consumers. However, certain problems exist in the dairy industry like lack of Good Hygienic Practice (GHP) in milk production, poor quality in terms of milk handling, inadequate provision of cold
chain, safe processing of dairy products etc. Chatterjee strongly believes that whatever the demerits in the field of milk production, it will not create any hassle to the booming of dairy processing industry. “With various ongoing government milk schemes, proper training and education about dairy processing from field to process plants by different institutions and organisations, awareness on nutritional quality and advanced process technology for dairy products, consumers are satisfied with the way the dairy sector is progressing,” he says.
Dairy processing
In the past, Indian consumer was only concerned about the purchasing price of milk and milk products, but nowadays quality matters to him/her. Therefore, while in the earlier decades, less than 10 per cent of total milk was processed through processing plants, now it has risen to 25-30 per cent. More than 70 per cent of milk is supplied to local sweet makers to produce various dairy products. However, they lack the knowledge of Good Manufacturing Practice (GMP). “Here the quality aspect of dairy products are neglected to prepare less costly milk products. Hence, modern technology and state-of-the-art process engineering become essential to maintain global quality and acceptability with economical process cost,” points out Chatterjee. Moreover, increase in volume necessitates sophisticated technology in dairy plants and products. “The volumes are growing and if the methods of processing and testing are not fool-proof, it could end up in major disasters or product recalls,” points out Jayant Shah, Managing Director, Shah Brothers.
Modernisation in progress In past few decades, the industry had witnessed changes in various process technologies for preparing milk and milk products. “During the 60s and 70s, milk powder was produced through drum dryer; but now the sector is adopting the latest technology of milk spray dryer to enhance the quality of milk powder,” says Chatterjee. Like production of milk powder, emerging technologies have revolutionised the dairy sector by increasing energy efficiency of processing plant and machinery. Earlier, during milk concentrating, it was a challenge to evaporate moisture from liquid milk by using less energy in the form of steam. “But now, the evaporation technology reaches its height where 7 kg of moisture can be evaporated by use of 1 kg live steam, thus reducing energy as well as processing cost,” he points out. In this direction, SSP has developed the world’s first evaporator that does not require any condenser. “This evolution in evaporator will save energy
and meet the other challenges too in the days to come,” claims Chatterjee. “Our Traditional Indian Dairy Products (TIDP) need to be mechanised to meet its process simulation works. Mechanisation of various TIDP will result in minimisation of process cost, enhancement in product quality and shelf-life,” says Chatterjee. National Dairy Research Institute plays a major role in establishing mechanisation process for various traditional dairy products like continuous khoaa making machine. State-of-the-art technology contributes significantly to better performance, flexibility and optimisation of raw material consumption as well as product quality. “Additionally, they enable faster production as well as save all types of resources, ie, labour, capital, energy, space and time,” points out Devendra Shah, Chairman, Parag Milk Foods Pvt Ltd. With the increasing population in India, the consumption of milk is likely to grow manifold in the next few years, so it is necessary to meet the demands and this could be achieved by adoption of sophisticated technology. According to Devendra Shah, today Indian dairy industry is moving towards adoption of state-of-the-art technology as it helps in boosting production. “Our dairy plants are of international standards, fully automated and equipped with the best European technology. Right from reception of milk to the finished products, we maintain strict no-human contact through the entire manufacturing process,” he says. The Manchar plant of Parag Milk Foods Pvt Ltd churns out 1,000,000 litre of milk per day, and has an output capacity up to 10 MT of butter, 25 MT of ghee, 10 MT of dahii (yoghurt) and 65 MT of milk powder.
How to minimise wastage? Dairy waste is one of the main causes for increasing pollution of air and water; and it also affects the processing cost of the product. In the recent times, the adoption of various sophisticated technology enables to reduce milk powder emission in open air. After incorporating cyclone separator, bag filter, the emission can be reduced up to marginal level, which not only stops
polluting the surrounding air but also saves processing cost. Besides the manufacturing of milk powder, wastage happens in milk processing floor during Clean in Place (CIP) process and draining the paneer/cheese r whey. These drained products create high value of Chemical Oxygen Demand (COD) and Biological Oxygen Demand (BOD). “Latest technology for automated sensing CIP circuit helps to minimise the usage of raw water and chemical compounds to clean all milk processing units. Paneer/ r cheese whey can be reutilised for producing whey protein concentrate (WPC), whey powder and lactose recovery. We are wellaware about the nutritional value of whey protein and lactose. Using nano-filtration, demineralisation and spray dryer like ultra modern technology can help reduce wastage. This also gives us an idea about not only reducing the wastage from dairy processing plants, but also reusing and recovering health beneficiary components from milk,” explains Chatterjee.
R&D imperative The overall performance of dairy processing plant depends on in-depth knowledge and experience about the subject. The Government of India has set up various research institutes for improvement of process technology of various dairy products. National Dairy Research Institute and Indian Institute of Technology, Kharagpur, play a major role in developing new technologies for dairy processes and products. Besides leading technological institutions, there are various prestigious state dairy colleges, which are not only responsible for improving latest technology in dairy but also educating and providing subsequent training to meet industrial requirements. Establishing research institutes serve the purpose. Perhaps not. “R&D is excellent but we need to disseminate, educate, and address the knowledge, findings, information to all persons involved in this sector,” points out Jayant Shah. It is time for more co-operation among the people involved in the dairy segment. Email: prasenjit.chakraborty@infomedia18.in
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SPECIAL FOCUS Dairy market
Prasenjit Chakraborty
W
ith a population of 1.2 billion, India represents one of the largest consumer markets in the world. Additionally, the country enjoys one of the largest and most balanced demographics in terms of age, as India has more than 50 per cent of its population below the age of 25 and more than 65 per cent below the age of 35. Currently, 63.38 per cent of the population is between 15-59 years. All these factors amount to significant changes across the segments in the food industry, and dairy is no exception. As young population drives the demand for processed and healthy foods, dairy has emerged as a lucrative segment both for domestic companies and MNCs. Growing affluence and higher spending capacity provide further momentum to the dairy sector. “Indian market offers a vast consumer base to MNCs, which look forward to investing in the Indian market. India is the largest producer as well as consumer of milk and milk products. Traditionally, Indians enjoy rich and tasty food. With rising incomes, India promises a significant growth in dairy industry, which is luring MNCs,” points out Devendra Shah, Chairman, Parag Milk Foods Pvt Ltd. According to Dr Meeta Punjabi Mehta, Managing Director, Creative Agri Solutions Pvt Ltd, most of these multinational companies – Danone, Britannia, Nestle etc – have invested in product development over the years and have evolved a wide range of products, such as flavoured yoghurt, dessert, mousse, wide varieties of cheese, etc. “In contrast, the existing product range in India is limited to traditional products such as butter, few types of cheese, paneer, traditional yoghurt etc,” she says. Investment in product development has been minimal in the country as private sector entry in this field is relatively new. The tastes and preferences of the Indian consumers are changing, driven by higher disposable incomes, quality and health-consciousness along with increasing exposure to overseas markets. “The MNCs have already invested heavily in product development to meet the requirements of the Western countries. While those markets are now mature, India presents a huge opportunity for their products. MNCs consider the Indian market quite lucrative for these products and are competing fiercely to make their entry here through several mergers and acquisitions in this sector,” states Dr Mehta.
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The rise in disposable income coupled with focus on health has widened the scope for dairy products in India. Taking due cognisance of the fact, multinational companies (MNCs) are evincing interest in the dairy market in the country. The Indian market offers greener pastures to them as compared to Western countries where the markets are already matured.
A closer look says that packaged dairy products are by and large available in urban areas and majority of the dairy industry falls in unorganised sector. These two factors also contribute towards MNCs focussing on Indian market. “India is still in a nascent stage and unorganised to a large extent, when it comes to dairy processing. As a result, there is huge potential and probably that is what is attracting MNCs. The challenge lies in customising products in a manner that it not only addresses the taste expectations of Indian consumers but also keeps them affordable,” points out Munish Soni, Deputy General Manager, Marketing-Dairy Products Division, Mother Dairy.
Changing dynamics The dynamics of dairy sector involves three important factors. First, the image of Indian dairy segment is changing drastically from being self-sufficient to one facing shortfalls in supply known in the pre-Operation White Flood days. According to National Dairy Development Board (NDDB) estimates, while the supply is growing steadily at an average annual growth rate of 4 per cent, the growth rate of demand is double that of supply. In keeping with the norm of higher protein consumption with income increase, the demand for milk products is increasing rapidly, driven by higher incomes and health-consciousness. “The implications of this widening demand and supply gap are observed in the increasing incidences of adulteration along with about 100 per cent increase in retail price of packaged milk from ` 19/litre in 2006 touchingg ` 40 now,” Dr Mehta points out. Second, following liberalisation and changes in Milk and Milk Product Order (MMPO) in 2002 whereby all controls on private sector entry to dairy sector have been done away with, Indian corporates as well as multinationals are investing heavily in this sector. Consequently, the share of unorganised sector – currently at about 85 per cent of marketed surplus – will decrease with more milk moving through organised sector. The organised sector has been traditionally dominated by co-operatives; with recent changes, the share of private sector within the organised sector is likely to go up. “Recent developments involve entry of national and multinational corporates investing in Indian dairy sector including Reliance, DCM group, Danone, Fonterra, among others, while the existing players
Dairy market
ROLE OF MNCs IN DAIRY SECTOR GROWTH o Co-operatives traditionally dominate organised sector o Investment in product development minimal o MNCs can help in product development o MNCs can bring in management practices
better
o For MNCs, the challenge lies in customising the product
Amul, Nestle are up-scaling investments,” says Dr Mehta. One big lacuna in the dairy sector is that most private players focus on milk procurement and marketing of various processed products, with little or no investment in enhancing production and productivity. “The recently launched 15 year-long National Dairy Plan (~ $ 352 million) funded by the World Bank and implemented by NDDB will emphasise
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these aspects along with addressing several key issues in the sector,” she says. Finally, an important shift is witnessed in the range of dairy products available in the market. “We see a wide range of new products such as yoghurt, various types of cheese, etc on the retail market shelves in India. This change is the result of the entry of MNCs in the country,” observes Dr Mehta.
How successful are MNCs? “While India presents a growing market for new dairy products, the scope of the market is likely to be restricted to metros and urban areas. Also, the distribution of MNCs is likely to be limited as they are new entrants to the sector,” opines Dr Mehta. Despite these issues, MNCs have a strong role to play as the dairy sector in India is at the threshold of a second white revolution. The MNCs can tie up with national players to enhance reach in the Indian market. “In the coming years, with increasingly stringent
food quality norms as the Integrated Food Law applies to the dairy industry, MNCs can bring with them better management practices for enhancing quality along with upgrading the milk processing techniques and enhance the ability to meet quality norms,” points out Dr Mehta. Finally, dairy sector is dominated by small holders and has been the face of social change by empowering women responsible for dairy activities at the household level. Hence, involvement in the sector has strong socio-economic implications. By investing in dairy development at the grass roots level, which will be inevitable for ensuring quality of milk, MNCs along with the Indian counterparts can be a part of this social development with positive implications for the Indian and global market. Multinational players can take advantage of the prospective opportunity to land in a win-win situation for all players. Email: prasenjit.chakraborty@infomedia18.in
Photo: Aamir Kadri; Location courtesy: Mother Dairy, Gandhinagar - a unit of GCMMF Ltd
SPECIAL FOCUS Dairy packaging
Consumer-centric innovations for better acceptance Packaging can provide the much-needed momentum in popularising dairy products in India. Today, acceptance of packaged dairy products by and large is restricted to metros and some cities. Due to the perishable nature of these products, consumers are apprehensive about their quality. However, modern retail and innovation in packaging can work wonders for the dairy industry and increase sales volume manifold.
consumers of India. Compared to other products in food, products in dairy segment tend to get spoiled fast. This is certainly a huge challenge for the dairy sector. And to overcome the challenge, packaging is bound to play a significant role. Till today in India, acceptance of packaged dairy products among the consumers is quite low. This is purely because of mindset and consumers are rather apprehensive about the quality. No doubt, modern retail and awareness are instrumental in bringing the packaged dairy products closer to the consumers. “There is fast change in expectations of Indian consumers of dairy products due to exposure through retail chains. The increased competition is also forcing dairy industry to introduce innovative packaging for their products,” points out R J Raynade, General Manager, Marketing, Nichrome India Ltd. The major dairy products offered through retail chain are dairy whitener, liquid milk, ghee, curd, yoghurt, lassi, flavoured milk, cheese, paneerr etc. “The aesthetics of the packs is of prime importance for shelf display and hence innovation in packaging plays an important role in modern retail. Due to availability of proper cold chain facility at modern retail, the availability of dairy products has increased as against the earlier conventional distribution of products like pasteurised milk through home delivery system,” Raynade explains.
Packaging infusing growth Prasenjit Chakraborty
T
he primary role of packaging is to protect a product from external influences and to keep it safe from contamination, both deliberate and inadvertent, from point of production to point of consumption. When it comes to dairy products, packaging becomes more sensitive because of the nature of the product. With the passage of time, various issues associated with packaging are becoming stringent. For example, food safety and sustainability are interrelated such that for innovative technologies
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and practices to be economically viable for the industry, it is imperative to safely deliver dairy products to the end-users. Packaging for dairy or any other products must be as cost-effective as possible and also in accord with changes in consumer lifestyle trends; for example, increased mobility and on-the-go consumption require packaging that can be easily transported by the consumer and also enable one-handed consumption. In the context of India, fast developing organised retail calls for more emphasis on packaging of dairy products. No doubt, suitable packaging will help popularise dairy products among the
Innovative packaging actually add value to the product, if it meets consumers’ needs such as recyclability, tamper-proofing, child-proofing, easy-to-open, easy-tostore, easy-to-carry, and non-breakability. Manufacturers, who leave no stone unturned to have packaging that maintains the key equities of the brand, have stand out appeal on the retailer’s shelf, and is sustainable but with lower production costs. The customer can choose a product on the basis of its innovative packaging, which shows the relation between buying behaviour and innovation in packaging. All these aspects are quite important for dairy products as the packaged dairy
Dairy packaging
product segment is at nascent stage. The right packaging will definitely facilitate rapid acceptance of dairy products among consumers. “There is a big opportunity for dairy sector through modern retail. The innovative and aesthetically best package will attract consumers, which will in turn result in increased business volume for dairy sector,” says Raynade. Worldwide, there is huge opportunity for dairy packaging. The new research from Tetra Pak has identified 2.7 billion low-income consumers in developing countries as the dairy industry’s next big growth opportunity due to an expected rise in prosperity, purchasing power and desire for packaged liquid dairy products (LDP). According to the research findings, consumption by low-income consumers in developing markets is forecast to increase from about 70 billion litre in 2011 to almost 80 billion litre in 2014. The Dairy Index (as the research dubbed as) tracks worldwide facts, figures and trends in the global dairy industry. Many of these consumers are expected to switch in coming years from drinking loose milk to packaged milk. This is a clear opportunity for dairy packaging. Tetra Pak has identified three key challenges for dairy processors seeking to reach consumers in this growth market. They need to make products that are affordable, available and attractive to consumers with limited incomes. That means dairy processors must produce healthy, safe and nutritious packaged dairy products without adding unsustainable costs.
Opportunities galore Where India stands as far as innovation is concerned? Replies Raynade, “Experimental success of Western countries has led to the development of specialty polymers that changes colour in the event of tampering. Such polymers are to be made available for dairy sector through indigenisation efforts for mass packaging of liquid milk. This will help in addressing the serious issue of adulteration.” Packaging will play an integral role in the future of the liquid dairy market. Until recently, most emerging markets used only basic packaging. The trend of increased awareness about hygiene and food safety issues coupled with higher incomes & urbanisation has led to a sustained requirement for quality packaging solutions throughout the world. According to him, the tamper evidence feature for liquid milk is serious challenge for the dairy sector. “The solution needs to be made available through specialty polymers with marginal increment in price to pack sensitive products for masses,” Raynade points out. The type of packaging depends on dairy product to be packed. The flexible packaging is the most widely accepted and offered packaging solution by dairy sector due to huge handling requirement of dairy products on day-to-day basis. It is time for the packaging industry to concentrate more on R&D and come out with solutions in the areas that remain a challenge for the dairy products. There has to be more synergy between packaging and dairy industries. Email: prasenjit.chakraborty@infomedia18.in
June 2012 | Modern Food Processing
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SPECIAL FOCUS Probiotic foods
consists of over-the-counter (OTC) products, which are aimed at geriatric and pediatric patients.
Competition getting stiffer
Functional foods such as probiotics essentially enhance nutritional properties of standard food with certain additive advantages. These supplementary foods have gained much attention in recent times because nowadays, consumers prefer to take the precautionary path rather than adopting a remedial approach. Given this approach, the prospect for the Indian probiotic industry, which is still at an embryonic stage, looks promising. Shushmul Maheshwari
P
robiotics can be bacteria, yeast and moulds. But, the most commonly used probiotics are bacteria – live bacteria that have symbiotic relation with humans. The lactic acid bacteria are quite popular. Probiotics in India can be broadly classified as milk and fermented milk products, with the former accounting for 62 per cent of the marketshare and latter constituting 38 per cent according to Indian consumer survey, 2010. Presently, Indian probiotic products include dahi (yoghurt), flavoured milk and butter milk. As per research findings, the probiotic market in India is at an escalating stage. At present, it stands at about ` 1.2 billion and is poised to double in near future due to the Indian and multinational companies coming into the fray. The existing probiotic products in
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India are popular among urban people, young adults and people with particular needs such as geriatry, pregnancy, immunodeficiency and lactation among others. As a result of the rising awareness about the benefits offered by these products, a burgeoning demand for the probiotic foods is expected, thereby expanding their market size. Probiotic food market in India largely constitutes organised players. Major players include Nestle, Yakult Danone, Amul and Mother Dairy. Moreover, there are some small players operating in different regions. The supportive fundamental factors for the probiotic industry will pave the way for its betterment in the near future. Companies are also launching packaged products, for eg probiotic-based nutritional supplements that are aimed at consumers with special nutritional requirements. Another variety of probiotic formulations
On the competitive front, with the entry of international giants, the probiotics food market in India is poised for rapid expansion and higher efficiency. Besides, the increasing competition in this market has encouraged companies to go for customisation of products, considering Indian preferences. Companies are spreading awareness about the benefits of such food because for creating demand, the prerequisite is to educate people about these food products. New product launches is an ongoing trend to create a fascination for probiotic food among people. Furthermore, leading foreign players like the US chain Red Mango, Smoothie Factory, South Korean Yogurberry and Canadian yoghurt chain Kiwi Kiss are all set to enter the Indian food market with their brand of yoghurt and yoghurt-based products. Frozen yoghurt and smoothie brand Red Mango is catering to India with its first outlet in the capital and it further plans to open 12 to 15 stores in 2012. Presence of foreign players in the market will make the competition stiffer, which will force companies to further improve their product offerings and marketing strategies for gaining bigger slice in the pie.
