20 minute read
BAKERY
Colour is an innovation game
Consumer requirements for clean labels show no signs of slowing down. To tackle the drive towards vegetarian and vegan food product options, colour manufacturers must constantly innovate.
INTERNATIONAL COLOURS AND
ingredients supplier Roha aims to provide highly stable and economical solutions to food producers based on a variety of raw materials. A key market shift is a move from the use of carmine. This colour is obtained from the scale beetle cochineal and is not vegetarian or vegan compliant.
This is no easy task. Carmine is highly stable and provides an intense pink to red shade across a multitude of applications. One potential replacer for carmine comes from red beet, which suffers from heat instability. The colour can fade completely in a short space of time with temperatures above 60°C.
Some anthocyanin-based products can also give the required shade, but there are strict pH limitations and heat stability to consider. To combat this, Roha developed Natracol Cerise, a high strength red beet-based food colour capable of handling high temperatures for the bakery and prepared food industry. This natural colour works well in products like red velvet cake
giving dark red shades. An excellent replacement for carmine or synthetic pinks/reds, Natracol Cerise answers consumer requirements for clean label natural colours while maintaining the required shelf life. Although only available in a powder format Natracol Cerise is extremely water-soluble for dilution if required. In terms of other shades, Roha has several new product developments with notable stability based on a variety of raw materials. Yellow is a key colour in bakery and Roha has developed multiple products depending on the labelling requirement.
Natracol Bright Yellow (e100 labelling) is a high strength, encapsulated curcumin-based product with an excellent cost in use and low dosage offering bright yellow shades. For an E number-free option, Futurals Pro Bright Yellow (curcumin extract) is the go-to-product. It offers excellent stability to heat and light while maintaining the intense yellow shades at a slightly higher dosage.
For those who require beta carotenebased products, Natracol Vibra Yellow provides the required labelling (natural identical or fungal beta carotene). It is available in shades from yellow to orange depending on the dosage. It can also be provided in a liquid or powder form. Due to consumer demand, some manufacturers are moving away from caramel e150d. This is owing to potential issues with the production of the colouring material. Other caramel options (e150a-c) do not give the intensity or shade required.
Roha has now developed its clean label caramel alternative, Futurals Pro Cinnamon Brown XL derived from apple extract. This product is completely clean label and preservative-free. It offers a golden to dark brown shade associated with caramel colour and is suitable for bakery applications. These thoughtful and dynamic innovations are just a few in an impressive portfolio of natural colours and fruit/vegetable juice concentrates from Roha.
‘As a global company, we pride ourselves on working closely with our customers on-site to troubleshoot colour issues. We can also provide customised solutions to any labelling requirement.
‘Roha’s South African site has a variety of application facilities and food industry experts who can assist in offering customised colour solutions or advice if you need to switch from synthetic to natural colours. The facility is also FSSC22000 certified and has access to all Roha’s global regulatory team for any requirements outside of South Africa. I can comfortably say that Roha is a one-stop shop for your food or beverage colour requirements,’ says regional head Africa, Carlos Reis. •
Roha – www.roha.com
With some popular food trends, a compromise is almost inescapable. Take packaged bread products. At the mention of clean label, manufacturers must consider the potential implications for volume, sensory quality and processing. Shorter ingredients list and what it means for you
WITH FORECASTS NOW highlighting clean label as a major emerging growth area in African bakery markets, the race is on to find efficient solutions curbing trade-offs.
According to Polaris Market Research, the clean label bakery trend in Africa is roughly aligned with the global forecast for compound annual growth, hovering around 7.5% from 2019 to 2026.
It seems that consumers everywhere are expressing a similar desire for bakery products with fewer additives and preservatives on the label – or none at all.
The current COVID-19 pandemic may add further fuel to the trend as consumers make a link between shorter ingredient declarations and foods that can better maintain and protect their health.
“COVID-19 has made consumers reprioritise their purchasing criteria and shopping habits. Clean label expectations are likely to be broader in the long run, requiring the bakery industry to adapt to altered consumer needs,” says Paal Ladsten, regional industry leader Enzymes MEA at DuPont Nutrition & Biosciences.
