Food Manufacturing Africa Q2 2021

MAY 2021 • JUL 2021 Vol. 10 • No. 2

FOOD Manufacturing Africa

Capture the essence with Spirit Signatures Bakery technology shares a proud heritage

Put the sun back in your products with functional Vitamin D

Technology puts your labels first

FOOD Manufacturing Africa

CONTENTS

MAY 2021 • JUL 2021 Vol. 10 • No. 2

10 “With the launch of Spirit Signatures, a portfolio of taste solutions for beverages, Symrise has discovered the taste mystery behind brown spirits like scotch, bourbon, whiskey, brandy and dark rum”

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NEWS

Demand for CBD soars Anufood celebrates successful event Digital watermarks for complete peace of mind SAAFoST 2021 firmly on track Africa Automation Fair postponed

9

WEBINAR

GT’s Masterclass for formulating A vegan products

00

COMPANY FOCUS

Understanding spirit signatures

12

INDUSTRY TALK

Quality processes across the value chain

14

BAKERY

Why you need steel belt ovens

A digital transformation journey

18

FUNCTIONAL INGREDIENTS

What’s next for Vitamin D? Understanding food pigments Innovative ingredients for plant-based meat

22

WATER PROCESSING TECHNOLOGY

Enhanced aseptic production flexibility

24 Labelling Let your labels speak for you Tamper-proof labelling for Africa Labels are getting smarter

ADVERTISERS’ INDEX Bragan Chemicals.........................................................7.............www.braganchemicals.co.za Cereal & Malt.................................................................17...........www.cerealandmalt.com Clomark............................................................................IBC........www.clomark.com Endress & Hauser ........................................................13..........www.endress.com Heat & Control SA.........................................................OBC......www.heatandcontrol.com IPCO International .......................................................15..........www.ipco.com/bake Koel Colours...................................................................IFC.........www.koelcolours.com Mitas Corporation .......................................................27..........www.tracepack.co.za NSI Label.........................................................................24, 25....www.labelandpack.africa

Polyoak Packaging........................................................30..........www.polyoakpackaging.co.za Savannah Fine Chemicals..........................................19..........www.savannah.co.za Shanghai Dase-Sing Packaging Technology Co...29..........www.dasesing.com Siyakha Imperial Printing Co....................................28..........www.labelprint.co.za Symrise SA .....................................................................OFC.......www.symrise.com Syspro .............................................................................16..........www.za.syspro.com Vega Controls SA ..........................................................8............www.vega.com/vegabar

2021 Quarter 2 | 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 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

Processing and ingredient innovation that will scale up your NPD

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HE FOOD AND beverage industry had every hope that 2021 would bring more stability to the sector, but with COVID-19’s third wave currently underway there are still some challenges ahead. One major theme that hasn’t changed and will continue for the foreseeable future is health. Companies will continue to launch foodstuffs with immunity-boosting ingredients. Plantbased and alternative food space will also grow, but will take on new forms with new ingredients, such as algae and mushrooms.

In this edition of Food Manufacturing Africa, we unpack some of the latest ingredient and technology innovations that will assist you in formulating new products that tick the health and wellness box.

After the initial alcohol frenzy that underpinned the first lockdown, alcohol consumption dropped worldwide as the appeal of drinking at home, weight gain, and health concerns began to set in and consumers were again making

resolutions to do things like lose weight, drink less, and boost their immunity.

On page 10, Symrise takes us on a very informative journey on the future of beverage category experimentation and how it can impact your future NPD. Another great read is found on page 18 where we place the spotlight on one of the hottest nutrients right now, Vitamin D. Earthlight Whole Food Vitamin D is a clean label, plant-based ingredient that can help you create cutting-edge supplements and fortified food that responds favourably to the latest consumer trends in the market. Earthlight delivers concentrated Vitamin D with low use levels, which means it won’t affect the taste or texture of your formulations.

It is a well-known fact that the colour of a food or beverage product can impact how a consumer engages with it: we eat with our eyes first. Impactful colour plays a vital role during purchasing decisions by enhancing the sensory appeal and overall consumption experience.

More on page 20.

During the development stage, special attention needs to be given to labels and overall packaging presentation. It represents how your product or brand interacts with consumers (page 24). It is vital to remember that connecting with your consumer on a personal and emotional level achieves something money can’t buy – brand loyalty.

I hope you enjoy this edition, and please don’t hesitate to drop me a line at maryke.foulds@newmedia.co.za if you have any topics you would like us to investigate further.

Happy reading,

Sales Executive: Càndida Giambò-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

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Food Manufacturing Africa is published by New Media, a division of Media24 (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.

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Food Manufacturing Africa | 2021 Quarter 2

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15 – 30 Online International Food Expo Online www.intfoodexpo.com 23 – 25 Africa’s Big 7 Johannesburg, South Africa www.africabig7.com

2021 Quarter 2 | Food Manufacturing Africa

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NEWS

DEMAND FOR CBD SOARS DURING LOCKDOWN THE ASSOCIATION FOR the Cannabinoid Industry (ACI) and Centre for Medicinal Cannabis (CMC) has launched Green Shoots – Sowing the Seeds of the New UK Cannabis Industry report with a new assessment of the size of the UK consumer cannabidiol (CBD) market.

The sector is now estimated to generate £690m in annual sales for 2021. This figure surpasses predictions made in the seminal market-sizing study undertaken by the CMC in 2019 which estimated the market would be worth £526m in 2021.

The report concludes that the UK now has the most evolved regulatory framework in the world for CBD, and other consumer cannabis extracts, citing recent interventions by the Foods Standards Agency – to regulate products as dietary supplements, and to consider what are safe and tolerable levels of THC contained in products. However, the report calls for more government intervention and investment to ensure that the UK optimises what it describes as “Britain’s quiet cannabis revolution”.

The report claims that, due to domestic restrictions on hemp cultivation and processing in the UK, the bulk of the profits for this industry is going overseas. This is because UK farmers must destroy the parts of the hemp crop which lucrative CBD is extracted from.

The report argues that the market represents a key growth sector for the UK and it is time for the government to adopt a proactive strategy to seize opportunities in the cannabinoids sector.

The report makes 20 recommendations drawing on a submission recently made to a new governmental taskforce on innovation, growth and regulatory reform, established by British Prime Minister Boris Johnson in February, to stimulate post-COVID economic growth. •

ANUFOOD CHINA 2021 CELEBRATES A SUCCESSFUL EVENT SOUTH CHINA’S F&B industry is celebrating a much-needed boost with the successful conclusion of ANUFOOD China, which was held between 21 and 23 April 2021 in Shenzhen.

ANUFOOD China 2021 spanned more than 20 000m 2, featuring a host of products under its roof including sweets and snack foods, staple foods and condiments, beverages, meat, organic food, dairy products, seafood and aquatic products, fruits and vegetables, and F&B services. With 460 exhibitors hailing from 34 countries and regions, the stands featured over 2 000 brands with 19 773 trade visitors during the three-day period.

The inaugural edition saw heartening industry support in the form of country pavilions from Germany, Ireland, Poland, Greece, South Korea, the United Kingdom, Czech Republic, Uruguay, Tajikistan and Indonesia.

In addition, to serve international exhibitors who were unable to physically attend the exhibition, the Virtual Plus business platform on-site was equipped with professional bilingual staff that could facilitate communication with buyers online, and in real time.

Exhibitors from Poland, the US, Lithuania, Portugal, Belgium, Argentina, Russia, Brazil, Ukraine, Turkey, Cyprus, South Korea, Japan, Singapore, Pakistan, Vietnam, Sri Lanka, Tajikistan, Hong Kong and Macao

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(Macau) made full use of this service to live stream their product offerings.

Visitors enjoyed as many as 30 conference sessions, cooking competitions, customised F&B tasting experiences, covering hot topics of the entire industry, and providing a more diversified showcase and interactive experience.

As a supporting value-added service tailored to exhibitors’ and buyers’ needs, the on-site business matchmaking programme was made up of an exhibitor-led segment based on product categories, and an invited buyer-driven segment by market channels. More than 1 100 meetings were held during two days in the matchmaking area, playing its hand as a catalyst for the region’s economy. •

Food Manufacturing Africa | 2021 Quarter 2

SAB LISTS B-BBEE SCHEME WHICH WILL OWN R5.4 BILLION WORTH OF AB INBEV SHARES THE SOUTH AFRICAN Breweries (SAB) has announced that its latest B-BBEE scheme, SAB Zenzele Kabili to list in May 2021.

