FEBRUARY 2018 - APRIL 2018 Vol. 6 • No. 1
Your preferred partner for
tasty and healthy success Food safety in materials handling and conveying
Effective mineral addition in dairy food
Africa tackles plastic recycling
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CONTENTS FEBRUARY 2018 - APRIL 2018 Vol. 6 • No. 1
7 NEWS
GEA launches new cooling system
EABL predicts long term growth
Corn capacity increase in the UAE
A sustainable future for Firmenich
12 DAIRY FOOD
Make mineral fortification work for you
PAGE
10
14 MEAT, FISH & POULTRY
Control fat in coated products
Frutarom celebrates a successful integration with Unique Flavors
22 Beers & Ciders
16 MATERIALS HANDLING & CONVEYING SYSTEMS
Successful ERP implementation in the supply chain
Five ways to improve productivity
How much will functional safety cost you?
Mineral fortification in dairy PAGE
12 IED F I T FOR
“As a major supplier to beverage companies, CCL is known for its range and scope of premium decoration in South Africa and neighbouring countries”
27 Packaging “The African continent has one of the most diverse food and beverage markets. The industry is projected to reach US$1 trillion by 2030. With the increase in diversity and interest in food across the continent, many countries are beginning to experience the impact and fallout of such a booming industry”
ADVERTISERS’ INDEX ABB South Africa......................................... 19...............www.new.abb.com/africa Albrecht Machinery.................................... 15...............www.albrechtmachinery.co.za CCL Label....................................................... 23...............www.ccllabel.com Constantia Printing Inks........................... 21...............www.constantia-inks.co.za Coperion........................................................ 12...............www.coperion.com/food Fried International Imports..................... 18...............www.fii.co.za Frutarom SA.................................................. OFC...........www.frutarom.com GEA Africa...................................................... OBC...........www.gea.com Ishida Europe............................................... IBC.............www.ishidaeurope.com Koelnmesse.................................................. 9.................www.anugafoodtec.com
Omron............................................................ 29...............www.industrial.omron.co.za Polyoak Packaging...................................... 30..............www.polyoakpackaging.co.za Protea Chemicals........................................ 13...............www.proteachemicals.co.za Savannah Fine Chemicals........................ 26..............www.savannah.co.za Siemens......................................................... 25...............www.siemens.co.za Sollich............................................................ 5.................www.sollich.com/world Specialised Exhibitions............................. 8.................www.foodandhospitalityafrica.com Syspro............................................................ 17...............www.syspro.com Tromp Group................................................ IFC.............www.trompgroup.nl
2018 Quarter 1 | Food Manufacturing Africa
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EDITOR’S COMMENT
EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmediapub.co.za Assistant Editor: Aarifah Nosarka +27 (0) 11 877 6209 aarifah.nosarka@newmediapub.co.za Layout & Design: David Kyslinger david.kyslinger@newmediapub.co.za Contributors: Doug Hunter, Jorgen Saxeryd, Markus Gerhart, Martin Schottenheimer, Polly Duffee ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmediapub.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmediapub.co.za
Africa: The new business hot spot
T
HE BURGEONING AFRICAN consumer sector offers attractive opportunities for businesses looking to enter new markets. The key to unlocking these opportunities is sound commercial navigation and strong sector insights. An understanding of the intricacies of the local consumer landscape is also critical. Frutarom, known for its aggressive acquisition trail has identified Africa as a favourable landscape for food and beverage production. The company is aligning its product range and services to the continent’s growing appetite for good products. Turn to page 10 now to see how Frutarom’s range of taste solutions impact the market. Africa has millions of expectant consumers-in-waiting. Retailers and businesses with competitive strategies and the right local partners, are well positioned to benefit. The global functional food market is dominated by dairy products with sales valued at US$9.23 billion. This is a prime growth opportunity for the dairy industry. Our article on page 12 looks at mineral fortification and what opportunities exist to formulate these products. The food industry is prone to serious industrial accidents. Jorgen Saxeryd, safety products and functional safety advisor to ABB’s food and beverage programme takes us through the steps to develop food safety procedures on page 20.
The ability to use smart ingredients for longer shelf life, better hydration and low hygroscopicity is a key factor in developing new beverage products. For example, the ingredient Palatinose (page 26), mimics the popular sweetness profile of sucrose, but without the use of high glycaemic carbohydrates. We end this edition with a fascinating look at how the African continent is dealing with the fallout of food and beverage packaging. Our article on page 27 looks at how governments within Africa are dealing with this issue. I hope you enjoy this edition of Food Manufacturing Africa. We love hearing from you, so if you have any thoughts and suggestions about the publication or our editorial content, please let me know at maryke.foulds@newmediapub.co.za. Happy reading,
Sales executive +27 (0)82 976 6541
INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com
Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmediapub.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmediapub.co.za Production Manager: Rae Morrison Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park 2092 Tel: +27 (0)11 877 6111 Fax: +27 (0)11 713 9024 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published on behalf of Media24 by New Media Publishing (PTY) Ltd. MANAGING DIRECTOR: Aileen Lamb CHIEF EXECUTIVE OFFICER: Bridget McCarney EXECUTIVE DIRECTOR: John Psillos NON-EXECUTIVE DIRECTOR: Irna van Zyl HEAD OFFICE New Media House, 19 Bree Street, Cape Town 8001 Tel: +27 (0)21 417 1111, Fax: +27 (0)21 417 1112 Email: newmedia@newmediapub.co.za Postal address PO Box 440, Green Point, Cape Town 8051
TO ADVERTISE IN Anita Raath
Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmediapub.co.za
Candida Giambo-Kruger Sales executive +27 (0)71 438 1918
Carla Melless
Sales executive +27 (0)83 260 6060
Food Manufacturing Africa is published by New Media Publishing (Pty) Ltd quarterly and circulates to executives in the food and beverage industries. Views expressed in this journal, other than where specifically stated, are not necessarily those of the publisher. The editor welcomes for publishing consideration news items, press releases, articles and photographs relating to developments in the food and beverage industries. No responsibility is accepted should contributions be lost. Food Manufacturing Africa is printed and bound by CTP Printers - Cape Town. Copyright: all rights reserved. ISSN 2309-5334
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NEWS
Cooling systems that work THE AGROECO GROUP, is the largest pig farming enterprise in the Voronezh region in Russia. The seven districts in the region contain 11 successfully operating, modern pig farms, a genetics and selection center, and a high-tech feed mixing plant with an elevator. The company has enforced stringent requirements on suppliers of its equipment. The cornerstone for best product quality should be laid with state-of-the-art equipment and advanced technologies. A detailed design of all systems and equipment for future business is currently being drawn up. The GEA cooling system is an energy-efficient, reliable and fully automated exothermal refrigeration unit using NH3 and CO2. This includes compression equipment, evaporative condensers, portioning equipment, air coolers and blast freezers.
