FEBRUARY 2019 - APRIL 2019 Vol. 7 • No. 1
Looking for more than just a beer line? This is performance. Bottled.
Ingredient and technology Ingenious and flexible advances in meat, fish & poultry materials handling systems
How to develop lean and profitable strategies in packaging
beverages
dairy farming
dairy processing
utilities
transport
food
core technologies
Milking & Cooling
Seperators
Decanters
Homogenisers
Valves
Spray Drying
Aseptic Filling
Brewery & Dairy
Compressors
Packages & Skids
Ice Machines
Freezers
GEA Southern & Eastern Africa 48 Reedbuck Crescent, Corporate Park South, Midrand 1682, RSA Tel. + 27(0)11 392 7114, Fax. +27(0)11 392 7000 info-sea@gea.com
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engineering for a better world
CONTENTS F E B R U A R Y 2 019 - A P R I L 2 019
9 Overcoming digital dread As African manufacturers begin to upgrade operations, mapping out an incremental approach is essential. Smart factories, digitisation and the Internet of Things (IoT) are hot topics in the manufacturing sector right now.
22 Accuracy and efficiency This system will enable 100 per cent shipping accuracy, efficiency and real-time supply chain visibility.
Vo l. 7 • N o. 1
6
NEWS
Afriplex opens dedicated cannabis laboratory
Milco offers R4.8 billion for Clover
World class plant for International Breweries
ADM forges partnership with General Mills
9
INDUSTRY TALK
Don’t fall prey to digital dread
10
EVENTS
All you need to know about Industry 4.0
11
MEAT, FISH & POULTRY
IFFA: flexibility in a digital world
Solutions for clean label deli meat
Crumb coated products ditch the fat
New ingredient can aid food safety
Developments in collagen casings
Keep your meat fresh with MAP
20
MATERIALS HANDLING & CONVEYING SYSTEMS
Improved visibility with social ERP
A smooth ride with universal handling systems
Real time visibility for assured accuracy
24
BEERS & CIDERS
Efficient canning lines boost beer production
Brewers need lean solutions
Sacmi partners with US craft brewers
Introducing KHS’s Innofill glass filler
27
RIGID PLASTICS
Sidel offers alternatives to hot-filled beverages in PET
Polyoak Packaging tackles sustainability
Are your products inspection ready?
Lean strategies for tough times
ADVERTISERS’ INDEX Propak West Africa............................................7................www.propakwestafrica.com Afrocet Montgomery (Nigerian Food Event)......................................6................www.nigerianfoodevent.com Annelie Coetzee..................................................17..............www.anneliecoetzee.com CCL Label South Africa ...................................OBC..........www.ccllabel.com GEA Africa..............................................................IFC............www.gea.com Poly-clip.................................................................8................www.polyclip.com Polyoak Packaging............................................29..............www.polyoakpackaging.co.za ROHA SA..................................................................IBC...........www.roha.com
Savannah Fine Chemicals.............................13..............www.savannah.co.za Sensient Technologies South Africa........15..............www.sensient-cosmetic.com Sidel..........................................................................OFC..........www.sidel.com Sollich KG...............................................................23..............www.sollich.com/world Syspro......................................................................20.............www.za.syspro.com Tomra Sorting NV...............................................19..............www.tomra.com/food Vivit Foods.............................................................18..............www.vivit.co.za
2019 Quarter 1 | Food Manufacturing Africa
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EDITOR’S COMMENT
EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmedia.co.za Layout & Design: Andipha Nkoloti Contributors Hans Strydom, Huiuso Huang ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmedia.co.za Sales Executive: Gayle Kihn +27 (0)82 457 0896 gayle.kihn@newmedia.co.za
Embrace the
digital revolution! M
ANUFACTURERS ON THE African continent are seeing the value of upgrading operations and implementing smart technology to optimise output and productivity. In this edition of Food Manufacturing Africa, we unpack some of the latest innovations that can assist this call to action. Optimised production processes based on digitisation and interlinked networks is the focus of the IFFA trade show, which kicks off from 4 to 9 May in Frankfurt, Germany. On page 11 you can read all about how smart sensors, condition monitoring and digital twins can impact the way you do business. Despite missing a legal or commonly accepted definition, clean label pushes the industry to re-evaluate ingredients, formulations and processes. It is open to interpretation as ‘all natural’, ‘minimally processed’ and ‘non-GMO’. Find out how Lallemand’s solutions for deli meat can allow your company to tick clean label on its ingredient listing (page 12). The primary role of modified atmospheric packaging is to extend shelf life of fresh food. This is done without artificial additives, chemicals, freezing, preservatives or processing – while retaining fresh food taste, texture and appearance. On page 18 we look how Afrox’s gases can assist in reducing cost, while satisfying demand for fresh and naturally preserved food. The industrial bakery market is evolving and consumers are seeking authenticity, improved quality and a broader, diverse range of bakery, pastry, patisserie and snack products. In this instance, too,
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mechanisation plays a vital role for manufacturers in the sector. Mecatherm (page 21) recently launched three handling systems which offer significant advantages in terms of product quality. We end this edition with an in-depth look at solutions and systems rewriting the beers and ciders industry (page 24) and look at some of the latest innovations in rigid packaging. Don’t miss our article on packaging guru Kishan Singh’s tips for implementing lean, profitable strategies in the packaging industry. Turn to page 30 for the full story. I hope you enjoy this edition. If you have any comments or suggestions, we would love to hear from you! Email me at maryke.foulds@newmedia.co.za. Happy reading, Maryke
Food Manufacturing Africa | 2019 Quarter 1
Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmedia.co.za
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@newmedia.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmedia.co.za Production Manager: Pam Moodley 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)11 877 6198 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published by New Media a division of Media24 (Pty) Ltd 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@newmedia.co.za Postal address PO Box 440, Green Point, Cape Town 8051
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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DIARY
March 12 – 15 Propak Africa 2019 Nasrec, Johannesburg www.propakafrica.co.za
18 – 20 Pro2Pac 2019 London, UK
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Full Name:........................................................................................... Designation: ........................................................................................ Company: ........................................................................................... Postal Address:................................................................................... .................................................................Code:................................. Country: .............................................................................................. Tel: (
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E-mail:................................................................................................. Main activity of company:................................................................... Approximate number of employees: ..................................................
April 7 – 9 The Specialty Food Business Summit Chicago, US www.specialtyfood.com
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May 4 – 9 IFFA Frankfurt, Germany www.iffa.com
6 – 8 Bakery China Shanghai, China www.bakerychina.com
TAX INVOICE REQUIRED
6 – 9 TuttoFood
(Please tick) SOUTH AFRICA
(PRICES INCLUDE VAT @ 14%)
FOREIGN
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Milan Italy, www.tuttofood.com
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14 – 16 SIAL China
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2019 Quarter 1 | Food Manufacturing Africa
5
NEWS
SA’s first cannabis laboratory opens Afriplex has announced the establishment of its dedicated cannabis laboratory. The facility will meet the requirements of an exploding cannabis industry for high quality processing and testing in South Africa. THE LAB HAS been in development for the last 18 months. It forms part of work being done to bring its cannabis processing facilities up to Department of Health and the South African Health Products Regulatory Authority (SAHPRA) regulations. ‘We have invested in a specialised team of experienced professionals and researchers to bring the cannabis laboratory online. Our clear focus to cannabis and cannabinoid testing has resulted in the South African Cannabis Research Institute (SACRI) nominating the Afriplex Cannabis Laboratory as the laboratory of choice in South Africa,’ Robert Longrigg, Afriplex responsible pharmacist enthuses. The Cannabis Laboratory includes an intricate security system, which limits unauthorised access. Stringent, good laboratory practice (GLP) is in place to ensure correct control throughout the laboratory. Documentation and an integrated laboratory
information management System (LIMS) will keep track of: arrival, storage, client and partner research projects and details of samples from seeds and plants. It will track right through to the development of active pharmaceutical ingredients (APIs) and other extraction samples of tetrahydrocannabinol (THC), cannabidiol (CBD) and cannabinol (CBN). Laboratory equipment will be maintained and serviced, calibrated, sterilised and decontaminated in accordance with good GLP and GMP practices laid out by Afriplex and the SAHPRA. The Afriplex Cannabis Laboratory has a three-tiered approach: 1) Receiving, identifying and processing 2) End-product analysis 3) Research and development. ‘The processing laboratory is set up to ensure reproducible and effective cannabis products by handling receiving aspects like investigating
the appearance of the arriving, cultivated cannabis’ morphological and microbiological presentation. This will ensure the appropriate, respective cannabis strain has arrived on site prior to the extraction process proceeding,’ Longrigg notes. Quantitative assays using GC-MS, GC or HPLC will be used to ascertain the volume of THC, CBD or CBN in the respective identification samples. Afriplex will make use of existing and create new libraries of identification markers to identify stock arriving at the plant. Samples from the final powders, tinctures, oils and APIs will be tested in the Cannabis Laboratory for stability, quality, reliability, and reproducibility.
Afriplex – www.afriplex.co.za
Co-located with:
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Food Manufacturing Africa | 2019 Quarter 1
NEWS
Israeli food group offers R4.8 billion for Clover THE MILCO CONSORTIUM is led by Israeli-based Central Bottling Company (CBC). The company has offered to purchase 59.5 per cent of the South African food-drinks producer, while JSE-listed Brimstone are offering to buy an additional 15 per cent of Clover’s shares. Other members of the Milco consortium include Ploughshare Investments (10.9 per cent) and IncuBev (8.3 per cent). Clover’s management will retain a 6.3 per cent stake. CBC is a privately owned international food and beverage group whose subsidiary companies serve more than 160 million consumers worldwide. Milco believes that Clover presents a uniquely attractive investment, given its expansive chilled distribution capability, strong market position for key brands and experienced management team. With its extensive knowledge of the dairy, juice and non-alcoholic beverage industries, it has the technical and research ability to bring healthier food to consumers; access international brands and connections, coupled to operating experience in sub Saharan businesses. The company intends to combine its capabilities with those of Clover to unlock value through key strategic initiatives with expansion into select sub Saharan Africa territories.