While the concerns of global consumers may be similar, expectations from a clean label product are likely to vary depending on local cultural traditions. In African markets, Mintel reports that the top two claims on bakery product launches overall – vegetarian and Halaal – are also strongly linked with clean label launches. Wholegrain, low/no trans-fat and added fibre are other key claims that feed into the clean label bakery category.
For bakery manufacturers, satisfying the clean label perceptions of consumers typically involves a compromise in terms of reduced production speed, higher cost and lower quality and taste. It can be a real challenge to find the right balance. The highest-ranking buying criteria for African consumers, after all, remains affordability. Manufacturers must think carefully before choosing a clean label solution and the impact it may have on the price of their products.
“At DuPont, we have identified five degrees in the clean label scale, starting with conventional bread products made with blends of emulsifiers to products at the cleanest level, comprising the building blocks of bread recipes, such as flour, yeast and salt,” explains Emeline Commun, bakery marketing specialist at DuPont Nutrition & Biosciences.
“As we move along the scale, the impact of clean label reformulation on processing tolerance and sensory quality becomes increasingly pronounced.”
In other words, maintaining product quality and a stable, reliable process are the two primary concerns. This is where the latest commercial solutions may turn out to be the bakery manufacturers’ best friend.
New opportunities include PowerBake 6000 & 7000 series, an enzyme-series based on lipases with a supporting oxidative enzyme module. Used in combination, they are an efficient clean label alternative to commonly used emulsifiers in, for example, white bread and burger buns, where they provide volume, structure and a soft crumb.
At DuPont, the bakery application specialists have tested a series of singleaddition possibilities to produce clean label toast bread with minimal trade-offs during processing and in the final product. “The idea of PowerBake Clean 901 was to develop a complete solution for producing white toast bread with no E-numbers. What we have achieved is a flavour, softness, resilience, colour and volume very close to that of a white bread made using a traditional formulation,” says Commun.
DuPont has launched both solutions on the market to address all types of customer needs but, as Commun adds, this does not mean the clean label challenge has been solved completely. Bakery traditions, raw materials and clean label priorities still vary enormously from one market to the next. She expects there will always be a need for tailored solutions that secure the price and quality that consumers will keep coming back for.
In Africa, big opportunities lie ahead as more consumers equate a cleaner product label with better-for-you food. A product label with fewer or no additives is easy to relate to. If the product itself is just as delicious and appealing as the others on the shelf, there are few reasons left why the consumer should choose anything else. •
In the African market, the top claims are vegetarian and Halaal, which are strongly linked with clean label launches.
DID YOU KNOW? DuPont – www.dupont.com PowerBake’s 6000 & 7000 enzyme-series is based on lipases with a supporting oxidative enzyme module for use in white bread and buns
Sweetener meets the demand of the health-concious consumer Ingredion EMEA has launched its first polyol sweetener, Erysta Erythritol. The sweetener enables manufacturers to reduce or replace sugar to achieve nutrition-related claims, such as ‘no added sugar’ or ‘calorie-reduced’, in multiple applications.
THE INGREDIENT SUPPORTS functional build back and sweetness when sugar is removed in products including ice cream, desserts and chocolate confectionery, while providing consumers with the mouthfeel and texture that they expect in their favourite products. Other applications include baked goods, beverages and fruit preparations.
Working with culinology and technical experts at Ingredion’s Idea Labs innovation centres across the region, manufacturers can collaborate on recipe formulation to develop new and on-trend products with a focus on getting to market quickly. From a decadent low-calorie chocolate brownie ice-cream with reduced sugar, to a sumptuous no added sugar rhubarb and rose cordial, food and beverage producers can create products that tap into the consumer demand for healthier alternatives that still deliver on taste, texture and an indulgent eating experience.