Demand for healthier food There is a significant shift in the behaviour of Indian consumers. Building inner strength and fitness is given due importance. The new values reflect increased awareness about good health and fitness among consumers. This changed value system is quite supportive for the development of probiotic foods category as they offer numerous health benefits. The acceptance of probiotic products has been increasing particularly among the urban middle class. This unparalleled evolution in eating habits of people has stemmed from several factors. Rapid urbanisation and growing awareness
Probiotic foods
about the benefits of probiotic products have pushed the demand for these products. Besides, the propagation of retail outlets, influx of food multinationals and rising income levels gradually infused a change in the perception of Indians to supplement their traditional eating habits with new probiotic nutritional products.
Regulatory framework Probiotic products are regulated as ‘general food’ in India, and are not subjected to any specific regulations. In the absence of guidelines and defined standards, there will always be a space for forged products with fake claims being sold. Therefore, it becomes crucial that these food items fulfill some obligatory criterion before being labelled as probiotic product. Thus, in 2011, a committee was formed by Indian Council of Medical Research (ICMR), which comprised experts from different specialisations to draft guidelines for assessment of probiotic food. The committee issued the draft Guidelines for the Evaluation of Probiotics in Foods. The document provides manufacturers guidance on the use of probiotics in food, health claims and product labelling, as well as the requirements for safety and efficacy assessments of the probiotic strain. Though the draft guidelines are currently pending approval from India’s Drug Controller General; once endorsed, the government aims to use them to reduce the occurrences of false and exaggerated claims for probiotic products.
Issues to be addressed Despite the numerous health benefits offered by probiotic foods, the demand for the same has not increased at the pace that it should have been. India has a low consumption of such products as compared to world average. Although with the rapid urbanisation, high disposable incomes and changing lifestyles, the country offers lucrative opportunities to new entrants, there still exist some constraints that may hold back the potential growth of this industry in future. Some of them are as follows:
Lack of infrastructure: The biggest hurdle in expanding the probiotic food market is lack of adequate infrastructure such as proper storage, preservation and distribution facilities. Probiotic products have a specific shelf-life and they should be suitable for consumption when they reach the customer. This requires apt distribution and cold chain facilities for their transportation, which is a concern for this industry. Low awareness: The concept of probiotic foods is new in India. People beyond metro cities have hardly any knowledge about such products. Price-sensitiveness: Pricing remains an important factor in analysing the growth of this industry. Since these products offer better nutritional content and quality, their higher price is justifiable but it is not easy for consumers to understand and accept it. Concentration in metro cities: Another important drawback is the availability of probiotics in metro and tier-I cities only. Companies are not targeting rural areas, as these products call for some amenities, which are not being met at that level, the essential being refrigeration. Lack of standardisation: Lack of standardisation is a major challenge for the Indian probiotic industry. As the industry is in its initial stage, there are no proper standardisation parameters at present. This scenario will improve with the entry of more established players into the Indian market. Hence, to overcome these challenges, companies need to follow a multi-pronged strategy for increasing penetration, which is mentioned below. o Spreading awareness about probiotic health benefits: Companies need to tactfully handle the problem of lack of awareness. Through intensive promotion and marketing strategies, this issue can be addressed. supply chain o Maintaining management: Probiotic products are perishable, which calls for adequate distribution and supply chain management. Companies should
take initiatives to ensure efficient supply chain. o Investment in R&D: Companies should utilise their funds for conducting joint research, and intensive research for understanding product health benefits, application and efficacy. This will help in formulating a competitive pricing strategy, which might help in tackling the issue of price sensitivity among Indian consumers. o Technological advancement: It is an important aspect for the development of the probiotic industry. Players should focus on enhancing techniques and methods used in the production of probiotic foods.
Towards healthy growth The probiotic food market in India is expected to witness double-digit growth every year. As long as consumers will show a liking towards food with additional benefits, the industry will keep moving upwards. If the companies can create awareness among the population especially rural people and urban lower middle class with adequate delivery systems, Indian probiotic industry can earn huge profits. The fundamental factors like abundant supply of raw materials, skilled human resource, and amiable investment climate with proactive government support will pave the way for the probiotic industry to make colossal strides in the country. Excellent growth opportunities subsist for both domestic and foreign players to make the most of the existing situation. 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
June 2012 | Modern Food Processing
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SPECIAL FOCUS Interface - Pradeep Chona
How is the demand trend for dairy products, especially ice creams in India? Ice cream industry will witness gradual growth in near future due to shift in consumers’ perception about ice creams from an impulse/on-the-go treat to an affordable indulgence that can be enjoyed at home with family members. This phenomenon has also resulted in a gradual reduction in the seasonal nature of ice cream in India, though sales continue to rise in summers as usual. The per capita consumption has moved to over 300 ml from around 200 ml in
free variants are expected to appeal to affluent, health-conscious consumers as such products would be ideal replacements for traditional desserts that are usually laden with butter and sugar. Further, market is also leaning towards scoops with fusion and unusual flavours.
How rising milk prices impact Havmor? Milk, cream and milk powder are major ingredients used for making ice creams at Havmor. Thus, rising prices have adversely impacted us as compared to small-time operators and those producing frozen desserts. Due to rising cost, many companies have switched
rising raw material costs, food safety rules etc. Despite the challenges, there are many opportunity areas as well for the industry like untapped rural market, rising income, changing lifestyle, increasing awareness etc. Moreover, low per capita consumption means scope is good for selling ice creams.
How will be the demand for ice creams in future? Ice cream industry is expected to continue to grow robustly in India as purchasing power is increasing and manufacturers are investing considerable amounts for expanding the availability
“The market is leaning towards scoops with fusion and unusual flavours” …says Pradeep Chona, Managing Director, Havmor Ice Cream Ltd. In an interaction with Avani Jain, he underlines the emerging trends in the ice cream segment and its key growth drivers.
India, which is a good sign though far less compared to many developed and developing countries.
What are the key growth drivers in ice cream segment? In Indian context, key growth drivers are distribution network and cold chain infrastructure. Other influencing factors are health and nutrition, convenience, sensory experience, newness in range and, most importantly, value for money.
over to making frozen desserts, which are perceived as ice cream by common man, and this is impacting the growth of dairy premium and pure ice creams in India. In last three years, milk prices have almost doubled and so has prices of cream & other commodities. Besides, taxation is also adversely impacting the growth of this sector as making ice cream has become expensive. Thus, the government should offer subsidies to manufacturers making genuine and pure ice creams as it is a nutritive product.
What are the emerging trends in this segment?
What are the major challenges and opportunities for ice cream manufacturing companies?
The new trends in ice cream industry are preference towards premium treats, and ice cream catering to health & wellness quotient. Low-fat and sugar-
Some of the major challenges faced by the industry include low per capita consumption, seasonal business, unbranded players, heavy taxation,
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of ice cream in kirana stores. The growth is expected to be up, with consumers increasing their at-home consumption and substituting ice cream for traditional desserts. Single portion dairy ice cream and bulk ice cream are expected to be the fastest-growing categories. The demand for ice creams can also go up further, if rural markets are tapped and exploited fully.
What are the growth plans of the company? Havmor looks forward to achieving over ` 500 crore by 2015 by doubling the existing production capacities and also having its presence in several other states. We are also looking forward to establishing more number of ‘Hav Funn’ parlors and eateries. Email: avani.jain@infomedia18.in
SPECIAL FOCUS Roundtable
Will National Dairy Plan help increase productivity? The Government of India has sanctioned ` 1,700 crore to the dairy sector under the National Dairy Plan (NDP) to augment milk production in India. Prasenjit Chakraborty speaks to experts to ascertain their views on how this will benefit the industry.
Devendra Shah Chairman, Parag Milk Foods Pvt Ltd
Vivek Nirmal CEO, Prabhat Dairy Pvt Ltd
Jayant Shah Managing Director, Shah Brothers
NDP aims at boosting milk production using scientific breeding and feeding programmes covering about 2.7 million milch animals in 40,000 villages. It will also focus on modernising village-level infrastructure for milk collection and bulking. But it is essential to utilise the sanctioned ` 1,700 crore on the required parameters to boost the sector in real terms. If the fund is going to be used to bail out sick co-operatives, it will not fulfill the goal of boosting growth. For attaining this objective, the NDP should not only cater to the co-operatives but also the private dairies. This will bring healthy competition among all players – co-operatives and private. Also, 70-80 per cent of the amount should be invested at the farmers’ level for the purpose of farm d development, l cattle l b breeding di etc. Only then, the plan will be able to offer the much-needed boost to the sector.
It is heartening to know that the government has come up with such a visionary NDP. The Operation Flood was launched to give farmers a sustainable livelihood opportunity and ensure regular supply of this ‘complete food’ (milk) to the fast growing population of India. The dairy co-operatives have been instrumental in building the capabilities in the Indian dairy industry by empowering the farmers since last 30-40 years. Today, if NDP has to give a boost to the sector, private organisations must also be considered as active partners of the industry. It must utilise the dynamism of the private players to complement the efforts undertaken by the co-operatives. The producer company model suggested is sustainable, where the benefits are shared by the farmers as well. ll NDP is i exactly l hi hitting i the nail by emphasising on animal health, nutrition, breeding and improvement in dairying practices.
Indians enjoy milk and milk products; as a result, our per capita requirement is overwhelmingly higher than the availability. There have been milk revolutions in India from time to time, yet the demand has been mounting. The problem is far more complex, and providing funds is only one fragment of resolving it. It has to be tackled by allotting specific amount of land for high-yielding fodder, creating excellent milk collecting systems, state-of-the-art milk processing units etc. Apart from this, capabilities for packaging milk and milk products, with excellent shelf-life, and modern milk storage capacities are must. Then comes appropriate milk transportation and distribution where technology plays an important role. Excellent R&D and on-line testing laboratories are the need of the hour. We could be on the h top off the h world, ld if (b (besides id allocating the ` 1,700 crore) we plan and execute with determination & perseverance.
EDITORIAL TAKE The NDP is no doubt an excellent plan to boost the dairy sector. But success, to a large extent, depends on involving the private sector as well. Today, in every arena, private sector plays an important role. Apart from this, while spending the money, there has to be proper identification of priority areas.
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FACILITY VISIT GCMMF Ltd
Photo: Aamir Kadri
for a dairy plant, which can handle 10 lakh litre of milk everyday specifically to cope up with the milk procurement in the flush season by the co-operative dairies. Thus, the MDG plant was commissioned in September 1994 under Operation Flood – III. At the time of establishment, it was clearly spelt out that the dairy plant would serve two objectives, ie receive surplus milk from the member unions in Gujarat in the flush season and convert it into milk products; and supply milk round the year to meet liquid milk market demand in Ahmedabad and adjoining areas. A K Dhagat, General Manager, MDG, notes, “We have been given the task to develop infrastructure in such a way that none of the dairies face a milk holiday and we are living up to this task. From 10 lakh litre per day (LLPD), we have gone up to 25 LLPD of milk handling capacity. It is one of the most modern PLC-controlled dairy plant in Asia and almost ` 380 crore has been invested in this plant.” The state-of-the-art facility of MDG is spread over 70.60 acre. Initially, the dairy was commissioned with the facilities for processing and packaging of liquid milk, manufacturing of ghee and milk powder. However, as the flow of milk increased, the facility expanded and various milk products and frozen pizza production began. Milk storage silos
MILKING SUCCESS through
QUALITY APPROACH With the Indian dairy industry growing at a fast rate and the total milk production in the country reaching 122 MMT per annum, the industry is set to touch new heights in the coming years. Moreover, milk processing units like Mother Dairy, Gandhinagar (MDG) – a unit of Gujarat Co-operative Milk Marketing Federation (GCMMF) Ltd – can further fuel the growth of dairy industry. Avani Jain
I
ndia is predominantly a vegetarian society and milk is an important source of protein. Thus, it is imperative for the country to focus on milk production. At present, India accounts for 15 per cent of the world’s milk production and the market value of the total milk produced in the country is around $ 70 billion annually. This milk production is projected to reach 174-180 MMT by 2020. Due to favourable conditions in India and above all the presence of modern dairy plants like the MDG, which has in-built capability of manufacturing milk products matching the best quality standards prevalent, the dairy industry is booming here.
Tracking the history Taking into consideration the expansion plans of other co-operative dairies in Gujarat, a need was felt by GCMMF Ltd
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Broad product portfolio MDG presently has a wide range of products that includes liquid milk supply in pouch for local and nearby upcountry markets (11.50 LLPD), ghee/butter oil manufacture and packaging (75 MTPD), milk powder manufacture and packaging (160 MTPD), ice cream manufacture and packaging (100 KLPD), frozen pizza (5,000 per day), UHT milk and milk products processing and aseptic packaging (400 KLPD), traditional Indian dairy product – gulab jamun (2 MTPD). Of all the products, liquid (pouch) milk has the largest marketshare, ie approximately 58 per cent. The manufacture of milk products involves different processes. Sameer Saxena, Assistant General Manager, MDG, states, “Once the milk reaches the reception centre, it is tested and if it meets all the parameters, it is taken forward to perform the different processes. The recipe of each product is set online
GCMMF Ltd
by the team leader and then the product is manufactured through the use of automated machines.”
Towards excellence and automation The MDG plant undertakes PLC-based operations, which include receiving raw milk in silos, processing, standardising and transferring, concentrating and drying etc. It also uses high-speed milk pouch packaging machines, which do not need pneumatic pressure for dispensing milk for packing. Online Standardising Assembly (OSTA) for efficient standardisation is also employed. The company performs lecithination for full cream milk powder for better instantiation effect even if dissolved in chilled water. Dhagat notes, “The company has also recently installed a candy machine; green fuel captive power plant (3.6 MW ), which utilises three forms of energy from natural gas; powder plant (100 MT/day); high speed Tetra Pak machine, pouchmaking machine etc.” MDG is continuously evolved in generating higher volumes. Anil Bayati, Officer on Special Duty, MDG, observes, “The main thing about being competitive is how best you can keep your cost low without compromising on the quality. We do this by running the plant efficiently, reducing losses, automating most of the
processes, so as to reduce labour costs. In simple terms, it means giving a better product at lesser cost so as to generate volumes. If you do not have volumes in business, you cannot go for automation and this will hamper growth.”
Total quality management Right from the inception, MDG has adopted Total Quality Management (TQM) as a tool for integrated approach in delighting customers (both internal as well as external) by meeting their expectations on a continuous basis. The major thrust areas include total employee involvement, total waste elimination and total quality control. MDG has opted for implementation of Integrated Management Systems and has obtained ISO 9001:2008 for Quality Management System, ISO 14001:2004 for Environment Management System, ISO 22000:2005 for Food Safety Management System. Also, Mother Dairy Quality Assurance Laboratory houses the state-of-the-art testing equipment to test the various parameters of milk, dairy and culinary products before reaching the customers. It is NABL (ISO 17025:2005) accredited for its product testing facilities.
Green initiatives MDG is environment-conscious and has initiated ‘Clean Development Mechanism’ project. Under this, it has
Our aim is to build a modern and competitive structure to work on longterm basis; overcome cyclical structure, consolidate market by building external network and clients, and increase local consumption through marketing initiatives & new products. A K Dhagat General Manager
undertaken the task of reducing methane gas emission to atmosphere by anaerobic treatment of wastewater and utilisation of captured biogas, so generated in canteen and boiler house as fuel. Further, reduction in carbon dioxide gas emission by commissioning of natural gas-based power generation plant is also taken up by MDG. The plant indulges in continuous monitoring of electricity consumption. MDG firmly believes in reducing wastes and undertakes green initiatives by way of 3Rs – reducing, reusing and recycling. There are various steps taken for water conservation as well. There is also an effluent treatment plant for handling trade wastewater, installed at the facility. Further, MDG has followed the green building concept for the new godown.
Expansion plans MDG has planned its expansion in three phases. The phase 1 is already completed with the commissioning of 100 MTPD new powder plant. For phase 2 (20122013), another 10 LLPD milk processing line, and butter oil manufacturing facilities are planned; and for phase 3 (2017-2018), expansion of milk drying capacity is planned. Dhagat concludes, “Our aim is to build a modern and competitive structure to work on long-term basis; overcome cyclical structure, consolidate market by building external network and clients, and increase local consumption through marketing initiatives & new products.” Liquid milk being packed in pouches
Email: avani.jain@infomedia18.in
June 2012 | Modern Food Processing
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INSIGHT & OUTLOOK
FILLING & SEALING TECHNOLOGY FILLING & SEALING EQUIPMENT Ful‘filling’ flexible packaging demands .....................44 NOVEL SEALING PROCESSES Preserving quality and integrity of contents ............46 CAPS AND CLOSURES Opening new avenues for brand differentiation ......48 INTERFACE - Dr Guenther Burkhard, VP Sales - Business Unit Liquid Food, Bosch Packaging Technology “Bosch is targeting India’s edible oil market” ..........50 INTERFACE - Kerstin Bernhart, Marketing Manager, Mettler-Toledo Garvens “Automated checkweighing systems are crucial for optimising efficiency”...............................................52 ROUNDTABLE Hot fill or aseptic: Making the right choice ............54 PET CONTAINER Adding fleexi xibi bili lity t to food packagingg ....... .... . ..............56
June 2012 | Modern Food Processing
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INSIGHT & OUTLOOK Filling & sealing equipment
Courtesy: Krones AG
Ful‘filling’ flexible packaging demands
A tomato ketchup in flexible packaging or 60 ml miniature pack of your favourite scotch in PET is a reality, probably not imagined a few decades ago. The revolution in food and beverages packaging has been made possible because of the evolution in filling & sealing technologies. Mahua Roy
T
here was a time when branding of food and beverage products was limited to the labelling options. But now, with advancements in Polyethylene Terephthalate (PET) and Polypropylene (PP) chemistry, companies can experiment with customisations of the container too. Thus now, an orange flavoured soft drink from one company can be differentiated from its rival by one look at the bottle! This calls for complementary support from the filling and sealing machinery industry. As per analysts from Chemicals, Materials & Foods Practice, Technical Insights, Frost & Sullivan, the flexible filling and sealing machinery market was more than ` 75 crore in 2011, growing at a rate of around 15-20 per cent.
Top three demands Filling and sealing machinery manufacturers have to take care of the following three demands by the food & beverage processing industry towards product development and improvement.
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1. High efficiency: As in the case of any industry, the major deliverables expected out of filling and sealing machinery revolve around higher performance and efficiency. As most food processors are turning global with exports to numerous destinations, such a tough global trading environment requires increasing productivity from existing equipment. Says Umesh Sharma, Managing Director, Julison Packaging, “There has been an upsurge in the filling and sealing machinery requirement by food & beverage processing units in India. Modern retail chains are favouring procurement only from those vendors complying with good packaging.” 2. Flexibility: Another strategy of food and beverage processing companies is that of offering various pack sizes at attractive price points. So incorporating a level of flexibility is an added advantage. Simple but sophisticated design is crucial for operational ease, and maintenance also gets simplified. In order to keep up with this trend, filling and sealing systems require rapid product changeovers coupled with reduced downtime. Digitisation of packaging lines can allow food processors to keep up with demand of the consumers. 3. Safety: The biggest priority for the food and beverage industry today is the commitment made to consumers about safety and integrity of the product. Filling and sealing system plays the most important role in assuring this. According to Frost & Sullivan, “The major reason for the growth of filling and sealing technologies in India is due to the mandated requirement by the government to be compliant with the latest food safety regulations. The modern filling and sealing technologies apart from being regulatory compliant, also extend the shelf-life of the product, which is a much-needed value addition. Basically, the technology reduces human contact, which makes the process a more reliable technique for aseptic preparation of foods and beverages.”