BOOK YOUR STAND NOW
The plant promises to create 600 direct and over 2 000 indirect jobs along the value chain
International Breweries inaugurates world-class plant NIGERIAN PRESIDENT MUHAMMADU Buhari affirmed government’s commitment to securing the business environment so that foreign direct investment could flow into the country during the event. The brewery is the sixth largest listed company on the Nigerian Stock Exchange with N275 billion market capitalisation. The impact of the brewery would cut across various sectors of the economy, ranging from agriculture, manufacturing to haulage services while boosting activities in the small and medium enterprises sector. ‘The brewery will be instrumental to empowering farmers and local manufacturers, as most of the raw materials required would be sourced locally. This will contribute to the overall economic development of the country,’ highlights International Breweries Plc, managing director Annabelle Degroot.
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2019 Quarter 1 | Food Manufacturing Africa
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NEWS
ANALYTICA LAB AFRICA 2019 New specialty FOOD SAFETY AWARENESS is at an all time high and food quality assurance and testing is important to ensure consistency, safety and customer satisfaction. Analytica Lab Africa 2019, presented by international exhibition organiser, Messe München will curate leading edge modern technologies for food testing, sampling and quality assurance. International market leaders
will present products for testing food ingredients and preservatives, contaminants, origin of raw materials, animal species identification and microbiological contamination, among others. The event will feature a comprehensive range of leading solutions for sample preparation, chromatography, titration and spectroscopy, with a focus on digital innovation for Laboratory 4.0. Following Messe München South Africa’s acquisition of Lab Africa, South Africa’s only laboratory and analysis trade fair, the new-look analytica Lab Africa will bring to Africa the best of Lab Africa and the international analytica trade fair series. The event will include three days of industry specific conferences, workshops and special features, with knowledge sharing by international leaders in their fields. The event will be held at Gallagher Convention Centre in Midrand, South Africa from 9 to 11 July.
starches launched
ARCHER DANIELS MIDLAND Company (ADM) has announced a long-term partnership with General Starch Limited (GSL), a leading tapioca starch producer located in Thailand. The company has exclusive distribution rights of the GSL modified tapioca starch products in most European countries, the Middle East and Africa. This range of specialty tapioca starches will be sold under the ADM brand in a second phase of the partnership. These non-GMO specialty ingredients provide excellent viscosity with a clean neutral flavour profile, and can be used as an effective alternative to the modified waxy corn and potato starches in a wide range of food applications. ‘We are very excited to expand our European portfolio with another raw material, which will generate great opportunities and new developments supported by our Starch Lab in The Netherlands,’ enthuses Johan Schrijver, sales director Starches EMEA. ‘This partnership puts ADM in a position to develop innovative customer solutions through a broad range of starches, each with unique properties.’
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Food Manufacturing Africa | 2019 Quarter 1
01.03.2019 16:29:40
INDUSTRY TALK
Overcome digital dread As Africa's manufacturers begin to upgrade operations, mapping out an incremental approach is essential. Smart factories, digitisation and the Internet of Things (IoT) are hot topics in the manufacturing sector right now.
W
HILE THESE Now is the time to determine goals TECHNOLOGIES for the investment and tactics to get are creating a there. Most digital technologies, like buzz, their complexity can IoT, are not out-of-the-box solutions be overwhelming. ‘With a you simply plug in. ‘A customised practical, incremental plan approach is critical,’ Rossouw of action, including options advises. ‘Setting a well-defined plan with minimal disruption with measurable milestones will help and low-risk, even those eliminate project ambiguity. Focus Adriaan Rossouw who have been reluctant to on building a plan that is practical, embrace next-generation doable, and cost-effective.’ technology can get started on the journey,’ Start with viable phase one goals: advises Adriaan Rossouw, director of EOH • Prevent unexpected down-time and keep Infor Services. shop floor assets running There are five steps to embracing the • Better manage inventory levels with fewer digitisation journey: easing in; determining stock-outs the goals; addressing funding issues; • Meet customer demand for highly prioritising actions and delineating the size personalised products of the move. • Avoid broad goals like ‘double profits’ or To ease in, it’s important to realise ‘increase sales’. equipment can be modernised, processes Funding issues must be hashed out at the upgraded and new technologies adopted outset. If the business isn’t ready for a huge gradually while controlling risk. ‘With a investment in IT solutions, start small with gradual approach, manufacturers can turn a subscription-based cloud deployment, to edge applications, hybrid solutions, eliminating the need for large capital and a phased roll-out to build confidence investment. ‘This allows you to reap the and gain buy-in from the various teams,’ benefits of cloud computing while protecting Rossouw adds. ‘A gradual approach also critical customer data and moving forward provides time to establish data security and while easing stakeholder anxiety,’ states ensure compliance with modern regulations, Rossouw. ‘With no need for hardware and like the EU’s General Database Protection systems such as servers, security, and Regulation (GDPR).’ back-ups, the IT team can focus on other Smart factories are the future of manufacturing
issues, rather than continually worrying about upgrades and back-ups.’ Another way to overcome funding issues is to use the savings generated from Phase One to fund Phase Two projects. From business intelligent tools for tracking real-time results, to CRM solutions; shop floor scheduling,
planning and time-tracking; field service management, tracking warranties and service agreements; and inventory management to improve accuracy, massive savings potential is offered. Building the business case to prioritise steps is important. There are some prerequisites that are must-have basics for modernising operations. ‘These are the foundations for growth. Consider end-toend visibility; mobility; attractive, easyto-use interfaces; self-service reporting; workbenches and dashboards and nonmodified software. All these elements can be achieved with one modern Enterprise Resource Planning (ERP) solution,’ Rossouw points out. The size of the move often guides the strategy. Moving to a servitisation model is a good example of this. Offering the product as a service or outcome-based solution, rather than selling the product, is gaining traction in some industries (especially ones where the traditional product is high-value). ‘This often requires new strategic thinking and the integration of unfamiliar technologies,’ Rossouw states. Deciding whether to increase services and/or scale can be a difficult decision. This decision could be made easier by taking hold of the competitive landscape, to guide the level of adaptation required, but prioritising the customer is a better approach. ‘Analyse customer needs and provide solutions. With complete supply chain visibility and real time insights, organisations have better control of their product and provide control to the customer, allowing them to track progress in real time,’ he adds. ‘For customers seeking specialised customisation, companies can leverage existing data by applying smart analytics and AI to determine and predict customer needs on an individual basis.’ This is an exciting time to be in manufacturing. ‘The multitude of opportunities and technology options can also make it overwhelming. With a pragmatic view, manufacturers can transgress common barriers, set realistic goals and find funding to make innovative ideas come to fruition,’ Rossouw concludes. •
EOH - www.eohinforservices.com
2019 Quarter 1 | Food Manufacturing Africa
9
EVENTS
New efforts bring hope for Industry 4.0-ready workforce Smart new automation tools and technologies are changing the face of manufacturing and industry around the world.
W
ITHOUT A CONCERTED effort to change industry processes and infrastructure, and upskill the workforce, countries on the continent risk falling behind in their efforts to become players in the global manufacturing market. New initiatives are emerging to address the skills shortfall and help propel Africa into a smarter era of manufacturing. Speaking ahead of Africa Automation Fair 2019, automation industry stakeholders said aligning with the global Industry 4.0 revolution would demand a great deal of change and progress. A key priority had to be skills.
“... aligning with the global Industry 4.0 revolution would demand a great deal of change and progress. A key priority had to be skills” Dave Wibberley, managing director at Adroit Technologies, notes that Industry 4.0 itself is not a silver bullet that will change manufacturing. ‘Industry 4.0 refers to a set of tools and services. To be effective, these tools and services depend on the necessary resources and knowledge being in place. You need to achieve world-class manufacturing and tooling first,’ he points out. Frikkie Streicher, business development manager at process instrumentation
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manufacturer Vega, says a greater effort is needed to develop the automation engineering skills pipeline, to allow industry to prepare for Industry 4.0: ‘Automation engineering is not yet recognised as a separate field in some countries in Africa. We need to step up our focus on automation engineering if Africa is to achieve its ambitions of becoming a manufacturing giant in Africa.’ Annemarie van Coller, president of the Society for Automation, Instrumentation, Measurement and Control (SAIMC), says that while automation presents massive economic growth opportunities, it does threaten the current environment’s workforce structure. ‘If you look at the current triangle of training, we have a small number of engineers at the apex, and many artisans at the bottom. We need to invert this triangle, and produce a far greater number of engineers capable of supporting automation in future.’ Efforts are underway to fast-track this process, developing new curricula for automation engineers and introducing new learning models to upskill employees. SAIMC and other industry stakeholders are moving to introduce a skills development model for the automation sector, based on the successful model introduced in the tooling sector. Driven by Johan Maartens, SAIMC director and COO, the initiative will see the launch of an education and training system for automation personnel modeled on the National Tooling Initiative Programme (NTIP) for the tool and die industry in South Africa. The launch of the new programme includes the renaming and rebranding of the tooling programme as the National Technologies Implementation Platform (NTIP) under the oversight of the Intsimbi Board. The programme is intended to serve as a fullyfledged 4th Industrial Revolution programme including training in robotics, mechatronics,
Food Manufacturing Africa | 2019 Quarter 1
ABOUT THE SHOW: Africa Automation Fair is a focused networking platform for the Automation and Control Industry and works closely with industry associations including the IIG and SAIMC. The fair targets senior buyers from South Africa, the rest of Africa and invites participation from international buyers. Presented by Reed Exhibitions, Africa Automation Fair, the Connected Industries Conference and Pollution & Waste Technology Africa will be staged from 4 to 6 June 2019 in Johannesburg, South Africa.
and industrial maintenance, and involving over 500 companies. Launching the new Intsimbi Future Production Technologies Initiative (IFPTI) NTIP's Centre of Excellence in Cape Town, South Africa earlier this year, Trade and Industry minister Rob Davies said government was committed to building capacity in response to the impact and opportunities that the 4th Industrial Revolution will bring about. While funding models and curriculum development are still under discussion, Van Coller is optimistic that the new initiative will drive the change the sector needs. ‘We’re very excited about its potential. It will bring new opportunities for upskilling. This model allows for free, flexible, home-based learning using online tools, along with some facilitator-led learning. Stakeholders are also looking at the necessary infrastructures for participants in rural areas with limited internet access. It presents the hope that we can develop our own advanced automation skills pipeline and stop relying on imported skills,’ she says. The Connected Industries Conference at Africa Automation Fair 2019 will focus on the challenges, opportunities and economic impact of the Fourth Industrial Revolution (Industrie 4.0 / IIoT) on South and subSaharan Africa. •
MEAT, FISH & POULTRY
Remain flexible in a digital world Optimised production processes are based on digitalisation and interlinked networks. The objective is to increase security of production and optimise the use of machinery. This allows energy efficiency and the ability to react flexibly to market changes.