Rodolfo Garza, regional growth platform leader, marketing, says, “Increasingly health-conscious shoppers are paying close attention to the sugar and calorie content of their favourite foods. In fact, 64% of consumers in Europe, the Middle East and Africa say that a ‘low in calories’ claim is important to them when buying food or drinks .
FACT BOX
Ingredion’s range of Erythritol sweeteners include Erysta C40 Erythritol crystalline particle size and Erysta C100 Erythritol fine particle size for high and low moisture applications. Produced by fermentation, it has zero calorie content (measured according to EU Regulations, as compared to 2.4kcal/g for other polyol alternatives), enabling manufacturers to make consumer-winning energy reduction claims*. When used as part of a sweetener system in certain applications, there are synergistic effects to boost sweetness of the product.
“Consumers want it all – the guilt-free indulgence of lower-sugar, lower-calorie alternatives. European consumers in particular seek pleasure and health in equal measure , but the challenge for manufacturers is delivering the same functional properties in a product when sugar is removed. Erysta Erythritol delivers around 70% sweetness compared to sugar, delivering functional and textural properties such as bulking, ease of processing and mouthfeel enhancement when replacing sugar in formulations.” •
*Manufacturers are advised to satisfy themselves regarding the use, labelling and suitability of Ingredion’s products in their final products. In particular, food additives (for example, sweeteners) should be used in accordance with the relevant local regulations.
Products are pH-independent and offer good light and heat stability as well as a good shelf life. They are 100% plant-based, Halaal and Kosher, and made without any chemical solvents. They offer a perfect clean-label replacement for artificial colourants and additives such as annatto,
An orange twist on bakery icing
Bright orange makes products stand out
IT IS IDEAL for compound coatings, spraycoated oil seasonings and other fatbased applications.
beta carotene and paprika extract.
Sonja Scheffler, product manager at GNT, notes, “With a liquid format available it means we can help manufacturers deliver stunning orange shades for a vast range of food and drink applications.”
Exberry Coloring Foods are made from fruit, vegetables and edible plants using only gentle physical methods such as chopping, heating and filtering.
GNT Group has launched two new Exberry Coloring Foods that deliver bright orange shades in powder and oil-dispersible formats. Made from paprika and carrot, the products provide solutions for a range of applications such as non-aerated confectionery, bakery and savoury products.
Ingredion – www.ingredion.com
They retain characteristic properties of the source material and the concentrates are not selectively extracted. As a result, they qualify for clean- and clearlabelling declarations. •
Assured visibility in processes
Quality demand on food products is reaching an all-time high. Vega’s highly compatible design and standardised adjustment concept creates flexible application possibilities and allow for individual configuration.
VEGA HAS EXPANDED its product range to include a compact instrument series. Standard applications can be automated economically with the new compact pressure sensors and level switches. Integration into the system and adjustment are easy to carry out. In this performance class, multi-device connection options are also available, which supports the continuous improvement of production facilities.
The new Vegabar and Vegapoint instrument series is the answer to the growing demand for simple sensors with optimised variants that support efficient food production. This requires standardised products that are easy to use, but still cover all the basic hygiene requirements. It also calls for better networked products with easy connectivity to existing control systems and mobile devices.
A uniform standard extends through all areas of application. This applies to the fully hygienic adapter system – designed to be compatible with Vegabar pressure sensors, Vegapoint capacitive level switches and existing Vegaswing vibrating level switches. All new instruments are built to withstand intense CIP processes.
THE ACID TEST OF CIP CLEANING
CIP cleaning is one of the most necessary but time-consuming process steps. The ability to clean and sterilise systems quickly, through consistent hygiene standards and system design is non-negotiable. Vegabar and Vegapoint instruments can tolerate high temperatures without loss of function, and even cope with the combination of high temperature and long exposure times.
HYGIENIC DESIGN DOWN TO THE LAST DETAIL
Surfaces of Vegabar 29 and 39 sensors that encounter the product are made of stainless steel and feature optimal surface roughness values. Vegabar 28 and 38 are available with high-strength ceramic versions and Vegapoint sensors in highly resistant PEEK material.