At a special virtual special general meeting held for members of its current B-BBEE scheme, SAB Zenzele, a quorum was secured with 8 339 shareholders casting their votes and 95% of the shareholders who voted, voted in favour of the new scheme, satisfying the requirement for listing.

The SAB Zenzele Kabili scheme, which replaces SAB Zenzele, will own R5.4 billion worth of AB InBev Shares, the world’s largest beer maker.

SAB Zenzele Kabili will be listed on the B-BBEE Segment of the Johannesburg Stock Exchange (JSE) to facilitate liquidity and broaden ownership to other B-BBEE investors, including qualifying SAB employees through a new employee stock ownership plan. The qualifying public will be able to trade from the listing post on the 28 May 2021, through a JSE broker or existing trading platform.

The listing price is set at R 40 per share.

SAB Zenzele shareholders have been given the option to reinvest a minimum of 63.5% or all of their remaining proceeds into the new scheme.

Those who do so will henceforth become global shareholders, receiving 25% in dividends annually, without having to wait ten years before being able to sell shares or get paid out. Additionally, SAB Zenzele Kabili shareholders will be able to trade immediately after listing. SAB employees will need to wait five years before being able to trade.

SAB Zenzele which will reach maturity in May 2021, is the largest B-BBEE scheme in the history of South Africa in the fast-moving consumer goods sector, having reached a total maturation value of R9.7 billion. Launched in 2010, the landmark SAB Zenzele transaction endeavoured to give our retailer partners – taverners, bottle store owners, retailer customers and our employees, the life blood of SAB’s business, an opportunity at real ownership in a company that has brought South Africans together for over 125 years. Retailer shareholders who invested R100 in 2010 will have received a total pre-tax pay- out of R77 518 when the transaction fully unwinds later this month. SAB Zenzele Kabili was envisioned to launch in April 2020. However, COVID-19 driven restrictions prevented the necessary shareholder AGM from taking place, and as such, the plans were postponed. While SAB Zenzele was a fixed term scheme, SAB Zenzele Kabili is perpetual and will remain listed indefinitely.

Company secretary Duncan Pask comments, “We are thrilled that the SAB Zenzele shareholders voted in favour of the new B-BBEE scheme. SAB Zenzele Kabili is set to deliver even more value over time, and we look forward to continuing to generate wealth for all of our retailer partners, employees and qualifying members of the public who invest in the scheme.” •

NEWS

BASF JOINS DIGITAL WATERMARK INITIATIVE FOR SMART PACKAGING RECYCLING HOLYGRAIL 2.0 – DIGITAL WATERMARKS for Accurate Sorting and High-Quality Recycling has gained BASF as a member. The initiative aims to increase plastic recycling rates by adding imperceptible digital watermarks to product packaging.

Under the auspices of AIM, the European Brands Association, BASF and 120 companies and organisations from the packaging value chain joined forces in the initiative to prove the viability of digital watermarking technologies for accurate sorting and the business case at large scale.

“Plastics used for packaging are extremely valuable materials that protect goods and reduce food waste. When plastics are sorted properly, we can offer a suitable additive package to return them to highperformance applications. We are excited to support HolyGrail 2.0 in its search for optimised and circular plastic packaging,” notes Dr Achim Sties, senior vice president, performance chemicals Europe, BASF. Ineffective sorting is one of the fundamental barriers to wider recycling of lightweight packaging

waste and in achieving a circular economy for packaging. The better the sorting and identification of packaging, the more efficient the mechanical recycling process and the better the quality of recyclates. The discovery of digital watermarking was made under the New Plastics Economy programme of the Ellen MacArthur Foundation, which investigated

different innovations to improve post-consumer recycling. Digital watermarks were found to be the most promising technology. The HolyGrail 2.0 initiative will include the launch of an industrial pilot to prove the viability of digital watermark technologies for more accurate sorting of packaging and higher-quality recycling. •

SAAFOST’S 2021 ORGANISATION IN FULL SWING THE CONGRESS WILL be presented from 20 to 22 September as a virtual event. “The virtual platform was agreed upon, paid for and debuted on 22 April with a webinar featuring John Cahalane, president & CEO for Kerry APMEA (Asia-Pacific, Middle East and Africa),” says LOC member James McLean. “All of this is very exciting, new and innovative, and we’re confident you’ll enjoy this congress tremendously.” The organisers have shared the main features during the event, which should assist you in navigating this successfully.

“The main highlight of the event is an unparalleled scientific programme being finalised, currently with 20 international speakers confirmed – three South Africans resident in

overseas institutions amongst them, together with the cream of local and African food scientists.

You would need to attend between seven and eight conferences to hear all these speakers under normal conditions, so it is a remarkable achievement and opportunity for all attendees from which to benefit. “Another highlight is the exhibition hall, where you will be able to browse the exhibitions, interact with the exhibitors by live chat or scheduled appointment, download brochures, business cards, product and equipment videos into your briefcase for later review, taste sample products sent to you by exhibitors whilst learning about the product offerings – all very interactive.

Johannesburg Head Office Seven Warehouse Complex 3 Bernie Street, Unit 3, Kya Sands Tel. No.: +27 (0) 11 708-0007

Durban Office Tel. No.: +27 (0) 31 942 9624

www.braganchemicals.co.za

Port Elizabeth Office 67 213 421 9288 5187 Tel. No.: +27 (0) 71

“The networking abilities are fabulous – formal or informal meetings can be requested on the platform and can be held in meeting rooms or lounges. All the delegates/exhibitors are shown, with an indication whether live or not, so contact is easy – just a click on their profile, and you can send an email, have a live chat, schedule a discussion, swop details or just say “hi”! When you need a break, you can have a gathering with your friends and colleagues by live invite and just chill as though you’re together – even if kilometres apart,” McLean concludes. For more info, go to www.saafost.org.za. On the home page, click on SAAFoST virtual congress 2021, under items of interest, to browse or register. •

Cape Town Office Tel. No.: +27 (0) 21 000 3121

WE DO WHAT IT TAKES 2021 Quarter 2 | Food Manufacturing Africa

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NEWS

AFRICA AUTOMATION TECHNOLOGY FAIR POSTPONED TO 2023 FOLLOWING FEEDBACK GATHERED from in-depth exhibitor and visitor surveys and close collaboration with industry stakeholders, the Africa Automation Technology Fair (AATF) has made the decision to postpone the September 2021 in-person event and reschedule it for 9 to 11 May 2023.

To fill the gap left by this, Reed Exhibitions Africa created Virtual Connect!, which will take place in September 2021 and again in 2022.

Virtual Connect! will allow African and international industry decision makers and exhibitors to have dedicated and focused meetings, while gaining insights through critical industry content throughout the threeday event.

“Transparency with industry stakeholders is extremely important to us. As a result of our

ongoing discussions with these stakeholders, we have collectively decided to postpone the AATF live event until May 2023. We are, however, very proud to be able to launch Virtual Connect! as key opportunities for the industry at large to come together, virtually,” explains Carol Weaving, MD of Reed Exhibitions Africa.

Johan Maartens, CEO of the SAIMC NPC (Society for Automation Instrumentation Mechatronics and Control) notes, “The decision to postpone is absolutely the right one as COVID

is still very much a reality in South Africa. The SAIMC is very enthusiastic about showcasing our ever-growing and evolving industry at the live event in 2023, and looking forward to engaging with the industry virtually through content, podcasts and great virtual showcases in September.”

For more information about the Africa Automation Technology Fair, please visit the event website: www.africaautomationtechnologyfair.com •

HIGHLY PATHOGENIC AVIAN INFLUENZA UPDATE: NO NEW OUTBREAKS ALTHOUGH NO NEW outbreaks of avian influenza have been reported since the previously confirmed cases, South Africa’s poultry and ostrich industries remain under national high alert with strict biosecurity measures in place.

An appeal is also made to hobbyist keepers of any birds, including poultry, to remain vigilant and report any signs of illness in their birds to their veterinarian. Avian flu is also an airborne virus and is not restricted to infection only by contact.