I
NTERNATIONAL COMPANIES WILL be showcasing their latest technologies at IFFA, providing information on major trends and developments in the meat processing industry. The show is held from 4 to 9 May in Frankfurt, Germany.
SMART SENSORS In a smart factory, products and individual machines must communicate with one another; organise, regulate and monitor. This requires ready availability of status data on products, machinery and drive mechanisms - a task undertaken by smart sensors. In conjunction with the actual sensor, it includes integrated micro-processors for processing and analysing signals. This should take place in conjunction with traditional parameters such as temperature, power usage, torque and pressure. They also record gases and microbial contamination.
PARADIGM SHIFT IN CONDITION MONITORING Traditional maintenance at fixed intervals or at a given number of hours of operation usually takes place too early for reasons of safety. This shortens running time of serviceable components such as drives, shafts and bearings – resulting in a loss of income and valuable resources. Mechanical damage makes itself known well in advance with unusual noises, vibrations that suddenly appear or temperature increases. Increased power consumption is another factor. These changes can be picked up with the help of intelligent sensors in real time, monitored online and assessed, using appropriate condition monitoring software (CMS). This makes it possible to target maintenance more specifically and provides valuable information on further optimisation of machinery and plant.
RFID CHIPS PROVIDE A CONVINCING ELECTRONIC JOB TICKET
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3
Radio Frequency Identification (RFID) makes it possible to transmit data wirelessly in real time between transponders and read-write heads. Integral transponders in slaughtering hooks, feeding troughs, palettes, packaging or machine parts communicate bi-directionally with read-write heads installed at the processing and packaging stations. Not only do the factory-fitted RFID chips in slicer knives store the geometrical data of blades, they also store sharpening schedules and the encoded item and serial number. The RFID read-write head installed in the sharpening module reads data from the blade, identifies it, carries out the appropriate sharpening procedures and then updates transponder data, including details of remaining serviceability. This principle can be applied to many other processes and procedures along the value creation change.
VISUALISATION SYSTEMS MAKE FOR EFFICIENCY, TRANSPARENCY AND QUALITY
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The combination of digital camera and imageassessment software provide machines with the ability to see, opening the possibility of
1 reacting in specific and appropriate ways to changes in the environment and in taking decisions. They can recognise location, position, orientation, shape, size and colour on conveyor belts. Data acquired in this way can be used to control robots and extraction/ rejection units or to assess proportions of fat and lean in the in-line classification of bacon cuts as A, B or C class goods. Further applications include checking that packages are complete in number and undamaged, as well as the correct positioning and printing of explanatory and address labels.
MORE EFFECTIVE PLANNING WITH A DIGITAL TWIN Digital simulations are more than just a 1:1 digital representation of its physical counterpart. It possesses the same sensors, behaviour qualities and software. It is linked to other systems in the same way. That makes it the ideal development tool for designers and builders of plants and installations. Typical areas where the principle can be used include virtual simulations of processes and functional testing of components, component modules, machines and whole installations, including control and application software. This enables designers to flag and correct errors in advance of actual manufacture, saving cost, time, resources and energy. Professionals working in sales, planning, manufacture and maintenance, from both the manufacturing and consumer sides, can run through, discuss and optimise the different options with the help of the digital ‘twin’, as if they were working in the real world. Other possibilities that arise because of digital simulation include training for future machine and plant operators and maintenance staff relating to both the system itself and the virtual commissioning system. Digital simulators can be used to operate and maintain the real plant and equipment in the real world. This can be done across geographical borders. •
1, 2,3,4 IFFA is the gateway to the global meat processing industry
2019 Quarter 1 | Food Manufacturing Africa
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MEAT, FISH & POULTRY
Natural and clean label deli meat Amidst trend vagaries in the food industry, clean label remains one of the more stable developments. In fact, many consider it the new norm in food manufacturing.
D
ESPITE MISSING A legal or commonly accepted definition, clean label pushes industry to re-evaluate ingredients, formulations and processes. It can be interpreted as all natural, minimally processed and non-GMO. It is driven by demand for reducing the number of ingredients, while avoiding those perceived to be artificial or synthetic. The aim is to replace these with natural looking, recognisable and transparent pantry ingredients. Consumers are not willing to compromise on taste, while food safety remains a priority. In some cases, food safety has been key in speeding up desirable changes in food ingredient lists. Consumer desire is what drives the industry to not only abandon some ingredients, but create substitution practices considered traditional in food manufacture. Clean label represents a big opportunity for food manufacturers to increase market share and value proposition. A survey run by Food Manufacture magazine in 2017 looked at 1 300 consumers across Europe, North America and Asia-Pacific. Of these, 76 per cent said they would be more likely to buy a product if it contained ingredients they recognise and trust. In the same survey, 52 per cent of respondents said they would spend over 10 per cent more on a food or beverage product if it contained ingredients they recognise and trust. Lallemand’s bio-ingredients division and specifically its savoury segment,
focuses on high-value yeast products from Saccharomyces cerevisiae and Torula yeast. This includes whole cell nutritional yeast, yeast extracts and yeast derivatives. These ingredients have been used for thousands of years in the production of bread, beer and wine and are well known and appreciated for their functionality. One of the drivers is applied research. During this step, the company looks to find applications where the inner characteristics of inactive yeast and yeast fractions are not yet tapped. This development could play an active role in the development of clean label solutions. Looking at the meat industry, Lallemand identified two main areas that are challenging for producers: phosphates and nitrite/nitrate substitution. Phosphates used in meat and meat products have several functions, such as pH adjustment, buffer properties, sequestration of selected ions and changing the ionic charges distributions and/or bacteriostatic effects. Sequestration of metal ions such as Ca2+, Mg2+, Fe2+, Fe3+, will enhance the water holding capacity and improve the degree of tenderness and colour of meat. Whole cell yeast has emulsifying, flavour enhancing, water and oil binding properties that can be useful in processed meat products. Combining characteristics Clean label demands force the industry to re-evaluate ingredients and formulations
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Food Manufacturing Africa | 2019 Quarter 1
of selected inactive yeast and specific process suggestions, Lallemand reached very interesting results at laboratory and industrial scale. Specific, selected inactive yeast allows the stabilisation of water holding capacity while maintaining colour and flavour release in emulsified sausages and deli hams. There is an opportunity to extend the success of these trials to a variety of similar applications. Nitrates and nitrites have traditionally been used as curing agents in the production of cured meat products. Beneficial effects of their use are the improvement of quality characteristics and microbiological safety. Nitrates and nitrites are, in the main, responsible for the development of the distinct flavour, colour stability and protection against lipid oxidation in cured meat products. Nitrates are relatively nontoxic, but nitrites, and nitrites’ metabolic compounds such as nitric oxide and N-nitroso compounds have raised concern over potential adverse health effects. Designated yeast fractions by yeast extracts and yeast peptons (LBI) in combination with selected Lallemand specialty culture strains in meat starters have proved to work in dry salami and
MEAT, FISH & POULTRY
fresh sausages. This achieves the colour development normally achieved with the use of nitrates. The meat product, nitrate free, shows a comparable flavour and texture development to more traditional products. Levain is another concept for new cured meat products, such as firm, less fatty dry salami. The yeast fraction boosts
the effectiveness of the meat starters. It could also reduce maturation time and will contribute and improve certain benefits: • Flavour: the salami develops an authentic taste profile and intensification of smell • Texture: the salami firmness improves • Colour: achievement of the typical red colour. •
ABOUT LALLEMAND Lallemand Bio-Ingredients (LBI) develops, manufactures and markets high-value yeast. The range includes whole cell nutritional yeast, yeast extracts and yeast derivatives. The LBI business includes three application areas: savoury, health and fermentation. Savoury ingredients’ activity is mainly oriented to food and flavours. The savoury ingredients proposal for the meat industry spans from flavouring to functional solutions such as food additives substitution. Lallemand Specialty Cultures (LSC) is dedicated to specialty cultures for dairy and meat applications. Its expertise spans from the selection of microorganisms of interest to industrial production within the highest quality standards. LSC cultures bring unique appearance, colour, flavour and texture for product differentiation. The division boasts in-depth knowledge based on more than 60 years of experience as a supplier of meat cultures. Its broad range of products delivers unique functionalities and produces a variety of different dry fermented meats.
Savannah Fine Chemicals – www.savannah.co.za
Yeast-based ingredients for additive-free solutions The Savory product range is distributed by Savannah. To learn more:
LALLEMAND BIO-INGREDIENTS www.savannah.co.za
1620 Préfontaine, Montréal QC H1W 2N8 Canada +1 514 522 2133 | Fax +1 514 522 2884 info@bio-lallemand.com | www.bio-lallemand.com
2019 Quarter 1 | Food Manufacturing Africa
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MEAT, FISH & POULTRY
Ditch the fat for crumb coated snacks New technology from food coating system experts, Crisp Sensation, enables manufacturers to produce crispy, crumb-coated snacks without the need for pre- or deep frying.