All materials are approved and tested to FDA and EC 1935/2004. The design of the instruments is certified to the European EHEDG Directive and the North American 3-A Sanitary Standards. Both standards prescribe the use of corrosion-resistant materials, and components are also designed in accordance with good manufacturing practices (GMP) regulations so that all micro-organisms are reliably removed by cleaning and cannot multiply on surfaces or in gaps.
To ensure that the status of a process can be recognised at a glance, the development of the new sensors focus on simple handling – and the fast and easy readability that comes along with it. Thanks to the round, 360° display, switching states can be visually detected from any direction.
FIT FOR THE FUTURE WITH IO-LINK
During maintenance, plant operators rely on status data, which forms the basis for optimal planning of shutdown times. Almost all system builders now implement intelligent sensors with IO technology as it offers universal advantages when it comes to data availability. Not only can these be quickly and cost-effectively installed using standard three-core cable, but, with IO-Link, sensors can also be replaced easily and without the risk of errors. The system can be put into operation correspondingly faster with the standard protocol, which reduces production downtime considerably.
The option of having all sensor parameters written automatically into the new instrument by the IO-Link master or the controller during a replacement also makes for additional efficiency. Fast format or recipe changes, which are typical in the food industry today, can be carried out quickly and centrally in this way.
WIRELESS TRANSMISSION OF MEASURED VALUES
The Vegabar and Vegapoint instrument series can be easily read out and configured with a smartphone or tablet. Especially in environments such as clean rooms, where physical access involves a lot of effort, it means setup and operation become considerably faster and easier. In combination with the Vega Tools app, which has already won an App Award, the sensor data enquiry over shorter distances in these areas also becomes convenient. •
Vega – www.vega.com
BEVERAGES Technology that answers the beverage industry’s needs
The food industry is looking for natural and environmentally friendly processes. The aim is to assist processors in keeping the flavour and nutrient characteristics of fresh food while providing food safety and extending shelf life. In this scenario, high-pressure processing (HPP) appears to be a sure fit.
HPP IS A non-thermal preservation technology that applies high hydrostatic pressure during seconds or minutes to packaged products (in-pack). Its advantages are well known: - Premium quality: Sensorial, nutritional and functional properties are preserved up to three months in refrigerated conditions. - Brand protection: Ensures food safety, reaching five log reduction of pathogenic microorganisms. - Market expansion: Extends shelf life by up to 10 times. This technology allows the positioning of innovative products in new markets.
It is applied in a wide variety of products including wet salads and dips, meat products, seafood, ready-to-eat meals and beverages.
‘HPP technology has become popular in the beverage industry, particularly in the premium juice segment as it enables a product to retain its freshly squeezed attributes,’ explains Dr Carole Tonello, applications and commercial director at Hiperbaric. The company is a leader in designing and manufacturing HPP units. ‘Other beverages such a vegetable soup, probiotics, fermented beverages or non-dairy milk also benefit from these advantages. Very few products cannot be processed by HPP,’ she points out.
STRATEGIC AND TECHNICAL ADVANTAGES OF HPP
- Versatile design: Intensifiers (high-pressure pumps) can be installed alongside the machine, in a service corridor or a platform on top of the vessel. This last design reduces the footprint and facilitates its implementation in a food industrial environment. - Wide range of industrial machines: From 55 to 525 litres, HPP machines meet the requirements of start-ups, small-medium enterprises and large corporations. - Labour saving and greater flexibility: HPP units are integrated with their loading and unloading lines and systems. Hiperbaric can provide further turnkey automation solutions adapted to customer needs. - Aftersales service and support: Offers highly specialised field technicians, diagnostic services and remote monitoring, after-sales portal, etc. All are customeroriented to satisfy its requirements. - Green technology: An environmentally friendly process because HPP machines only need water (which is recycled) and electricity.
These advantages can reduce time-outs, resulting in fast and reliable processes. Since 2018,
Carole Tonello
the beverage industry has a specific unit designed to achieve the highest efficiency and profitability in high-pressure processing. ‘HPP in-bulk technology is a global innovation developed by Hiperbaric. This new technology allows the processing of a large volume of beverages in bulk (before bottling). The unit features a simpler process with fewer steps, but higher productivity,' Dr Tonello notes.