Trade restrictions imposed by South Africa’s neighbours have relaxed somewhat or remained the same, with Botswana reducing its national ban to the affected farms only, Namibia restricting imports from the one affected compartment on the

East Rand, and Lesotho restricting imports from Gauteng. Swaziland has restricted the affected compartment, and Mozambique has no official restrictions in place.

SAPA is grateful that, whilst the financial impact on the farms affected is significant and has had a severe negative effect on the farmers, avian influenza incidents have not increased these past few weeks. The support of DALRRD and all veterinary staff involved have been invaluable.

Supplies of both poultry meat and eggs remain fully stocked, with less than 1% of the bird stocks producing poultry meat and eggs affected by avian influenza to date.

Consumers are advised that poultry meat and eggs remain safe to eat, and should be

256 colours Individually selectable: Measurement in progress Sensor switching Process malfunction

cooked properly according to acceptable cooking protocols, achieving temperatures above 60°C. No products from the infected farms were placed in the market. •

We bring colour into view!

Compact pressure sensors and switches with 360° custom-colour status display

www.vega.com/vegabar

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AD-VEGABAR-Clamp_177x65+5_EN-ZA_ohne-Preis.indd 1

Food Manufacturing Africa | 2021 Quarter 2

03.02.2020 11:50:36

WEBINAR

AGT’S MASTERCLASS MAKES

formulating with vegan ingredients a cinch

With plant-based ingredients and products on everyone’s lips, AGT’s webinar scheduled on the 24th of June will offer a first-hand look behind the scenes with a celebrated chef who will demonstrate new recipe options, new product formulations and product applications.

T

he aim of the webinar is to introduce and create awareness of the plant-based product range and to demonstrate the application of the products and is aimed at new product developers, food manufacturers, the spice industry, ready to eat meals and those involved in all things vegan.

Topics under discussion include AGT’s new texturised pulse protein.

This is a 100% plant-based solution for meat replacement and extension applications, snacks foods and other unique products for mainstream and alternative markets.

The webinar will also discuss the uses of AGT’s two new innovative additions to their plant-based range.

Veggipasta is a single ingredient formulation 100% yellow pea flour, which is gluten free, non-GMO and features a neutral taste. Additional benefits include that the product is shelf stable and superior in frozen meal and soup applications.

Veggicrumb is the breadcrumb replacement made from only one ingredient, namely peas. The product’s value proposition includes that it is a single - ingredient formulations with 100% peas, non GMO and gluten-free, with a kid-friendly taste and texture.

It also features excellent water absorption and is ideally for use as a binder in ground meat applications, such as burgers and sausages.

The event will conclude with a live Q&A session, hosted by Donovan Will - from PROVEG, and a panel of experts, including Gabrielle Jackson who is an expert in her field regarding regulatory and nutrition knowledge and Dr Tulbek, director at AGT Foods Research and Development Centre.

The day concludes with a live draw for two stunning Woolworths vouchers.

ABOUT THE SPEAKERS: Dr Mehmet C. Tulbek, director - Research & Development at AGT Foods & Ingredients Inc. (AGT) Saskatchewan, Canada Mehmet is currently leading research, development, technical services and regulatory affairs functions of the AGT Foods Ingredient Division. He concluded his B. Sc. in Agricultural Engineering with the emphasis of Food Science and Technology at Ankara University, his M. Sc. in Food Engineering at Istanbul Technical University in Turkey and his Ph. D. in Cereal Science at North Dakota State University, Fargo, ND. Scan the QR code to register for the webinar

Donovan Will, director ProVeg South Africa, the South African chapter of ProVeg International.

Before moving to ProVeg to found their South African chapter, he was the brand manager at The Fry Family Food Co. (Fry’s), South Africa’s leading manufacturer of plant-based meat replacements, with distribution to over 30 countries. Donovan is a passionate advocate for a more conscious lifestyle, and believes in highlighting the health, environmental, economic and ethical benefits of eating a more plant - based diet and moving towards following a vegan lifestyle.

Gabrielle Jackson, dietitian - Head of the FACTS regulatory and nutrition division.

Gabrielle is a registered dietitian.

She heads up the regulatory and nutrition division at FACTS, where she consults on nutrition, health, food regulations and labelling projects, in addition, she consults in a private practice in Johannesburg.

011 762 5261

sales.za@agtfoods.com www.agtfoods.co.za

COMPANY FOCUS

Spirit Signatures: the Taste of Fine Spirits

While it’s true that the brown spirits category continues to grow, it’s also true that millennial and Gen Z consumers are seeking reduced alcohol or even alcohol-free alternatives.

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ITH THE LAUNCH of Spirit Signatures, a portfolio of taste solutions for beverages, Symrise has discovered the taste mystery behind brown spirits like scotch, bourbon, whiskey, brandy, and dark rum. Spirit Signatures represent Symrise’s flavour, applications and technology expertise put to life to design, decode, and deliver the essence of premium spirit brands without the alcohol.

In order to create these exceptional flavours, the Symrise beverage team took a deep dive into deciphering each step in spirits production. They then decoded these steps to understand more about the molecular levels and chemical compositions that result from each process.

Using scotch whiskey distillation as an example, there are a total of ten individual processes involved in production: malting, kilting, peating, mashing, fermentation, distillation, maturation, filtration, blending, and bottling.

Every one of these ten steps have an effect on flavour formation. The Symrise team – including flavourists and certified Master Distillers – applied their expertise to the analysis of the flavour characteristics that each step imparted to the whiskey. This knowledge, coupled with Symrise’s proprietary technologies including SymOak advanced maturation and SymBouquet spirits taste modulation, led to the creation of a Symrise flavour top note plus botanical extract that can now mimic premium scotch whiskey in an alcohol-free form.

Many factors come into play in formulation of whiskey, brandy, and rum. Since they are typically aged in oak barrels, maturation in these wood barrels forms the distinct taste sensations of spirits. The composition of oak is quite complex and imparts

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“The Spirit Signatures toolbox was created using various Symrise taste solutions, including our Code of Nature Botanical Essentials” different taste characteristics depending on the type of oak used in the aging process.

Ahmed Nour, category director beverages, Symrise Flavor Division North America, further explains, “The

Spirit Signatures toolbox was created using various Symrise taste solutions, including our Code of Nature Botanical Essentials. By using this specialised extraction capability, we can create botanical extracts that are unique compared to other extracts currently available in the market.

Food Manufacturing Africa | 2021 Quarter 2

“Through our patented gentle processing technique, we capture many of the volatiles and complex notes from the botanical and add them to the finished beverage to deliver proper mouthfeel, along with a unique taste experience. The Symrise team created different oak extracts that will help to complete and distinguish the taste profiles of classic brown spirits, premium whiskey, brandy, and rum.”

The Spirit Signature portfolio of flavours are best applied to low alcohol/no alcohol products. They are also an ideal fit for CBD/THC drinks that can offer consumers the experience of a cocktail, but which legally cannot contain any alcohol.

CBD and THC infused beverages represent huge potential; a recent report from Grand View Research indicated that the global cannabis beverages market size is expected to reach $2.8bn by 2025 at a CAGR of 17.8%. The report looked at alcoholic and non-alcoholic beverages using either TCH or CBD. It said, “The demand of THC infused cannabis beverages is majorly driven by rising product demand from adult consumers for recreational purposes. Rising demand for the therapeutic effects of the component along with the euphoria it provides is expected to bode well for the growth of the segment in the forthcoming years. Lack of psychoactive effect in the CBD drinks is widening its scope and many consumers are considering CBD drinks as wellness and antiinflammatory products.”

The Spirit Signatures toolbox currently includes Kentucky Whiskey, Tennessee Whiskey, Scotch Whiskey, Brandy and Rum flavours. These elements recreate top notes that mimic all the spirit processing steps involved in the formation of a premium alcoholic product, including the barrelaging component. •

COMPANY FOCUS

RISING INTEREST IN REDUCED ALCOHOL BEVERAGES

A

T THE START of the COVID-19 lockdown, alcohol sales went through the roof as people stocked up and got ready for lots of time at home away from their favourite bars. As the months went on, however, alcohol consumption dropped worldwide as the appeal of drinking at home, weight gain, and health concerns began to set in for many people.

As the start of 2021, consumers were again making resolutions to do things like lose weight, drink less, and boost their immunity while also trying to piece together a “new normal” that for many, no longer includes consuming as much, if any, alcohol. The trend of non-alcoholic bar drinks being included on menus and in stores was increasing before COVID, and now it is back on track to become a major market as we head towards a post-pandemic world of beverage category experimentation.