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Zero Fry allows crumb coated snacks without deep frying
HIS BREAKTHROUGH INNOVATION is suited to the needs of health conscious consumers who don’t want to compromise on taste or convenience. ZeroFry coatings guarantee the same crunchy sensation and taste as pre-fried products. It does however allow for a fat reduction of 50 per cent and a considerable reduction in calories. Crumb coated products are among the most popular snack products on the African continent. Until now, it was only possible to achieve a crunchy outer coating and moist core by deep frying. In the case of convenience products designed to be oven-
Innovative solutions for processed meat
Kemin Industries are a global provider of shelf life extension and food safety solutions for the food industry. It recently launched NaturCease Dry.
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HIS CLEAN-LABEL combination of buffered vinegar and natural plant extracts was developed to keep processed meat products safe and fresh. ‘Meat spoilage can be divided into two criteria: oxidative rancidity and microbial spoilage. Both have a sensory impact and an impact on colour. More importantly, microbial
contamination affects meat safety,’ explains Anja Verbiest, customer laboratory services and quality assurance manager, Kemin Food Technologies for the EMEA region. NaturCease Dry combines multiple benefits into one blend. The one-stop solution controls spoilage bacteria while maintaining the bright red colour and fresh flavour of processed meat products. The solution offers a total freshness package. It’s user-friendly for customers and provides convenience. Consumers are demanding natural food products without artificial ingredients. The meat industry is facing this trend as retailers push for cleaner, clearer and simpler labels. The ingredient allows meat manufacturers to better meet this growing demand for cleanlabel ingredients and transparency. • New clean-label product with antioxidant properties protects freshness, flavour and colour
Kemin Industries – www.kemin.com
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Food Manufacturing Africa | 2019 Quarter 1
“… significant
savings on oil,
energy and cleaning can be achieved, coupled to an increase in production and product safety” heated at home, the pre-frying process uses considerable amounts of fat during the production process. Manufacturers can also profit from several technical and processing advantages. As pre deep frying is no longer necessary, production output is not limited to the capacities of the deep fryer. This is often the bottleneck in the production line of crumb-coated snacks. The existing line set-up can still be used with the addition of an oil sprayer. Another benefit is that significant savings on oil, energy and cleaning can be achieved, coupled to an increase in production and product safety. For substrates that don't require heating or cooking, this step in the production process can be skipped. With ZeroFry, the typical Crisp Sensation benefits remain unchanged: long-lasting, outstanding crispy bite, with a juicy core that does not dry out, and the large variety of preparation methods for the consumer at home. Visual appeal remains an important factor. Aside from having less fat and fewer calories, ZeroFry-coated products feature an appetising gold-brown crust. Christien van Beusekom, chief technical officer at Crisp Sensation concludes, ‘We are proud to bring this innovation to market. Snacking is an emerging global trend, so there is a real need to make snack products healthier without compromising on taste and texture. With ZeroFry, we also tackle the issue of acrylamide in fried products by offering safe alternatives. With this safe and tasty solution, snack manufacturers around the globe can easily adjust their range to modern nutrition needs.’ •
Crisp Sensation - www.crispsensation.com
Your secret recipe calls for our natural ingredients‌ Spice up your life with variety, purity and consistency and bring extraordinary flavour and colour to your table with Sensient’s innovative product range.
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MEAT, FISH & POULTRY
The case for
red chrome in collagen casings Casings have been utilised for centuries to maintain meat quality, extend shelf life and minimise off flavour and discolouration due to oxidation in meat and poultry products. Natural casings are traditionally used for sausage casings, but various other types are under development. By Huiuso Huang
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ATURAL CASINGS ARE made from the sub-mucosa of an animal intestine and consist mainly of collagen. These products can also be made from the bladder, stomach, caecum or esophagus. The advantages of using a natural casing are that they are extremely permeable to moisture and smoke. It can help develop a beautiful smoked appearance and enhance a product’s nutritional value since it is a protein-based material. They are edible and tender enough to be easily chewed and don’t create off-flavours in sausage products. On the downside, they are least resistant to breakage, yield the least amount of product and are non-uniform in size. This makes it difficult when used in industrial production and handling. Collagen is the perfect answer for sausage manufacturers looking for faster and more reliable ways of producing high quantity sausages. Compared with natural casing, collagen provides a more uniform product and is easily applied into meat manufacturers’ existing production lines. There are two types of collagen casings: regenerated and co-extrusion collagen. Regenerated collagen casings are used for any size of comminuted meat sausage products. Collagen comes from a layer of beef hide, removed and refined by either dry process or wet process. The dry process involves alkaline treatment of hide coriums followed by acidification to a pH of three. The wet process starts with acid or alkaline dehairing of cattle hides.
COLLAGEN CASING PROCESSES The production of collagen casing is a complex and sophisticated process. Natural material forms the basis of the product. It is broken down and reformed into a collagen gel. Originally, collagen is obtained from the corium layer of the hide of mammal animals. The collagen rich corium layer is also called collagen split. The collagen split is extracted with alkaline solution to remove and wash off the soluble components then swollen with acid to develop a viscous mass of acid food grade collagen. After washing, decalcification and buffering processes, this food grade collagen is used for forming tubes. These tubes are fixed by moving it through an alkaline bath and the neutralised collagen returns to its original state. The pH for this process ranges from two to eight. Some
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may only show slight fluctuation, but it is difficult to distinguish by the naked eye. The usage rate is based on customer need up to two per cent inclusion.
Figure 1. Comparison different pH values and heat vs without heat the redness changes
Figure 2. The Delta E changes at different pH values in collagen slurry.
manufacturers add colourants once the food grade collagen has developed.
CONSIDERATIONS FOR COLLAGEN CASING COLOUR OPTIONS Collagen casings sometimes add either natural or synthetic food grade colourants approved by the FDA. Sausage manufacturers use coloured collagen casings to enhance the external appearance to make various attractive sausage products. Collagen casings should match attributes for a variety of meat sausage products and compatible on various sausage manufacturing equipment. Besides the wide pH range in collagen casing production, drying conditions also affect the colour options available.
STABILITY TEST OF CHROME RED WITH DIFFERENT PH AND THERMAL PROCESSES OF COLLAGEN GEL
Method Collagen gel was supplied by a local casing supplier and melted in a glass beaker at 180˚F for 20 minutes. Chrome red and caramel colour solutions were used in this study. The pH of this collagen slurry was adjusted with 1M ammonium hydroxide and one per cent citric acid between a range of two to eight, and the final collagen slurry was stabilised around a pH of five. Colour changes were evaluated by a colorimeter at different pH values before and after heat treatments. Results and Discussions Figure 1 shows two per cent chrome red in a collagen slurry. Results indicate chrome red is not heat sensitive and tolerant of pH ranges from two to eight. The difference among various pH points are acceptable or slight changes with delta E values less than 2.0 (Figure 2). It shows similar appearance when chrome red is applied into different collagen slurry and solidified into white tiles with different thickness layers (Figure 3). •
ROHANATRACOL CHROME RED The company developed a natural, orange-red β-Carotene emulsion product, suitable and stable for casing products. It is a good option to replace natural carmine and synthetic colours, such as FD&C red 40 and red 3. Natracol chrome red is a water dispersible beta-carotene emulsion. It develops an opaque red colour once dispersed into water. When added into a collagen slurry, it is evenly distributed and develops the desired colour shade and intensity. Another advantage of chrome red is that it is stable to the wide pH range used in collagen production. The colour
Food Manufacturing Africa | 2019 Quarter 1
Figure 3. Visually compare colour performance at different pH ranges
Roha - www.roha.com
Training
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ISO 22000 F 1 0 SS 90
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Food safety
Auditing
Implementation
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CP AC
PRPs
Quality happens through people
Cell: +27 (0)83 440 0460 • Tel: +27 (0)21 871 1563 • Fax: +27 (0)86 275 5678 • Email: anneliec@anneliecoetzee.com www.anneliecoetzee.com 482 Main Road PAARL 7646
MEAT, FISH & POULTRY
MAP: for good-looking red meat Foodfresh’s range is designed to enable providers of fresh produce to increase sales and reduce costs while satisfying demand for fresh and naturally preserved food. Food Manufacturing Africa spoke to Hans Strydom about the unusual requirements for packaging red meat.
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HE PRIMARY ROLE of modified atmospheric packaging is to extend shelf life of fresh food. 'This is done without artificial additives, chemicals, freezing, preservatives or processing – while retaining those fresh food tastes, textures and appearances,’ Strydom notes. For most food products, oxygen (O2) levels in MAP package are kept as low as possible, typically by substituting the air surrounding the food with gases such as carbon dioxide (CO2) and/or nitrogen (N2). ‘Red meat products are an exception and oxygen is an important constituent of the packaging gas. Oxygen reacts with myoglobin in red meats to give it its rich red colour,’ Strydom continues. When fresh meat is first exposed to oxygen it ‘blooms’ to a bright red colour, making it look fresh and appetising on supermarket shelves. Oxygen eventually leads to browning of meat surface and growth of spoilage bacteria. This renders it unacceptable to consumers after a few days, even when it is held near 0°C. Myoglobin is a protein found in muscle tissue and this governs the colour of fresh meat. It has three main forms. Deoxymyoglobin is the deoxygenated form responsible for the purple colour of freshly cut meat, vacuum packed meat or meat stored in oxygen-free (anaerobic) conditions. When exposed to oxygen, deoxymyoglobin is transformed into oxymyoglobin, changing the colour from purple to the bright red colour associated with freshness. The third form, metmyoglobin, is brown and is formed due to the further oxidation of oxymyoglobin. The brown surface
colour, which is irreversible, is perceived by consumers as a loss of freshness and is therefore undesirable. The formation of metmyoglobin can be delayed by either excluding O2 completely. This is done by using vacuum packaging or a low O2 MAP gas mix – or by maintaining much higher O2 levels in the MAP gas, along with CO2 to selectively inhibit the growth of spoilage bacteria. ‘Main MAP gases used for red meat are oxygen, carbon dioxide and nitrogen. Oxygen and carbon dioxide are most significant and the relative proportions of each of them directly affect how the colour changes over time,’ Strydom reveals. While the O2 promotes the red oxymyoglobin formation, CO2 dissolves into the food’s liquid and fat phase, reducing its pH value and penetrating the muscle meat. This causes changes in permeability and function and creates an environment that inhibits the growth of microorganisms that would usually occur in high-oxygen atmospheres. Nitrogen, the third constituent in oxygenrich MAP gas mixes for red meat is nonreactive. Its sole role is to protect the package structure.