Addressing new features There are certain unaddressed challenges that need to be overcome for smoother functioning of the food and beverage processing industry. As Sharma puts it, “Interestingly, out of filling and sealing, the former is a more complicated process because the product has to be weighed, counted or measured in volume. There are Form Filling and Sealing (FFS) machines available for every product, but the weigh metric filling, which is more accurate with wider range of applications, is quite expensive. Sealing, on the other hand, is less complicated except in cases where the product is required to be vacuumised and flushed with nitrogen or other preservatives.” Finding out solutions to these issues stands as a practical demand towards which further R&D has to be carried out. Apart from this, addressing contamination is a big challenge, especially when it comes to fresh produce. For example, a rotten apple in a package of apples has the ability to spoil the whole case. Instead during packaging, if each apple were individually covered, the rotten apple can be isolated with ease. Such is the potential of modern packaging technology. However, according to Frost & Sullivan the economics need to be worked out in the current Indian scenario to enable such technology adoption. Email: mahua.roy@infomedia18.in
INSIGHT & OUTLOOK Novel sealing processes
QUALITY and INTEGRITY of CONTENTS Affairs & Consultancy, Sanex Packaging Connections Pvt Ltd. Seal integrity is a critical parameter towards the commitment made to consumers.
Identifying inherent challenges
Connssum Co umer ers st stru r ggling ru ggg ng n with wi thh ttea eaariring ngg ooppe pen a kkeettcchu hup sa sach chet or reje chet ch reeje ject ctingg a pa pack ck of pota pota po tato ttoo chiipss, whic wh ich is is nnot ott flu luff ffeed ff ed is a com mmon sigghht. si t. TThe he ffin innal a sta tam mp of prrod oduc u t uc inte in tegr teg grityy is grit is asssurred e by proper seaaliling n . ng Inve In vest sttin ingg inn sopphist stic i ated sea eaaliling ng teech chno noolo logi gies es cann ggo a long way towa w rdss bu wa buililldi d ng a bbra r ndd image gee. Courtesy: Bosch
Mahua Roy
T
here are lessons to be learnt from a popular milk chocolate brand, which revolutionised its sealing technology after an uproar arising out of contamination. The loyalty that the brand enjoys today is out of the rapid response to the improper packaging. The company did engage an influential brand ambassador to build back the trust, but it is obvious that the trust sustained due to the company’s renewed emphasis on packaging, especially the sealing technologies. Food and beverage companies now need to be extra careful regarding food safety as a result of pressure from media agencies and consumers. “Consumer safety is of prime importance. Proper package sealing is mandatory for the preservation and integrity of the contents. Any leakage could mean product contamination and loss of nutritional value, besides raising the possibility of health hazards,” says Adwait Rajwade, Head, Asia-Pacific Sales, BarryWehmiller International Resources. Sealing technologies are one of the ways to address the issue of food safety. “Adulteration of food and beverages can be minimised to a large extent by the employment of sophisticated sealing technologies. Besides, issues of pilferage and counterfeit can also be addressed,” says Amita Venkatesh, Associate: Scientific
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Sealing technologies come with their own set of operational challenges. Most of these are dependent on the food or beverage product to be packaged. It is necessary to identify and pre-empt the bottlenecks to avoid breakdowns of conveying lines. However intensive the hygienic considerations may be or however tidily the filling operation be maintained, there always is a possibility of a cast-off. A cast-off is a fine droplet or a tiny particulate matter that can lead to a discontinuous seal. Such abnormalities are difficult to detect visually, or sometimes, even mechanically. But they can lead to massive loss in the form of leakages. Another consideration is the product composition. “The edible oil industry is largely affected by adulteration issues. Leakage is a big problem in this sector and addressing contamination is of utmost priority for this sector,” adds Venkatesh. Oily substances can easily degrade a seal by penetrating and thereby causing its softening. “In India, the edible oil sector is still dominated by plastic pouches and sachets that despite being highly economical for the average consumers remain undifferentiated among all players. Also, the oil needs to be poured into a receiving container after being opened. This poses huge concerns about its durability, cleanliness and waste during handling,” opines Rajwade. Another impediment in sealing is due to packaging material. This case usually arises in matters related to metal packaging, especially aluminium. Aluminium foil has high barrier properties, however, it is not a sealant. As a result, the sealing layer should be able to provide adequate adhesion to aluminium.
Demand for productivity Increased competition in the food and beverage space where companies are vying for a space in the shopping trolley of the modern retail shopper, productivity remains the top-most demand of the food and beverage companies. “Today in India, due to poor packaging, most of the filling lines are of low speed. In many cases, international brands and renowned Indian ones, with a complete control over their packaging can afford and receive the benefits of high speed and efficient production lines. This also means the added capability to distribute products nationally with low wastage and high quality,” puts forth Rajwade. Choice of sealant is another variable to be considered in order to boost productivity and bottomline for the food and beverage processing companies. The sealant needs to
Novel sealing processes
be compatible with the machinery employed for packaging, the product and the packaging material. Also, since temperature is the operational variable under the control of the packager, the sealant’s temperature profile is fundamentally important to assure seal integrity. Sealing equipment undergoes certain temperature fluctuations and thus the corresponding sealant chosen should complementarily possess a wide sealing temperature range. This will eventually reduce the need for equipment recalibrations, thereby increasing productivity. “Heat sealing has been and even currently continues to be the most widely used sealing method. Now, the new generation ultrasonic sealing techniques are taking over heat sealing in many of the areas, like in cheese packaging,” says Venkatesh. There are various ways to produce a heat seal. The industry has the options of using wax, polyolefin, ionomer, Ethylene Vinyl Acetate (EVA), etc. Yes,
the considerations are multiple, but the stakes are high as well.
Suiting consumer needs The sealing expert and the food & beverage processor have a common consumer to please. Venkatesh puts forward the common problems faced by consumers due to faulty sealing. She says, “Easily tearable smaller units like ketchup sachets are still tough to find. Leakage in the screw capped and induction sealed cans of oils is one of the major issues faced by industry. Anti-counterfeit for food and beverages, especially in commodities like mineral water are seeing a fast emergence of counterfeits, which need to be countered and a unique seal can be a big aid. Resealable options for food and beverage products like yoghurt, which come in induction sealed cups, offer a big opportunity area.” The next best thing to avoiding loss of seal integrity is to catch it at the earliest stage, before it has had a chance to pile on the costs. This depends
on the emphasis offered to quality assurance, which, in turn, should be based on reliable testing. In case there is outsourcing to a contract packager, that third-party provider’s quality assurance should be an extension of the product manufacturer’s commitment towards food safety. Another trend is that of providing convenience to the consumers. “An additional trend will be the extension of the package personalisation to enhance the branding and the consumer’s recognition of each products and its value. This will mean an improvisation of shape, shades, design features not only in the container and label but also in the caps and closures,” says Rajawade. High functionality of the packaging can be contributed by sealing procedures. “Consumers will look for convenience, as there are a lot of choices available to them today. Easy open, easy pour, easy storage, easy reopen are the attributes that are scouted for,” concludes Venkatesh. Email: mahua.roy@infomedia18.in
June 2012 | Modern Food Processing
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INSIGHT & OUTLOOK Caps and closures
Mahua Roy
A
s per renowned market research agency Freedonia Group, the world market demand for caps and closures is projected to rise 4.6 per cent per year to $ 40 billion in 2014. Also, according to the report, some of the best opportunities for caps and closures will be found in the Asia-Pacific region, which will account for more than two-fifths of aggregate market value gains between 2009 and 2014. Beverages continued to remain the dominant market for caps and closures, accounting for almost 65 per cent of unit demand in 2011. Within the beverage sector, strongest gains for caps and closures are witnessed in the non-traditional products such as sports drinks and flavoured milk. milk
Aesthetic branding tool Brand differentiation forms an integral part of the marketing strategies. Achieving brand differentiation by way of innovative caps and closures is an area being explored increasingly by food & beverage processors. Crossing the barrier of caps and closures is the first step towards
product experience. In these days of increased activity in the food and beverage space, the primary requirements of caps and closures have been extrapolated beyond reliable closure performances.
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Besides offering leak-proofness, caps and closures are expected to provide a pleasant visual appeal, easy convenience of opening and brand differentiation. Also, safety features of caps and closures such as anti-counterfeiting are highly sought. Caps and closures are also being customised to suit needs of consumers falling in every age bracket. Child resistance and senior-friendliness are features that are being employed. Caps and closures are increasingly used in combination with other packaging attributes to offer shelf appeal. They are continuously evolving to accommodate the preferences of the dynamic consumers. “The extension of package personalisation will help enhance branding and recall in the mind of the consumer. Functional closures, which have already established
themselves in the home and personal care industry are now slowly making inroads into the food & beverage industry,� says Muthu Kumaran, New Business Development Manager, Arol India.
Combatting high raw material prices
The advent of heat-stable Polyethylene (PET), clarified Terephthalate Polypropylene (PP) and multilayer containers is opening up new markets to plastic caps & closures. The demand is highly driven by increased penetration of PET bottles in dairy applications and growing substitution of glass packaging by plastic containers in baby food and dehydrated snack products. New applications for plastic caps and closures continue to emerge in hot-fill foods such as pickles and sauces. P Plastic caps and closures continue to supercede traditional opttions like metal and cork, supported by technologiical advances. Plastic cllosure for the liquid ffood segment constituutes 18 per cent off the end-use of closuure applications globally. Even alcoholic beveragess have started experimeenting with PET packaaging, and thus plastic caps and closures. Corks are also being replaced byy screw caps in wine packaging. Howevver, as the entire Quite under-rated world figh hts heightened and taken for granted, process oof crude, PET but caps & closures prices haave eventually have the ability to soared. T This has directly sprinkle functionality affected the packaging in a packaged food industryy. Since PET or beverage. Five-litre packaging is most widesp pread in the package of mineral water food and beverage or flexible packaging of ind dustry, vendors mayonnaise, life has been off plastic caps & made much simpler for consumers closures have to due to unlimited innovation in caps deal with this and closures. challenge.
Caps and closures
However, innovative strategies have been employed to combat this. As Kumaran explains, the size of the cap in packaged mineral water has been reduced in the past few years, thereby using less amount of material. The ribs in the neck have been reduced accordingly. Besides promoting cost savings, it is also a green and sustainable way of packaging.
Huge scope for plastic closures Given the growth in blow-moulded bottles, plastic closures is an optimistic area of strong growth within the rigid plastics packaging market. The output is of more than 220 billion units/year, as per figures released by Freedonia Group. It is estimated that plastic caps and closures now have a market penetration of over 50 per cent of the total closures market, exceeding metal closures in terms of unit demand. The drivers evidently remain cost reduction and lightweighting. Single piece standard beverage caps increased their market penetration from less than 64 per
cent in 2007 to 73 per cent in 2010, as per AMI Consulting. It is expected that within the next 5-7 years, the standard caps will completely change from two piece into the single piece for cost reasons. While standardised one-piece and twopiece beverage closures form the majority of the closures business, custom closures represent an even greater opportunity to moulders in terms of added value. Cap and closure demand in the food & beverage market will benefit from trends towards convenience-oriented packaged foods. This will especially boost demand for plastic closures like those providing dispensing convenience. Even certain flexible packaged products are employing use of caps and closures, like those of refills of ketchups or cooking sauces.
Advancements in capping technologies The most important capping technology advancement of the past few years has been the acceptance of servo-driven
cappers to the mainstream industry. “Traditionally, servo-driven capping has served the purposes of high hygiene, high accuracy, high speed state-of-the-art aseptic capping,” points out Kumaran. An additional feature, now used and highly appreciated also by mainstream high speed carbonated soft drinks (CSD) lines is the extreme accuracy in capping given by servo motors. “The closing torque is delivered by means of a highly repeatable and accurate electric current and not by a mechanical closing head. This accuracy can be measured and recorded at will with active alarms each time,” says Kumaran. Futuristically speaking, the ultimate advancement lies in virtual cam capping. “It is already available but too expensive for extensive marketwide utilisation, where the camtrack (designed at purpose for each type of closures) is servo-driven and each capping profile can be achieved via software and not by changing a mechanical component,” adds Kumaran. Email: mahua.roy@infomedia18.in
June 2012 | Modern Food Processing
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INSIGHT & OUTLOOK Interface - Dr Guenther Burkhard
probiotic & liquid yoghurt drinks and alcohol-based pre-mixes. Having started use of flexible packages over 15 years ago, Southeast Asia sees the value of flexible packs and is ahead of most Western countries in terms of its usage. Bosch Packaging Technology’s Business Unit Liquid Food can work with Indian beverage manufacturers to introduce new flexible pack styles with value-added features that meet consumer demands for convenience and portability. For example, we recently launched the SurePOUCH flexible pack styles, which feature reclosable spouts that are ultrasonically welded to the outside of the stand-up or pillow pouch. This production method allows the spouts to be positioned in various places to best optimise the product drinking or pouring experience. Additionally, the pouch provides easy evacuation, showing consumers that less product remains inside the package.
How is the demand for packaging solutions for liquid food in India? Consumers want containers that can easily be taken on-the-go and consumed directly from the package. Indian manufacturers have long been interested in flexible packages and the market most opportune is edible oils. Recent statistics indicate India is the world’s largest importer and the third-largest consumer of edible oils. The growing population coupled with both an increasing consumption rate and rising per capita income make it especially ideal for innovative pack styles that suit edible oils, a variety of beverages and other foods, such as yoghurt.
Bosch is targeting India’s edible oil market ...says Dr Guenther Burkhard, Vice President, SalesBusiness Unit Liquid Food, Bosch Packaging Technology. In conversation with Rakesh Rao, he highlights the latest trends in filling & sealing technology and growth opportunities in India. How will the formation of the Liquid Food Business Unit help Bosch Packaging Technology serve the Indian beverage industry? Flexible packaging is a lightweight, durable, convenient, and in some cases, reusable format, making it ideal for a variety of beverage, liquid food and non-food applications. Globally, more beverage segments are embracing flexible packaging as an alternative to rigid, including pure & flavoured waters,
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What are the emerging trends with respect to filling technology for liquid food? One of the most important trends we see is flexibility in machinery, H clean-fill (SPC) machine. which Bosch offers with the SurePOUCH It allows manufacturers to adjust hygienic conditions, format sizes and filling requirements for products with and without particulates. With change-parts, the SPC can produce different formats and change spout sizes, all on one single system. Additionally, increasing automation in aseptic filling has helped create documentation to prove that proper processing parameters are being followed. Every aspect of a machine’s design and function needs documentation, such as electronic signatures, records of temperature use and software configurations. This documentation is especially essential in India to ensure food integrity against wide temperature fluctuations during transport as well as a lack of cold chain.
Dr Guenther Burkhard
Is Bosch planning to increase investment and technology/product offering in emerging markets? Bosch is highly interested in emerging markets, particularly India and Russia, where both have a niche market for liquid food. As noted above, Bosch is targeting India’s edible oils market and sees great opportunity for growth there. Russia’s ketchup and mayonnaise market is particularly opportune for the SurePOUCH. H These condiments are heavily consumed and mayonnaise is used as a sauce in Russia’s most popular salads. In addition to convenience, flexible pack styles benefit consumers with easy evacuation of these condiments, leaving less inside the package.
Food safety regulations are becoming stringent in India. How will this impact the filling and sealing technology? Food safety is a global concern that Bosch understands and addresses with
its technologies. Specific to India, stringent food safety regulations make hygienic solutions especially important due to the lack of cold chain and varying temperatures to which food is exposed during transport. Bosch’s new vertical form, fill and seal machine, the SPC, is capable of filling a variety of products, achieving hygiene standards up to ultra clean-fill. SurePOUCH H packs are fitted with reclosable spouts, which are ultrasonically welded to the exterior of the pouch. During production, the spouts are injection-moulded at approximately 270º C and directly packaged within a clean environment. They provide an enhanced hygienic feature as the product is filled directly into the pouch and not through the spout. The closure only comes in contact with the product when the consumer opens the package. In addition to the SPC machine, Bosch supplies both the spouts and the lightweight film or laminate structures
for the SurePOUCH H packs, guaranteeing seal and package integrity while ensuring easy handling, storage and dispensing of products. The SurePOUCH H will soon be available with aseptic filling capabilities, broadening its food portfolio by adding higher level of hygiene.
Going forward, what will be the demand for filling and sealing technology in India? Machinery suppliers will continue to increase flexibility and operational efficiency. Suppliers will also continue to develop filling technologies specifically for liquid food and beverages as formulations are becoming more complex and sensitive to the elements. The advances in aseptic, ultra clean-fill, and clean-fill machine systems will also enable a larger variety of liquid food and beverages to be filled in flexible packaging styles providing the high quality and food safety demanded by the consumer. Email: rakesh.rao@infomedia18.in
June 2012 | Modern Food Processing
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INSIGHT & OUTLOOK Kerstin Bernhart
Automated checkweighing systems are crucial for optimising efďŹ ciency ‌stresses Kerstin Bernhart, Marketing Manager, MettlerToledo Garvens. In an interaction with Rakesh Rao, she explains how automatic weighing systems can enhance efficiency and improve productivity in the food & beverage industry. What is the demand for automatic weighing systems in the food and beverage industry? Checkweighers have been an integral part of global food production lines for many years. They are one of the most efficient tools to ensure quality control, compliance with global and local packaging regulations, enhancing efficiency, and reducing operational costs. In recent years, there has been a marked and growing demand for automatic weighing systems in Indian and Asian markets. The number of Asian brands is growing rapidly and as each one expands its business in response to consumer demand, they are increasingly turning to systems that enable them to automate their product inspection systems to improve productivity while reducing operating costs. By automating the weighing process, manufacturers are able to inspect 100 per cent of their products as they pass through the production line, ensuring due diligence, improving product consistency and satisfying retailer and government requirements. There is also an increase in requests among Asian brand owners for the inclusion of system features, such as advanced feedback to control filling
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systems as well as connectivity solutions to fully automate the production process without the need to stop the conveyor.
How developments in weighing machines are catering to the changes in the food industry? The biggest trend in the food and beverage industry driving the demand for automatic checkweighing systems in Asia is cost-effectiveness. Growing consumer demand in booming economies, such as India and China, coupled with a rise in the cost of raw ingredients, has led to an increased need among food and beverage manufacturers to enhance the efficiency of their production lines to reduce manufacturing costs and boost productivity. Large Asian global players now realise the need to maintain their competitiveness in a market where the cost of raw materials and operations is rising. By automating their weighing systems, brand owners are able to comprehensively monitor the performance of their filling systems for adverse trends, reducing instances of wasteful product giveaway, maximising efficiency and reducing production costs. The rising use of automatic
reject systems in Asia also help food and beverage manufacturers to comply with increasingly stringent initiatives regarding weights and measures, such as China’s National Institute of Metrology, reducing the risk of damaging product recalls due to incorrect product weight.
How important are automated weighing systems for increasing efficiency? Automated checkweighing systems are crucial for optimising efficiency in the food and beverage industry, as they can effectively detect substandard products and automatically adjust production processes to minimise downtime due to recalibration of filling machines. Modern checkweighers are able to alert operators of adverse weight trends in their products before they become a problem, enabling them to adjust filling machines, minimising instances of product giveaway. With innovative feedback control mechanisms, checkweighers can now communicate this information directly to filling machines, so that they can decrease the flow of product into the empty packaging, preventing product overfill in future. Email: rakesh.rao@infomedia18.in
INSIGHT & OUTLOOK Roundtable
Hot ďŹ ll or aseptic: Making the right choice Aseptic packaging technologies have been integrated into Food & Beverage (F&B) packaging. It is gradually replacing hot fill in certain sectors of F&B industry. But aseptic filling too has its own limitations as it has advantages. Mahua Roy speaks with eminent experts who offer a steady comparison of the two technologies.