GEA Grasso SP1 series of single stage screw compressors
The NH3 circuit’s refrigerative capacity is 6 500 kW at T0=-11 and a further 6 500 kW at T0=-14. To reduce losses incurred in transforming electricity, and in the cost of constructing the transformer substation, it was decided that high-voltage motors (10 kV) would be installed on the compressor units for the NH3 circuit. For the receptacles of the -44 and -29 circuit, CO2 is used as the working substance, whereas for mediumtemperature receptacles, an aqueous solution of propylene glycol, cooled to -8°C, is used. The equipment is supplied through GEA.
Restructure strengthens markets PYROTECHNICAL MARKETING (PYROTEC), which includes the Tower,
Beattie says Tower will be separated from the Pyrotec brands to enable each company to focus on PackMedia and PackMark brands, its strengths and has been operating continue to grow as one company within its markets. for the past 50 The brand years. In the last will move to new two years, the facilities with PackVerifi, Pyrotec its ownership Finance and and leadership PackLink brands in the hands have been added of managing to the company’s director, Stephen service offering. Beattie and his ‘These new current team. brands relate to Tower is PackMark and Pyrotec’s management team dedicated to PackMedia, which supplying self-adhesive labels. For both service industrial sectors. the Pyrotec brands – PackMedia, Tower incorporates office and PackMark, PackVerifi, Pyrotec Finance hardware products, kids and signage and PackLink – it’s business as usual. ranges and MyTowerLabels. It serves With their relevant teams, both GMs completely different industries – Timothy Beattie and Brandon Pearce retail and commercial customers,’ continue to head up PackMedia and says Rowan Beattie, Pyrotec’s PackMark respectively. managing director.
EABL invests in long term growth EAST AFRICAN BREWERIES Limited (EABL) has announced Kshs 36.8 billion in revenues and Kshs 4.95 billion in profit for the halfyear ended December 2017. EABL’s volumes grew by four per cent and revenues rose by five per cent for the period. Net earnings were impacted by consumer weakness in the Kenyan market. This relates to the protracted election process and excise-tax changes in Uganda. In addition, EABL increased investment in sales and advertising and accelerated capital investment to boost future capacity for Senator Keg and spirits. EABL group managing director Andrew Cowan explains, ‘This is a solid set of results, delivered in a period of drawn out electioneering in Kenya, which impacted consumption in the value segment. Bottled beer is in recovery and mainstream spirits continues to grow strongly. Increased investment behind our brands in sales and advertising underlines our bold strategy to pursue existing and emerging growth in all segments of our business.’ Excluding Senator Keg, Kenya’s volume performance was up eight per cent driven by the resurgent performance of bottled beer and a double-digit growth in spirits. Senator Keg was down 22 per cent as its performance was impacted by a partial shut-down to expand capacity and higher consumer prices exacerbated by an extended period of elections that impacted consumer activity and expenditure. Uganda’s volume grew 15 per cent, but the negative impact of excise on imports, downtrading and the contribution of spirits packaged in sachet formats reduced margins and resulted in overall flat net sales. The Serengeti brand portfolio led the recovery in Tanzania, up 28 per cent overall on the back of the successful launch of the Lite variant. ‘We have refreshed our focus around our marketing strategy, expanded our route to consumers while innovating at scale. I am impressed by our innovation agenda with our brands such as Tusker Cider, Serengeti Lite and Uganda Waragi Coconut. The latter contributed 21 per cent to our half-year net sales,’ Cowan concludes.
2018 Quarter 1 | Food Manufacturing Africa
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NEWS
Saudi Arabia’s increased corn capacity A JOINT VENTURE between Cargill and
Arasco has resulted in a new corn milling facility for the Kingdom of Saudi Arabia (KSA). Middle East Food Solutions Company (Mefsco Corn Milling Facility) is Cargill’s first investment in KSA. The investment marks the company’s commitment to the Middle Eastern economy and support for the region’s food and beverage manufacturers. The Mefsco facility was built to serve the Gulf Cooperation Countries (GCC). These include Saudi Arabia, UAE, Kuwait, Oman, Bahrain and Qatar. With the new plant, the joint venture can double its glucose and starch production capacities, triple total production volume and expand its product portfolio to include high fructose corn syrup. This will meet the growing demand across the confectionery, juice, bakery and catering segments. Julian Chase, global
leader for Cargill starches, sweeteners and texturisers explains, ‘The Middle East food industry is one of the world’s fastestgrowing markets. The Mefsco facility gives regional food and beverage manufacturers access to high quality, innovative products produced specifically for them. Arasco’s local knowledge and supply chain infrastructure were critical in our ability to design a facility that best serves local market needs.’ The expansion allows Mefsco to offer enhanced, market-specific solutions for Middle Eastern customers.
Ziyad Alsheikh, chief executive officer of Mefsco concludes, ‘In the Middle East, consumer awareness around food safety and hygiene is growing steadily. Cargill’s expertise in processing agricultural commodities into high-quality sweeteners and starch-based products will provide regional customers with an edge in making products that respond to this consumer trend. Customers will be able to serve the market’s demand with products that Mefsoco will manufacture to the strictest food safety and hygiene standards.’
The joint venture will double glucose and starch production capabilities
Powering
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Food Manufacturing Africa | 2018 Quarter 1
2018/02/20 2:52 PM
NEWS “Being awarded an “A” in climate change and water management illustrates our deep commitment to environmental sustainability.”
Firmenich recognised by CDP
Firmenich received an award for excellence in water management
THE COMPANY HAS announced its ranking
on CDP’s Supplier Climate A List, among the top two per cent of corporations participating in the programme. Adding to its “A List” for Water, the recognition confirms Firmenich’s position as a world leader for its actions and strategies in response to climate change, water security and deforestation.
‘Firmenich is committed to leading our industry in climate change mitigation. We have set ourselves ambitious environmental goals and have a vision to be carbon neutral,’ said Gilbert Ghostine, Firmenich CEO. ‘Reaching CDP’s Supplier Climate and Water A Lists is testament that our actions are making a difference for our colleagues, our customers and the planet.’ Jane Sinclair, Firmenich general counsel adds, ‘Being awarded an “A” in climate change and water management illustrates our deep commitment to environmental sustainability. Today, 100 per cent of our European manufacturing sites solely rely on renewable electricity. We are well on the way to achieving our objective of 100 per cent of our plants powered by renewable energy by 2020. ‘Protecting and preserving our planet for the generations to come is part of our DNA. Firmenich’s excellent performance echoes our team’s indefectible pledge to the environment,’ commented Neil McFarlane, Firmenich senior vice president global quality, health, safety, security and
environment. ‘Being ranked in CDP’s Supply Chain A Lists demonstrate how our close collaboration with our suppliers leads to more environmentally-friendly products and more sustainable manufacturing processes for our customers.’
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2018 Quarter 1 | Food Manufacturing Africa
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COVER STORY
Integrate passion and good taste
Frutarom is known for its aggressive acquisition trail. Last year’s acquisition of Unique Flavors has been favourably concluded. Chief executive officer Darrell Gray, predicts the company will regroup and integrate fully in 2018. It aims to do this by focusing all its efforts on business activities throughout the sub Saharan region. By Maryke Foulds
F
RUTAROM’S BUSINESS MODEL has proven to be very attractive to customers on the African continent. The company is committed to driving this model across a broader product offering. ‘While integrations often don’t meet the desired outcome, we are happy to report the integration with Unique Flavors was a tremendous success,’ Gray enthuses. ‘By the end of 2017 we registered positive growth. Our aim this year is to leverage the benefits of integration into the market place. We expect a very positive response from our customers.’