THREE PACKAGING APPROACHES To retard metmyoglobin formation and browning and to preserve microbiological quality under high concentrations of O2, MAP gas mixtures of 60 to 80 per cent O2 and 20 to 40 per cent CO2 are commonly used. ‘Temperature control is critical to the success of this application, however, and poor cold-chain control will lead to the growth
of spoilage organisms and premature browning of the meat,’ Strydom warns. Low O2/high CO2 MAP is a second option, which fully exploits the inhibitory effects of CO2 on spoilage bacteria. It is ideal for products that are transported long distances or stored for several weeks. The MAP gas used can be CO2 alone, although the addition of N2 to prevent the pack collapsing is more common. Gas mixtures used in these MAP solutions will often contain greater than 65 per cent CO2 with the balance volume being nitrogen. Long storage life of, typically, over 12 weeks at 0°C is possible when using high CO2 MAP mixture. As with vacuumpacked meat, however, the oxygen-free atmosphere keeps the meat purple and prevents it from blooming. Overcoming the drawback of the purple colour are the dual layer solutions. Retail cuts can be placed in pre-formed plastic trays and, immediately after the surrounding air has been replaced with a high CO2 MAP gas mixture, a dual-layer film is applied to seal the pack. Underneath the peelable film is a semipermeable layer. When the meat packs are removed from storage for presentation and the peelable film is removed, oxygen is allowed into the package so the meat can begin to bloom. Dual-layer processes allow retail meat cuts to be stored for much longer periods of time prior to display than high O2 MAP solutions, while still enabling excellent visual presentation in supermarket fridges •
GEA – www.gea.com
We offer creative and innovative solutions through in-house research, customised products and packaging
Our Promise is inside Phone - +27 (0)11 4526730 Email - info@vivit.co.za Web - www.vivit.co.za
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Food Manufacturing Africa | 2019 Quarter 1
Manufacturer of cake pie fillings, toppings, yoghurt fruit pulps,caramel treat, milkshake syrups, salad dressings,mayonnaise and sauces.
FSSC 22000 Certified Halaal and Kosher
For more than 40 years, TOMRA Food designs and manufactures sensor-based sorting machines and integrated post-harvest solutions for the food industry, using the world’s most advanced grading, sorting, peeling and analytical technology. food@tomra.com
www.tomra.com/food
MATERIALS HANDLING & CONVEYING SYSTEMS
Social ERP’s got everyone talking In a highly competitive business environment, companies need improved visibility into operations; the ability to do more with less and to effectively communicate and collaborate across the entire organisation.
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ECH-SAVVY MILLENNIALS are entering the work force in large numbers. Their familiarity with Twitter, Facebook, Instagram, and LinkedIn is driving contemporary social mediatype interaction in the workplace. It helps promote a more collaborative way of working by harmonising data with people, thereby providing users a familiar, easy and effective away to connect, communicate and conduct their daily business. By accessing, and relating real-time information, insights, and trends through Social ERP, users can act instantly and decisively. This assists in increasing responsiveness, lead times and overall productivity.
BENEFITS OF THE SYSTEM INCLUDE: • Enterprise-wide collaboration and seamless communication between colleagues, workstations, divisions, branches and territories. • User engagement. Harmony answers the needs of the contemporary user by incorporating a familiar and personalised
Syspro's Harmony facilitates ease of communication
social media-type interface on which to do business. • An effective way of communicating and engaging with ERP – simplifying complex technologies and business processes and encouraging system usage across the entire organisation. • Collaboration and streamlines business processes and improves communication between colleagues, workstations, divisions, branches and territories by seamlessly connecting the workforce. This promotes a new and collaborative way of working. • Connecting business information to people and people to each other. Syspro Harmony provides direct, 24/7 access to the people and the information that’s relevant and critical to your role and tasks with the ability to communicate instantly with your network of associates. • Increased responsiveness to share and relate critical business insights, data and intelligence with your co-workers to solve problems faster. With a centralised, realtime view of operational, product and customer information, you are armed with the decision-making power you need to act and respond quickly. • Identification of significant trends by taking proactive steps with an instant and ever expanding view into customer sentiments, relevant emerging data trends, and significant business movements. Harmony allows posting and collaboration within the network of the organisation using real-time information from the Syspro
“Data Sentiment enables a complete spectrum picture of customer opinion about your services or products for informed and strategic decision making. ” database. When collaborating, users have full and secure access to the data in their Syspro databases. This enables them to query information directly in the chat, such as stock information, sales order statuses, customer information amongst others. Data Sentiment enables a complete spectrum picture of customer opinion about your services or products for informed and strategic decision making. Visual cues (the equivalent of emoticons) help alert users by attaching sentiment to specific items. Key notes attached to these items are detected. This tracks potential future issues before they arise regarding customer service. Using intelligent machine learning algorithms, and predictive analytics, Harmony detects trends from the messages that are being posted, as well as transactions happening on the Syspro database and aggregates this data. Harmony then presents the information in the form of a chart, eliminating the need for a manual search. •
Syspro – www.syspro.com
Stay on Top of the Food Chain with SYSPRO ERP for the Food and Beverage Industry. For more information or to arrange an appointment, please contact us on 011 461 1000 or info@za.syspro.com. Copyright © 2019 SYSPRO (Pty) Ltd. All rights reserved. All brand and product names are trademarks or registered trademarks of their respective holders.
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Food Manufacturing Africa | 2019 Quarter 1
MATERIALS, HANDLING & CONVEYING SYSTEMS
Ingenious and unique handling Specialist of automated production lines for industrial bakeries, Mecatherm, launched three major innovations in 2018. These included the M-UB - a universal and simple handling system that ensures the smooth transport of products during proofing, cooling and freezing.
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HE INDUSTRIAL BAKERY market is evolving and consumers are seeking authenticity, improved quality and a broader, diverse range of bakery, pastry, patisserie and snack products. These developments have implications for production processes and require equipment adapted to new demands, without compromising industrial performance or operating costs. Mechanisation plays a vital role for industrialists in the sector. It is involved in many stages of processing, proofing, cooling and freezing. It is also used in the storage of products and trays. Patented handling systems offer a tool, adapted to market and industrial developments and demands.
UNIVERSAL HANDLING SYSTEM The M-UB divider enables all kinds of baking sheets, assemblies and peelboards to be transported, for the seamless transition of products to proofers, chillers and freezers. With intelligent design, Mecatherm’s new handling system transports trays through the mechanisation unit via a continuous loop. This solution allows for the fluid transfer of trays (such as baking sheets and assemblies) from the ascending stack to the descending stack. Instead of a conveyor belt at the base of the unit, a flighted chain ensures each mechanisation unit loads smoothly. During different stages, and particularly while products are in the proofing chamber, it is essential products are handled gently to ensure optimal quality. The elimination of impact and friction guarantees uniform and gentle handling during processing stages. A continuous loop system provides another benefit: transported trays pass through the mechanisation unit along the same path. This guarantees uniform handling and perfect consistency in products, whatever the selected processing time. Food safety is also considered. With no transfers in the upper part of the unit, risk of contamination of the finished product is avoided as no contact is possible. The handling system has been designed to be adaptable and flexible, whatever the product type or production volumes and
constraints imposed by industrial facilities. Dimensions of the handling system are modular and its width, height and loading depth can be adjusted. The wide range of dimensions offered by the new system allows the transportation of up to 104 trays per unit. Adjustable to all widths, the system is available with three different intervals to adapt to product height. The modular nature of the new handling system allows manufacturers to use the same equipment for all stages of processing, proofing, cooling, freezing or storage. Dedicated to product diversification, this new handling system works with all types of trays i.e. muffin trays, flat baking sheets or moulds, mould assemblies, peelboards and grills. Operators can also reduce or increase time spent in the module according to product type. Timing is adapted by suspending one or various units in the processing stage. Each unit works autonomously. It is possible to bypass one of them, even in the middle of the chain, without interrupting processing. Using this bypass function, trays simply travel through the lower part on the conveyor belt and to the next unit. Excess trays in the line can be stored inside the stopped unit. The speed of each unit is configurable. Operators have instant access via the line’s human/machine interface to adjust settings. This makes it very easy to switch from one product to another, without requiring major or time-consuming work.