Dr J V Parekh Technical Consultant for Dairy and Food Industry
Adwait Rajwade Head, Asia-Pacific Sales, Barry-Wehmiller International Resources
Dr Sven Fischer Vice President - Aseptic & Process Engineering, R&D, Krones AG
Generally, aseptic packaging is performed in sterilised conditions whereas hot filling does not require such conditions. Hot-filled products have limited shelf-life as compared to those aseptically packaged. The investment is more for aseptic packing as compared to the hotfilling system in terms of machinery investment and packing material. In Ultra-High Temperature (UHT) treatment, the product (usually milk) is heated at 140ËšC for a brief period and then rapidly cooled to room temperature. This results in eliminating all the microorganisms without losing the nutritional value of the product and making it safe. UHT treated milk when packed aseptically gives a longer shelflife at ambient temperature. The modern automation technologies save labour costs and minimises production d i llosses. The Th compact construction and flexibility means economy even in small volume plants. Aseptic technology is better than hot filling, which is generally not used in the dairy industry.
Both technologies are viable, provided they are both well understood. However, with hot fill the product is thermally stressed during pasteurisation and filling, and then its nutritional content remains rather constant during its shelf-life. In aseptic filling, the product is mildly stressed during pasteurisation and filling, but even if properly stored and distributed, its nutritional content, flavours would start to diminish. Nowadays, only few low acid products like natural (not reconstituted) milk and other dairy-based drinks really cannot be hot filled. For all the other products, the choice is mostly linked to marketing and consumers’ acceptance of the added value given by aseptic vs hot fill. Apart from the product range for each bottler, the main driving factors of choice remain i upfront f capital i l investment i (higher in aseptic) vs higher operational costs (less than in the past but still higher in hot fill) as well as skill and procedures available at each individual plant.
From the product quality point of view, aseptic packaging is a better technology. Both technologies have the goal to kill micro-ogranisms. The aseptic process suits both, low acid and high acid products whereas the hot fill process is mainly used for high acid products. Less energy is needed for the aseptic process because the thermal energy for sterilising the product may be recovered to a large extent, whereas for hot fill solutions less heat may be recovered. Aseptic packaging allows lightweighting of PET-material in packaging to a larger degree than with hot fill. The design freedom for aseptic PET-packaging is higher than with hot fill. Besides, hot fill is not suitable for every product. Aseptic packaging economically makes sense only if there h iis a three-shift h hif operation i and d the batch sizes are large enough to run such a line continuously. The investment costs of an aseptic line are usually higher than the one for a hot fill line.
EDITORIAL TAKE The thumb rule of packaging can be summarised as: if a product can be hot-filled, it should be hot-filled. Even though hot-filled products are thermally stressed, they commit a longer shelf-life. Also, new technologies in PET and packaging lines are resulting in low investment costs in hot-fill. However, dairy products are an exception, which need to be filled aseptically only.
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INSIGHT & OUTLOOK PET container
Rakesh Rao
T
he growing market for processed food and beverages is bolstering the demand for PET packaging in the world, especially Asia. The demand for flexible packaging chemical PET witnessed growth of around 7 per cen nt CA CAGR GR iin n th thee la last st decade due ttoo it its diverse application in a w widee range of new products deve de velo loped by fast-moving consumer good go ods (F FMCG) and nd foo ood d
other BRIC countries, Brazil, Russia and India, will also play a dominant role in this market. India’s large population is causing consumption of packaged goods to rise, creating increased demand for PET capacity additions. “India’s food and beverage packaging sector is expected to witness a significant growth towards 2020 when compared to the rest of thee BR th BRIC nations. According to GBI estimates, the Indian packaging sector is expected to g ro row with an annual rate of 11.9 per c en ent towards 2020.
2010, while the food and beer sectors accounted for respective shares of 22.4 per cent and 11.4 per cent.
Hot fill driving demand According to GBI Research, new hot-filling processes are opening up opportunities for PET packaging for pasta and sauces. “Hot-filling process is past a neew technology to improve the shelflife of non-carbonated beverages like milkk, fruit juices, etc. This technology need ds more promotional activities and markketing in India for good growth in
Adding g
flexibilityy
to food packaging The booming market for processed Food and Beverages (F&B) is leading to robust demand for flexible packaging, thus giving a push to PolyEthylene Terephthalate (PET) consumption in India. Technological advancements such as hot filling are likely to aid this development further.
sector companies, according to GBI Research – which recently released its report titled ‘PET global market to 2020: Increasing demand from carbonated soft drinks (CSD), food and beer packaging in BRIC nations driving growth’. The report indicates that fast-growing economies and strong production industries will lead Brazil, Russia, India and China (BRIC) to become dominant forces in the global PET market. While China is anticipated to be the PET market leader towards 2020,
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This demand for F&B packaging, coupled with FMCG sector demand demand, is expected to keep Indian PET demand moving at a good pace with a CAGR of 13.5 per cent towards 2020,” opines Mohan Krishna, Analyst - Chemical Practice, GBI Research. Flexible packaging will continue to grow in importance as major retail chains demand greater product protection and longer shelf-life for various products. CSD accounted for an impressive share of 31.5 per cent in the demand for PET during
the future. As the capital investment for the hot-filling equipment is relatively higher than with traditional packaging, this set-up is only suitable for large-scale producers, which drags down the popularity of this technology in developing countries like India. However, towards 2020 we are expecting an improvement in opportunities as this technology becomes economical and available for small-scale producers,” avers Krishna. Similarly, PET packaging is expected to increase its share in the
PET container
Making new inroads While PET has been replacing glass and metal packaging as preferred choice of packaging in non-alcoholic beverages, its acceptance among the alcoholic drink manufacturers is still low. But this is likely to change in near future. According to GBI Research, during 2011, beer distilleries adopted PET bottles for packaging, which is expected to continue towards 2020 due to advantages in product quality, transport and bar regulations concerning the use of glass in outdoor areas. Experts believe that one can expect similar developments in India as well. “Countries around the world, and especially BRIC nations, with the exception of India, have introduced
ADVANTAGE PET Following are some of the factors that support the growth of PET in food and beverage applications: o PET is relatively cheaper o Gross weight for the product will decrease with PET packaging. This will in turn decrease logistics costs o PET is unbreakable when compared to glass containers
PET in alcoholic beverage packaging. The Indian alcoholic beverage packaging segment is primarily driven by consumer sentiment, where consumers feel that glass packaging is superior when compared to PET packaging. However, PET consumption in the Indian alcoholic beverage sector is expected to grow towards 2020, due to low-cost packaging and decreased gross weight of the product, which, in turn, decreases logistics costs,” observes Krishna. The demand will be further fuelled as food and beverage processors switch to PET from other packaging materials such as metal, glass, etc. He adds, “Food and beverage companies are considering PET as a potential substitute for their glass & metal packaging applications. This was supported by recent innovations in biodegradable PET from major CSD players like CocaCola and PepsiCo.”
Figure 1: Contribution of Asia-Pacific region in the global demand for PET Asia-Pacific’s contribution (in %)
packaging sector towards 2020 due to better gas barriers and ultraviolet (UV ) light protection, which extends the shelf-life of PET-packaged products. He adds, “Improved gas barrier properties for PET support the increment in food and beverage shelf-life by preventing oxygen, carbon dioxide and harmful gases permeation. Common dyes used in food, beverages and personal care products can lose colour when exposed to UV light. Nutrients like vitamins are receptive to UV light as it can initiate oxidation reactions ensuing in taste and odour changes. UV light can also degrade product emulsifiers used to affect product texture. These factors increase the scope for PET as a substitute to other packaging materials.”
47.8% 40.6%
2020 *
2010 *: Estimated
Year Source: GBI Research
Figure 2: Contribution of end-user sectors in the global demand for PET (in 2010)
31.5%
34.7%
Infusing demand Global PET demand is expected to reach 23,452,281 tonne by 2020 from 12,621,553 tonne in 2010. And India, along with other BRIC nations, is likely to play a major role in driving up PET demand. Krishna opines, “India’s large population, coupled with demand initiatives from downstream sectors like water and CSD packaging sectors, favours future growth in consumption and demand for PET in India. Anticipated changes in traditional packaging demand, along with altering lifestyles and the increasing number of working couples have aggravated the growth for readyto-cook and ready-to-eat foods. Meanwhile, changes in food packaging technology to increase the shelf-life of ready-to-cook products by packing in PET containers and films will also support the growth of PET packaging industry in India in future.” According to GBI Research, enduser segments for PET in India are diversified when compared to other
11.4%
22.4%
Carbonated soft drinks Food Beer Others Source: GBI Research
regions in the world. Apart from water, food and beverage packaging, PET packaging applications fill an important niche in the healthcare and personal care industries. These sectors are expected to witness significant growth rates of 13-14 per cent towards 2020. Krishna says, “Owing to diversified PET applications, PET consumption in India is expected to witness a significant growth towards 2020 when compared to other BRIC nations. Indian PET demand is expected to witness a significant growth with a CAGR of 13.5 per cent towards 2020, which will be mainly driven by water, other beverages, CSD and food packaging sectors.” Email: rakesh.rao@infomedia18.in
June 2012 | Modern Food Processing
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AUTOMATION TRENDS Dairy industry
Virendra Deshpande
A
ccording to the ‘Vision 2015: Strategy & Action Plan for Food Processing Industries in India’, the key issues in milk processing include lack of availability of milk in the lean season, demand and supply imbalances & lack of scale. These are further compounded by rising input costs, growing concerns over milk quality and safety and the huge variety in stock keeping units (SKUs). The increasing complexity of operations demands a
commensurate investment in processes and systems. As the industry serves the nourishment needs of the nation, it will have to nourish its operations as well to sustain production over the long term. Automation can help here.
Making an impact There are three areas of dairy operation that automation serves: Milk receiving: Yields and efficiencies through all production processes depend on managing critical information right from milk reception.
Ensuring that characteristics such as fat content, protein content and bacterial load are properly measured, as milk is unloaded and fed to processing, gives producers the chance to adapt recipes and processes in real-time. So, yields are maximised and risks are managed. Milk processing: Automation enables precise control of processes along with deep insight into process performance, product quality and food safety measures. This enables milk producers to minimise solids losses and deliver consistent outputs.
Enriching production through operational excellence Although India is the leading producer of milk in the world, its contribution in the global dairy trade is miniscule. Low productivity and large amount of wastage are the main reasons for this. By adopting automation solutions, dairies can optimise their resources and enhance production efficiency. Automation improves all areas of a dairy operation Chilling Separation Filtration Pasteurisation Homogenisation Water management Environmental monitoring
Deodorisation Metering
Energy management
Butter churning
MISSION AUTOMATION Courtesy: GE Intelligent Platforms
o Deliver consistent quality o Improve packaging efficiency o Leverage HACCP procedural control o Reduce raw material handling cost o Control milk loss and increase margins o Ensure food safety and compliance
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Dairy industry
Packaging: To help milk producers respond to the continually increasing market demands for new products, a flexible manufacturing and automation solution enables quick changeovers, innovative packaging designs and faster time to market. A well-implemented automation solution can offer dairies powerful realtime data directly from the production floor and immense value-added capabilities that help them manage their operations better.
Showering benefits The benefits of automation for the dairy processing company include: Reduction in total cost of ownership for greater profitability: Dairies need access to critical real-time information across the entire production line to identify and address bottleneck operations, process alarms, equipment failures as well as resource availability (labour, materials, etc). An automation solution based on critical real-time information helps them uncover cost-saving opportunities; whether it is minimising milk loss or optimising equipment time or reducing expensive accidental misprocessing – to positively impact their bottom line. Drive increased productivity and efficiency: Dairies need to leverage manufacturing data across different production areas – from raw materials receiving to milk processing and packaging – so they can better co-ordinate operational activities. Automation helps them leverage enterprise-wide real-time production data and digitised processes to synchronise activities along the whole production line, reduce inventories across the supply chain, and co-ordinate short-term material and logistics plans to boost productivity. Enable greater flexibility for improved market responsiveness: Dairies increasingly need the ability to quickly add new products, change recipes ‘on the fly’ and implement new operational procedures quickly and cost-effectively to match changing consumer tastes. Automation supports revolutionary
processing and packaging strategies by delivering the flexibility needed for faster product turnover, greater variability and shorter production runs – so dairies can continually drive innovation and maintain high levels of market responsiveness and brand leadership. Ensure product safety and meet regulations: Operational transparency and control is essential to comply with stringent food safety requirements. Automation starts with the milk receiving process and tracks & traces product genealogy throughout the manufacturing process, providing dairies with the increased visibility, control and accountability needed to deliver safe and compliant products.
Operational journey While there are a number of benefits from automating dairy operations, plant managers need to be cognisant of limited resources (budget, manpower, systems) that management can allocate for such automation plans. Hence, it makes sense to prioritise and implement these in steps. This can be termed the ‘operational excellence’ journey. It begins with improving visibility over the process, progresses to a structured way of computing Overall Equipment Effectiveness (OEE) over the packaging line, subsequently manages specifications and recipes, and eventually digitises standard operating procedures (SOPs). Given the emphasis on product safety in this industry, it is important to track and trace the genealogy of ingredients early in the journey. The final destination is a better visibility over the entire supply chain and the process’ impact on the environment. This stepped approach particularly suits the Indian context. A distinct feature of Indian dairy sector is the huge variety in Indian milk and milk-based products. Seasonal variations, changing consumer tastes, cultural and regional preferences demand frequent changes in production and packaging lines. It is estimated that around 30 per cent of downtime on packaging lines is attributed to adjustments and
settings during changeovers on machines. Automation offers higher agility on such lines through machine control with advanced motion solutions supporting electronic reconfiguration that reduces changeover time from a few hours to few minutes. Even during power outages, machine start-up time can be reduced through auto sequencing that positions the machine to the same status as its breakdown, in turn improving OEE. Raw milk sourced from various cattle farms across the country has its unique characteristics. Coupled with the parameters set during the process, it has a huge bearing on the quality of the end-product. Advanced statistical algorithms can help bring consistency in various batches of production. Here is how it works – the process data captured through Distributed Control Systems (DCS) or Programmable Logic Controllers (PLC) is archived in a central data repository called Historian. The Historian further feeds this data to a sophisticated analytics’ software offline to determine correlation between various process parameters and identify the most optimal operating zones. The dairy technologist can use this data to recommend suitable settings for process parameters, which maximise yield and produce the desired quality of products.
The technology driver Rising input costs, changing consumer tastes and increasing emphasis on milk safety and quality is driving dairies to invest in automation. Given scarce resources, it is imperative to select technologies that can scale from one application area to another, one line to the entire plant and even to geographically dispersed plants. Only such solutions will sustain an industry that nourishes a population of over billion. Virendra Deshpande is the Vertical Leader (Consumer Packaged Goods) at GE Intelligent Platforms, India. For details, contact Milesh Gogad on email: milesh.gogad@ge.com
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ENERGY MANAGEMENT Ultrasonic sealing
green g
The seal of energy efficiency
Courtesy: Bosch
Ideally suited for heat-sensitive products, ultrasonic sealing is an energysaving alternative to heat sealing. Ultrasonic technology not only simplifies the production process, but also reduces the cost of production.
Ultrasonic sealing is an energy-saving, quality-enhancing alternative to heat sealing
Rakesh Rao
W
hen the first plastic car was created using ultrasonic welding way back in 1960s, nobody would have thought that this technique would prove to be a boon for packaging industry. Nearly all packaging materials and laminates with a thermoplastic sealing layer or coating can use ultrasonic technology as it can create strong hermetic and peelable seals. This method is based on the conversion of high frequency mechanical sound waves in a thermoplastic material into frictional heat creating a molecular bond between two or more sealant layers. Dr Bernd Wilke, Head - Research and Development, Bosch Packaging Technology, observes, “By using high frequency vibrations, the new technology creates a tight, strong seam for closures in different packaging
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formats and represents an attractive alternative to other sealing methods used till date such as cold and heat sealing.”
sensitive products, which are particularly used in delicate confectionery, grated cheese, fresh produce and frozen food. He adds, “Heat-sensitive products such as chocolate can melt and be damaged by a heat-seal process. A popular alternative in the past, when packaging heat-sensitive products was, therefore, to use an expensive cold sealing film. One disadvantage of this approach is the limited storage life of the film, which tends to stick together or to the product. Furthermore, the relatively high costs involved with cold sealing film have encouraged manufacturers to consider alternative sealing methods like ultrasonic technology. With ultrasonic sealing technology savings can be made with material costs.” For horizontal packaging applications, manufacturers can use less expensive film materials, replacing the kinds of films previously required for heat sealing with thinner and more costeffective alternatives. “Even if product or particles remain in the seam area, the new technology avoids the risk of diminished seam quality and leakage due to contamination of the sealing area by using high frequency vibrations that remove product residues. The resulting seams are secure, ensuring that the product is tightly packaged,” adds Dr Wilke.
Protecting heat-sensitive products
Power savings
The ability to seal without applied heat makes ultrasonic sealing particularly suitable for food products that are temperature-sensitive. Dr Wilke opines, “The technology is ideal for heat-sensitive products. One drawback associated with the often-used heat-sealing method is the negative influence on product quality by the required sealing heat. The high temperature of the sealing jaws can cause product damage. Here ultrasonic sealing’s ‘cold’ approach is a major advantage. Since the tools used are cold, the sealed seam can be placed close to the product without having a negative impact on its quality.” Removal of the heating element enables food processors to ‘cold’ package
In the conventional heat-sealing process, the heat is transferred from the outside to inside the laminate, while ultrasonic technology initiates the sealing process inside the seal joint. Equipping machines with ultrasonic sealing capabilities allows manufacturers to use less energy than heat sealing as jaws do not need to be preheated and film is only heated in the precise sealing area. Experts claim that food manufacturers using ultrasonic process instead of heat to seal packages can reduce the cost of raw material and energy required for packaging. It has been observed that ultrasonic seals are narrower and packages require less headspace compared to the conventional
Ultrasonic sealing
heat-sealed packages. Dr Wilke points out, “Ultrasonic sealing technology is one possibility that enables manufacturers to reduce both costs and product waste while providing strong product protection. With the ultrasonic technology, the packaging film is not heated from outside inwards, but as a result of molecular vibration within the film. As such, the temperature needed for welding purposes is generated inside the film in the actual sealed seams.”