An inspiring and creative environment results in innovative thinking, knowledge and knowledgebased development. This approach underpins the core values of Frutarom. Support from the best raw materials, latest technologies and comprehensive know-how is a sure-fire recipe for business success. A key activity for the year is to showcase the combined portfolios of Frutarom and Unique Flavors with the company’s global product portfolio relevant to the African market.
“Frutarom’s unique style fits well with the typical customer’s habits and needs on the African continent”
‘Our sales force has vast experience across the African continent. In our typical Frutarom style, we will continue to drive our activities across a widely accepted product range, delivering the correct value equation,’ Gray notes.
TASTE SOLUTIONS Frutarom’s global supply chain and operating flexibility allows for a broad range in local and global tastes. Divisions are broken into:
Flavours – unique, high quality sweet and savoury flavours
Savoury solutions – value added functional savoury solutions
Food systems – Comprehensive range of sweet and savoury. Holistic solutions with fruit, spice, vegetables and meat for fresh dairy, ice cream, bakery, convenience food and beverages Frutarom currently produces product at two facilities situated in Midrand and Centurion, South Africa
DID YOU KNOW? Frutarom South Africa is home to a state of the art emulsion production line. A priority has been set to target all users of emulsions to leverage advantages in emulsion capability.
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Food Manufacturing Africa | 2018 Quarter 1
COVER STORY AWARDS EVENING
The glorious and much anticipated year-end function was also an opportunity to award staff for their hard work during the year
Leosha Singh, Lloyd Chaza, Connie Molefe and Sivile Lao
Frutarom has implemented a systematic activity for almost a century. The need approach towards innovation, based on for companies like Frutarom to align with the principles of professional project this trend will serve local companies and management, rapid prototyping and joint people favourably in the future by creating innovation. ‘Our innovation teams across business opportunities and jobs. Europe make this philosophy visible and At the core of a successful enterprise is tangible by bringing its staff. ‘Frutarom is rapidly together resources of expanding in Africa. Our FACTS & FIGURES know-how and inspiration investment into recruitment for new product and training of staff is high developments, spanning on our agenda to develop our customers everything from creative people. Frutarom’s unique in over brainstorming, designing style fits well with the typical 150 countries new flavours, tailored customer’s habits and needs and customer oriented on the African continent. all-in-one solutions, to As we build our business, concept evaluation and we remain committed to research and communication.’ the local needs of the food development laboratories and beverage industry on Looking at Africa the continent. Frutarom Population growth respects its competitors estimates for sub and we are continually production sites Saharan Africa present looking for ways to ensure a favourable outlook the value we bring to our for food and beverage customers is at a superior manufacturing across the level,’ Gray concludes. • continent. The appetite Frutarom – www.frutarom.com for locally produced employees globally products in Africa is certainly a milestone shift from the historical trading preferences that products dominated business
30 000
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Darrell Gray handing over the Most Valued Player of the Year Award to Marius Smit
67
globally
5 000
70 000
Ernest Masemula and Fanie Mbonani
Chantell Wolmarans, Yvette Render, Natasja de Jager, Elize Wilby and Mariando Kruger
2018 Quarter 1 | Food Manufacturing Africa
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DAIRY FOOD
Mineral fortification in dairy The global functional food market is dominated by dairy products, with sales valued at US$9.23 billion. In this edited article, Markus Gerhart and Martin Schottenheimer talk about the growing scope for innovative and healthier products.
F
ORTIFICATION IN PRODUCTS can contribute 50 per cent and more of daily diet requirements. In Europe, functional dairy products are impacted by health claims regulations. Claims regarding popular functional ingredients like pro-or prebiotics are restricted. In this space, the feasibility of additional minerals must be considered. Milk products are a complex food matrix and high fortification levels are challenging. The right selection of the appropriate mineral component and application can ensure success. Calcium, magnesium or zinc offer a wide range of claim
IED F I T FOR
options that address topics like bone health, immunity, energy or cognitive functions. Jungbunzlauer, supplied locally through Savannah Fine Chemicals, aims to understand the applicability of mineral salts in dairy products. Calcium, magnesium, zinc fortification in milk, yoghurt and drinking yoghurt should receive special mention. Milk is an important source of minerals - about 40 to 74 per cent of daily calcium is provided by dairy food. With magnesium, potassium and sodium, calcium plays an important role in the structure and stability of casein
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Food Manufacturing Africa | 2018 Quarter 1
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DAIRY FOOD DID YOU KNOW?
miscelles. In whole destabilise the system, milk, about two thirds especially during heat Studies indicate organic of its calcium and treatment. This may mineral salts like citrates, one third of its lead to coagulation, lactates and gluconates outperform inorganic mineral magnesium is bound syneresis and reactions sources such as oxides, in the micelle and with further ingredients carbonates and phosphate with regards to relative the remaining mineral of the milk product like bioavailability. fractions are dissolved phosphate and proteins. in the aqueous phase. Addition of chelating agents Mineral supplementation such as potassium citrate can of milk is challenging, enable high fortification levels by because the soluble phase is adjusting the pH level and competing with considered saturated at its normal pH, calcium to reduce cross-linking. making further addition difficult. The In contrast to soluble minerals, low or selection of the appropriate mineral source insoluble minerals remain dispersed within for a specific application is extremely the products, with a much lower impact on important. Properties of the respective the dairy matrix. Their influence on taste is mineral compounds such as mineral less pronounced, as bitter and astringent off content, solubility and taste are essential tastes are related to free ions of dissociated parameters for product development, while minerals. Mainly suspended, insoluble bioavailability and economic considerations minerals can affect mouthfeel in terms of are important. grittiness and chalkiness and can lead to Suitable mineral salts can be roughly sedimentation in low viscous products. subdivided into soluble or insoluble Micronised mineral salts are a good option minerals. When using soluble salts, to address these undesired effects. sedimentation and influence on mouthfeel The challenge for dairy product are negligible. Impact on taste and pH value manufacturers is to provide products with increases with rising fortification levels the highest mineral content and appealing and pH changes. Additional free ions can sensory properties. Since micronised
tricalcium citrate has been available, it has replaced inorganic and organic salts such as calcium lactate in dairy applications, enabling manufacturers to fortify products to more than 50 per cent RDA of calcium per serving. The combination of outstanding technological properties and a high nutritional value makes micronised tricalcium citrate the number one option for calcium fortified milk products. In contrast to calcium, fortification with magnesium and zinc is not as established. In Europe, where health claims on products are regulated by the new EFSA health claim regulation, magnesium and zinc offer various options for new product concepts. Growing awareness for these two minerals should gain importance in dairy, alone or in conjunction with calcium and other nutritional ingredients. As technological hurdles increase with higher fortification levels, trimagnesium citrate and zinc citrate will prove their performance in dairy applications. â&#x20AC;˘
Savannah Fine Chemicals â&#x20AC;&#x201C; www.savannah.co.za
2018 Quarter 1 | Food Manufacturing Africa
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MEAT, FISH & POULTRY
How to control fat in coated products JBT has launched its integrated in-line Dry-Fry System. The technology is designed to process coated products with up to a 50 per cent reduction in oil pick-up.