SIMPLE EQUIPMENT FOR OPTIMISED OPERATING COSTS R&D teams developed equipment that’s easy to understand, use and maintain. All control systems, such as sensors and motor are accessible from a peripheral groundlevel passageway. The transport of trays via a continuous loop allows all maintenance operations to be carried out at ground level. Trays can also be accessed from the side of the machine. Intended for daily use, the design of the system, which complies with EHEDG standards, makes cleaning equipment simple. Mecatherm uses materials that are easy to maintain and has eliminated or adapted parts to reduce cleaning time. Equipment features a stainless steel body, polished material, plastic support brackets, no steel wire trays in the machines or struts on the conveyor belt. To make maintenance easier, each conveyor module uses the same model of motor, whatever the system’s dimensions. A stop and go system ensures motor is lessened and less energy is consumed. This type of motor also allows manufacturers to reduce the number of parts they store. Risk of a system module breakdown crippling the production process is eliminated thanks to the bypass function. This allows one module to be isolated at any time, without interrupting production. ‘This system provides significant advantages in terms of product quality, food safety, flexibility and operating costs,’ Olivier Sergent, president of Mecatherm concludes. •
The handling system is modular with adjustable dimensions
Mecatherm – www.mecatherm.com
2019 Quarter 1 | Food Manufacturing Africa
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MATERIALS HANDLING & CONVEYING SYSTEMS
Accuracy and efficiency through real time visibility
Zetes has installed a state of the art shipping verification solution for a company that specialises in the production of coleslaw, wet and side salads, soups, sauces and mayonnaise to retail and food service customers. The system will enable 100 per cent shipping accuracy, efficiency and real-time supply chain visibility.
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S A SUPPLIER to M&S, Irish-based Avondale Foods was faced with the challenge of overhauling its outbound shipping systems to comply with the retailer’s new requirements for improved inbound logistics visibility. Delivery lead times are very short with orders typically received at 6 AM for shipping accuracy for dispatch the same day. Speed and the absolute elimination of shipping errors are paramount to efficiency and on-time service commitments. Previously, Avondale used RFID as a means of verifying shipping contents prior to transportation. This is no longer suitable for the increased speed and accuracy required. In consultation with Zetes, who had also provided M&S with its real-time visibility platform for its food supplier network, Avondale opted to implement an automated image based data capture solution for their Advance Shipping Notification (ASN) process. Incorporating Zetes’ unique camera based ImageID technology, the solution dramatically reduces the entire shipping verification process time, with 100 per cent accuracy and no human errors or additional tag costs. It achieves this through capturing a full view of the loaded totes, rapidly detecting and decoding its multiple barcodes simultaneously, with 100 per cent accuracy. It compares barcode data to shipping orders providing operators with real-time visual alerts about any discrepancy while pinpointing missing or unreadable labels. Digital images are stored for visual evidence. Upon confirmation an order is correct, ASN data is captured in Avondale’s host system and M&S’s visibility platform simultaneously. John Ferguson, head of supply chain at Avondale explains, ‘We initially set out to solve one challenge that caused our existing RFID solution to fail. In speaking with Zetes it became apparent that by implementing their ZetesMedea shipping verification solution we would not only realise complete compliance with our customer’s updated ASN requirements, but also benefit from increased accuracy through automated processes and greater visibility.’
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Alain Wirtz, CEO Zetes adds, ‘We are delighted to be working with Avondale Foods and pleased that ZetesMedea will be used to help improve operations across the business and allow them to respond effectively and efficiently to new market challenges. The introduction of a single system will not only ensure compliance with a key customer but it will also allow them to reduce complexity and build a solid foundation for other potential visibility and traceability projects in the future.’
100 PER CENT SHIPPING ACCURACY Granot Avocado, an Israeli cooperative of agricultural farms, selected the ZetesMedea shipping verification solution, to maximise efficiency and eradicate errors from its loading verification operations. The new system enables the cooperative to achieve 100 per cent accuracy and traceability of outbound pallets combined with dramatic improvements in processing and loading onto vehicles.
TIME-CONSUMING MANUAL PROCESS Granot Avocado is a cooperative of 43 agricultural farms growing about 30 per cent of the total production of avocados in Israel. The fruit harvested by the different farms are gathered in the Granot’s packaging house, where 75 per cent are shipped to be sold on the European market. An average of 200 pallets leave the packaging house every day. In the past, warehouse operators manually checked labels on boxes and pallets to confirm the origin of the products and their shipping destination. This time-consuming manual process broke the flow of outgoing pallets and led to more than 50 per cent error rate. Granot Avocado needed a solution that would allow them to provide traceability on
Food Manufacturing Africa | 2019 Quarter 1
the pallets and their content, improve data accuracy, and streamline their outbound logistics processes.
MACHINE VISION TO STREAMLINE OUTBOUND LOGISTICS Part of the ZetesMedea warehouse execution portfolio, ImageID technology, based on Machine Vision, is positioned at each loading dock capturing images of the pallets to be shipped as they flow through. The system instantaneously reads the carton and pallet labels in real-time to check for any mistakes, such as a missing box or a box on the wrong pallet. The system triggers a go/no go signal, ensuring the right pallet is loaded onto the right truck. If items are incorrect or mislabelled, visual identification is shown on screen so remedial action can be taken.
MAIN BENEFITS Eran Rotem, COO at Granot Avocado concludes, ‘Since implementation of ZetesMedea, we’ve seen a significant increase in our data accuracy, reaching 100 per cent. We can scan all pallets without human intervention, considerably reducing our error rate and making us save valuable time. Zetes’ palletisation software also drastically limits customer disputes as we can now provide our customers visual proof of the condition of the pallets when they leave our warehouse.’ •
Zetes – www.zetes.com
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T3MP3R1N6 TURBOTEMPER T H E K E Y T O “PERFECT TEMPERING” ®
www.sollich.com/world
BEERS & CIDERS
Efficient canning lines boost beer production Heineken Vietnam was looking to significantly increase beer production output of its Tien Giang site, located in the south of the country.
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ONG-TERM PARTNER and expert in turnkey solutions for the beer industry, Sidel supported this ambitious goal with a complete line project. It features among other highly efficient and high-performing solutions, the new Sidel filler EvoFILL Can. A subsidiary of the Heineken Group, Heineken Vietnam is the second largest brewer in the country, operating six breweries and employing around 3 000 people. With a focus on high output and high efficiency lines, they produce the most famous international and local brands through dedicated single-format lines.
A PROVEN PARTNERSHIP RESULTS IN A SUCCESSFUL, COMPLETE CAN LINE PROJECT The primary consideration at the Tien Giang site was that the brewer was looking to increase production output. Paul Bleijs, supply chain director at the brewery explains, ‘We wanted to buy a new complete can line, doubling capacity of the existing ones. ‘A typical challenge is that you have to install the equipment while the brewery is in operation. This is why you must know and understand the layout clearly. Thanks to the experienced line design team from Sidel, we overcame this obstacle.’ Gianmatteo Bigoli, strategic account director for Heineken at Sidel comments, ‘A stable expert team supports all customers on their projects. They can capitalise on customer proximity, easily grab their requirements and quickly implement the right solution for them.’ ‘What cemented our cooperation through the past 13 years is our continuous focus on innovation: this is key for a global leader like Heineken,’ Bleijs says. From line design through installation up to the commissioning phase, the Sidel
team assisted the brewery to take each step quickly. This was instrumental in starting production seven days ahead of schedule. Sidel’s vertical start-up programme, including dedicated training specifically developed for the team, reduces timeto-market by 40 per cent, while securing ongoing efficiency of line operations.
HIGH PERFORMANCE PAIRED WITH OPTIMAL SUSTAINABILITY Sustainability is absolutely key for the Heineken group. In 2017, the brewery was recognised as the most sustainable manufacturing company in Vietnam by the Vietnam Chamber of Commerce and Industry (VCCI), based on the annual Corporate Sustainability Index. ‘Besides good productivity levels, this line is consuming less energy and water, thus contributing to a very good return on investment for us,’ Bleijs points out enthusiastically. Ha Minh Thanh, packaging manager at Heineken Vietnam, values the design of the can filler. ‘The
ergonomics and safety architecture of the solution are great. It is very easy to operate, maintain and clean.’
A JOB WELL DONE Sustainability, coupled with performance, was also high on the agenda when Sidel engineered Swing. The technology is simple-to-operate and maintain, making Swing the ideal solution for pasteurising, heating or cooling cycles for cans of all formats and sizes. It also allows significant resource savings. Increased output paired with consistently high product quality and optimal resource savings are all achievable for Heineken Vietnam thanks to the new complete canning line. Bleijs concludes, ‘Let the result speak for itself. If you can run four weeks after starting the first canning, in three shifts, at a good operational performance indicators level it means the job was well done.’ •
Sidel – www.sidel.com
The new line will focus on high output and efficiency
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Food Manufacturing Africa | 2019 Quarter 1
BEERS & CIDERS
Crafty process and filling technology GEA Vipoll, a Slovenian subsidiary of GEA has achieved its first project in the craft beer segment in South Africa.
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HE BOTTLING SPECIALIST is currently in the process of manufacturing an all in one filler with filling capacity of 4 000 bottles and cans per hour for its customer, East Coast Brewing Company, situated in Unkomaas, KwaZulu-Natal. Vipoll launched the innovative technology in 2017. It is capable of filling glass and PET bottles and cans in the small and medium output range. The order includes a mixer and a flash pasteuriser, which will be installed at the same time as the filler in the spring of 2019.
LOOKING FOR LEAN SOLUTIONS East Coast Brewing Company is one of South Africa's emerging craft breweries. In 2017, the manufacturer equipped its new brewery with a 50 hectolitre GEA Craft-Star brewhouse. Rocco Antonio Fontana, third-generation brewer and beverage producer wants to fill not only craft beer at two degrees Celsius, but also niche carbonated drinks at 20°C and still water. ‘We met and got to know each other at drinktec 2017,’ says Stanko Zver, managing director and co-founder of GEA VipollI. ‘We were able to showcase the technology’s flexibility. It is possible to produce on on a very small area – in the process saving a lot of time when filling and changing formats. The decision to invest in our technology was made easier as the brewer worked and had an excellent experience with our brewery colleagues in Kitzingen.’ ‘The All In One is the third solution we have purchased from GEA. We are excited to have the line commissioned early this year,’ says Rocco Fontana. ‘We produce a wide variety of products in-house and offer a specialised contract packing service. We needed an allrounder that makes financial sense in terms of our capacities. This is our vision of smart, lean technologies.’