ALCOHOL-FREE SPIRITS While modern mocktails are steps ahead of the Shirley Temples of the past, they often are still missing what makes a mocktail feel like a cocktail the most, and that’s, obviously, alcohol.

The same argument has been made with vegetarian/vegan foods trying to capture the same dish sans meat and going from black bean veggie “burgers” to a whole revolution in meat alternatives that give the taste, feel, and smell of meat in a plant-based way.

In response to wanting a more authentic experience, more convincing non-alcohol versions of just about any hard liquor are being sold that boil down the essence of drinking alcohol without the booze.

For gin, the flavours lean heavily into juniper and spiced flavours to give it that sharp, piney taste and smell, while whiskey alternatives has notes of oak and caramel and rum tastes woody and very molasses-forward. It’s more about mimicking the experience than the taste, and they achieve this with spices and extracts that recreate the familiar burn of an alcoholic drink.

STOCKING THE BAR WITHOUT ALCOHOL Not everyone is interested in being an at-home bartender, however. While COVID has put a wrench into a growing trend of mocktails appearing more prominently on restaurants, most prevalently in fine dining and upscale restaurants, many quick-service and casual dining restaurants offering takeout do continue to list and expand their mocktail menus, often offering the same or elaborate house cocktails in both alcoholic and alcohol-free alternatives.

There is also the growing demand to find non-alcoholic beer, wine, and spirits on shelves, leading to developments in more sophisticated flavours and styles with more thought put into them than the flat bottled lagers with alcohol removed of the past.

Now, hard liquor, non-alcohol versions of IPAs, stouts, ales, and more can be found from reputable brewers filling a need in a satisfying and delicious way.

Because of the 0% rating, general stores are able to stock up and coffee shops, like Getaway in Brooklyn, NY, can pour a glass of alcohol-free wine alongside a latte, essentially creating a new genre of alcohol-free bars but with the same social atmosphere as going out for a pint.

SYMRISE – www.symrise.com

2021 Quarter 2 | Food Manufacturing Africa

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INDUSTRY TALK

A reliable partner for every step Safety, quality and efficiency play essential roles in the food & beverage industry. Endress+Hauser helps this industry meet constantly growing requirements across the entire value chain. Milk production illustrates one example of this.

F R

OR COWS TO produce enough milk, they need the right type of nourishment.

Good soil and the optimal application of fertiliser ensures are fed ED HAS LONG that beenthe ananimals iconic shade high-quality, contamination-free feed crops. in the world of cosmetics, beauty, Soil analyses theand foundation of we farmers’ fashion,are film design. As activities.

They show if the soil is healthy and approach 2021, red is now ready to invigorate what type of minerals and trace elements the world of food and drink. theThe crops need.

This is where Analytik Jena’s global pandemic has taken consumers instruments elemental analysis come outside theirfor comfort zones, leading them into play.free Inductively plasma mass to break from oldcoupled habits and search spectrometry (ICP-MS) for example can for something new. GNT believes red can measurewith a wide range of elements in a and short connect this desire for discovery period of time, minuscule help signal the detecting start of a even new era. traces of metal.

Associated with sporting dominance, red After milking, the raw milk is filtered and It is a shade that signifies power and energy. kept in chilled storage tanks. dairy is globally recognised as the The colour of will love, test it’sstrong released, the too, the withmilk the received. ability to Once fire up feelings milk is processed in a completely hygienic of passion and desire. environment. & beverage GNT is also Food highlighting red’smanufacturers ability to are obliged to eliminate any health risks to consumers. Therefore, the design, materials, surfaces, and welding seams of measurement devices are subject to stringent hygienic requirements. No other manufacturer offers such a wide selection of instrumentation with hygienic design as Endress+Hauser. As many as 37 EHEDG-certified flow, pressure, level, temperature and liquid analysis devices are currently available.

The raw milk is transported from the dairy’s storage tanks to various systems and either turned into powder, skimmed to separate the cream (both products are used separately) or processed directly into drinking milk. The typical pasteurisation process – heat-treating the milk – destroys any microorganisms and extends the shelf life of the product.

Temperature, level, pressure and flow must

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be monitored, regardless of how the milk is processed. Endress+Hauser boasts a wide range of level measurement devices that allow users to select the measuring principle add a sense of excitement and exploration that best suits the process conditions and to food and drink, with its appeal among the requirements. For pressure measurement, Instagram generation providing another key Endress+Hauser developed the Contite reason for the shade’s growing popularity. cell, a hermetically sealed measuring cell Maartje Hendrickx, GNT’s market that prevents condensed humidity – which development manager says, “Red was the frequently occurs in food & beverage industry natural choice for our new Love Color with processes – from penetrating the instrument.

Exberry campaign. It epitomises human Temperature is a critical measurement vitality, creating energy, passion and positive during pasteurisation. action, and brings real excitement to food Endress+Hauser’s iTherm QuickSens and drink products. Red is well known for its supplies the correct value three times ability to command instant attention and it’s faster than comparable sensors to ensure a colour you won’t be able to ignore in 2021.” energy efficiency and to keep the milk With consumers demanding clean and from unnecessary thermal impact. The simple ingredients in their food and drink, flow measurement helps to control flow GNT offers a range of red colouring foods velocity and heat holding times during the made from raw materials such as radish, pasteurisation process. Apart from flow, electromagnetic devices from Endress+Hauser also monitor the temperature and conductivity parameters. On top of that, the instruments can carry out permanent selfmonitoring thanks to Heartbeat Technology.

The milk is fermented in large tanks and processed into cheese using lactic acid bacteria or rennet.

Through pH measurements in the cultivation and fermentation tanks, dairy producers acquire information about the quality of the product and how the process is running. Non-glass pH sensors and digital Memosens technology from Endress+Hauser make it possible to carry out inline measurements. Memosens sensors can be precalibrated in the laboratory and exchanged while the process is running.

Filling and bottling systems are at the heart of dairy production, where bottles, cups or bags are rapidly filled with milk or dairy beverages. As a complete offering

Food Manufacturing Africa | 2021 Quarter 2

in instrumentation and in-depth industry expertise, Endress+Hauser not only provides direct support to dairy producers, but also serves as a strong partner for plant carrot, sweet potato, hibiscus and berries builders, OEMs and engineering companies. including elderberry and chokeberry.

Endress+Hauser flowmeters also form the GNT’s red shades are made from fruit, basis for automation solutions: preconfigured vegetables and edible plants using physical systems for filling applications. manufacturing processes and no chemical Milk powder – a common base ingredient solvents. As a result, they can provide for baby formula – is produced by extracting the perfect clean-label replacement for the water from the milk through an colorants such as the azo dye Allura Red AC evaporation process, determining milk and carmine. powder quality, plus the mineral and nutrient GNT also controls the entire supply content, can be accomplished with the chain, enabling the company to guarantee high-resolution continuum source atomic all products meet its rigorous quality and absorption spectrometers from Analytik sustainability standards as well as ensuring Jena. These instruments use a single light year-round availability. • source with a continuous spectrum and high-resolution optics to quickly analyse all elements within a sample and detect even the tiniest traces.

If the label says, “milk from cows,” that’s what the product must contain. To meet mandatory declaration and health guidelines, food & beverage processors examine the origins of animal-based ingredients.

A lot of effort goes into producing glass of milk, while at the same time making it available to consumers at low prices in the stores. Like all food & beverage companies, dairy producers have the same goals: consistent quality, fewer resources and lower production costs. •

ENDRESS + HAUSER - www.endress.com

We understand how you strive for constant product quality and optimized costs.

CONSISTENT + CONFIDENT You are poised to meet your safety and quality requirements while optimizing resources and securing process repeatability.

Improve your processes with our comprehensive portfolio of measuring instruments:

Promag H 100: The flow measurement specialist with an ultra-compact transmitter is designed for hygienic applications.

Contact us Email: info.za.sc@endress.com Tel: +27 11 262 8000 www.endress.com

Liquiphant FTL33: The compact point level switch saves your resources with a reliable overfill protection.

Smartec and Indumax CLS54D: The toroidal conductivity systems optimize cleaning and reduce product loss.