T
HE SYSTEM PRODUCES coated products, which are considerably healthier than traditionally fried products. Most critical is that it still retains its excellent taste and appetising appearance. JBT’s Dry-Fry System can deliver controlled amounts of oil to products following the coating or breading stage. This enables processors to manufacture or market low fat or lower fat options on a wide range of food. The range can include poultry, fish fillets, vegetables and re-formed products. The system is geared at retaining an appetising appearance coupled to maximum flavour delivery. The system integrates three of JBT’s equipment brands: • Stein Ultra V breading line • Double D Revoband continuous protein oven • Frigoscandia GYRoCOMPACT spiral freezer. The system also incorporates an oil spray system. The
“We’re confident the Dry-Fry System is the perfect answer for producing tasty, coated products”
technology can deliver controlled amounts of vegetable oil to the product depending on requirements. Torbjörn Persson, JBT’s portfolio and applications director, explains some of the systems’ key features, ‘What sets the technology apart is its ability to provide exactly the required colour and consistency of finished product. This is due to impingement technology and the high temperature capability of the Revoband’s continuous protein oven – a unique system in the industry. ‘As there is no pre-frying stage, the oil is much fresher. This provides a cleaner taste and better texture. We believe up to a 50 per cent reduction in oil pick-up is the maximum desired. Anything more than this would be detrimental to taste. ‘There are considerable cost-savings to be made when using less oil. Not least, it means less waste and reduced health and safety risks. The system gives processors excellent opportunities to introduce new tastes and exotic flavours by using different types of vegetable oils, such as olive oil, or oils flavoured with herbs or spices,’ Persson enthuses. No special coatings are required for the Dry-Fry System. The only prerequisite is the coating must be oven bakeable, such as Japanese or tempura crumb. Coating is set by flash cooking in the Revoband continuous protein oven for around 1.5 to two minutes, before being marshalled straight to a Frigoscandia GYRoCOMPACT Spiral Freezer. ‘Flash cooking ensures the coating is efficiently set,’ Persson continues. ‘Final product colour can also be carefully controlled. The Revoband continuous protein oven has a unique high impingement system. This provides high temperatures up to 280°C degrees, so customers can easily achieve their desired colour. ‘We’re confident the Dry-Fry System is the perfect answer for producing tasty, coated products, which respond to consumer demand for healthier choices. It also gives processors significant cost savings and massive opportunities for new product development. JBT is supplied locally through Albrecht Machinery •
The technology delivers controlled amounts of vegetable oils
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Food Manufacturing Africa | 2018 Quarter 1
Albrecht Machinery - www.albrechtmachinery.co.za
MATERIALS HANDLING & CONVEYING SYSTEMS
How ERP helps the
whisky supply chain When you are nestling a glass of comforting and familiar whisky in your hand, do you ever consider how it travels along the supply chain? Maybe you should, writes Doug Hunter.
I
N THIS ARTICLE I’ll focus on advancements in technology, particularly in the enterprise resource planning (ERP) space. ERP will track how the product can be brought through the supply chain, from endto-end; crop to consumer.
The supply chain logistics of whisky You have whisky – but it’s still in Scotland. You need to add the normal retail logistics, inventory management, landed cost tracking etc. to get the bottle to your local liquor store for your enjoyment. On the distribution side, there needs to be some marketing, promotion planning and forecasting, packing and shipping, customs clearance and duty. These are all vital parts of the supply chain. With the latter in place, ERP can effectively streamline and assist.
Cost tracking A variety of costs come into play when handling a good malt whisky. This depends on the age/vintage of the product, materials handling costs, outbound and inbound logistics, including warehouse and
distribution costs. Subtle cost shifts in any operational area can quickly change a profit to loss. ERP functionality such as quoting automation can assist in easily managing variations in pricing and trade promotions from a single system. Raw materials need to be purchased wisely and inventory turnover maximised. This will minimise value loss while on the shelf. Integrated scheduling, inventory forecasting and materials requirements planning solutions provided through ERP allow you to order just what you need, in response to demand. This reduces costs and waste.
decide which batch to pack with the correct packaging and food information for that specific country. This prevents the return of a good batch of whisky from customs.
Consignment control
Quality tracking
Batch manufacturing operations need to be considered when manufacturing and selling malt whisky. While the latter can become extremely complex, increases in globalisation mean companies must respond faster to demand and decrease time to market. ERP software enables batch manufacturers to improve control over goods being produced, reducing associated costs and downtime. 360 degree visibility allows you to easily
Functionality that allows you to inspect the quality of goods purchased allows you to control the quality of food purchased. Work-inprogress inspection facilities enable validation of quality and the grading of products. ERP enables you to associate documentation to loads with applicable certifications, specifications and quality records. •
Shelf life management ERP software enables manufacturers to manage product expiration dates on the shelf. This ensures shoppers will have enough product-life left after purchase date. Manufacturers can include expiry dates in materials requirement planning calculations. This reduces waste and assures compliance with food and beverage safety regulations.
Syspro – www.syspro.co.za
“ERP functionality such as automation of quoting can assist in easily managing variations in pricing and trade promotions from a single system”
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Food Manufacturing Africa | 2018 Quarter 1
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MATERIALS HANDLING & CONVEYING SYSTEMS
WAYS TO IMPROVE PLANT FLOOR PRODUCTIVITY
In manufacturing, accurate and comprehensive real-time information about plant floor operations is essential to make informed decisions. Downtime, detrimental to any business, is especially damaging and costly for manufacturers.
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ANY ORGANISATIONS lack the insight and visibility to refine operations in a costeffective and proactive way. Asset managers are under severe pressure to keep equipment performing, despite constrained budgets and ageing infrastructure. Advanced enterprise asset management (EAM) solutions offer companies deep visibility into their assets. It allows them to plan and prioritise maintenance activities more effectively. This could curb the tendency to overspend or underspend on maintenance practices. Barry Diedericks, EAM subject matter expert at Softworx, says there are five distinct ways that effective EAM improves plant floor productivity. ‘The right EAM solution will reduce movement to optimise task efficiency. It will also improve supply chain scheduling to reduce bottlenecks and increase equipment reliability. By optimising inventory levels, shortages are reduced. Automated data collection automates processes, which speeds up plant floor operations.’ Movement is considered one of the seven wastes of lean manufacturing. This occurs when temporarily locating, filing, stocking, stacking or moving materials, people, tools or information. Effective EAM decreases the
time and labour needed to complete tasks by reducing movement. During manufacturing it is clear that things do not always go according to plan. ‘Production is impacted by the availability of material or by disruptions,’ Diedericks adds. Early detection capabilities and realtime access can assist. It offers access to information needed to adjust schedules to accommodate disruptions. Information lends itself to efficient supply chain scheduling, minimising delays and downtime. Poorly maintained equipment affects the quality of products being manufactured. It also reduces plant floor productivity even further by creating additional rework
hours. This problem is easily avoided through innovative EAM. Through a strategic approach to asset management, equipment performance data can be analysed for key trends and anomalies. This empowers the organisation to act proactively rather than reactively. A key element of plant floor productivity is material required to manufacture the product. If not available, production grinds to a halt. Diedericks believes the best approach is to ensure accurate and timely visibility into your inventory is at hand. This allows you to know exactly what components are running low in stock, detect potential issues, and rectify them before they become real problems. Automated plant floor processes with automated data collection tools like barcoding, drastically speeds up inventory and asset data collection and analysis. It also improves data accuracy. ‘With barcoding, key inventory and asset data is automatically captured. Barcoding technologies, such as RFID, also reduce equipment downtime. Manufacturers can identify usage patterns and reduce costs by implementing a need-based (rather than a calendar-based) maintenance schedule,’ Diedericks concludes. •
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Food Manufacturing Africa | 2018 Quarter 1
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MATERIALS HANDLING & CONVEYING SYSTEMS
The cost of functional safety for food processing In 2014 in the UK, a large food manufacturer had to pay a £800 000 fine after a serious industrial accident. An engineer was trapped by machinery while examining a conveyor belt and suffered major injury and ongoing nerve damage. Jorgen Saxeryd explains how safety procedures must be developed in food processing plants.