HIGHLY FLEXIBLE AND EASY TO OPERATE Customers, like those in the craft sector, are looking for flexible solutions that can assist in the switch to different container formats within a few minutes. The multifunctional elements of the All-In-One block allow for this. For example, the rinser is equipped with universal grippers and the filler with electro-pneumatic filling valves that don’t require changing to run bottles and cans
with different neck sizes. The twin head Functions are so smoothly coordinated the O2 capper, in which every second seaming absorption during filling is as low as possible. head is activated for can lids and crown The All In One can be easily controlled via a caps on one turret and touch panel. East Coast an additional turret Brewing Company has for metal (MCA) and chosen the All In One plastic (PCO) caps, have filler with 16 grippers, individual cap feed 16 volumetric filling systems. Can seamer valves and two capping/ and crown cap heads seaming turrets. The first are servo-driven. In turret combines crown contrast to conventional corks and different lid systems, the sizes of cans whereas The All in One filler 16 grippers All In One system has the second turret is minimal product losses designed for aluminum due to the unique capping/seaming system. and plastic screw caps. • In total, format and product changes on GEA – www.gea.com the filling block take less than 20 minutes.
Sacmi partners with
US craft brewers
This year the task of hosting the now-traditional Craft Brewers Conference & Brewexpo America falls to the city of Denver. The event will be held from 8 to 11 April at the Colorado Convention Centre.
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KEY PLAYER at the event is the Sacmi Group. The company will be out in force with an array of technology and plant engineering solutions that will respond to the need for flexibility, reliability and efficiency. The industry has, after years of double-figure growth, seen a production increase of five per cent in 2017. This is according to statistics released by the US Brewers Association. Sacmi’s integrated beer making range spans from capsule production to labelling and labelled bottle inspection. Of interest is technology developed for craft beer brewers. In the US, this sector accounts for over 13 per cent of the market. Worth highlighting is the Sacmi combi bottling system for bottles (glass and aluminium) and cans. This all-embracing solution allows for fast size changeovers. It also lets users manage different container types with a single machine.
Advanced Sacmi solutions are aimed at ensuring filling process quality Sacmi’s technological and plant engineering range is specifically and hygiene. The designed for brewers use of electronic flow meters for instance assured brewers of beer quality, but also solidity, reliability, ease of use and maintenance. In conjunction with the four-inone monobloc, Sacmi supplies a complete range of traditional beer and wine filling machines with both electronic and electro-pneumatic control. Like the combi system, these are designed to handle different container types and sizes with ease. All Sacmi solutions are certified and tested by the group research and development laboratory, accredited with the main international players in the beverage industry. •
Sacmi – www.sacmi.com
2019 Quarter 1 | Food Manufacturing Africa
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BEERS & CIDERS
The next step in
glass filling A German brewery has opted for the KHS Innofill Glass DRS filler. The flexible inline machine features 132 filling stations and can handle up to 50 000 bottles per hour. Hygienic filling is assured with low CO2 and product consumption. Four key areas have been updated.
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HE BREWERY FILLS 0.5l and 0.33l bottles. Fast format part changeovers ensure a high level of flexibility during production planning and line efficiency. KHS provides its hygienic Quicklock fast-acting locking system as a new standard. Bottle guide parts can be exchanged with a few manual adjustments. These remain securely in place thanks to the positive fit between the mount and format part. Conversion time for fillers with a crowner is cut by up to 33 per cent to between 15 and 20 minutes. ‘Simple lever knobs release and lock parts. They are robust and can withstand broken glass or chemicals,’ states Ludwig Clüsserath, head of filling technology development at KHS.
“Conversion time for fillers with a crowner is cut by up to 33 per cent to between 15 and 20 minutes” CLEVER TECHNOLOGY IN A COMPACT FORM To prevent bottle breakages from the outset, the Innofill Glass DRS is equipped with a SoftStop system, which is registered as patent pending. This compact, hygienic bottle flowgate is activated at full power. A light barrier measures the distances of containers as they are fed into the filler. A brake wedge gently decelerates bottle flow so the filling and foaming process takes place at a constantly high output. This ensures stable filling quality. No conversions to other formats are necessary and the new braking ramp means there is no additional scuffing and less noise.
UNIQUE SELLING POINT FOR MORE QUALITY
Broken bottles are continually detected across the processing line
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Food Manufacturing Africa | 2019 Quarter 1
During the subsequent filling process, the unique DIAS diagnostic assistance system carefully logs the filling
process. Pressure sensors are present in every single filling valve monitoring pressure, time and step sequences without interruption. This ensures any deviation from target values is recognised. A further special mention should be given to the fact that evacuation and CO2 purging processes are monitored to ensure low oxygen pickup. Broken bottles are consistently detected across the entire processing angle and a bottle burst routine triggered. Sensor data can be invoked as a pressure graph on the monitor. ‘This gives operators the chance to detect faults quickly,’ Clüsserath points out. In practice, this makes fast, targeted repairs possible; relieves operator workload and provides a basis for preventive maintenance. Data enables the results to be statistically evaluated and future error sources can be eradicated in advance. This ensures consistent quality and limits stops during operation. Another significant feature is the cameracontrolled Opticam HPI control system. Foam generated by HPI displaces residual oxygen from the bottle - of great importance for beer quality. Foaming is dependent on various parameters in the filling process. The Opticam system KHS enables the foam head to be constantly monitored and regulated - irrespective of the machine operator. This means the brewer not only prevents undue beer loss due to excessive foaming, but also detects and rejects bottles with insufficient foaming. If the beer error rate becomes too high, production is stopped. Operators can access a full and clear analytic report on the cause of the fault. • KHS – www.khs.co.za
RIGID PLASTICS
Generate more revenue with PET BoostPRIME is an innovative PET packaging solution. The system offers a great alternative for hot-filled beverages in PET bottles. It expands opportunities for product premiumisation and revenue generation with no compromise on packaging performance and consumer experience.
Producers can save on label costs when switching from a sleeve to a roll-fed application
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HIS PATENTED SOLUTION addresses the single serve market of juice, nectar, soft drink, isotonics and tea (JNSDIT) filled in PET bottles of up to 1.2l at a temperature of between 85 to 88°C. The packaging solution removes the need for restrictive vacuum panels or gas addition into PET bottles. This is normally required for containers to resist hot-filling temperatures. Final bottle shape is achieved with an active base inversion. This relies on three key features with minor impact on the packaging manufacturing line layout: • Packaging design requires specific base geometry and specifications. • Base OverStroke System (BOSS) allows mechanical forming of the bottle base during the blowing process. • Inverter contributes to base inversion. This step takes place after filling and capping, tilting and cooling, but before labelling. It balances negative pressure induced by the beverage cooling in the bottle from 85°C to ambient temperature.
INCREASE PACKAGE APPEAL TO STAND OUT The removal of technical constraints of the bottle vacuum offers total freedom of shape to attain premium and distinctive PET bottles. It allows a uniform look and feel for hot and aseptically-filled bottles for consistent brand continuation. Iconic bottle shapes with panels can be easily adapted without impacting consumer perception. It also enlarges branding opportunities as the bottles’ labelling surface with no vacuum panel is smoother and contributes to a greater, more impactful look and feel. Labelling quality for both roll-fed labels and
sleeve labels is improved due to an inner bottle pressure during label application.
COST-EFFECTIVE SOLUTION WITH SIGNIFICANT SAVINGS BoostPRIME packaging solution significantly reduces consumption of PET resin: it can decrease current heat resistant (HR) bottle weight by up to 30 per cent compared to regular HR PET bottles. It also allows producers to save on label material by enabling the switch from a sleeve to a rollfed label application. All process parameters such as air blowing pressure and air cooling are optimised at maximum mechanical speed. When investing in the BoostPRIME solution for a new hot-fill PET line to produce a one litre hot-filled bottle, beverage producers can quickly reach a one-year payback when considering the additional investment versus traditional line configuration. 1 By shifting from regular HR bottles with vacuum panels decorated with sleeve labels to lightweighted BoostPRIME bottles decorated with roll-fed labels, bottle lightweighting potential is estimated to be between three and seven grammes. This is complemented with a ten time reduction in label costs.
TOP BOTTLE QUALITY AND PACKAGE PERFORMANCE The complete packaging solution ensures a very consistent blowing process and final bottle base profile for a top bottle quality and great consumer experience. Although
it is light, the bottle is just as strong when cooled. This is due to the fact that the inner bottle pressure stemming from the base inversion reduces risk of deformation. Quality label application is especially optimised as the container is stronger and the bottle wall surface smoother. Large seating diameter of the base improves the bottle’s stability through the packaging line and on the pallet contributing to line efficiency. Sidel’s BoostPRIME packaging solution has been validated with a key customer in Mexico, where the industrial production has successfully started early this year. With nearly 50 SKUs in production, the beverage producer achieved tremendous bottle weight savings up to 32 per cent. 2 Hot-filled drinks including juice, tea and isotonics are produced by using a variety of production configurations. These include: • Off-line and in-line production • Existing and new Sidel blowing and filling equipment • Stand-alone Sidel blower and Sidel integrated blow-fill-cap Combi • SBO Universal and SBO Sidel Matrix blower ranges • Contact filling and flow meter filling • Applying roll-fed and sleeve labels. All lines configured for BoostPRIME can produce standard heat-resistant bottles with or without panels, which increases the versatility of this packaging solution. • 1 Line with 20 blowing stations, running at 1 800 bottles/hour/mould and 5 000 hour production/year. 2 The savings of 32 per cent are in relation to a 237ml bottle format.
Sidel BoostPRIME - sidel.com/boostprime
2019 Quarter 1 | Food Manufacturing Africa
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RIGID PLASTICS
Committed to PET recycling Polyoak Packaging (Polyoak) is intensifying its commitment to extend producer responsibility, by partnering with customers to optimise recyclability of packaging.