BAKERY

Steel bake oven belt technology backed up by service support IPCO is a prominent manufacturer of solid and perforated carbon steel bake oven belts, supplying OEMs and end users across Africa’s bakery industry.

Dairy substitutes are dominating the global market for animal product alternatives.

T

HE KEY QUALITIES of a steel belt include outstanding thermal properties for efficient baking; the inherent ease of cleaning of a belt compared with mesh; and exceptional levels of durability that deliver an attractive return on investment. Steel belts are also extremely versatile, being suitable for products as diverse as bread, biscuits, brownies, crackers, pastries, sponges, allbutter cookies and pizza bases.

As a conveying medium that’s completely flat and smooth, there are no gaps, recesses or crevices in which carbon deposits could collect. This means that steel belts are inherently quicker and easier to clean than mesh belts and also results in less water consumption, reduced use of chemicals/ detergents, and easier changeover from one product to another.

In terms of maintenance, qualities such as good tension and tracking characteristics and resistance to stretching combine to result in significantly less downtime than other belt materials.

Ensuring this level of reliability means that every IPCO belt has to be engineered

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to specific tolerances, as global product manager Marko Leber explains.

“The baking process requires not only specific thermal properties but also mechanical ones: the belt needs to provide stable working conditions when tensioned and to transfer the heat from the heating media to the product in an even way. The necessary mechanical properties are created during the production process, engineering long lasting flatness and straightness into the belt.

“A consistent belt colour is important too. Dark areas absorb heat and light areas reflect heat, so uneven belt colour can result in an uneven bake. This quality has to be engineered into the belt.”

The company can produce belts in widths from 800mm to 3 500mm. This makes it possible to achieve significant improvements in productivity without having to invest in factory extensions or new facilities. An oven with a 1 500mm wide belt offers almost twice the productivity of one with an 800mm belt without any increase in the line length.

In addition to a long working life and low maintenance requirements, the relative lightness of a steel belt can result in lower operating costs.

Solid steel belts are lighter than wire mesh – perforated steel belts lighter still – so cost up to 30% less to heat. Each time the belt exits the baking chamber, it begins to cool and has to be heated up again, so the savings are continuous. As much of 25% of an oven’s energy consumption is needed to heat the belt, so these savings can be considerable.

OVEN UPGRADES TO SOLID STEEL BELTS While most of IPCO’s work with the bakery industry is focused on the manufacture and supply of steel belts, the company can also support OEMs in system design and supply a full range of conveyor equipment from sheaves and shafts to bearings and breakpoints.

Other ancillary equipment available includes active and passive belt alignment

Food Manufacturing Africa | 2021 Quarter 2

“… steel belts are inherently quicker and easier to clean than mesh belts and also results in less water consumption, reduced use of chemicals/ detergents, and easier changeover from one product to another”

solutions such as belt edge detectors, guide rollers and compact/automatic tracking devices.

As a result of this close cooperation between IPCO and OEMs, it is often possible for manufacturers to gain the extra production flexibility delivered by upgrading the conveyor system from mesh to solid or perforated steel, without having to replace their existing oven.

Service and maintenance support This level of expertise means that IPCO’s engineers are able to offer maintenance support that looks beyond the belt.

“The belt acts as a window into the performance of the entire oven,” says Marko Leber. “We understand how a belt interacts with the many other components that make up the system as a whole. An inspection by our service team goes beyond the belt – we look at the whole line to understand how the entire system is performing.”

“We offer comprehensive Preventative Maintenance Agreements (PMAs), designed to identify and rectify potential risks of failure before they have chance to disrupt production.”

IPCO has fully trained and equipped service teams on the ground in all key markets, including Africa. As well as enabling a quick response to any service or repair needs, this also means that work is carried out by qualified people with a real understanding of customers’ needs and values. •

IPCO – www.ipco.com/bake

Bake more, bake better with IPCO steel belt technology Our solid and perforated steel belts have helped bakeries produce premium quality products for almost 100 years. Flat, straight, durable and easy to clean, they provide a baking surface that’s ideal for everything from rich, chewy all butter cookies to traditional biscuits and crackers.

The other reason for choosing IPCO is our global service capability, providing the reassurance of premium productivity too.

• • • • •

ipco.com/bake

High productivity wide belts up to 3500 mm.

Maximum versatility – bake more on an IPCO steel belt.

Energy efficient – lighter belt means lower carbon footprint.

Belt only or full range of conveyor components.

Installations, upgrades (mesh replacement), repair, maintenance and spare parts.

BAKERY

Supporting Umfolozi Sugar Mill’s digital transformation journey

Based in South Africa’s northern KwaZulu-Natal region, Umfolozi Sugar Mill (USM) was established in 1916 and is a leading producer of very high polarity brown sugar.

I

N 2019, THE mill upgraded from Syspro 6.1 to Syspro 8 - using all its distribution and finance modules, from purchase requisitions to procurement, purchase orders, sales orders and dispatch. This has enabled USM to reduce its month-end processing times from 2.5 hours to 30 minutes. “We are a 24-hour production plant, so any unavailability of the system means our trucks have to wait before leaving on deliveries. In addition to making us more productive and enhancing our operational efficiency, this has enabled us to provide better service and turnaround times to our customers,” Bongani Xaba, management accountant of USM and a board member of SYSPRO’s SUGA User Group.

USM can now dispatch higher volumes and meet greater demand which wouldn’t have

been possible on Syspro 6.1. Searchability across the business, for example to identify a specific supplier, has also improved considerably.

Xaba highlights several benefits of using Syspro 8, from the increase in field lengths to predictive search, the ease of getting additional reports and faster processing speeds. The company also used the upgrade as an opportunity to explore more functionality and provide additional training to help users get up to speed, making the experience more beneficial, meaningful and easy.

“We learnt that with the right partners, the end result is successful,” he says. “This is largely due to the USM team, which is open to continuous improvement, and to the support

we receive from Syspro and iOCO, our valueadded reseller. We are able to address any issues that arose, find improvements and learn how to use Syspro more effectively in our environment.

“We make extensive use of the Syspro Learning Channel to continuously expand and enhance our knowledge of the system. It contains a wealth of knowledge and has been extremely useful,” Xaba concludes. •

Syspro – www.za.syspro.com

Discover how SYSPRO can turn three simple letters into a world of opportunity for your company. Email info@za.syspro.com or call +27 (0) 11 461 1000. Say Yes to Next.

Copyright © 2021 SYSPRO (Pty) Ltd. All rights reserved. All brand and product names are trademarks or registered trademarks of their respective holders.

723425 OSFF

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Food Manufacturing Africa | 2021 Quarter 2

2021 Quarter 2 | Food Manufacturing Africa

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FUNCTIONAL INGREDIENTS

What’s next for Vitamin D? As one of the hottest nutrients in the world right now, Vitamin D is finally getting the attention it deserves as consumers become more concerned about improving their immune health and response. The nutrient has an important role to play in overall health during the COVID-19 pandemic as people spend less time outdoors.

E

ARTHLIGHT WHOLE FOOD Vitamin D is a clean label, plant-based ingredient that can help you create cuttingedge supplements and fortified food that responds favourably to the latest consumer trends in the market. Earthlight delivers concentrated Vitamin D with low use levels, which means it won’t affect the taste or texture of your formulations.

UNIQUE OPPORTUNITIES IN FOOD FORTIFICATION Earthlight’s high concentration of Vitamin D will allow food, beverage and supplement producers to offer ‘Good’, ‘Excellent’ and ‘High Potency’ source label claims with only a few milligrams of the ingredient.

This low level of addition means that Earthlight will not affect the organoleptic properties of the products in which it is included and contributes to the costeffectiveness of this Vitamin D solution.

A minimally processed ingredient, Earthlight is considered a whole food form of nutrition – responding to consumer desire for cleaner labels on their food, beverages and supplements. This ingredient solution is being introduced to the market at a time when concern about adequate levels of Vitamin D is at an all-time high in the nutrition and medical communities – a concern that is gaining awareness among consumers as well.

According to Devin Stagg, COO for PLT Health Solutions, Earthlight Whole Food Vitamin D allows food, beverage and supplement producers to address a convergence of consumer wants. “First it

FAST FACT: • Non-GMO, whole food mushroom powder • Organic grade available • 1 000μg (40 000IU) of Vitamin D per gram – independently verified • Low use levels offer excellent economics • Won’t affect the taste or texture of formulations • Consumer-friendly, clean label ingredients

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was natural.