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CROSS THE GLOBE, there are a variety of different regulations for food processing plants. North America and Europe have strict regulations for safety in these potentially dangerous environments. This also applies to the safety of employees in the processing plants and employers who fail to make adequate safety considerations can face large fines. Authorities can enforce these in the case of accidents, they can also be enforced during regular inspections. In Europe, the Machinery Directive 2006/42/ EC requires machinery to be designed and built so it can be used safely. In food processing plants, there are many dangerous machines for which plant managers should follow safety regulations, or the plants may face closure or high fines. Machines such as decanters operate at high centrifugal forces and it is not unknown for the machine’s g-forces to reach more than 2 000 times gravitational force. This is clearly a dangerous environment for employees to work. As these machines are essential for use, the key concept is risk management. In the 1970s, the increase in heavy machinery such as the creation of the steel press led to increased safety guards. Many safety conscious companies undertake a risk analysis in the initial stages of machine development. In the case of decanters, it is
not possible to remove risk, but it is possible to mitigate it to an acceptable level by putting safety guards such as enclosures or emergency stops in place. Companies often find it difficult to manage the complex world of safety regulations alone. It is better to consult professional services rather than not complying with regulations. ABB’s experts can provide specific advice on regulations, which also considers the requirments of food processing plants. As companies become more knowledgeable about regulations and regulations become more stringent, the need for retrofitting old equipment with additional safety measures may arise. Although it may seem instinctive, the safest answer is not always to shut a dangerous moving machine away behind an enclosure or barrier. In the food processing industry, companies should consult functional safety experts who have experience in the sector. Experts will suggest equipment such as a light grid, which
Neglecting functional safety can have serious consequences
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Food Manufacturing Africa | 2018 Quarter 1
performs an emergency stop on a machine when it is broken by an object. These devices are more appropriate for the food processing sector than using physical guards or barriers. They allow easier access for maintenance and washdown - essential for hygiene in food processing plants. Managers of food processing plants in all countries, regardless of the country’s regulations, should consider safety a priority. From the safety of single pieces of equipment to line safety and then plant safety, plant managers must be aware of what they can do to mitigate risks. Plant managers have a responsibility to put in place an accurate safety strategy to protect their employees and the business from costly infringements of worldwide safety regulations. •
“In the food processing industry, companies should consult functional safety experts who have experience in the sector”
Jorgen Saxeryd is safety products and functional safety advisor to ABB’s food and beverage programme.
ABB – www.abb.com/africa
Official INX distributors for South Africa Constantia Printing Inks are proud agents for INX International, Salchi and CTI. INX Low Migration inks and coatings for non-food contact surfaces are created in a dedicated, state-of-the-art facility to meet stringent government regulations and compliance requirements. First impressions do make a difference, and one way for a brand to break through the clutter is with the use of special effects in the printing process. INX inks and coatings in this category include soft touch, pearlescent, raised glitter and spot gloss coatings; reticulation varnish; and fluorescent, foil stamp and metallic inks. With BiocopacPlus Salchi Metalcoat is developing the first bio-based varnishes for food packaging obtained from agro-industrial waste from the tomato industry. CTIâ&#x20AC;&#x2122;s food safety technologies are on the cutting-edge of ensuring proper pasteurization, heat-sealing, and transportation. CTI provides technology that alerts consumers if a productâ&#x20AC;&#x2122;s quality has been compromised in various stages within a supply chain. Options from CTI include; Thermochromics , Photochromics , Glow-in-the-dark , Reveal inks , Trigger inks,HPP indicators and Colour changing Plastic.
Tel: +27 011 524 0715 / 0716 Email: mwcpi@mweb.co.za Web: http://constantia-inks.co.za
BEERS & CIDERS
A world of premium
beverage decoration As Africa’s food and beverage market grows, producers are becoming committed to the concept of brand differentiation. To catch consumers’ attention in a highly competitive market landscape, a product must stand out from the crowd.
R ECENT SURVEY* indicates that 65 per cent of consumers will purchase a product for the first time when the packaging speaks to them. This shows how the development of the right decorative solution is a decisive factor for achieving maximum brand awareness, resulting in the success of a product. Future oriented companies understand the impact of packaging and are progressively boosting demand for modern high-quality decoration. CCL has been serving the packaging and promotional industry for more than sixty years. The company has the expertise, network and know-how to support companies of the consumer goods industry on a global and local scale.
Hard at work in Africa As a major supplier to beverage companies, CCL is known for its range and scope of premium decoration in South Africa and neighbouring countries. Through the sales office in Johannesburg, customers are provided with labels, reliable service and on-site strategic and technical support. In the past, CCL was honoured with supplier awards by their long-term customers such as SAB Newlands. The market is currently supplied with labels produced at the German plant in Meerane - CCL’s global beverage competence centre. Thanks to its strong research and development focus, engineers are constantly revolutionising the world of packaging and decoration. Numerous ground-breaking innovations and industry firsts were developed at the facility.
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MEET CCL AT AFRICA’S HOTTEST EVENT
The CCL Label team in Johannesburg with their second Newlands Supplier Award
Global companies are using WashOff labels to improve the circulation process of returnable glass bottles. Patented CCL technology makes sure the decoration is removed from the container inside the bottle washer. Currently EcoStream is conquering the PET bottle market. Innovative construction ensures that bottle-to-bottle recycling and premium self-adhesive decoration are no longer at opposite ends of the spectrum.
New possibilities With the construction of the new production site this year, CCL could soon offer local customers the same high-quality products they know and rely on - combined with even more flexibility. The goal is to supply customers in the most efficient way by enabling shorter lead times and reducing transportation and storage. Premium decoration made in South Africa will open up new possibilities for existing customers and all other manufacturers looking to enhance their products through outstanding packaging. • * WestRock Packaging Matters Pulse (March 2017).