Beverages are processed in a bag hosted inside the vessel. This occupies 90 per cent of the total volume, which is roughly double than the one achieved with conventional HPP technology. In-Bulk technology fits perfectly into any large beverages production line and allows the use of any kind of packaging after HPP, no matter the material, design or size.
Hiperbaric also offers advice and consultancy for the development of new drinks by HPP in its pilot plants in the US and Spain. In this way, producers will be able to know the process adapted to their brand. •
A sunny solution for the manufacturing sector
A solar installation at SAB's Alrode Brewery
African businesses are waking up to the potential of renewable energy, and the manufacturing sector is no different.
RENEWABLE ENERGY - particularly solar PV - is easy to deploy and will decentralised, clean and affordable. Other sectors have long recognised the benefit of installing solar PV systems on their commercial buildings. The cost reductions of installing solar PV in recent years meant that industrial sectors, including food manufacturing, have taken notice.
One such entity is AB InBev, who entered into a multi-tiered Power Purchase Agreement (PPA) with the Sola Group. The agreement will see solar facilities built across seven different breweries in South Africa by early March 2020. In total, the breweries will support 8.7 MW of solar power installations - enough to produce almost 14 GWh of clean electricity per year.
According to the International Energy Agency, distributed solar PV systems have almost tripled since 2014. It predicts that distributed energy, such as the solar PV systems installed at AB InBev, will grow as much as onshore wind by 2024, making up half of all new solar PV capacity.
This is likely due to the flexibility and affordability of PV plants compared to other forms of energy generation. The rollout of large-scale solar PV systems takes much less time than other generation technologies.
There is also a greater demand and expectation that businesses will take more responsibility for the way in which they operate. This is particularly apparent in the food and beverage sector, whose customers are starting to demand sustainable products. The industry is also likely to be more acutely affected by climate change than other sectors.
As such, many large food and beverage companies have set sustainability targets, often at a global level. Gugulethu Nogaya, the renewable energy procurement manager at AB InBev Africa, explains that “procuring renewable energy is part of our sustainability objectives global renewable energy commitment is to ensure that 50% of our purchased electricity will come from renewable energy sources by 2020, and 100% by 2025.”
Simonsig Winery, situated in Cape Town is another beverage company that has benefited from purchasing solar power through a PPA. Completed in 2019, the solar PV system at the winery produces 180 000 kWh of solar electricity per year - about the same as taking 34 vehicles off of the road per annum. “We are committed to sustaining the source of our wines, so producing our power from the sun is directly aligned to our goals,” says Billy Sendin, CFO at Simonsig.
Fair Cape Dairies has recognised the benefits of solar too, and is now milking their cows during the day through a solar powered system at their milking parlour in Durbanville, South Africa. The dairy has committed to environmental sustainability initiatives, with CMO Louis Loubser commenting, “As a company, we are totally committed to environmental stewardship and reducing our impact on the environment [buying solar energy] is part of that commitment.”
PPAs work well for the food manufacturing sector, because they allow companies to concentrate on their core business, leaving solar PV to energy experts who can design, operate and maintain them efficiently. This helps companies to save directly through their operating budgets, as solar energy tariffs are often significantly cheaper than the state utility.
“For large commercial and industrial companies, procuring renewable power enables saving costs, whilst reducing their carbon footprints,” says Chris Haw, chairperson of the Sola Group, who designed, constructed and owns the solar PV systems at AB InBev, Simonsig and Fair Cape Dairies. The PPAs allow these food and beverage companies to pay for the power they consume, rather than laying out large sums of capital for the construction of the systems.
According to the International Renewable Energy Agency, the costs of solar PV modules have fallen by 80% since the end of 2009, making them much more affordable than utility-provided power. During the course of a solar PPA, a client is likely to save significantly due to lower tariff costs. •