Easy maintenance Ultrasonic sealing process is cost-effective and potentially safer than other methods because it generally does not require heat or hazardous materials such as solvents or adhesives. The closure can be effective even if there is contamination of the seal area by food product. Typical heat sealing systems often require intensive cleaning as the product tends to melt and accumulate in the sealing zone. The ultrasonic process can seal film structures that have been contaminated by product, minimising stoppages and reducing downtime. He opines, “Typically, heat sealing systems require intensive cleaning as the product tends to melt and accumulate in the sealing zone. The ‘cold’ ultrasonic technology eliminates this need. By reducing the issue of film sticking to the heated jaws, ultrasonic technology ensures that there is less material residue after sealing and fewer defective packages, all of which can help to reduce equipment downtime. As a result, manufacturers can see significantly
Ultrasonic sealing not only reduces energy consumption, saves material and increases machine availability, but also saves production costs; so manufacturers can be ‘greener’ and more profitable. We envision strong growth for this technology. Dr Bernd Wilke Head - Research and Development, Bosch Packaging Technology
ADVANTAGE ULTRASONIC SEALING
o Requires exceptionally low energy o No warm-up and cool-down time, reduced sealing time and quick cool-down of sealing seam increase output o Cold sealing tools avoid thermal damage of product and packaging material o Less cleaning and maintenance, as melted product does not clog the sealing tools o Sealing through product reduces rejects and product wastage o Seals through contaminants such as powder, liquids, foamy products or fibres, which may occur during the filling processes o Narrow sealing width and sealing above product level consumes less packaging material Source: Bosch Packaging Technology and Herrmann Ultrasonics Inc
increased operating times and a reduction in waste material.” By removing the heating element in their sealing process, manufacturers can potentially reduce the thickness of the sealant layer of packaging film structures, reducing material costs. So can ultrasonic sealing technology help in reducing the consumption of raw material? Yes, it can, believes Dr Wilke. He adds, “Bosch’s machines equipped with ultrasonic sealing provide savings with regard to material costs. Not only can manufacturers use more cost-effective film, but also require thinner seams, saving material. With vertical form, fill and seal machines, up to 16 millimetre of film can be saved per package in terms of bag length.”
Simplifying processing The ultrasonic process is used in many stand-up and flat-pillow pouches, form, fill, seal bags, carton, blister/clamshell, cups/trays and tube type applications. Due to recent developments in ultrasonic sealing, both continuous longitudinal seals and intermittent cross seals can now be integrated into one packaging system. Although common applications of ultrasonic sealing include joining thermoplastic resins (such as polyethylene or polystyrene), metal and plastics can also be joined using this method. Seals can be as simple as overlapping layers or can bond an insert into a base or stake a post perpendicular to the base. The strength of the seal can make this process suitable for tamper-resistant packaging as well. In order to produce consistent and reliable seals, microprocessor-controlled
ultrasonic sealing machinery can be used. Fully automated machinery requires only limited training without affecting speed or quality. Adjustment of the microprocessor settings permits quick changes to sealing specifications such as frequency, size, and source material.
The seal of green With energy cost going up, food packers are evaluating various options to bring down the cost of production. Ultrasonic sealing technology can provide viable option to food and beverage manufacturers as it eliminates the cost of generating heat. Hence, one can expect steady rise in demand for this technology from the emerging markets such as India. Dr Wilke says, “As ultrasonic sealing is an energy-saving, quality-enhancing alternative to heat sealing that serves to reduce production costs, it is gaining importance among our customers, both in developed and emerging countries.” The market for ultrasonic technology will grow further as food and beverage manufacturers focus on packaging sustainability using environmentallysensitive methods, including energy efficiency, recyclable and biodegradable materials, reusability, etc. “Sustainability is a buzzword in the packaging industry that is continuing to grow in importance. Ultrasonic sealing not only reduces energy consumption, saves material and increases machine availability, but also saves production costs; so manufacturers can be ‘greener’ and more profitable. We envision strong growth for this technology,” concludes Dr Wilke. Email: rakesh.rao@infomedia18.in
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POLICIES & REGULATIONS National Mission on Food Processing
Prasenjit Chakraborty
T
he government, in the latest Budget, has proposed the implementation of NMFP scheme in co-operation with state governments during next fiscal to provide the much-needed thrust to the food processing sector. Under the scheme, the state governments will set up food processing units on a large scale, while the Centre will provide them technological and logistical support. Processing will be started in co-operation with the state governments in 2012-13. The scheme aims at providing more flexibility to suit local needs.
In order to ensure adequate returns to stakeholders, it is essential that suitable post-harvest management be adopted to add value and reduce wastage. Here lies the importance of the scheme, and if the scheme is properly implemented, it would address the wastage problem and take the industry to the next level from what it is now.
Combatting the bane of food wastage Against the backdrop of huge food wastage in the country, such scheme is a necessity. A country like India where a substantial number of people falls in below the poverty line category cannot
Mission on Food Processing will help add value to food processing sector and develop new technology,” opines V Gokuldas, Managing Director, HRS Process Systems Ltd. Of late, the processed food sector has registered encouraging growth. This is evident from the consumption of processed food in India. In this background, food processing industry in India is increasingly seen as a potential source for driving the economic development, as it brings synergy between industry and agriculture. A developed food processing industry is expected to lead the increase in farm gate prices translating into increased
prosperity vision through value-addition A
to
The National Mission on Food Processing (NMFP) aims at addressing issues pertaining to storage, logistics and technology, among others, to infuse growth in the food processing industry. Proper implementation of the scheme will help reduce wastage, which is the biggest stumbling block in the progress of this industry. Agriculture continues to be one of the cornerstones of the Indian economy. Though the share of agriculture in GDP has been declining over the years, its role remains critical as it accounts for about 52 per cent of the employment in the country. Slowdown in investment and declining productivity raises serious concerns about the economic sustainability of millions of farmers. It is estimated that if the country has to maintain a GDP growth rate of over 8 per cent, the agricultural sector has to grow at the rate of at least 4 per cent. Government has initiated massive programmes for investment infusion in the agriculture sector during 11th Plan through Rashtriya Krishi Vikas Yojana and National Horticulture Mission. This has led to increase in production.
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afford to let its food grains go waste. But it is indeed ironical and extremely unfortunate that there is lack of proper storage and distribution infrastructure in the major grain-producing areas of the country when an overwhelming majority of the population is wallowing in extreme poverty, famine and hunger. Current logistics scenario in the country is equally poor resulting in huge loss of food grains. Encouraging large, organised players and private investments in quality transport and storage facilities is essential, given the large investment required. To top it, food prices are skyrocketing owing to shortage of food supplies. Also due to poor storage and handling whatever grain is reaching the poorer sections of the society is also of extremely inferior quality. “National
rural incomes, reduced wastages, value addition, crop diversification, employment opportunities as well as export earnings. It is now clear that the NMFP scheme has potential to address the perennial problem of food wastage. The scheme has come at an appropriate time as India’s strength in processed food arena has already been proven to the world. Such schemes not only will help solve the problems in the food industry but also help in bringing foreign investment to the sector. Rajheev Agrawal, Director and CEO, Nilon’s Enterprises Pvt Ltd, rightly says, “One can expect a boost to the food processing sector. This will come from the provision of National Mission on Food Processing.” Email: prasenjit.chakraborty@infomedia18.in
STRATEGY Marketing communication
Mahua Roy
A
fter the film industry and cricket, food happens to be one of the biggest levellers in India, which is called the Italy of Asia because of the gastronomic vulnerabilities of the inhabitants. But even most common foods that have a national footprint carry with them their own sets of intricacies and nuances. Aalu chaatt in Delhi cannot be replicated in Chennai, and Vada pav of Mumbai cannot be parallelled in Kolkata. Marketing expert Harish Bijoor, CEO, Harish Bijoor Consults, notes, “India has as many as 236 styles of sambar made in millions of homes. Every sambarr differs from another.” So what cue does thiss offer to marketers? Is this a huge opportunity to tap a larger set consumers? of Or is it a roadblock entailingg customisation of marketing communication? One of the most decisive but underrated characteristics of the Indian market is the emphasis on culture and cultural differences. Generally, marketers attempt to either visualise India as one demographic of consumers and look for a common unifying theme, or consider it rather diverse to generate complex branding measures. Says Neeraj Chandra, Vice President and COO, Britannia Industries Ltd, “The underlying emotional drivers need to be recognised in different geographical zones of the country. Each zone has its own sensory perception and contextual requirements. Developing variants under an established umbrella brand is the key.”
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Surpassing imaginary boundaries It is judgemental to assign stereotypes to geographies. However, certain evident traits do differentiate people from various geographies in India. North Indian inhabitants harbour a sense of power. Down south, a conservative approach is observed, coupled with deep-rooted traditionalism. Whereas in Western India, typically in Mumbai, one is tremendously practical and equates
name. This generally flops. The taste, whether it is LCD or HCD, falls between two extremes. No one is able to identify with it. In the bargain, the brand struggles with low volumes for decades. If one is to succeed, one has to offer at least 16 different blends for India of the same sambarr powder, catering to local tastes.” There is a reason why mustard oil is still preferred in the East, sunflower in West, soya in the North and coconut oil in Southern India. And oil forms a tiny part of the huge food & beverage industr y. This obser vation provides a deeper insight into p the habits of consumers and how marketers can create influential marketing strategies.
Making distribution robust Is India really four different ecosystems – North, South, East and West? Are consumer psyches a function of regionalistic boundaries? Can a brand make its presence felt with the same grandeur in each of the four y ecosystems?
time to money. By extrapolating these traits, marketing and branding measures can be personalised. Another strategy is to introduce variants depending upon cultural preferences. Taking the example of sambar forward, Bijoor says, “A national marketing company arrives at the lowest common denominator (LCD) or a highest common denominator (HCD) taste and markets one blend for the entire country under one brand
Distribution logistics and definitely play a prime role in making a brand have a national appeal. Availability of the product will boost sales after proving advertising and branding efforts successful. “Distribution is the cutting edge. This is one thing that most brands are unable to achieve. India is a large country with diverse sets of realities, which are both, physical and attitudinal. These need to be surmounted before achieving the status of a big national brand,” says Bijoor.
Engagement via BTL activities Below-the-line (BTL) or on-ground activations are gaining importance increasingly in these days of competitive fast-moving consumer goods environment. Consumer engagement is amplified manifold once BTL
Marketing communication
Distribution is the cutting edge. This is one thing that most brands are unable to achieve. India is a large country with diverse sets of realities, which are both, physical and attitudinal. These need to be surmounted before achieving the status of a big national brand. Harish Bijoor CEO, Harish Bijoor Consults
activities are carried out. And now, due to the abundance of malls and modern retail, BTL activities have become a common phenomenon. “BTL is an important part of the brand mix. Most companies under-value its importance. You can build a brand in India and in rural India, in particular, on the BTL basis alone.” Rural markets pose a challenging atmosphere to define the loyalty of a brand. In all the four
zones, consumer psyches of rural India differ too. “Success in rural geographies can be achieved by tweaking pack sizes by studying consumption patterns,” says Chandra.
The branding of brand equity Do old and established brands have an edge when it comes to establishing a national favouritism? Does their brand equity hold an additional brand value? Chandra says, “Established brands carry an equity, which has critical relevance and offers differentiation.” But new brands too can create an impact. In the ability to connect with the audience lies the differentiating factor. Whether it is by employing local celebrities or multi-lingual jingles, the consumers are looking for a common factor of engagement. When the right connect is established, whether by rhythm or marketing communication, boundaries
The underlying emotional drivers need to be recognised in different geographical zones of the country. Each zone has its own sensory perception and contextual requirements. Developing variants under an established umbrella brand is the key. Neeraj Chandra Vice President and COO, Britannia Industries Ltd
become non-existent. Not very long ago, a Tamil (rather Anglo-Tamil) song broke all records and became a viral rage over national social networking sites, mobile ringtones, callertunes, ever yday usage, T-shirt quotes and media headlines. The entire nation overlooked the barriers of language and hummed in unison, “Why this Kolaveri Di?” Email: mahua.roy@infomedia18.in
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TIPS & TRICKS Dehumidifier
Food and beverage processing requires large quantity of water, whether to cook, wash or sanitise. This often leads to increase in moisture level in the processing unit and also rise in temperature due to high humidity. Dehumidification system can help control humidity, which greatly affects the quality of food.
F
ood spoilage can occur when there are slight changes in relative humidity (RH). Moisture, which can condense on the surface of a product, can be one of the main causes of food contamination due to microorganism growth. Microbial growth and dispersal can be controlled if the food processing facility is kept dry. Neither fans nor conventional refrigeration units will control humidity. Here are some useful guidelines to control moisture by using dehumidifiers.
1
Traditional HVAC remove systems excess humidity by overcooling. By cooling the air to dew point, these systems pull humidity from the air through condensation. The condensation is collected on coils and drip pans, which often produces microbial build-up. To solve this problem, dehumidification systems can be used.
2
Dehumidifiers come in two types – mechanical and desiccant. While a desiccant wheel costs more than a mechanical system, it does more dehumidifying than a mechanical system. Decision to use mechanical or desiccant dehumidifier will depend on the conditions of the plant.
3
A variety of food processing applications requires conditioned space to be maintained below 45°F dew-point humidity. For this, dehumidification equipment in combination with refrigeration can be used for humidity and temperature control. A desiccant dehumidification in combination with refrigeration generally is a more energy-efficient and practical method of producing low-humidity air
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than refrigeration alone. However, it is an energy-intensive process; the cooler and drier the process air, the more energy is required, regardless of which process is used.
4
If a desiccant dehumidifier is operated continuously and delivering fairly dry air, it is not unusual for annual operating cost to exceed the purchase price of the dehumidifier. This highlights the importance of making the desiccant dehumidification process as energy efficient as practical.
5
Liquid desiccant, a natural salt water solution that removes humidity directly from the air, can offer an ideal solution to remove moisture. Because the units do not require the extra step of adding excess cooling or heating that conventional dehumidification processes use, the liquid desiccant humidification technology can reduce energy consumption by about 30 per cent, lowering the operating cost.
6
In addition to being energy efficient, liquid desiccant
is also a natural disinfectant. The salt solution removes almost all air-borne bacteria and microorganisms in a single pass, and eliminates the need for drip pans or coils to collect condensation. Hence, the technology offers additional benefits of improving air quality, removing odours and eliminating hazards associated with food safety.
7
In processing powdery food such as milk powders, moisture hinders the free flow of powders/ granules making many downstream operations (eg packaging, filtering and handling) difficult and expensive. In such cases, dehumidifiers, in conjunction with spray dryer/fluidised bed dryer, can be used to improve the quality of drying.