Food Manufacturing Africa | 2018 Quarter 1
IN 2016 CCL Label (CCL) made its debut at Food & Drink Technology Africa (FDT). This is the third successful satellite fair for Messe München’s Drinktec, a leading trade fair in the beverage and liquid food industry. Designed specifically for the needs of the local market, the event is evolving into an important networking and business platform. It offers visitors a comprehensive overview of the latest developments in the industry. CLL opened its sales office in Johannesburg a few years ago, already instrumental in supplying products to numerous customers in Africa. Business is growing, and a local production site will soon follow. To spread the word and promote its capacities, CCL Label will present its latest premium decoration solutions at FDT, held from 4 to 6 September at the Gallagher Convention Centre in Johannesburg, South Africa. Different types of decoration, a vast range of printing technologies, effects and innovations will leave a lasting impression and inspire new packaging ideas. Revolutionary technologies such as WashOff, coupled to new ecological and recycling-friendly solutions will shape the future of labelling. CCL’s booth will be the pit stop for brand inspiration, latest technologies and trends and discussion of future and current projects.
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BEERS & CIDERS
How Digitalisation changes the production process New technologies provide us with an initial impression about possibilities in producing food and beverages of the future. With a rapidly expanding world population, we must start producing on a large scale. The digital revolution can have a real impact on production processes.
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HANGING CONSUMER AND market trends represent a challenge for industry as they mean increased amounts of product variants, recipes and brands developed, produced and managed. This makes food and beverage products (typically mass produced) much more complex. It is mandatory to consistently monitor raw materials and product over the entire production process. Managing a huge product variety, smaller batch sizes and maintaining high quality levels requires a major change in the way these items are produced. Both discrete and process workflows can benefit from Digitalisation. Siemens refers to this portfolio as the Digital Enterprise. It is based on a holistic approach that transforms the traditional value chain of a product into an integrated product and production lifecycle – from product design to production planning, engineering, execution and services. Only a fully digitised business model with a consistent digital thread has the power and flexibility to speed up processes and optimise production operations. Siemens’ new solution can create digital twins of products, plants and production lines to stimulate and optimise the entire workflow. It also enables the integration of individual machines in the plant (known as the bottom up approach) and the top down approach that allows central engineering of the entire plant. Both approaches ensure the comprehensive Digitalisation of the engineering process. After design and engineering, digital twins allow for virtual commissioning, so that all previous development steps are efficiently validated. Production process and bottling also benefit from simulation and optimisation with digital twins. Machines and production lines connected to MindSphere (an open, cloud-based IoT operation system) enables an entirely new dimension of transparency. This results in additional opportunities for optimising processes with added value for the client. This equates to shorter time to market, flexible engineering, optimal product quality and greater plant availability and efficiency. •
1. PRODUCT DESIGN
4. PRODUCTION EXECUTION
CHALLENGE: New products are
CHALLENGE: Production execution links
continually introduced. With factories located in different countries using different raw materials, consistent product quality is a must. All national regulations when marketing a brand in a different country must also be fulfilled.
the virtual world of planning with the real world of production. To achieve this, manufacturers must synchronise manufacturing operation with business processes.
SOLUTION: The Simatic IT R&D Suite
possibility to plan and schedule orders based on cost, energy consumption, availability of material, equipment, employees and other process related constraints like cleaning-in-place. Siemens technology makes it easier to get transparency of production assets, calculate and report KPI’with line balancing algorithms. This minimises downtime.
allows you to define product composition and simulate product performance to meet product requirements. It supports formula optimisation and includes a regulatory assessment to ensure compliance to national and international law. Teamcenter NX allows the creation of a digital twin of the product package. This enables the right fit between cost efficiency and an appealing design.
2. PRODUCTION PLANNING CHALLENGE: After design the product
must be produced on a large scale bearing in mind that R&D and the production department are often disconnected. SOLUTION: Comos and Tecnomatix
meets this challenge with efficient planning and simulation capabilities. The creation of a digital twin helps simulate critical processes, checks material and product flow, validates production capacity and identifies bottlenecks and overcapacities.
3. PRODUCTION ENGINEERING CHALLENGE: During this phase, all
mechanical and electrical components and automation steps are engineered in detail. Integrated workflows increase engineering efficiency during production, filling and the packaging process. SOLUTION: Braumat, in combination with
Simatic IT MES, allows meshing of all relevant data including packaging and offline topics. When used in combination with Simatic IT Unilab it reacts to your production.
Siemens – www.siemens.com/food-beverage
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Food Manufacturing Africa | 2018 Quarter 1
SOLUTION: Simatic IT Preactor offers the
5. SERVICE CHALLENGE: To unlock data assets and
put them to profitable use to increase availability, quality and efficiency across the value chain. SOLUTION: MindSphere is an open
ecosystem that enables connection to all industrial devices. It makes data from worldwide distributed machines and assets valuable. Two new MindSphere applications are dedicated to the F&B industry. With dozens of plants across the world, companies can display and benchmark relevant KPI’s for their production lines. The focus can fall on product quality and efficiency of the filling and packaging lines. MindSphere provides the right information to all stakeholders within a complex and distributed organisation.
New flexibility through consistent digitalization
Innovative products and solutions make you more competitive Food and beverage manufacturers must consider many factors: a consistently high level of product quality, maximum plant availability, optimum resource efficiency â&#x20AC;&#x201C; and, increasingly, the greatest possible flexibility in order to meet more and more individual customer requirements. Mastering all these challenges today and in the future is possible only with digitalization. We offer the products and solutions you need to fully or gradually integrate and digitalize your entire value chain. Find out more on Siemens innovative solutions for Food and Beverage: www.siemens.com/food-beverage siemens.co.za
BEVERAGES
Break boundaries between
sweeteners and functional carbs PalatinoseTM can be included in all kinds of beverages without any change to the production process. Its acid and temperature stability results in longer shelf life; supports better rehydration after exercise, while low hygroscopicity prevents powder drinks from lumping.