Then it was clean label, and often consumers want vegetarian or vegan added to their labels.

“Today’s answer to all of these consumer preferences is whole food nutrition. A recent IFIC survey showed that 60% of consumers strongly like the idea of getting their nutrition from food with naturally occurring health benefits. With Earthlight Whole Food Vitamin D, consumer products companies can offer their customers this important nutrient with a positive label experience in a nutrient dense formulation,” he points out.

Earthlight is manufactured by Oakshire Naturals, a division of Pennsylvania-based Oakshire Mushrooms – one of the largest growers of mushrooms in the US. Premium white button and Portobello mushrooms are exposed to light to naturally enhance Vitamin D content in a proprietary process.

Each gram of Earthlight contains 40 000 IU of Vitamin D, which means the FDA Daily Value (DV) of 800 IU (20 mcg) can be attained with just 20mg of the ingredient.

A ‘Good’ source claim requires 1mg, (10% DV) while an ‘Excellent’ or ‘High Potency’

Food Manufacturing Africa | 2021 Quarter 2

source claim can be achieved with just 2mg (20% DV). The ingredient is Kosher and Halal certified. It is considered GRAS since it is a food, and is non-GMO. Tests have shown a minimum two-year shelf life stability with a reproducible nutrient content.

According to Dr Jeremy Appleton, director, medical & scientific affairs at PLT Health Solutions, adequate Vitamin D intake is a topic of great interest in the nutrition and medical communities.

“For a nutrient we’ve heard about since we were children, the amount of research and interest in the health benefits of Vitamin D is quite high today. Data from the NHANES study, 2005 to 2008, indicate that 94% of US adults are not consuming adequate amounts of Vitamin D, causing it to be classified as a shortfall nutrient by the USDA. “To assist consumers in choosing food that will increase their vitamin D intake, the updated Nutrition Facts panel requires Vitamin D labelling with a higher DV,” he said. “Consumers are starting to pick up on the Vitamin D discussion - possibly as a result of being told about it by their doctors.”

FUNCTIONAL INGREDIENTS

HOW EARTHLIGHT IS MADE

1

Wholesome White Button & Portobello mushroom are harvested from farms in Pennsylvania, US

2

3

Mushroom are blended using an innovative process

Stagg elaborates further, “Consumers are really starting to become aware of the need for more Vitamin D. With consumers opting for cleaner labels and more natural, wholesome ingredients, companies are concerned about working with animal-based sources of Vitamin D or highly processed extracts that might not

5

4

Blended mushrooms are exposed to safe UV light like the sun. This increases Vitamin D uptake

be considered wholesome. With Earthlight, consumer products companies can continue – or start – to include this important nutrient in their formulations, while offering the most attractive label experience possible. We like to say that Earthlight is where the world is coming next for Vitamin D,” he concludes.

The product undergoes a final quality check, including Vitamin D concentration

The high Vitamin D product is dried and turned into a powder

Earthlight is supplied in South Africa and Africa by Savannah Fine Chemicals. • Additional information sourced from: nutritioninsight.com

Savannah Fine Chemicals – www.savannah.com

INGREDIENT INNOVATION THAT’S VALUE DRIVEN

BASIC FOOD INGREDIENTS FOR EVERYDAY SOLUTIONS

We supply food manufacturers with quality ingredients and a wide range of additives to help create the taste, texture, performance and appearance you need for your food nutritional products. We represent leading global manufacturers & our specialists can provide you with unrivalled sales support bringing the highest quality products to market: Bakery ingredients: flavour, texture and fortification - Beverage ingredients for innovation - Confectionary: healthier & tastier alternatives to enhance your brand - Culinary solutions for sauces, dressings and prepared meals that will innovate - Dairy & Desserts: texture & functionality - Flavour & fragrance creation - Health & Sports nutrition.

Johannesburg: +27 11 856 4500 Cape Town: +27 21 551 5353

Durban: +27 31 202 0794 Email: info@savannah.co.za

www.savannah.co.za

2021 Quarter 2 | Food Manufacturing Africa

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FUNCTIONAL INGREDIENTS

Don’t compromise on food quality when using food pigments

It is a well-known fact that the colour of a food or beverage product can impact how a consumer engages with it: we eat with our eyes first.

Impactful colour plays a vital role during purchasing decisions by enhancing the sensory appeal and overall consumption experience.

T

RADITIONALLY ORGANIC LAKE pigments or FD&C lake pigments, iron oxides, titanium dioxide, carbon black and metallic pigments are used in various capacities to achieve a vast range of colour intensity.

EVERY FOOD COLOUR HAS A PURPOSE The use of mineral (inorganic) pigments, organic (lake) pigments and synthetic dyes in food often varies as per the function of the colours. Adding natural and synthetic colours in non-alcoholic beverages such as soft drinks and fruit-based drinks makes the drink look appealing. Here, the colour can attract the consumer to buy and try a product.

For wine production, colours such as Allura Red are used. Lake pigments are added in some foods such as candies to give the consumer an experience where the colour can be left on the tongue.

A manufacturer looking to source an ideal colourant looks for quality and stability with a vibrant top colour, but there are certain challenges and new trends which focus on key selection criteria for product manufacturers.

• Sustainability & clean label requirements This trend is headlining and fast turning into the new manufacturing normal. Clean colour labelling

•

•

FAST FACT: “Major food pigment suppliers are countered with issues of batch-to-batch shade variation which can be due to non-maintenance of batch records.

Ideally a manufacturer should maintain the retain sample library of each sample and commercial batch they ship to the customers”

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satisfies consumers' desire for healthy food that is naturally prepared. It is a sustainable counter-trend to the almost limitless supply of industrially manufactured food. Globally, food and manufacturers face key challenges such as batch-to-batch shade variations, supply issues and delayed production lead times which could impact the final product.

Batch to batch shade variation Major food pigment suppliers are countered with issues of batch-tobatch shade variation which can be due to non-maintenance of batch records. Ideally a manufacturer should maintain the retain sample library of each sample and each commercial batch they ship to the customers. Should they require any future commercial orders or repeat orders, they can refer to the sample retain library and do the exact shade match as per the parameters and send the matched commercial batch accordingly.

Pigment quality issues The tinctorial value of the FD&C lakes is dependent on physical properties and pure dye content. In all applications, lakes must be thoroughly mixed into the medium that is to be coloured. If not, then it leads to bleeding. This may involve grinding or mixing on special roll mills. The wetting out of the colour particle and the dispersion in the medium vitally affects the final colour properties.

Food Manufacturing Africa | 2021 Quarter 2

• Delayed Lead times The issue of delayed lead times is addressed by Koel’s production team by manufacturing and sourcing 95% of the raw materials locally. The reverse integrated manufacturing process enables Koel Colours to not be dependent on any supplier. Since Koel Colours is the proven manufacturer, they have the ability to control the production process and provide short lead times.

• Retain shade during supplier transition A manufacturer looking to change the colour supplier, needs to ensure that the shade variation from the new supplier compared to the established standard shade should not happen. That is why the pigment manufacturer needs to have a specialised team who can custom develop the shades of the pigments as per the customers standards.

This team should be able to match the exact shade to the customer’s standard and reduces the headache of the customer completely and customise the percentage of the dye content as per requirement.

Koel’s proprietary manufacturing technology ensures bold and vibrant shades for diverse applications of colouring food and beverages. •

Koel Colours – www.koelcolours.com

FUNCTIONAL INGREDIENTS

Keep plant-based meat alternatives fresh with innovative products Global ingredient manufacturer provides label-friendly solutions to support growing consumer demand for this market segment in the EMEA region.

K

EMIN INDUSTRIES, A global ingredient manufacturer that strives to sustainably transform the quality of life every day for 80% of the world with its products and services, is helping food producers respond to consumer demand for ready-to-eat plant-based meat alternatives that can be refrigerated for longer. Kemin Food Technologies provides label-friendly solutions that maintain taste and texture.

Consumers and retailers are looking for natural solutions that offer clear and transparent labelling with recognisable ingredients they can trust. Retail sales of plant-based meat alternatives reflect this shift in a dynamic category, as consumers are bypassing frozen products in favour of refrigerated ones.