8
D e s i c c a n t dehumidifier is ideal for many temperature-sensitive products, which cannot be spray dried easily at relatively high inlet temperatures. Use of dehumidifiers also reduces the drying time of the product inside the spray/fluidised bed dryer. Reference: Bry-Air (Asia) Pvt Ltd and Advantix Systems Email: rakesh.rao@infomedia18.in
PROJECTS
New projects and expansion activities are the barometers of industrial growth. These also present business opportunities to service providers like consultants, contractors, plant & equipment suppliers and others down the value chain. This feature will keep you updated with vital information regarding new projects and capacity expansions being planned by companies in the food & beverages industry. Dairy processing unit
Nestle India Ltd Project type New plant Project news Swiss dairy major Nestle’s Indian subsidiary, Nestle India, is reportedly planning to set up a dairy plant in Baramati, Maharashtra. The ` 7,490crore company, which has grown at nearly 20 per cent each year between 2002 and 2006, aims to become ` 25,000-crore dairy major in the next ten years. Project location Baramati, Maharashtra Project cost Not known Implementation stage Planning Contact details: Nestle India Ltd Nestle House, Jacaranda Marg M Block DLF City Phase II, National Highway 8 Gurgaon 122 002 Tel: 0124-2389300 Fax: 0124-2389399 Email: communication@in.nestle.com -----------------------------------------Ice cream
Hatsun Agro Product Ltd Project type New parlours Project news Hatsun is setting up a chain of ice cream parlours over the next 12 months and has earmarked an investment of over ` 50 crore for the same. Hatsun will launch an exclusive chain under the brand Ibaco in a standalone format. The chain will offer a range of flavours distinct from its flagship Arun Ice Creams brand. As per the plans, the company will set up 250 Ibaco outlets including 70 in Tamil Nadu. Project location Tamil Nadu Project cost ` 50 crore
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Implementation stage Planning Contact details: Hatsun Agro Product Ltd 5-A,Vijayaraghava Road T.Nagar, Chennai 600 017 Tel: 044-2815 0014, Fax: 044-2815 2508 Email: info@hatsun.com -----------------------------------------Mega Food Park
Uttar Pradesh Government Project type New food park Project news Uttar Pradesh Government has planned to set up a mega food park at Lucknow. The project is estimated to cost over ` 150 crore. The park will be spread over 100 acres, which is available with the government, and the project would be set up under the Union Ministry of Food Processing Industries scheme, wherein the Central Government would provide incentive. Project location Lucknow Project cost ` 150 crore Implementation stage Planning
company is investing ` 100 crore for the plant, which will start production in October 2012. It is also in the process of setting up another manufacturing plant at an investment of ` 50 crore at Harohalli near Bengaluru. Project location Bidadi, Karnataka Project cost ` 100 crore Implementation stage Work in progress Contact details: Manjushree Technopack Ltd 143, C-5, Bommasandra Industrial Area Hosur Road Bengaluru 560 099 Tel: 080-4343 6100 Fax: 080-2783 3479 Email: info@manjushreeindia.com -----------------------------------------Sugar refinery
Simbhaoli Sugars Ltd
Manjushree Technopack
Project type New plant Project news Simbhaoli Sugars Ltd is setting up a 1,000 tonne per day sugar refinery in a joint venture with global agri-business group E D F & Man Holdings near the Kandla Port in Gujarat. The project, which is being implemented through their joint venture company, Uniworld Sugars Pvt Ltd, is estimated to cost ` 2,350 million. Project location Near Kandla Port, Gujarat Project cost ` 2,350 million Implementation stage Planning
Project type New facility Project news Manjushree Technopack is in advanced stages of commissioning its new manufacturing plant at Bidadi near Bengaluru. It will have a capacity to produce 20,000 tonne in phases. The
Contact details: Simbhaoli Sugars Ltd C-11, Connaught Place New Delhi 110 001 Tel: 011-41510421 Fax: 011-23413088 Email: info@simbhaolisugars.com
Contact details: Director, Suchna Bhawan, Park Road Department of Information & Public Relations Lucknow 226 001 Tel: 0522-2239132 Email: upinformation@nic.in -----------------------------------------Packaging
EVENT LIST
NATIONAL International Foodtec India 2012 AHMEDABAD
PUNE
CHENNAI
LUDHIANA
Gujarat, Oct 5-8, 2012
Maharashtra, Nov 2-5, 2012
Tamil Nadu, Nov 22-25, 2012
Punjab, Dec 21-24, 2012
INDORE
AURANGABAD
RUDRAPUR
Madhya Pradesh, Jan 11-14, 2013
Maharashtra, Feb 1-4, 2013
Uttarakhand, Feb 23-26, 2013
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 1stt
Infomedia 18 Ltd
Ruby House, Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. • Tel: 022 3003 4651 • Fax: 022 3003 4499 • Email: engexpo@infomedia18.in
GIM Expo 2012 A platform, which will address all the needs to do business in Karnataka, will be held concurrently with the Global Investors Meet (GIM) and focus on industries such as agrotech & food processing, energy & environment, aerospace & defence, automobiles, tourism & hospitality, etc; June 06-08, 2012; at BIEC in Bengaluru
For details contact: Sambit Mund Hitex Exhibition Centre Near HI-TEC City, Madhapur Hyderabad 500 084 Tel: 040-2311 2121/22/23, Ext: 7015 Fax: 040-2311 2124 Email: sm@hitex.co.in
Food & Technology Expo For details contact: MM Activ UNI Building, First Floor, Thimmiah Road Millers Tank Bed, Bengaluru 560 052 Tel: 080-4113 1912/13 Fax: 080-4113 1914 Email: venkat@mmactiv.in
Conference on Food Safety in Dairy Industry A conference, organised by Ecolab in association with Vidya Dairy, will highlight on importance of food safety and hygiene in dairy industry; June 30, 2012; at Madhuban Resort, Anand, Gujarat For details contact: Reema Sathe, Assistant Manager – Marketing Ecolab India Plot No. A-373, MIDC, TTC Industrial Area, Mahape Navi Mumbai 400 701 Tel: 022-6644 5048, Mob: 97691 08818 Fax: 022-6644 5050 Email: reema.sathe@ecolab.com
Dairy Show 2012 Exhibition and conference on animal husbandry & dairy development; July 13-15, 2012; at Hitex, Hyderabad
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Specialised industry event for the food processing industry and allied stakeholders; July 27-29, 2012; at IARI, PUSA, New Delhi
An international exhibition on n food processing and packaging technology to be held concurrently with Dairy Universe India, Sweet & SnackTec India, and PackEx India; September 11-13, 2012; at Bombay Exhibition Centre, Mumbai For details contact: G Vamshidhar Koelnmesse YA Tradefair Pvt Ltd 1stt Floor, 6-3-885/7/B Somajiguda Circle Hyderabad 500 082 Tel: 040-6559 4411, Fax: 040-6668 4433 Email: g.vamshidhar@koelnmesse-india.com
International PackTech India and drink technology India International PackTech India, along with drink technology India (dti), will showcase latest trends in packaging, packaging printing, processing, beverage and liquid food industries; November 06-08, 2012; at Bombay Exhibition Centre, Mumbai
For details contact: Vinod Jain NNS Events & Exhibitions Meri Delhi House, 25/10 East Punjabi Bagh, New Delhi Tel: 011-4686 7500 Fax: 011-4686 7521 Email: nnsonline@nnsonline.com
For details contact: Messe Düsseldorf India Pvt Ltd Centre Point Building, 7th floor Junction of S V Road & Juhu Tara Road Santacruz (W), Mumbai 400 054 Tel: 022-6678 9933 Email: messeduesseldorf@md-india.com
Fi India 2012
Concurrent with Packplus 2012, this holistic show will feature the latest in food & beverage technologies, from processing, packaging, research, quality assurance, hygiene, among others; December 07-10, 2012; at India Expo Centre and Mart, Greater Noida
Exhibition with concurrent conference showcasing latest trends in food ingredient technologies; September 06-07, 2012; at Bombay Exhibition Centre, Mumbai For details contact: UBM India Pvt Ltd Sagar Tech Plaza A 615-617, 6th Floor Andheri Kurla Road Saki Naka Junction Andheri (E), Mumbai 400 072 Tel: 022-6612 2600 Fax: 022-6612 2626/27 Email: info.india@ubm.com
Food Technology Show
For details contact: Print Packaging.Com Pvt Ltd F 101, Tower No 7 International Infotech Park Vashi Railway Station, Navi Mumbai Tel: 022-2781 2619 Email: info@packplus.in
EVENT LIST
INTERNATIONAL Malaysia y International Food & Beverage Trade Fair Tradeshow for food and beverage industry professionals to explore business opportunities; July 12-14, 2012; at Putra World Trade Centre, Kuala Lumpur, Malaysia For details contact: Expomal International Sdn Bhd 7-2 Subang Business Centre Jalan USJ 9/5Q, 47620 Subang Jaya Selangor Darul Ehsan Malaysia Tel: +603 – 8024 6500 Fax: +603 – 8024 8740 Email: mifb@expomal.com
Propak China An exhibition on food packaging and processing machinery, materials & associated technology; July 18-20, 2012; at Shanghai New International Expo Centre, China For details contact: Tara Cai Allworld Exhibitions 12th Floor, Westminster Tower 3 Albert London, The UK Tel:+(44)-(20)-78402100 Fax:+(44)-(20)-78402111 Email: tara@chinaallworld.com
Hong Kong Food Expo Technology forum and tradeshow for the food & beverage processing and packaging industry; August 16-20, 2012; at Hong Kong Convention & Exhibition Centre, Hong Kong, China For details contact Florence Tang Hong Kong Trade Development Council Unit 13, Expo Galleria Hong Kong Convention & Exhibition Centre 1 Expo Drive, Hong Kong, China Tel:+(852)-(2)-25844333 Fax:+(852)-(2)-28240026 Email: exhibitions@hktdc.org
Food Week The 16 th edition of one of the leading exhibitions for food & beverage processing and allied technologies, November 06-09, 2012; at COEX Korea Exhibition Center, Seoul, Korea For details contact: Coex Center (Convention & Exhibition) 135-731, Samsung-dong, Gangnam-gu Seoul, Seoul-T’Ukpyolsi, Korea Tel: +(82)-(2)-60008160/60008126 Fax: +(82)-(2)-60008177 Email: koreafoodexpo@coex.co.kr
China Fisheries & Seafood Expo Event showcasing the latest in marine technology and trends of seafood business; November 06-08, 2012; at Dalian World Expo Center, Dalian, China For details contact: Sea Fare Expositions, Inc 4250, 8th Avenue NW, Suite, Seattle, USA Tel: +(1)-(206)-7895741 Fax: +(1)-(206)-7890504 Email: seafoodchina@seafare.com
Health Ingredients Europe One of the major tradeshows in Europe focussing on health ingredients for the growing functional foods industry; November 13-15, 2012; at Messe Frankfurt, Germany For details contact: CMP Information Industrieweg 54, PO Box 200, 3600 AE Maarsen, The Netherlands Tel:+(31)-(346)-559444 Fax:+(31)-(346)-573811 Email: jonathan.vis@ubm.com
Dubai Drink Technology Expo Specialised event featuring the latest in technologies & trends for the beverage industry; December 04-06, 2012; at Dubai International Convention & Exhibition Centre, Dubai, the UAE
For details contact: INDEX Conferences & Exhibitions Organisation Dubai Health Care City Block B Office 203, 2ndd Floor Dubai, the UAE Tel: +971-4-3624717 / 149 Fax:+(971)-(4)-3624718 Email: drinkexpo@index.ae
ISM Cologne One of the leading events in the niche area of confectionery processing; January 27-30, 2013; Cologne Exhibition Centre, Germany For details contact: Koelnmesse GmbH Messeplatz 1 Koeln Deutschland, Germany Tel: +(49)-(221)-8212313 Fax: +(49)-(221)-8212105 Email: ism@visitor.koelnmesse.de
Ingredients Middle East Tradeshow and conference on food & beverage ingredients; February 25-28, 2013; at Dubai International Convention & Exhibition Centre, The UAE For details contact: Dubai World Trade Centre P.O. Box. No: 9292 Dubai, The UAE Tel: +(971)-(4)-3321000 Fax: +(971)-(4)-3322866 Email: gulfood@dwtc.com
China Drinktec International tradeshow on the beverages industry; March 04-06, 2013; at China Import & Export Fair Pazhou Complex, Guangzhou, China For details contact: Adsale Exhibition Services Ltd 6th Floor, 321 Java Road North Point Hong Kong, China Tel: +(852)-(2)-8118897 Fax: +(852)-(2)-5165024 Email: exhibition@adsale.com.hk
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
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EVENT PREVIEW PackPlus South 2012
A knowledge platform to inspire innovative packaging solutions
Boasting of a footfall of more than 12,000 visitors in the previous edition of the event, the organisers of PackPlus South 2012 are confident of putting up a bigger and better platform for the packaging industry. To be held in Hyderabad from July 06-09, 2012, this event will feature about 300 exhibitors. Mahua Roy
U
ndoubtedly the Fast Moving Consumer Goods (FMCG) industry should be renamed as Fast Growing Consumer Goods industry! This sector has seen tremendous activity in the past few years and today stands at ` 2,00,000 crore, as estimated by Chemexcil, and is expected to grow 15 per cent year-on-year. This translates into big news for the packaging industry. The food and beverage processing industry is experimenting with various packaging innovations to keep up with the pace of the growing and competitive industry. In this backdrop, PackPlus South 2012, organised by print-packaging.com, is all set to open new avenues to the packaging industry and allied sectors. HITEX International Exhibition Centre in Hyderabad will be the venue for this event. Judging the pre-event buzz around PackPlus South 2012, the organisers have earmarked 3 Halls, instead of 2, as was the case in the previous edition. According to printpackaging.com, “In the last edition, we
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had around 12,454 visitors. This year, with an extended promotional plan, we certainly expect more than 14,000 visitors to turn up. In size (area & number of exhibitors) also the show has grown.”
Four specialised zones The event will feature the ‘Packaging Zone’, which will bring together worldwide manufacturers and providers of machinery, materials and services for food, pharma and packaging sectors. The ‘Converting Zone’ will encompass package designers & converters; providers of pre-press, printing & converting equipment for flexible packaging, cartons & labels, coating, laminating & finishing equipment, accessories, paper, film & foil, inks & varnishes, cylinders, dies & rollers, materials & supplies. The ‘Processing Zone’ will feature Pharma Technology Show, Food Technology Show and Automation 4 Packaging. Exhibitors from various segments process automation, including instrumentation & controls, robotics, motion drive automation, facility management, service & maintenance,
software & enterprise solutions, materials & services for food production & processing, brewing & distilling will be featured in this zone. This is not all; there will also be representation from packaging & storage, conveyance & distribution, pharmaceutical & parapharmaceutical product process, quality control, environmental control and handling & storage systems and other such fields. Bulk Pack, India Logistics Show and India AIDC Show make up the ‘Supply Chain Zone’ at the exhibition. Manufacturers and providers of rigid packaging, flexible intermediate containers, woven sacks, flexitanks, bulk filling machines, dosing weighing, endof-line packaging solutions, finished packaging, barcodes, RFID, material handling, warehousing systems and supply chain designers & integrators will exhibit in this zone. A print-packaging. com official says, “The visitors can expect new innovations, live running machines, one-to-one interaction with industry leaders, quality visitors and edifying conference sessions.” Email: mahua.roy@infomedia18.in
Food & Bev Tech 2012 EVENT REPORT
A technology forum
to exchange
novel business ideas
L to R: Pradeep Banerjee, Piruz Khambatta, Dr Sudhir Kumar Goel, Rakesh Kacker, and K D Vyas, Advisor (IB), iNDEXTb, Government of Gujarat
Food & Bev Tech 2012 brought varied technologies for the food processing sector under one roof. It was a platform to explore ways of making India the food factory of the world. The event was successful in garnering a large number of enquiries, which may culminate into actual business going forward. Prasenjit Chakraborty he 4th edition of Food & Bev Tech 2012 was held recently at NSE Complex, Mumbai. The event was inaugurated by Rakesh Kacker, Secretary, Ministry of Food Processing Industries (MoFPI), Government of India, in the presence of Dr Sudhir Kumar Goel, IAS, Principal Secretary - Agriculture & Marketing, (Additional Charge) Marketing Co-operation, Government of Maharashtra; Piruz Khambatta, Chairman, Food & Bev 2012; Pradeep Banerjee, Executive Director-Supply Chain, Hindustan Unilever Ltd. In his address, Kacker said, “Government of India is committed to the growth of the food processing sector. A lot of things
T
are happening in the sector, which grew by an average of 8 per cent between 2006 and 2010. This is higher than the growth of the manufacturing sector. Agriculture has also been growing 2-3 per cent, which means we are adding more value to agriculture.” He also said that MoFPI is trying to involve the state governments more and more in its schemes. Khambatta, in his address, said, “Food processing sector can do to rural India what IT has done to urban India – bring prosperity and growth. Food processing sector can act as a vehicle for 21st century India.” Elaborating further, he said, “The Government of India has so many schemes that industrialists need to be aware of to take advantage of them. Around 31 per cent of spending done by Indians is on food. We are an
agricultural nation and can expand food processing. There is a huge scientific & management talent and well-developed finance market. This sector is a boon for SMEs as they can start a business with less money.” Over 150 companies showcased their latest technologies and food products spread across 8,000 sq m of exhibition space. The new initiative at Food & Bev Tech 2012 includes ‘Food & Bev 2012’ and ‘Food & Bev Summit 2012’, which provided the platform for companies to market and promote their products & services to food and beverage industry professionals, supermarket chains, hotels, airlines, railways, food service providers etc. The event also hosted an international Foodtech Holland Pavilion wherein companies showcased their latest technology trends to the Indian market. The event also comprised Dalit Indian Chamber of Commerce and Industry Pavilion to promote dalit entrepreneurs.
New product launches The event witnessed a good number of product launches. HRS process System launched innovative processing solution for diced products. Similarly, Heat and Control launched Spray Dynamics range of coating and seasoning applicator. Ingersoll Rand launched refrigerated transportation solution. The Retail Pavilion at the exhibition offered a platform for retail chains and institutional buyers to have a face-to-face interaction exclusively with the exhibitors at Food & Bev 2012. An exclusive interaction of CEOs with Kacker was organised parallel to the event. Kacker, during the discussion, reiterated the need for greater quality-consciousness in food processing industry. Email: prasenjit.chakraborty@infomedia18.in
June 2012 | Modern Food Processing
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BOOK REVIEW
Food lipids: Chemistry, flavor, and texture Edited by: Fereidoon Shahidi, Hugo Weenen Price: ` 12,660
A resourceful anthology for food chemists and technologists, this researchoriented book provides ample information regarding food lipids. It discusses in detail the chemistry and functionality of fats in food sensory perception, and the underlying physicochemical and physiological properties & processes. Fats and oils profoundly affect our sensory perception and appreciation of foods. They also serve as a source of many flavour compounds, most of which result from oxidation of unsaturated fatty acids. The structural and physicochemical characteristics of fats and oils strongly influence flavour release. This book contains a detailed section on this feature. While fats and oils have beneficial ingredients because of their energy density, their intake however needs to be moderated and minimised due to incidence of lifestyle disorders. This is causing the food industry to develop foods that have the sensory and hedonic functionality but with less fat. This book provides information towards delivering this. It will thus prove important to food technologists and scientists as well as students with academic interest in this field.
Microbiology and biochemistry of cheese and fermented milk Fermented milk and cheese products are creating a buzz in the food processing industry. With new variants of cheese being launched increasingly, understanding their chemistry is of huge importance. This new edition brings together information on a wide range of fermented dairy products. It takes particular account of the profound influence that modern biotechnological sciences are having on the traditional biotechnology of dairy fermentations. This book lays special emphasis on contemporary technologies of development of low-fat cheese, control and enhancement of flavour of cheese; and role of rennet enzymes. Another important feature is the inclusion of a new chapter on the sensory evaluation of dairy flavours. This is a book for dairy scientists and technologists, both industrial and academic, particularly food chemists, dairy microbiologists and biotechnologists. It will also be an essential reference source for those in product development, processing and marketing, as well as regulatory officials in dairy companies and government laboratories.
Edited by: B A Law Price: ` 14,400
Reviewer: Rini Ravindran, Lecturer, Department of Biochemistry and Food Science & Quality Control, Ramnarain Ruia College, Mumbai
Available at: 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
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PRODUCTS This section provides information about the national and international products available in the market
Float switch
Extruding granulating machine
The float switch can be used for initiating high/ low level audio/visual signals or automatic level control of liquids in tanks. Switch actuation is by micro-switch having SPDT contacts of current rating 5 A at 240 V AC. It operates normally at 12 mm liquid level differential. Float and all wet parts are of SS 304/316, PVC or teflon. Designed for maximum pressure rating of 40 kg/ cm² and temperature of 300°C, the switch is suitable for mounting directly on the side of the tank.
Basket granulator uses gravity feed aided only by a rotary agitator to prevent arching, wetting powder falls directly into the extrusion area. The materials are wiped through perforated screen by extrusion blades, extrudes then fall on to the rotary table for discharge. This has adjustable gap between extrusion blade and screen allows optimising extrusion force. This machine finds application in feed supplements, flavours, insecticides, inorganic chemicals, pharmaceuticals, agricultural chemicals, etc.
Cristal Instruments Mumbai – Maharashtra Tel: 022 - 25693893 Email: cristalinstruments@vsnl.net Website: www.cristalinstruments.com
Toshniwal Systems & Instruments Pvt Ltd Chennai - Tamil Nadu Tel: 044 - 26445626 Email: mixer@toshniwal.net Web: www.toshniwal.net
Corrugated tube heat exchangers These are shell tube heat and exchangers, which use corrugated tubes instead of plain tubes. These tubes are corrugated to induce turbulence in both flows (product & service) at lower velocities. These increase thermal efficiency & eliminate product channelling. These exchangers offer long running times due to turbulent flow. These are used in various industries like chemical process, pharmaceutical, petrochemicals, fertilisers, paper & pulp, power, steel, coal, oil & refinery, automotive, food & beverage processing industry etc.
These separators/sifters are widely used in industries such as foodstuff, ceramics, pharmaceuticals, chemicals, bio-chemicals, plastics, electronics, grinding, water-treatment, recycling, etc. The company also offers specialised machinery and technical that meet solutions specified demands of the customers.
HRS Process Systems Ltd Pune – Maharashtra Tel: 020 – 25663581 Email: info@hrsasia.co.in Website: www.hrsasia.co.in .