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OST POPULAR SPORTS drinks contain high glycaemic carbohydrates like maltodextrin, glucose syrup and sucrose. This mix releases sucrose into the bloodstream at a fast rate, aiming to maximise carbohydrate utilisation. On intake before sports, these drinks can result in large spikes and drops in blood glucose levels. This is not an ideal situation for athletes to start their exercise and the value contribution of fat utilisation in the fuel mix is suppressed during exercise. Low glycaemic carbohydrates, such as Palatinose are exciting alternatives as they deliver a balanced release of energy. Palatinose has been shown to have a sustained effect on normal blood glucose levels, compared to other fully digestible carbohydrates. Generically known as isomaltulose, the ingredient is derived from sugar beet. It
consists of one glucose and one fructose unit. The difference lies in the bond between these parts. With its 1.6 glucosidic bond, Palatinose is a more stable molecule compared to the 1.2 glucosidic bond found in sucrose. This strong binding is why Palatinose offers a steadier source of energy when compared to sucrose. It simply cannot be broken down as fast as sucrose. Due to its specific molecular bond, Palatinose is fully absorbed slower than commonly known sugars or carbohydrates. It offers the full calorific value of carbohydrates (4kcal/g) but in a balanced and longer lasting way. Two aspects are important to understand this interplay. Carbohydrates consumed with food or sports drinks are used first in the energy supply to the muscle. This allows the body to save its
own carbohydrates and fat reserves when no external sources are available. The rate of glucose supply determines the extent to which mobilisation and utilisation of internal sources are suppressed. This means carbohydrates, which provide fast glucose to the body, lead to more extensive suppression of fat utilisation. The advantages of Palatinose are evident. Slow release provides carbohydrate energy steadily over a longer time. This allows the body to maintain a higher level of fat utilisation in the fuel mix to the muscles. In endurance exercises, a higher contribution of fat oxidation is said to have a glycogen sparing effect, and thus a beneficial effect to enhance endurance performance. •
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Food Manufacturing Africa | 2018 Quarter 1
Savannah Fine Chemicals – www.savannah.co.za
PACKAGING
Packaging across Africa The African continent has one of the most diverse food and beverage markets. The industry is projected to reach US$1 trillion by 2030. With the increase in diversity and interest in food across the continent, many countries are beginning to experience the impact and fallout of such a booming industry. By Polly Duffee
Many African countries are beginning to experience the impact of the food industry boom, with the accumulation of plastic and styrofoam packaging
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WHILE PLASTIC AND styrofoam are popular packaging materials across South Africa and other African countries, they create a huge problem for waste disposal because they are very difficult to recycle or destroy. The impact is being recognised and acted upon by many governments, industry representatives and manufacturers. Even the ProPak Cape exhibition promoted sustainability as the core focus of its 2017 event.
Zimbabwe In 2017, Zimbabwe’s Environment Management Agency ordered an immediate ban on the use of expanded polystyrene (EPS) containers, ordering them to be replaced with recyclable or biodegradable items. Anyone found breaking the ban can be fined up to US$5 000. A report from Voice of America says one reason EPS has been banned in Zimbabwe is because it emits toxic chemicals when burned the routine process for waste disposal in Zimbabwe. Containers are discarded as litter on the streets of large cities like Harare, which inevitably clogs drainage systems and causes flooding. EPS is not biodegradable and can take up to one million years to break down, meaning it can take a heavy toll on the environment. Waste is also often contaminated with food or drink, making it difficult to clean. EPS is
in Kenya also urges retailers and shoppers to look for alternative packaging materials like paper, aluminium or bamboo. 95 per cent air and therefore very porous. It is challenging to recycle, so a lot of governments avoid doing so.
Kenya Economic reforms mean the overall economic development and levels of consumer spending have recently risen in Kenya, improving the disposable incomes of the middle-class. As a result, the import of plastic materials has seen steady growth for the last two years as demand for plastic and packaged goods soars. It is estimated that 100 million plastic bags are given out by Kenyan supermarkets every year. This results in clogged sewers, damaged soil and risk to animals. In the summer of 2017, Kenya implemented the world’s toughest plastic bag ban to tackle the increase of plastic waste in the country. Kenyans who produce, sell or use plastic bags risk imprisonment of up to four years, or fines of US$40 000. While some industry commentators were against the ban, many say it will give rise to new businesses and traders selling canvas bags, baskets and tote bags. The National Environment Management Authority (NEMA)
“In the summer of 2017, Kenya implemented the world’s toughest plastic bag ban to tackle the increase of plastic waste in the country”
Across the continent Over ten other African countries have implemented taxes, partial or full bans on plastic bags, including Morocco and Mauritania. The east African community has also considered a regional ban on the product. Many other countries on the continent are yet to realise the full effect of their plastic usage. Ethiopia has emerged as a major importer of plastic goods since its adoption of a free market economy policy in 1992, whereas Uganda is host to one of the largest plastics industry manufacturers in the world. Smaller countries like Mozambique and Tanzania are playing a part in Africa’s significant plastic problem. Zimbabwe and Kenya have taken drastic action with their respective bans and many other countries may begin to follow. With growth in the food and beverage industry forecast across Africa in the next few years, it is important for manufacturers, retailers and consumers to consider the type of packaging and waste they are contributing with their products and purchases. • Polly Duffee is the general manager at Advanta South Africa, an international packaging manufacturer.
Advanta – www.advanta.co.za
2018 Quarter 1 | Food Manufacturing Africa
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PACKAGING
A world without waste The Coca-Cola Company is reshaping its approach to packaging, with a global goal to help collect and recycle the equivalent of 100 per cent of its packaging by 2030.
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HIS GOAL IS the centerpiece of the company’s new packaging vision for a world without waste. The Coca-Cola system intends to back it with a multi-year investment that includes ongoing work to make packaging 100 per cent recyclable. This begins with the understanding that food and beverage containers are an important part of people’s modern lives but there is much more to be done to reduce packaging waste globally. ‘The world has a packaging problem and we have a responsibility to help solve it,’ said James Quincey, president and CEO of The Coca-Cola Company. ‘Through our World Without Waste vision, we are investing in our planet and our packaging to help make this problem a thing of the past.’ The company and its bottling partners are pursuing several key goals: • Investing in the planet: By 2030, for every bottle or can the Coca-Cola system sells globally, it aims to help take one back. The company is investing its marketing dollars and skills behind this 100 per cent collection goal to help people understand what, how and where to recycle. The company will support collection of packaging across the industry, including bottles and cans from other companies. The Coca-Cola system will work with local communities, industry partners, customers and consumers to help address issues like packaging litter and marine debris. • Investing in packaging: To achieve its collection goal, The Coca-Cola Company is continuing to work toward making its packaging 100 per cent recyclable globally. The company is building better bottles, whether through more recycled content, developing plant-based resins, or reducing the amount of plastic in each container. By 2030, the Coca-Cola system aims to make bottles with an average of 50 per cent recycled content. The goal is to set a new global standard for beverage packaging. Currently, much of the company’s packaging is recyclable. These goals will be achieved with the help of several global partners: the Ellen MacArthur Foundation’s New Plastics Economy initiative, The Ocean Conservancy/
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Trash Free Seas Alliance and World Wildlife Fund (The Cascading Materials Vision and Bioplastic Feedstock Alliance). Coca-Cola will also launch efforts with new partners at regional and local level and plans to work with key customers to help motivate consumers to recycle more packaging. Speaking about the announcement, Kelvin Balogun, president of Coca-Cola Southern and East Africa said, ‘The company has taken great strides in reducing, reusing and recycling our packaging. We have worked closely with our bottling partners, local and national authorities, and recycling partners to improve the collection and local recycling rate of our cans, plastics and glass bottles.’