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OLYOAK’S NATIONAL EXECUTIVE for its specialist PET division, Polypet, maintains that PET has significant advantages as a packaging material. It offers strength, thermo-stability and clarity; is shatterproof, safe, hygienic, portable, resealable, lightweight, easy to recycle and cost-effective. The weight of PET packaging has reduced by more than 30 per cent in the last decade. Polyoak’s Wessel Oelofse agrees, ‘Over the last ten years Polypet has reduced the weight of its four and five litre PET bottles by an average of 30 per cent, while maximising robustness and improving top load strength. Smart design improves performance, whilst utilising less resources for a greener footprint.’
RECYCLABILITY OF PET Of all the bottles recycled, only 38 per cent were re-processed into bottleto-food grade products, such as new PET bottles. There is still headroom, as demand for food grade recycled PET (rPET) continues to grow. The challenge is only natural (clear) and light blue PET bottles can be re-processed into food grade rPET. It is essential for more trusted brands to switch from coloured to clear PET, to increase production and availability of recycled material, for inclusion in packaging. Clear PET has many other advantages over
coloured PET. It features a: these products, and surplus • lower cost and waste coloured PET can no longer component be exported to China, given • certainty of supply as Polyoak has been a their ban on recycled natural preforms are contributing member of Petco, plastics. the PET industry’s recycling usually stock items As a result, collectors body, since its inception • improved colour earn up to 40 per cent less in 2004 and actively matching when adding participates on the for coloured PET, than they rPET to clear PET. Petco board. would for clear PET. This If other African countries disincentivises the collection of follow the UK and EU legislation, it coloured PET bottles. is likely that packaging not easily Some brands are embracing the recyclable, or containing recycled material, need to move from coloured to clear PET in may incur penalties. a bid to improve recycling. Examples include Sprite Zero, and Schweppes Tonic Water and OPAQUE PET IS NOT Ginger Ale, who changed their bottles from RECYCLED green and brown PET to natural (clear) PET. Opaque and fluorescent In the dairy category, Fair Cape transitioned PET bottles are not from white to clear PET bottles for its milk and readily recycled, cream range, opting for a fully recyclable LDPE because there are no stretch sleeve. end-use markets. They ‘There is a significant opportunity for more cause blockages to categories to transition to clear PET bottles, die heads on the fibre including CSD’s (ginger beer and crème soda), plant due to the types lemon juice, sauces and dairy products. of masterbatches used. Polyoak invites brand owners to partner with Opaque PET bottles us to create recycling-friendly packaging that also have zero value to will help gain the respect and loyalty of their collectors as recyclers consumers,’ Oelofse notes. don’t want them. Often the rationale for choosing coloured PET is less technical, and more about the COLOURED PET IS PROBLEMATIC category nuance. Green is lemon juice. Ginger Coloured or highly pigmented PET bottles beer in a brown bottle packs more Kwesta! comprise about 15 per cent of all the PET Sometimes opaque or coloured PET is used to bottles collected by recyclers in South Africa obscure the contents of the bottle, especially currently. Coloured PET can only be used where settling or separation may occur. Who in the production of fibre, geotextiles and wants to buy a bottle with sediment lurking at strapping. There is not much demand for the bottom? There’s certainly an opportunity for marketers to help shift perceptions that hamper recycling. Polyoak offers various recyclingfriendly decoration alternatives, which would enable brands to switch to clear PET bottles, whilst still protecting their product and projecting appetite appeal. ‘It’s important to partner with a packaging supplier with the relevant experience and commitment, to ensure your pack is truly as recyclable as it can be. Design, functionality, material, decoration and closures all need to be taken into careful consideration, to deliver a truly recyclable pack,’ Oelofse concludes. •
Polyoak’s specialist PET division, Polypet, promotes clear PET to optimise the recyclability of its bottles.
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Food Manufacturing Africa | 2019 Quarter 1
DID YOU KNOW?
Polyoak Packaging – www.polyoakpackaging.co.za
RIGID PACKAGING
Be inspection ready
Quality inspection is critical in manufacturing and packaging lines, especially in the food and beverage sector. An unreadable barcode or an incorrect expiry date could result in perfectly good products being recalled and discarded.
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UTOMATED SYSTEMS can improve a line’s effectiveness, by performing tasks quickly and accurately. The real benefits only materialise when ‘smart’ automation is implemented, utilising such features as smart data. When this is applied to vision inspection systems, defects can be spotted and dealt with swiftly with minimal impact to the line. Omron’s system cover all parts of the production line, including quality inspection. Data sent from the vision system is processed locally and sent via the cloud for powerful analysis that allows the system to take appropriate actions. The system is interlinked, and the improved connection between machines in a manufacturing line delivers accurate quality control and higher efficiency. If any error is detected, the system can PPK023-17.pdf
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2019/01/17
MicroScan technology from Omron
often compensate automatically, allowing production to continue unaffected. For an inspection system to make smart decisions, it needs to collect data from a sensor, such as a vision camera. These can be set up to monitor different aspects of the product, check for imperfections, or check labels for misprints or missing
information. Powerful processing then analyses this data to monitor the process, comparing actual results with expected results. If any problems are found, the system follows programmed rules on how to respond to any changes. A further advantage of an effective inspection and process management system is flexibility. Omron’s Sysmac Studio, production lines can readily accommodate short production runs and adapt to market demands. Line set-ups can be changed quickly for new production runs, and the recognition pattern for quality inspection can be updated easily in the software. This ensures different variants or even different products are produced and packaged correctly. • Omron - www.industrial.omron.co.za
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2019 Quarter 1 | Food Manufacturing Africa
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RIGID PACKAGING
Develop lean, profitable strategies The packaging and design industries are experiencing unprecedented growth in. To deliver marketready materials to an end-market that demands innovative packaging solutions, material suppliers and packaging companies are investing heavily into new technologies.
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N THIS CONSTANT race to the top, business process engineering is one area that is often overlooked and neglected, even though it offers obvious benefits and savings to the entire company. This is the view of Kishan Singh, managing director of GI Business Solutions– a Durban-based consultancy that specialises in implementing business management systems. GI Business Solutions is a DNV.GL/ ISO9001:2015 Certified, level one B-BBEE company that specialises in the design, development and implementation of business management systems, auditing systems, process re-engineering and packaging optimisation solutions. The company offers various businessrelated training courses, couples to accompanying competency evaluations, through formal written assessments. ‘With more than 32 years of experience in automotive and packaging manufacturing/ quality management arenas, I realised the need for effective business support by consultants with the correct experience and competence,’ Singh points out. Amongst his many accomplishments, Singh is the Global Ambassador of the World Packaging Organisation (WPO) and National Education Officer of the Institute of Packaging SA (IPSA). He has achieved the coveted designation, Certified Packaging Professional (CPP) by the international Institute of Packaging Professionals (IoPP), based in the US. His in-depth knowledge of the industry sees him often being called upon to conduct global training on behalf of the WPO on issues ranging from packaging technology, graphic design and supply chain management. He has also been wearing the hat as CEO of MetPac-SA – the Kishan Singh producer responsibility
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organisation responsible for representing the interests of the local metals packaging industry in South Africa. ‘My passion is business process engineering coupled to the design and implementation of tailor-made solutions that are ISO compliant. I’ve seen what a difference it makes to companies that we have helped, including Amcor, Hulamin, Bidvest Silveray Stationery Company, Bleistahl Engineering, National Brands, and Polyflex,’ Singh points out. As proof of this passion and drive to pass on his knowledge and expertise, Singh recently acquired the Lean Six Sigma Black Belt status through Dr Mikel Harry’s Six Sigma Management Institute, US, and is currently busy with his Masters/PhD degree in Quality Management in South Africa, focussing on Business Modelling to Extract True Financial Value from ISO9001:2015 (as opposed to current ISO9001:2015 Business Models that lack positive financial impact. The ISO 9000 family of quality management systems standards help ensure that organisations meet the needs of their customers and other stakeholders while meeting statutory and regulatory requirements related to a product or service. It fundamentally deals with quality management systems, and there are various requirements that organisations wishing to meet the standard, must fulfil. If done and implemented correctly, Kishan and his team advocate that ISO certification helps ensure that companies implement lean, profitable business processes that not only saves money, time and resources, but also unlocks many other benefits for companies. The first step the GI Business Solutions team takes is to begin with an in-depth, baseline reporting. Once they have identified the client’s needs, they consult with the client and together decide upon the best
Food Manufacturing Africa | 2019 Quarter 1
“The ISO 9000 family of quality management systems standards help ensure that organisations meet the needs of their customers and other stakeholders while meeting statutory and regulatory requirements”
business management system to implement, such as ISO 9001:2015, ISO 14001:2015, ISO 45000:2015 (OHAS 18001), FSSC 22000, ISO 31000 or ISO 50000. They develop affordable, tailor-made, yet practical solutions for the effective implementation of such systems, coupled with the necessary training and education support their clients might need to sustain such systems. Obtaining third party certification of processes is also an important part of the service offering, and GI Business Solutions engages with various Certification Bodies (i.e. DNV.GL, SABS, SGS, Lloyds of London and BVQI) on behalf of their clients. ‘We ensure that systems implemented continue to deliver ongoing improvements and benefits. The best way to measure success, is to record an improvement on a company’s financials or balance sheet and this is achieved through effective value analysis and value engineering,’ he enthuses. ‘Consumers have become more aware of food packaging and are demanding unquestionable standards when it comes to their safety, the environmental impact and the protection of their rights. Packaging companies who are hoping to not survive, but flourish, will need professional training and support of their businesses. GI Business Solutions is this link that has been missing until now. We have the proof to back up our claims that our solutions work and are ready to lend a helping hand to anybody who might need it, and look forward to the next five years of growth,’ Singh concludes. •
Gib Solutions - www.gibsolutions.co.za
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