Euromonitor’s meat alternative market data illustrates this rapid growth, indicating the retail value of plant-based meat will grow 42% in Europe in the next three years, reaching a value of €2.3 billion.

“Many consumers want to reduce their meat intake while maintaining protein consumption, so they are substituting with plant-based meat alternatives that offer taste and texture similar to meat, but with nutritional benefits from plants. “As a result, flexitarianism – a diet that is centred on plant foods with the occasional inclusion of meat – is booming,” said Kelly De Vadder, marketing director, Kemin Food Technologies, EMEA. “While shoppers are looking for these ‘better-for-you’ products to promote health and wellbeing, they are also mindful of choosing products that are convenient and easy to prepare. As manufacturers move from frozen plant-based meat alternatives to refrigerated options, protecting product integrity is critical to ensuring taste and meatlike texture.”

Kemin offers a portfolio of label-friendly solutions to help brands control oxidation and microbial spoilage, maintaining the freshness, quality and safety of plant-based meat alternative products.

NaturFort, a blend of natural rosemary and green tea extracts, offers label-

friendly oxidation control, delaying flavour degradation to maintain texture, optimise the taste profile, retain colour for visual appeal and extend shelf life.

BactoCease NV, a trusted ingredient that offers clear and transparent labelling, protects meat alternatives from microbial spoilage while offering a balanced flavour profile. A buffered vinegar solution made with natural ingredients, BactoCease NV is manufactured with naturally sourced ingredients and contains 100% bio-based carbon.

“Refrigerated products that are exposed to light oxidation decrease in shelf life and quality much quicker. Fat systems are a key component of great-tasting plant-based meat alternatives, yet the oxidation of fat and oil components in these products is a common challenge for brands. Delivering the texture and flavour consumers desire can be very difficult if a product is not properly protected from oxidation,” De Vadder explained.

“Microbial spoilage can also be an issue, so preventing it, as well, is essential for delivering a safe product to the market.”

Kemin also offers in-house customer laboratory services (CLS) to help customerpartners get to market faster.

“The CLS team provides dedicated support throughout all phases of testing to understand the influences of all food ingredients on the stability of the final product,” said Anja Verbiest, CLS and quality assurance manager, Kemin Food Technologies– EMEA. “Whether formulating a new product or reformulating an existing one, our CLS team can reduce testing time and meet go-to-market goals.”

To find out more about the Kemin portfolio of shelf-life and food safety solutions for plant-based meat alternatives visit their website. •

Kemin – www.kemin.com

2021 Quarter 2 | Food Manufacturing Africa

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WATER PROCESSING TECHNOLOGY

Dry preform sterilisation enhances aseptic production flexibility Nongfu Spring’s latest additions to its beverage portfolio required a hyper-flexible and safe aseptic solution, able to process high- and low-acid, still and carbonated products in PET, while enabling impactful bottle designs.

W

ITH FOUR DECADES of supporting sensitive beverage producers worldwide, Sidel recently engineered and installed a complete aseptic packaging line, integrating the Versatile Aseptic Combi Predis. The line helped the leading Chinese beverage player launch a breakthrough in the domestic market: sparkling ready-to-drink (RTD) products, aseptically bottled in PET. Founded in 1996 in Hangzhou, Nongfu Spring is one of the key players in the soft drinks market in China, maintaining leadership in the packaged water market over the past eight years.

The company bottles not only high-quality natural drinking water, but also vegetable and fruit juices, functional beverages, teas and other high-quality soft drinks. Its portfolio includes plant protein yoghurt, premium water for elderly people and vitamin water. Its strong focus on innovation and premium brand positioning are contributing to the steady customer base increase, even within beverage categories.

The popularity of these RTD tea and coffee products reflects a large, overarching trend across Chinese consumers, as they continue to show a growing preference for better-for-you products that either exclude sugar or include functional ingredients.

DRIVEN SUPPLIERS ARE KEY FOR PREMIUM BEVERAGE PLAYERS Nongfu Spring offers high-end, unique product propositions from bottle design to drink quality and recipe formulation to Chinese consumers and aims to enrich the product portfolio on a yearly basis.

Sidel can thus fulfil Nongfu Spring’s mission as one of the strong partners that can combine forwardlooking technologies with professional support.

FLEXIBLE ASEPTIC BOTTLING THANKS TO DRY PREFORM STERILISATION TECHNOLOGY The beverage processor was already familiar with aseptic bottle decontamination technology in a standalone configuration. It also validated Sidel aseptic dry preform sterilisation solution in the past few years. This is efficiently supporting Nongfu Spring in the expansion of its portfolio, while ensuring reliability and product integrity. For further flexibility, the dry preform sterilisation technology solves the challenges presented by different bottle shapes, as the sterilisation takes place at the preform stage.

Additionally, Nongfu Spring decided to equip the Combi with Sidel’s patented active base mould system, the Base Over Stroke System (BOSS), in order

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“Nongfu Spring decided to equip the Combi with Sidel’s patented active base mould system, the Base Over Stroke System (BOSS), in order to differentiate some of its bottles and expand its marketing opportunities”

to differentiate some of its bottles and expand its marketing opportunities. In fact, the technology can be selected depending on the container’s shape. BOSS is a piston activated system in the blowing phase that strokes the base, thus raising and lowering it during the bottle-forming process, independently from the opening and closing of the two half-shells of the mould.

Nongfu Spring visited Sidel facilities in France and was impressed by the high-quality services and the long-standing expertise of the packaging team.

Food Manufacturing Africa | 2021 Quarter 2

They appreciated the support throughout project execution, starting from the validation of the new container shapes – with and without the BOSS base.

In addition, Sidel’s liquid packaging interaction scientists performed various flavour tests for the new drinks Nongfu Spring were evaluating, thus

WATER PROCESSING TECHNOLOGY

defining the carbonation level and the sugar residue in the bottle. Once the line was installed, food technologists handled the microbiological validation of both high- and low-acid products, which successfully achieved zero contaminated bottles in 30 000 units on the first attempt, as per the protocol specifications. To ensure this success, Sidel experts and project managers made sure to closely support Nongfu Spring’s operators.

“For Nongfu Spring, it was critical to operate a simple and safe solution, while being able to manage the sheer variety of products in the future,” adds Mark Li, technical sales manager sensitive products at Sidel. “The cost efficiency and sustainable benefits offered by our dry preform sterilisation technology were also key factors for them: using no water and very few chemicals, while pushing the boundaries of the lightweighting potential, represented a very valid argument with this leading company. Lastly, we were able to secure a very competitive lead time,” Li enthuses.

The new aseptic complete PET line at Nongfu Spring’s plant in Xin’anjiang (Eastern China) is running at 36 000 bottles per hour (bph). Aside from the Versatile Aseptic Combi Predis, it was also equipped with Capdis, the dry cap sterilisation technology from Sidel.

The line also includes Tetra Pak Processing Systems technologies, an easy-to-handle Sidel RollQUATTRO roll-fed labeller – for wrap-around labels – and Roll Adhesive labeller and a cooler with optimised water consumption.

The End-of-Line solution integrates a wraparound case packer and the modular PalKombi palletiser for medium to high speeds. Thanks to Sidel’s expertise in line design and engineering, deriving from its long-standing heritage in aseptic complete solutions for PET, the team at Sidel were also able to successfully and quickly cope with a very challenging line layout. It took merely three days to install the key pieces of equipment at Nongfu Spring’s plant.

PARTNERSHIP LEADS TO REPEAT ORDERS To quickly reach the committed line efficiency and maintain consistent volumes and quality of production, Sidel also ensured that two dedicated shifts of field engineers were working alongside Nongfu Spring’s personnel for 18 months.

Due to this fruitful cooperation, Nongfu Spring quickly decided to turn to Sidel again and invest in two additional Versatile Aseptic Combi Predis, installed in the company’s factories in Hubei and Zhejiang, respectively. Both equipped with BOSS and running even faster at up to 49 500 bph, those pieces of equipment have already been fully validated. Last autumn, Nongfu Spring acquired another Versatile Aseptic Combi Predis Combi from Sidel with speeds up to 54 000 bph. •

1,2,3 Dry form sterilisation systems offer cost-efficiency and sustainability benefits to beverage manufacturers

Sidel – www.sidel.com

2021 Quarter 2 | Food Manufacturing Africa

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LABELLING

Your packaging speaks to your customers before your product does Long after your merchandiser leaves, your packaging takes on its most important sales task - attracting the consumer to your product before any competitor.