Guan Yu Machinery Factory Co Ltd Hsien - Taiwan Tel: + 886-4-8965198 Email: info@guan-yu.net Website: www.guan-yu.net
Vibratory separators
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Modern Food P Processing | June 2012
PRODUCTS
Extra long hand type impulse sealer The hand sealer is ideal for a multitude of applications. It makes excellent air and water tight sealing on different materials. Extra long bar can offer the sealing from 450 mm to 1500 mm and this sealing is durable. Wu-Hsing Electronics Co Ltd Taichung - Taiwan Tel: +886 4 2271 1498 Email: sealer@wuhsing.com.tw Website: www.wuhsing.com
Vegetable and fruit pulper The pulper is available in various sizes for extracting pulp of fruits and vegetables. This consists of two brushes & two beaters, which give a combined beating and brushing action. All metal contact parts are made of stainless steel. All parts can be dismantled and reassembled for inspection, washing, cleaning and periodic maintenance. Jas Enterprises Ahmedabad - Gujarat Tel: 079-2743454, Mob: 09427417384 Email: info@jasenterprise.com Website: www.jasenterprise.com
Plant heat exchanger The plant heat exchanger is used for chilling and pasteurising milk, cream, ice-cream mix, whey, yoghurt, buttermilk, lassi and other allied products. Freeflow heat exchangers are also available for various fibrous products. The capacity ranges from 150 lph to 50 klph with plate/ tube holding. Special-purpose and high-efficiency pasteuriser modules are designed and manufactured incorporating advanced processes, like auto standardisation, bactofugation, clarification, de-aeration, homogenisation and holding time up to 20 minutes. IDMC Ltd Vitthal Udyognagar - Gujarat Tel: 02692-236375 Email: idmc@idmc.coop June 2012 | Modern Food Processing
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PRODUCTS
Sigma mixer The heavy-duty sigma mixer is designed to produce uniform mixing and kneading heavier viscosity materials. Mixing trough and blades are fabricated from mild steel/various grades of stainless steel. The product contacting parts are ground, buffed or smooth. Blades are designed to obtain thorough mixing of high viscosity materials. Blades are machined on a leading edge to keep minimum equal gap between walls and blades. These are provided with heavy-duty gears that are fitted to the blades. Paresh Engineering Co Mumbai - Maharashtra Tel: 022-28501794 Email: pecmarol@vsnl.com Website: www.pareshenggco.com
Lined carton machine The model RT-12 is a fully-automatic lined carton machine. It is a filling machine to handle liquids, powder, granules for both food and non-food 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 designed to reduce fatigue for the operator. It has filling accuracy of Âą1 per cent for 1 ltr/gm. Rollatainers Ltd Faridabad - Haryana Tel: 0129-4098800, Mob: 09811566112 Email: info@rolapak.com Website: www.rollatainers.com
Three-deck pre-cleaner The three-deck pre-cleaner is suitable for cleaning of cereals, grain, legumes and fine seeds. This machine is also used for separating oversize, undersize and light impurities from the feed. It is available with two aspiration systems – one for feeding material and the other for cleaned material. The pre-cleaner machine is equipped with feeder, which is driven by independent gear motor. Fine dust and light impurities are separated out before putting the material in the first sieve with the help of aspiration system. Sifter International Faridabad - Haryana Tel: 0129-4060039 Email: sifter@ndb.vsnl.net.in Website: www.sifterindia.com
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PRODUCTS
In-mould labelling system The in-mould labelling system offers several advantages – it ensures reduced costs, promotes hygienic production, offers resistance to heat & scratching, reduces in-house container inventory & overhead costs. It also provides better strain and squeeze resistance, improved sidewall strength and shelf-life. Application areas include injection moulding IML for cups & containers, thermoforming IML, blow moulding IML, and blister decorating applications for thermoformed PET/ PVC blister packaging. Neejtech India Ahmedabad - Gujarat Tel: 079-26561312, Mob: 09825040231 Email: info@neejtech.com Website: www.neejtech.com
Particle size reduction unit The Comitrol Processor (model 1700) 0 is a controlled particle size reduction unit. It accommodates all three types of reduction heads, which enables a broad spectrum of product processing capabilities. The machine is recommended for free-flowing dry and semi-dry product applications, including textured vegetable protein, peanut butter, chicken slurries, baby food, dehydrated potato flakes, fruit and vegetable pastes, horseradish and dressings, extruded products, biscuits and cookies, nuts, fruit pulp and various spices. Urschel Laboratories Inc Indiana - USA Tel: +1-219-4644811 Email: info@urschel.com Website: www.urschel.com
Twist wrapping machine The model 6IST T double-twist wrapping machine is used for wrapping chews, toffees and hard candy & eclair products. It is available with a number of standard features, such as Teflon liner in the feeder bowl to prevent product damage, no sweet no wrapper sensor, paper breakage sensors, paper jamming sensor, total product wrapped counter and VFD speed control. A M P Rose (P) Ltd Bengaluru - Karnataka Tel: 080-28473611 Email: sales@amprose.co.in Website: www.amprose.co.in June 2012 | Modern Food Processing
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PRODUCTS
Tri-clamp fitting The tri-clamp tube and pipe fitting is available in stainless steel for piping consultants/erectors and equipment manufacturers serving pharmaceuticals, bio-pharmaceuticals, food, beverage, dairy, cosmetics and allied process industries. This tri-clamp fitting conforms to FDA/cGMP standards and is designed to provide a uniformly smooth, non-contaminating or non-corrosive environment. The tri-clamp fitting is manufactured from stainless steel castings (SS-304/316/316L) duly buffed and electro-polished. Fluid Masters Mumbai - Maharashtra Mob: 08767668284 Email: fluidmastersindia@gmail.com Website: www.fluidmasters.com
Mass spectrometry system The Agilent 5975T LTM M GC/MSD is a transportable GC/MSD system that delivers the same high performance, reliability and quality C series GC/MSD results as the bench top 5975C in a size of more than one-third smaller and
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consumes about half the power. LTM technology is used for faster GC analysis by providing dramatically faster temperature ramp rates. Agilent Technologies India Pvt Ltd New Delhi Tel: 011-51496664 Email: agilent@agilent.com Website: www.agilent.com
Potato processing and frying machine This machine is available in capacities ranging from 100 kg/hr to 1000 kg/hr. The machine consists of peeler, slice washer, blancher/ cooker, fryer, flavour applicator and flavour drum. Abrasive-coated continuous abrasive peeler and batch-type peeler for continuous operations come with variable speed rollers and consume less water. The slice washer facilitates removal of slivers, nubbins and reduction of free starch. Flavorite PPM Technologies Pvt Ltd Indore - Madhya Pradesh Tel: 0731-2575258 Email: sales@flavoritefoods.com Website: www.flavoritefoods.com
PRODUCTS
Volumetric cup feeder system The volumetric cup feeder system is used 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 compressed air for machine operations. All contact parts are in SS-304/316 and 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. Simple Packolutions Pvt Ltd Mumbai - Maharashtra Tel: 09969000116 Mob: 09820643731 Email: packolutions@gmail.com
Washdown stations These washdown stations (mixing battery) are designed to provide instantaneous hot water economically by mixing steam and potable water to the required temperature. The mixing battery provides food, beverage, and pharma and cosmetics industry with economical hot water for cleaning applications wherever steam is available. It incorporates hydraulic fail-safe device so that when correctly installed and maintained, no steam regardless of its pressure can enter the mixing chamber until the water flows to raise the steam valve of its seat. Feliz Biotech Industries Mumbai - Maharashtra Tel: 022-26859440, Mob: 09892273314 Email: roque_ferns@rediffmail.com Website: www.felizbiotech.com
Lobe pumps The lobe pump is available with capacity up to 300 klph and pressure up to 20 bar with bi-lobe and tri-lobe design. This pump is used for various applications, such as butter, cream, chocolate, cheese, ice cream and a complete range of vicious products. Options available include mechanical/frequency variator, vertical/horizontal ports, aseptic, jacketed, etc. IDMC Ltd Vitthal Udyognagar - Gujarat Tel: 02692-236375 Email: idmc@idmc.coop
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PRODUCTS
Centrifugal sanitary pump The pump has special open-type impeller design in investment cast SS-316 with specially contoured blades set far into the suction cover, and spirally formed housing ensures great operational reliability. Height adjustable base frame is provided with cup-shaped feet for easy operation. Goma Engineering Pvt Ltd Thane - Maharashtra Tel: 022-21731801 Email: goma@vsnl.com Website: www.goma.co.in
Chip ice-making machine The chip ice-making machine comes with split condenser or condensing unit. It is available as standard and tropical version or in special designs. The machine has ideal ice temperature of -0.5°C providing easy handling, good ice quality and also provides fast and even cooling. Ice does not freeze together, not too hard and has no sharp edges, thus preserving the
cutter blades. As the ice does not form lumps, it provides a homogenous temperature for quality meat products. Weighing and dosage is done manually at the touch of a button, or by the processing system. Markmax Machines Bengaluru - Karnataka Tel: 080-23565308/40952278 Email: markmaxmachines@gmail.com
Rotary sifter This is a state-of-the-art nonvibrating dustproof continuous inline sieving machine. The rotating screw paddle feeder sifter is used for low density non-abrasive powders especially for screening powders from 60 mesh to 300 mesh. Material is fed into a screw feeder with flat paddles, which rotates at a speed from 600 to 1500 rpm. Finex Sieves Pvt Ltd Vadodara – Gujarat Tel: 09376232820 Email: padmak@finexsieves.com Website: www.finexsieves.com
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PRODUCTS
Packaging machine The Transwrap 16500 packaging machine is accepted in food and non-food packaging industry. This machine is suited for a variety of packaging needs, styles and budgets. The array of packaging options include package styles like pillow bags and side gusseted bags along with many other options pertaining to heat sealing, polyethylene welding systems, anti-static devices, chain packages and hole punch devices. All these options can be activated through simple setting procedures via an intuitive human machine interface. Bosch India Ltd Bengaluru - Karnataka Tel: 080-22999780 Email: boschpackaging@in.bosch.com Website: www.boschindia.com
Mini dall mill This mill is simple in construction and easy to operate and maintain. It consists of horizontal tapered roller. The roller is covered with emery coating surrounded by a screen through which the husk is discharged. The shelled pulse passes through aspirating fan on oscillating sieve unit, where appropriate grading of pulse is done. It is provided with a 2 HP electric motor/oil engine. Automatic arrangements are made for collection of de-husked and split pulses, un-dehusked pulses in separate containers and bags. Jas Enterprises Ahmedabad - Gujarat Tel: 079-22743454 Email: info@jasenterprise.com Website: www.jasenterprise.com
Disposable foam container ESSFOAM take away containers are manufactured with a unique extrusion technology. All types of platters, serving trays, meat trays, fruit trays are offered. Further, all types of hinged containers, burger boxes and pizza boxes are also available. The platters and trays are designed comfortably to handle heavy food servings. Essen Speciality Films Pvt Ltd Rajkot – Gujarat Tel: 02827-252021, Mob: 09825312701 Email: sales@essenspeciality.com Website: www.essenspeciality.com
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PRODUCTS
Colour sorter This multi-purpose colour sorter comes with highresolution CCD camera capable of detecting minute defects, like dots and subtle colour variations. It has a 2048 pixel high-sensitivity line scan double view CCD camera. It sorts rice (raw, parboiled, boiled & steam), toor, urad, moong, channa dal,l fried gram, tamarind seeds, sesame, poppy seeds, wheat and other food grains with minimum setting, using only control panel. The colour sorter has high-speed processing, which scans 20,000 lines/sec for accurate sorting. QED Agro Systems Pvt Ltd Bengaluru - Karnataka Tel: 080-2780 3074, Mob: 09341218299 Email: qed@vsnl.com
Food processing machine The Brambatii food processing machine is used for production of various food products, like bread, biscuits, confectioneries, cakes, baby food, coffee, breakfast products, etc. Online system for proportioning the raw materials to be weighed is carried out with a turbomax, which is one of the unusual characteristics of the plants. All various steps undergo a weight check carried out by a management computer with a printout of the quantities measured. A wide range of systems and precision built machines is offered that is suitable for smaller production as well as larger volume production, depending on the needs of the customers. Penguin Engineers Coimbatore - Tamil Nadu Tel: 0422-2315640, Mob: 09842231564 Email: penguin@vsnl.com Website: www.penguin.in
Liquid chromatography system The Agilent 1260 Infinity Bio-inert Quaternary liquid chromatography system is a dedicated solution for large bio-molecule analysis. The design of new metal-free components in the sample flow-path and the absence of iron and steel in solvent delivery ensure the integrity of biomolecule, minimise unwanted surface interactions and increase column life-time. Agilent Technologies India Pvt Ltd New Delhi Tel: 011-46237100 Email: agilent@agilent.com Website: www.agilent.com June 2012 | Modern Food Processing
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PRODUCTS
Homogenisers These high-pressure homogenisers are available in capacities ranging from 20 to 20,000 lph. The lubrication and air cooling system ensures optimum temperature for continuous duties. The homogenisers are 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 onepiece forged cylinder block is ultrasonically tested for long life. Goma Engineering Pvt Ltd Thane - Maharashtra Tel: 022-21731801, Mob: 09322654236 Email: goma@vsnl.com Website: www.gomaengg.com
Bottle filling machines These compact automatic volumetric high-speed bottle liquid filling machines consist of turntable, SS slat conveyor belt, filling & post-gassing SS-316 nozzles, precision built SS-316 syringes, non-toxic synthetic rubber tubing, easy-to-reach compact panel and no container-no filling system, etc. The matt-finished units are totally enclosed in stainless steel. The unscrambler is designed in the machine to eliminate dead ends and difficult-to-clean spots. All exposed parts are made of SS-304, matt finished to avoid any reflection. Laxmi Pharma Equipment Ahmedabad - Gujarat Tel: 079-25831600, Mob: 09426406754 Email: laxmipharma1@dataone.in Website: www.laxmipharmaequipments.com
Vegetable washer This is suitable for various fruits, like mango, apple; and vegetables, like carrot, cucumber, etc. The system has a specially designed takeoff conveyor to transfer the product from the washing tank to the discharge end. Jwala Engineering Company Mumbai - Maharashtra Tel: 022-65703038, Mob: 09820197764 Email: jwala_engg@vsnl.com Website: www.jwala-engineering.com
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PRODUCTS
Stainless steel tank A variety of tanks in different shapes and capacities for storing fruits, fruit pulps, vegetables, juices, etc, is offered. Also built are custom-designed tanks. The range includes holding tanks (round/ conical), balance tanks, blending tanks, mixing tanks, storage tanks, collection tanks, etc. Shiva Engineers Pune - Maharashtra Tel: 020-27129610, Mob: 09822499586 Email: shivaengineers1@gmail.com Website: www.food-processing.net
Food packaging equipment The food packaging equipment includes jar filling machines for pickles and insulated bottle filling tanks. These machines are useful for bottle and high weight pet bottles filling for mango, lemon, mix pickles suitable for bottle filling machines and jar filling machines. Jar filling equipment with 125 kg filling hopper has provision of suitable nozzles. Regulated speed motor is provided with auger filler. Special feature is that there are no damages
to the blended pickle and fruits. Weight filling is done by these machines and final weight is achieved by oil topping. Varada Engineers Pune - Maharashtra Tel: 020-26989087, 09823076601 Email: omvarada@gmail.com
Juice manufacturing equipment The ready-to-drink juice manufacturing equipment is available in the capacity of 100 lph to 1,000 lph. It is offered depending on customers’ requirements and budget, as either automatic or semi-automatic line. The fruit drinks include: mango, orange, pineapple, amla, pomegranate, tamarind, jamun, and many more. The complete line includes fruit washer, inspection conveyor, pulper, screw-type juice extractor, pulveriser, basket press, filtration unit, blending tank, homogeniser, pasteuriser etc. Tambes Farm Products Pune - Maharashtra Mob: 09423012005 Email: tfp@tfp.com
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PRODUCTS
Closure feeding system This fully automatic, hygienic and sanitationfriendly closure feeding system is used for crowns, PP caps, aluminium caps, etc. The system is suitable for high-speed bottle filler machines up to 600 BPM for industries, like beverages, breweries, distilleries, pharmaceuticals, dairy, etc, which ensures the flow of closure in gentle and controlled manner into the crowner/capper hopper, which nullifies the damage and bending of closures remarkably. The system is self-mounted, as the dies do not require any foundation, and can be moved anywhere in the bottling hall. Alien Fabricon (India) Ahmedabad - Gujarat Email: sanimesh@alienfabricon.co.in Website: www.bottlingplantconveyor.com
Portable vacuum heat sealer The portable vacuum heat sealer is a small machine with superior vacuuming ability. It seals all types of virgin plastic bags as well as multi-filament laminated bags. The sealer gives two lines of parallel sealing to keep food articles tamper-
proof and 100 per cent air-tight, thereby increasing the shelf-life. It is used to seal different types of food articles, like dried fruits, tea, coffee, spices, meats, vegetables, sweets, snacks, etc. The vacuum heat sealer comes with heat seal timer, digital setting, auto control and audio buzzer. Nikko Mumbai - Maharashtra Tel: 022-23864641, 23863117 Email: nikko@vsnl.com Website: www.nikkomachines.com
Speed controller The LIFO (last-in-first-out) speed controller operates without resistance during the storage process and only transfers its brake force to the pallets to be unloaded. Its main advantages include enhanced safety, greatly improved stock turn and longer service life than with standard controllers. Standard controllers can be easily replaced by LIFO speed controllers in existing storage systems. Also offered are flow storage modules for lanes of up to 41 pallet positions with integrated safety separators and speed controllers. Solutions for both FIFO (first-in-first-out) and LIFO applications and for special pallets and crates are also available. Interroll Drive and Rollers India Pvt Ltd Bengaluru - Karnataka Tel: 080-23864996, Mob: 09886223025 Email: ind-sales.ds@interroll.com Website: www.interroll.com
Digital colour mark sensors SUNX X (a brand of Panasonic) LX-100 series digital colour mark sensors can detect any marking because they are equipped with red, green and blue LED light emitting element. Furthermore, to expand the functionality these sensors come with dual mode, ie, mark mode (ultra high-speed response) and colour mode (high precision mark colour discrimination) to suit any application. These sensors come with Mode Navi technology for enhancing features and easy to use. The other special features includes 4-digit digital display, super simple teaching, external teaching, 12-bit A/D converter, D-code, key lock, timer, NPN or PNP outputs, IP67 protection, etc. Lubi Electronics Ahmedabad - Gujarat Tel: 079-22205471, Mob: 09327497006 Email: info@lubielectronics.com Website: www.lubielectronics.com
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PRODUCTS
Foodwaste disposal system Kitchen garbage/food waste disposal system is used for at-source disposal of all kinds of biodegradable food waste generated in hotel kitchens and food processing industries. Various models to suit each point of food preparation area/vegetable preparation area/non-veg preparation/butchery area/tableware wash/landing table/dining area/wet and dry garbage room applications are available. The system crushes all food wastes into a slurry form that pass through the drainage. Sree Devi Enviro Pvt Ltd Chennai - Tamil Nadu Tel: 044 -24512850 Email: bioclean_sde@yahoo.com Website: www.environmental-expert.com
Crate washing station The crate washing station is used in dairy, ice cream, food, beverage, pharma, bio-tech and allied process industries. The crate to be washed is conveyed by a chain conveyor into the wash chamber. It passes through high-pressure waterjet nozzles having accurate spray angles for washing. This ensures optimum cleaning in the shortest possible time. If desired, the crate can be washed by detergent solution or hot water. Industrial EquipWash Inc Mumbai - Maharashtra Tel: 022-26797941, Mob: 09869231815 Email: iewi@mtnl.net.in Website: www.iewi.net
Cold storage system The cold storage system used in hotels, hospitals, industries, canteens, etc, is available as cold stores, modular walk-in cold room, reach-in mini cold room and cold room with display shelves. The modular panel used for making cold storage consists of two galvanised steel sheets covered with food safe plasticised film and is available in ranges of 400-600-800-1200 mm wide and 40-150 mm thick. The modular structure is self-bearing and it can be disassembled. Industrial Refrigeration Pvt Ltd Mumbai - Maharashtra Tel: 022-22041185 Email: info@irl.co.in Website: www.irl.co.in June 2012 | Modern Food Processing
93
PRODUCTS
Ripening chamber The gas emission ripening system and ethylene generator system is available along with necessary controls for monitoring ripening parameters. The bananas ripened through these systems ensure even ripening, controlled output as per the demand, uniform golden yellow colour, longer shelf-life and improved marketability of bananas. Blue Star Ltd Mumbai - Maharashtra Tel: 022-66654000 Email: suneel@bluestarindia.com Website: www.bluestarindia.com
Vegetable process equipment The Soliaa series machine is used for washing and peeling carrots, onions, potatoes, and rooted vegetables. Capacity of the machine is 50-400 kg/hr. The equipment includes multi-purpose vegetable processors. The equipment is used for cutting, slicing, dicing, cubing, juliennes, strip cutting, shredding, etc. Stephan UM M universal mixer is used for chopping, cutting, blending, stirring, kneading, pureeing and emulsifying. It has a capacity of 50-60
per cent of bowl volume and can process 6-10 batches/hr. The Stephan MC microcut emulsifier has a capacity of 500-5,000 kg/hr. Tricon Pune - Maharashtra Tel: 020-26991782, Mob: 09370764704 Email: sales@shandliyaenergy.com Website: www.shandilyaenergy.com
Flour mixer machine This machine is made from unique quality of raw material. Its stunning features include capacity of 10 kg/ hr, height blade made from bright bar with zinc finish, total height of machine at 35”, and available in wooden case size of 36” x 24” x 24” without electric motor. Unisoft Pheripherials Rajkot - Gujarat Tel: 0281-2450300, Mob: 09825389070 Email: unisoftp@gmail.com, Website: www.taperlockpulleysindia.com The in inforrmation on publi lishe shed d in in this section n is as per the deetails furniished by thee respective ve man nufactu urer//distrib butor.. In n any case, it doees not repre resent the viiews of
Modern Food Processing
June 2012 | Modern Food Processing
95
LIST OF PRODUCTS
Sl. No.