at Extrupet and MPact, to create recycled PET for use in the beverage industry. 45 000 tonnes of PET bottles are diverted from landfills each year for reuse in the beverage industry. An estimated 288 000m3 of landfill space has been saved and 82 000 tonnes of CO2 emissions is reduced each year. More than 1 500 new jobs have been created due to these two world class investments. • Bottling partners and other members of the PET value chain helped to set up PETCO, the PET Recycling Company, which in 2016 achieved a recovery and local recycling rate of 55 per cent of post-consumer PET bottles. In Uganda, bottling partner Century Bottling Company (CBC) and subsidiary Plastics Recycling Industries (PRI) in 2016 collected 58 per cent of all PET sold to market. Through strong partnerships with municipalities and suppliers, the PRI initiative employs over 1 200 people, with the majority being women. Coca-Cola Beverages South Africa runs the biggest schools recycling programme in the country. Since its inception six years ago, R20 million has been invested in the programme resulting in 2 034 tonnes of waste collected. By selling recyclable waste to collectors, schools raise funds to develop their own infrastructure. ‘Bottles and cans shouldn’t harm our planet, and a litter-free world is possible. Companies like ours must be leaders. Consumers around the world care about our planet, and they want and expect companies to act. That’s exactly what we’re going to do, and we invite others to join us on this critical journey’, Quincey concludes •
The company aims to: • Reduce dependence on fossil fuels by introducing PlantBottle packaging. It is the first fully recyclable PET plastic bottle made with up to 30 per cent plant-based materials. • The company invested in two bottle-to-bottle recycling facilities
Food Manufacturing Africa | 2018 Quarter 1
2018 Quarter 1 | Food Manufacturing Africa
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FLEXIBLE PACKAGING
Invested in the
future of flexibles Food Manufacturing Africa explores the latest flexible packaging solutions, which includes a new range of thermal transfer ribbons and major investments in packaging solutions.
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RMOR AFRICA’S NEW range of branded thermal transfer ribbons is called inkanto. The range became available globally and in South Africa at the beginning of the year. It is the first time since the company’s establishment that it has introduced branded range of thermal transfer ribbons. ‘The rationale is to provide added benefits to our channel partners so they can add value to what they offer their own The inkanto thermal transfer customers,’ says Armor Africa’s ribbons from Armor Africa managing director, Andrew Fosbrook. The new branding initiative will create a DID dynamic in the thermal transfer ribbons YOU KNOW? market. It is also expected to differentiate Full resin thermal Armor ribbons with a creative new name, transfer printer ribbons are made of pure resin. They melt dynamic image and a range of value at a much higher temperature, added services. dissolving into the material Fosbrook says the new brand still on which they are printed, resulting in extreme relies on the business fundamentals durability. on which the company’s success has been founded. These extend to professional ethics, unchanged sales strategy and identical operational approach. Inkanto is not just a complete new visual identity of the company’s unbranded ribbons, it also comes with a range of value added offerings, based on four values: quality; security; simplicity and longevity. ‘To ensure the highest levels of quality assurance, each ribbon comes with an online Certificate of Conformity and a Technical Contact form. This provides the necessary product information in the value chain, from Armor partners to end-users,’ he notes. To reinforce security, trust and confidence in these ribbons, each comes with a lifetime warranty. ‘Simplicity has been the hallmark of the design of the new brand. The inkanto ribbons are easy to identify through a dedicated leader per product family, branded box and cardboard core and a readable label,’ Fosbrook explains. He highlights that packaging rules are rational and simple, with smaller quantities per box offering greater flexibility. ‘This will include several datasheets with messages tailored to all possible levels of technical expectations.’ To maximise longevity of the print-head, a cleaning-wipe in each box of ribbons is included. Additionally, the company redesigned its partner, extranet 2go2, which is a new inkanto version offering an enhanced user-friendly interface based on full interactivity. Partners can input all their demands via this tool, which integrates to the group’s CRM system. The site has comprehensive information on products and includes proactive, flexible and interactive business reporting. ‘The brand aims to increase support to distributors and endusers, while making thermal transfer technology easier to use,’ Fosbrook notes.
With the implementation of inkanto in South Africa, the company will introduce a make-to-stock programme for its resellers. This will ensure fast turn-around times and ready availability for high volume ribbon configurations.
Constantia Flexibles invests in film technology At its site in Weiden, Germany, the company has invested approximately €6 million in new technology to manufacture film-based flexible packaging. The investment will meet the growing demand for speciality laminates such as stand-up pouches with high property barriers in the confectionery market, for processed products in the coffee segment, dry food, snacks and processed meat industries. As part of the investment, Constantia Flexibles installed two blown-film (polyethylene) extrusion lines. One line is installed at its Competence Center Film, which develops in-house proprietary film formulations that enable efficient production and speeds up the time
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2018 Quarter 1 | Food Manufacturing Africa
robot_88,5x130_food_manufacturing_africa_ad_enza_01.indd 1
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FLEXIBLE PACKAGING
to market. The second line produces prematerial for the Weiden plant and other film production sites in Europe. Constantia Flexibles has several blownfilm lines in operation within its global manufacturing network. In the coming months, the company will also integrate an AlOx dual metalliser that will manufacture transparent, high-barrier film products catering for the latest consumer trends. The non-metal material is combined with additional barrier lacquers and films to create a barrier against aroma, moisture and oxygen. The consumer can see the product inside the packaging due to its transparency. ‘These investments mean we are now fully integrated into the film value chain at the Hueck Folien plant in Weiden. It will strengthen the credentials of Constantia Flexibles as a supplier of high-performance films for different food industries,’ says Stefan Grote, EVP of Food in Europe. The company’s Ebert plant in Wiesbaden will focus on being a leading manufacturer of film-based twist applications for the confectionery industry. The research and development activities of the Competence Center Film, established 2017/03/31 9:29 AM in 2015, has3.pdf yielded 1success. Its CompresSeal
Constantia Flexibles has installed two blown-film extrusion lines
product was one of the winners of the German Packaging Award 2017 in the sustainability category. A number of technologies were used to create a film that has a higher seal integrity than standard polyethylene. It weighs about 30 per cent less than normal films and features the same thickness as standard packaging. In addition, it ensures tighter packs and provides for constant processing on packaging lines, both in winter and summer. The company is also investing in expanding production capacity at Parikh Packaging, its Indian subsidiary, located in Ahmedabad, Gujarat. Constantia Flexibles broke ground in mid-2017, on a new greenfield site close to its existing production at Parikh. The site is currently under construction and meets the highest international environmental, hygiene and work safety standards. It will be home to a polyethylene blown film extruder, highdefinition flexo printing press and laminators to produce high barrier laminates that can be fully recycled. The extra capacity will come
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Food Manufacturing Africa | 2018 Quarter 1
on stream in 2019 and serve the growing demand from leading multinationals in the food and home and personal care (HPC) industries in India. The flexible packaging market in India is expected to show double digit growth in the mid-term, driven by the urbanisation megatrend and the expansion of the retail sector. ‘Our investment strengthens Parikh Packaging’s credentials as a leading provider of innovation and service to customers in the Indian subcontinent,’ says Grote. ‘Major FMCG companies are demanding the highest level of sustainability for their packaging material. They will have to comply with upcoming Indian Plastic Waste Management regulations that promote only fully recyclable flexible packaging.’ Parikh Packaging has been part of Constantia Flexibles since 2013 and already has a production unit in Ahmedabad that is equipped with rotogravure printing machines, PE extruders, various lamination technologies and pouch making equipment. It is fully ISOcertified and boasts more than 500 qualified employees serving the domestic and global food and HPC industries. •
Armor Africa – www.armor-tt.com Constantia Flexibles – www.cflex.com
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