Product
Pg. No.
Sl. No.
Product
Pg. No.
Sl. No.
Product
Pg. No.
Aata making machine ................................. 81
Conveyor belts................................................. 85
Flour mixer machine ....................................... 95
Acoustic enclosure .........................................FIC
Conveyor systems ............................................ 71
Food forming machine.................................... 95
Agitatorr ........................................................... 15
Corrugated tube heat exchangers .................... 78
Food packaging equipment............................. t 91
Air audit blowers............................................. 39
Crate washing station ..................................... 93
Food processing lines ..........................69, 91, 95
Air coolerr ........................................................ 11
Customised frost management systems .......... 33
Foodwaste disposal system .............................. 93
Ammonia liquid chillerr ..................................... 4
Customised machine ....................................... 86
Foot sealer machine ........................................ 86
Analytical instrumentation system .............. 3, 55
Cutter/slicer..................................................... r 95
Forced convection unit air coolerr ................... 11
Animal feed technologyy ................................. BC
Dairy machineryy .......................................... 4
Freezers ........................................................... 33
ATP hygiene monitoring system ...................... 8
Dal masterr ....................................................... 81
Fuelling systems .............................................. 39
Barcode & inkjet printerr ............................ 86
Dal polishing rollerr ......................................... 81
Gantry automation system.......................... 65
Batch disperserr ................................................ 15
Dehydration equipmentt .................................. 95
Gas chloronical gravity & vacuum feed system ...30
Blender and mixerr ........................................... 95
Digital colour mark sensor.............................. r 92
Gas flushing machine...................................... 86
Blowers ............................................................ 49
Disperserr ......................................................... 15
Gear pumps ..................................................... 67
Boiling/stirringg ................................................ 95
Disposable foam container.............................. r 88
Grain handling system ...................................BC
Bottle filling machines .................................... 90
Doors ............................................................... 92
Grill magnet.................................................... t 88
Brewing system ..............................................BC
Drawer magnet................................................ t 88
Grinding & dispersion system .......................BC
Bulk milk coolerr ................................................ 4
Drives ........................................................... BIC
Gyratory screen ............................................... 88
Butterfly valve ................................................... 4
Dry vacuum pumps ......................................... 90
Ham processing machine ........................... 95
Calorimeterr ............................................... 15
Dry van pump ...............................................FIC
Hand sealerr ..................................................... 86
Cap sealer ....................................................... 86
Dry-break couplings ........................................ 39
Heat resistant doorr.......................................... 92
Caster wheels ............................................... BIC
Dust control door............................................ r 92
Heating bath system ....................................... 15
Centrifugal monoblockk ................................... 88
Ejectors ..................................................... 39
Heavy industrial steel structures ..................... 19
Centrifugal sanitary pump .............................. 87
Electromagnetic feeder.................................... r 88
High-pressure homogeniserr ...................... 15, 17
Chillerr ....................................................... 33, 87
Emergency safety kit ...................................... 30
High-speed servo-driven system ..................... 84
Chip ice-making machine ............................... 87
Evaporating unitt ....................................... 11, 87
Homogenisers.................................................. 90
Chlorine gas cylinder/tonner........................... 30
Evaporation system ......................................... 53
Hopper magnett ............................................... 88
Chocolate/cocoa machine ..............................BC
Exhausters ....................................................... 49
Hot air gun ..................................................... 86
Cleaning section equipment........................... t BC
Exhibition - Dairy Show 2012 ....................... 94
Hot plate ......................................................... 15
Closure feeding system ................................... 92
Exhibition - International Foodtech 2012 ..... 82
HPLC ......................................................... 3, 55
Cold form sections.......................................... 19
Exhibition - Packplus South 2012.................. 42
Ice candy plant........................................... t 87
Cold room system ........................................... 87
Extra long hand type impulse sealer............... r 79
Ice machines .................................................... 33
Cold storage system ........................................ 93
Extruded productt ........................................... BC
Industrial chilling equipment.......................... t 87
Column & chemistryy .................................. 3, 55
Extruding granulating machine ...................... 78
Industrial doorr................................................. 92
Colour masterbatches ...................................... 51
Fastback revolution seasoning system ......... 71
Industrial fittingg ........................................... BIC
Colour sorterr ................................................... 89
Filling sealing machine ................................... 91
Industrial type unit air cooler.......................... 11
Colour sorting machine .................................BC
Fish processing system .................................... 95
Informatics .................................................. 3, 55
Compressors.............................................. 11, 39
Flexible transparent PVC strip door............... r 92
In-line disperserr .............................................. 15
Condensing unit.............................................. t 87
Float switch ..................................................... 78
In-mould labelling system............................... 83
Confectionery machines .................................. 47
Floor automation system................................. 65
Insulated containerr .......................................... 87
Continuous bag sealer..................................... r 86
Flour machine stone........................................ 81
Juice manufacturing equipment.................. t 91
Control panel .................................................. 87
Flour milling machine....................................BC
Kneading machine ..................................... 15
BC - Back Cover, BIC - Back Inside Cover, FIC - Front Inside Cover
Looking For A Specific Product? Searching and sourcing products were never so easy. Just type MFP (space) Product Name and send it to 51818
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Modern Food d Proce Processing | June 2012
LIST OF PRODUCTS
Sl. No.
Product
Pg. No.
Sl. No.
Product
Pg. No.
Sl. No.
Product
Pg. No.
Laboratory reactorr ..................................... 15
Plug valve .......................................................... 4
Solid-liquid mixerr ........................................... 15
Laboratory software......................................... 15
Pneumatic valve................................................. 4
Speed controllerr .............................................. 92
Large diameter welded pipe ............................ 79
Polystyrene product....................................... t 100
Stainless steel construction.............................. 33
Lined carton machine ..................................... 80
Portable vacuum heat sealer............................ r 92
Stainless steel pipe........................................... 79
Liquid chromatography system ....................... 89
Potato processing and frying machine ............ 84
Stainless steel tankk .......................................... 91
Liquid sealer.................................................... r 86
Power distrubution system .............................. 37
Storage tank equipmentt .................................. 39
Loading arms .................................................. 39
Power management software .......................... 37
Strapping machine .......................................... 86
Lobe pumps .................................................... 86
Pre-cooling system .......................................... 33
Stretch wrapperr ............................................... 86
Machine plastic parts ................................. 86
Pre-engineered metal buildings ...................... 19
Structural floor decking sheets ........................ 19
Magelis STU HMI panels ........................ 31, 45
Priming valves ................................................. 39
Submersible system ......................................... 88
Magnetic equipmentt ....................................... 88
Process tanks ..................................................... 4
Sugar herbs ........................................................ 6
Magnetic plate................................................. 88
Product handling equipmentt .......................... 71
Tank truck equipmentt ............................... 39
Magnetic stirrer............................................... r 15
Pump ..........................................39, 67, 90, FIC
Tanks and silos.................................................. 4
Magnetic traps ................................................ 88
PVC strip door................................................ r 92
Tapping-strapping machine ............................ 86
Mass spectrometry system............................... 84
Rail tankers ................................................. 4
Meat ball forming machine ............................ 95
Rare earth tubes .............................................. 88
Meat processing system .................................. 95
Refrigerant pumps ............................................. 4
Mechanical vacuum boosters .......................... 49
Refrigeration system.......................................... 4
Milk tankk ........................................................ 87
Rice makerr ...................................................... 81
Mills ................................................................ 15
Rice milling equipment.................................. t BC
Mini dal mill ................................................... 88
Rice rollerr ........................................................ 81
Mixing & drying system ................................. 53
Ripening chamberr ........................................... 95
Mixing processing machine ............................ 95
Robotic automation system ............................. 65
Monoblock high vacuum pump ...................... 90
Roofing & cladding sheets.............................. 19
Motor vibrators ............................................ BIC
Roots blowerr .......................................... FIC, 90
Multi-axis motion controllers ......................... 84
Roots vacuum pumps ...................................... 90
Multi-level steel car parks ............................... 19
Rotary evaporatorr ............................................ 15
Multiple belt combinations ............................. 33
Rotary gearr ...................................................... 88
Multiple temperature zones ............................ 33
Rotary gear pumps .......................................... 67
Natural herbal sweetener.............................. r 6
Rotary lobe pump............................................ 88
Oil lubricated vacuum pumps ..................... 80
Rotary pumps .................................................. 90
Oil milling system ..........................................BC
Rotary sifter..................................................... r 87
Oil seal high vacuum pump ............................ 90
Safety access equipmentt ............................. 39
Vacuum pumps and systems ........................... 39
Oval wheel flow meters................................... 80
Safety doorr ...................................................... 92
Vacuum system .............................................FIC
Overhead stirrerr .............................................. 15
Sanitary centrifugal pump ............................... 88
Vegetable and fruit pulperr .............................. 79
Packages/skids........................................... 33
Screw compressor.............................................. r 4
Vegetable process equipmentt .......................... 95
Packaging machine.......................................... 88
Screw pump..................................................... 88
Vegetable washer............................................. r 90
Pallet wrapperr ................................................. 86
Sealerr ............................................................... 86
Vertical inline pump ....................................... 88
Particle size reduction unit.............................. 83
Seals ................................................................ 79
Vibration motorr .............................................. 88
Pasta makerr ......................................................bc
Seamless pipe .................................................. 79
Vibrators ....................................................... BIC
Pilot plant........................................................ t 15
Self-priming monoblock pumps ..................... 88
Vibratory separators ........................................ 78
Piston/screw compressors ................................ 33
Shaker.............................................................. r 15
Volumetric cup feeder system ......................... 86
Plant heat exchangerr ....................................... 79
Shrink machine ............................................... 86
Washdown stations .................................... 86
Plastic masterbatches....................................... 89
Sigma mixerr .................................................... 80
Water jetting system ....................................... 39
Plastic pellett ................................................... BC
Single stage monoblock vacuum pump........... 90
Water ring vacuum pumps.............................. 90
Plastic sheets ................................................. 100
Single stage vacuum pump.............................. 90
Welded pipe .................................................... 79
Plate heat exchangerr ......................................... 4
Sleeve wrapping machine ................................ 86
Window hardnerr ............................................. 87
Thermal process system .................................BC Thermoform fill seal machines ....................... 13 Thermostat and vaccum dryer/mixerr .............. 15 Three-deck pre-cleanerr ................................... 80 TPU masterbatches ......................................... 51 Transmissions and PTOS ............................... 39 Tray sealerr ........................................... 77, 83, 93 Tri-clamp fittingg ............................................. 84 Triplex plunger................................................ r 88 Trolly wheels ................................................ BIC Tube ................................................................ 79 Twin-lobe roots blower............................. r 49, 90 Twist wrapping machine................................. 83 Universal type unit air cooler...................... r 11 UPLC .......................................................... 3, 55 UPS ................................................................ 37 Vacuum booster pump .............................FIC Vacuum machine............................................. 86 Vacuum pumps ............................................... 90
BC - Back Cover, BIC - Back Inside Cover, FIC - Front Inside Cover June 2012 | Modern Food Processing
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LIST OF ADVERTISERS
Advertiser’s Name & Contact Details
Pg No
A.M.P. Rose
47
Advertiser’s Name & Contact Details
Pg No
Bosch Limited
29
Advertiser’s Name & Contact Details
Gardner Denver Engineered Pro. (I) Ltd
T: +91-80-28473611
T: +91-91-832-669-2004
T: +91-79-40089312
E: sales@amprose.co.in
E: Amol.Matkar@in.bosch.com
E: info.ahm@gardnerdenver.com
W: www.amprose.co.in
W: www.boschpackaging.com
W: www.gardnerdenver.com
Aakanksha Technologies
69
Buhler (India) Pvt Ltd
BC
GEA Refrigeration Technologies
T: +91-09810193422
T: +91-80-22890000
T: +91-49-234-9800
E: aakankshatechnologies@rediffmail.com
E: mallikarjuna.s@buhlergroup.com
E: info@gearefrigeration.com
W: www.pigo.biz
W: www.buhlergroup.com
W: www.gearefrigeration.com
Acme Air Equipment Co Pvt Ltd
49
Dev Engineers
T: +91-79-25831985
T: +91-79-26403839
E: info@airequipments.com
E: info@devpumps.com
W: www.airequipments.com
W: www.devpumps.com
Alok Masterbatches Ltd
51
88
37
E: sales@alokindustries.com
E: eatonpowerqualityindia@eaton.com
W: www.alokmasterbatches.com
W: www.eaton.com/powerquality/india
T: +91-2752-241479
T: +91-09819552270
E: anivarya@sancharnet.in
E: engexpo@infomedia18.in
W: www.anivaryapumps.com
W: www.engg-expo.com
17
W: www.goma.co.in
Eaton Power Quality Pvt Ltd
Engineering Expo
33
E: process@goma.co.in
T: +91-11-42232329
67
39
T: +91-22-41614161
T: +91-11-41612244
Ani Engineers
Goma Engineering Pvt Ltd
Pg No
Gudel India Pvt Ltd
65
T: +91-20-25459531 E: info@in.gudel.com W: www.gudel.com 53
Heat And Control
71
T: +91-44-42103950 E: info@heatandcontrol.com W: www.heatandcontrol.com
Aqua Services
30
Essen Speciality Films Pvt. Ltd
T: +91-265-2331748
T: +91-2827- 252021
E: aquaas@sify.com
E: sales@essenspeciality.com
W: www.aquaservicesindia.com
W: www.essenspeciality.com
Ask Me
24
Everest Transmission
100 Hitex Exhibition Centre T: +91-9010549957 W: www.dairyshow.in FIC
IC Ice Make Refrigeration Pvt Ltd
T: +91-11-45457777
E: twitter.com/AskMe_35555555
E: info@everestblowers.com
E: info@icemakeindia.com
W: www.facebook.com/AskMe.infomedia18
W: www.everestblowers.com
W: www.icemakeindia.com
Bonfiglioli Transmissions (Pvt) Ltd
FX Multitech Pvt Ltd
11
IDMC Limited
T: +91-44-67103800
T: +91-79-27910993
T: +91-2692-225399
E: sales.buins@bonfiglioli.com
E: fxmultitech@gmail.com
E: idmc@idmc.coop
W: www.bonfiglioli.com
W: www.fxmultitech.com
W: www.idmc.coop
Our consistent advertisers
98
Modern Food Processing | June 2012
87
T: +91-79-65426394
T: +91-3555 5555
BIC
94
4
BC - Back Cover, BIC - Back Inside Cover, FIC - Front Inside Cover
LIST OF ADVERTISERS
Advertiser’s Name & Contact Details
IKA India Private Limited
Pg No
15
Advertiser’s Name & Contact Details
Pg No
P P I Pumps Pvt Ltd
90
Advertiser’s Name & Contact Details
Sterling Abrasives Ltd
T: +91-80-26253900
T: +91-79-25832273
T: +91-79-22870905
E: process@ika.in
E: sales@ppipumps.com
E: jigneshsengal@sterlingabrasives.com
W: www.ppipumps.com
W: www.ika.in Jaykrishna Magnetics Pvt Ltd
88
92
89
W: www.surajgroup.com
T: +91-11-47262000
Toshniwal Instruments (Madras) Pvt Ltd
T: +91-22-33071100
E: delhi@prayagmb.com
T: +91-44-26445626
E: info@jetpackmachines.com
W: www.prayagmb.com
E: sales@toshniwal.net
W: www.jetpackmachines.com
Print Packaging.Com Pvt Ltd
Joyam Engineers & Consultants Pvt Ltd
90
42
T: +91-22-27812093
Rac Equipment India (P) Ltd
W: www.joyamvactech.com
85
T: +91-129-4113187
W: www.PackPlusSouth.in
E: joyam@joyamvactech.com
80
W: www.toshniwal.net Ultraplast Chainbelts Pvt. Ltd
E: info@packplus.in
T: +91-79-26569533
79
E: suraj@surajgroup.com
Prayag Polytech Pvt Ltd 91
Suraj Limited T: +91-79-27540720
W: www.stripdoor.co.in
W: www.jkmagnetics.com Jet Pack Machines Pvt. Ltd.
Plast World
E: plastworld1@rediffmail.com
E: info@jkmagnetics.com
81
W: www.ricemaster.in
T: +91-9376128372
T: +91-79-22970452
Pg No
E: info@ultraplast.in 77;83;93
W: www.ultraplastindia.com
T: +91-09311198333 Kinn Shang Hoo Iron Works
95
T: +886-7-551-5397
Roechling Engineering Plastics (Ind
E: ksh6671@ms27.hinet.net W: www.ksh.com.tw Koelnmesse Ya Tradefair Pvt Ltd
United Steel & Structurals Pvt. Ltd
E: racglobal@gmail.com
82
86
E: admin@unitedstructurals.com
E: binit.mishra@roechling-india.com
W: www.unitedstructurals.com
W: www.roechling.com
V S International
Schneider Electric India Pvt Ltd
E: m.pathan@koelnmesse-india.com
T: +91-124-3940400
W: www.foodtecindia.com
E: babita.rawat@schneider-electric.com
Mech-Air Industries
6
Veripack Solutions India Pvt Ltd 8
Shende Sales Corporation
T: +91-22-66971133
W: www.veripackindia.com 79
Waters (India) Private Limited
T: +91-281-2461826
T: +91-20-24488005
T: +91-80-28371900
E: monarchrajkot@gmail.com
E: shende@shendesales.com
E: waters_india@waters.com
W: www.monarchappliances.com
W: www.shendesales.com
W: www.waters.com
Our consistent advertisers
13
E: makdum.j@veripackindia.com
W: www.shahbros.com 86
T: +91-129-2254165
W: www.vspackit.com
E: ceo@shahbros.com
W: www.freshnpure.net
84
E: info@vspackit.com
T: +91-22-24118874
E: info@freshnpure.net
Monarch Appliances
31;45
W: www.schneider-electric.co.in Shah Brothers
T: +91-265-2280017
T: +91-44-42321801
T: +91-22-42178706
T: +91-40-65707722
19
3, 55
BC - Back Cover, BIC - Back Inside Cover, FIC - Front Inside Cover June 2012 | Modern Food Processing
99
Registration No: MH / MR / WEST / 232 / 2012-2014; RNI No: MAHENG / 2008 / 25262 Licence to Post at Mumbai Patrika Channel Sorting OfďŹ ce, Mumbai GPO., Mumbai 400 001 Date of Mailing 3rd & 4th of Every Month Issue. Date Of Publication: 28th of Every Month
102