Your product package is responsible for most of your off-the-shelf sales.

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URING THE PRODUCT development stage, special attention needs to be given to labels and overall packaging presentation. It represents how your product or brand interacts with consumers. More than this, it showcases the product’s heart and soul while communicating key promises and information to your consumers. Use of colours and high-resolution images, placement of information and your consumer’s first reaction to your product is key to attracting customers. Connecting with your consumer on a personal and emotional level achieves something money can’t buy – brand loyalty.

Product communication attributes are constantly evolving, creating challenges for brand owners to keep up with popular market trends. Factors such as industry regulation, product improvements, variety of flavours and package delivery can hinder go-to-market strategies making it harder to compete.

Digitally producing your packaging, although more expensive when costing per unit, offers significant benefits to your organisation: • Flexibility to offer more variants, flavours, and packaging sizes • Lower packaging stock commitment, saving costs by reducing waste • Lightning response to topical opportunities • Control of production deadlines • Live packaging response testing • Personalised connections that promote brand loyalty • Limited and premier edition opportunities PRINT FOR YOUR OWN USE IN-HOUSE OR OUTSOURCE? “Some prefer to leave it to the traditional packaging developers and that is OK. We know the digital options are daunting and “drop-off” salespeople are plenty,” NSI LABEL’s business development director Shawn Bezuidenhout says. Minimum order quantities and slow turnaround of new product orders will however remain a challenge.

Going digital should be as complicated as desktop document printing - design-to-print at the click of a button. The right supply partner that is focused on your success, rather than short-term gain, is more important than the physical hardware solution. It doesn’t matter how expensive your machine is or how many amazing features it has. If your supplier isn’t committed to your success for the long term, it may all be for nothing.

“Some have burned fingers by making the wrong choices.

Hopefully, those burned have learned a valuable lesson that did not include giving up.

“The Industry emphasis is shifting towards product packaging lifecycle and recyclability. There is a big move towards being more environmentally compassionate with regards to product packaging across all industries. Paper trumps traditionally hard to recycle films.

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Using bright colours and high-resolution images is a key factor in attracting customers

“Even clear labels are no longer beyond the reach of the small producer as label media manufacturers in the digital space are constantly developing and improving substrates in line with diverse user preferences, environmental concerns and industry influence,” Bezuidenhout concludes. •

NSI LABEL – www.labelandpack.africa

Interroll – www.interroll.co.za

2021 Quarter 2 | Food Manufacturing Africa

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LABELLING

Unpacking tamper-proof labelling in Africa Food fraud has been around for over 200 years, and the more connected we become through social media and web-based media platforms, the more incidents of food fraud come to light. It is a broad term that encompasses fraudulent and intentional substitution, dilution or addition to a product or raw material, or misrepresentation of the product or material for financial gain.

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FRICAN CONSUMERS APPRECIATE the technology and see tamperproof labelling as a necessity. Brand owners operating in Africa rely heavily on tamper-proof technology to ensure that the packaging contents are safeguarded against counterfeiting. Without compromising the brand identity, tamper-proof label technology must evolve to keep growing illicit trade at bay. Anti-counterfeit labelling solutions are designed to ensure an original look for products and provide package traceability, effectively countering sales fraud and illegal distribution.

It has become evident that brand owners are looking for labelling solutions beyond the norm. Standard off the shelf tamperproof solutions isn’t adequate to fight the

“Brand owners operating in Africa rely heavily on tamper-proof technology to ensure that the packaging contents are safeguarded against counterfeiting”

battle against highly developed tech-savvy criminals. With the use of specialised technology and materials and, in some cases cutting edge traceability software, it is now possible to counter a variety of illicit activities.

It is estimated that 10 of the most common foods consumed are faked to one degree. Whether it is the entire product that is faked, or parts of the product substituted

The Combi labelling system is a fully automatic industrial labelling system customised to the customer’s application need

2020/2021

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by fake components, the fake food phenomenon is growing fast.

BiDiLase is a complete solution that provides a unique passport to each package; it is the most innovative and disruptive laser coding solution for coding and marking in the world for its unrivalled speed of 1 000m/ min, perfect quality offering class A high definition and micro-precision, personalise your brand experience with unique QR codes for every one of your end consumers A breakdown of what constitutes food fraud

thanks to Integra Promo & Serialisation software and premium scan ability offers excellent readability through smartphoneoptimised dot size. Unique QR codes enable interaction throughout the complete value chain, enabling traceability from production to end customer and allowing customer engagement through promotions, nutritional information, games, etc.

An all-in-one labelling machine for jars, bottles and food containers, the Combi labelling system is a fully automatic industrial labelling system customised to BiDiLase is a complete solution that provides a unique passport to each package

the customer’s application need. With the Combi, it is possible to create more than one application: top, enveloping, front/back or sealed on elliptical, round, rectangular or quadrangular products such as tanks, bottles, food containers or tray, the Combi can be used in stand-alone (offline), or it can be integrated with existing production lines. •

Tracepack – www.tracepack.co.za

A Division of MITAS Corporation (Pty) Ltd

TAMPER-PROOF LABELLING IN AFRICA It is estimated that 10 of the most common foods consumed are faked to some degree.

Contact TracePack to find out about labelling solutions that are beyond the norm.

+27 10 020 7221

www.tracepack.co.za

2021 Quarter 2 | Food Manufacturing Africa

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LABELLING

Labels are getting smarter!

Transparency regarding food and beverage products has become an urgent issue, in part by COVID-19.

People are asking questions around healthy choices and food safety with a desire for more insights into the product journey from farm to table.

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HEREAS OTHERS WISH to make smarter purchasing decisions with regard to minimising their impact on the environment. “The higher consumer demand for information and education is driving the need for labels to not only deliver ingredient data, but also facts about sustainability and traceability from raw materials to end product,” explains Henk Jacobs, GM of Lebone Paarl Labels. “Even though labels may be a small part of the packaging, they also play a role in ensuring the safety of the food contents within and keeping the environmental footprint as low as possible.”

In South Africa, there are stringent safety regulations regarding the manufacturing and labelling of food to protect the consumer.

“One consideration in the production of food labels is the migration of substances from labels to packed food that might impact consumer health and safety,” says Jacobs.

“For the food and beverage industries, we

“One consideration in the production of food labels is the migration of substances from the labels to the packed foods that might effect consumer health and safety”

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offer the printing of pressure sensitive labels using low migration inks, which are designed to dramatically reduce migration of chemicals from the ink printed on the packaging to the product contained within.” He adds, “Lebone Paarl Labels is also Foundation Food Safety System Certification (FSSC) 22000 certified, confirming the food safety management system is compliant for food products.”

“We are seeing clients taking into account the environmental impact of their labels in the design and its production,” Jacobs highlights. “From substrate selection to production, using the right and less resources can have a significant contribution to improving the sustainability of the project.” Advancements in technology allows for the development of new label substrates to help brands mitigate their environmental impact, focusing on lighter weight materials, alternative fibres, certified papers, recycled content, solventfree adhesives, wash-off and fossil free solutions. “TreeFree” paper is made from renewable sugar cane bagasse, is an example of a more green label material option that doesn’t compromise on quality and performance.

“In the design of responsible sensitive pressure sensitive label must also take into consideration existing recycling streams,” Jacobs notes. “Clear plastic and glass containers are far better for recycling than coloured so the label provides the opportunity to colour and decorate the surface of the container whilst avoiding colour contamination of the main material.”

Consideration must be given to a label’s removability during recycling or matching right labels with right packaging material to optimise the recycling process.

Company experts can offer excellent advice for the selection of the right substrate to meet each labels requirement in terms of functionality, visual and environmental objectives. “Our commitment to delivering the high quality pressure sensitive labels with the least impact on our world is demonstrated in our globally recognised Forest Stewardship Council FSC-C160814 CoC (Chain of Custody) certification,” Jacobs highlights. “Self-adhesive labels printed on FSC certified substrates can request to carry the FSC trademark, thereby informing consumers that the materials

used originate from environmentally and socially responsible sources.”

With consumers embracing virtual working, socialising, learning and shopping, it is easier to inform them through connecting labels with the virtual world. “Some of the labels we produce include a QR code, through which consumers with smartphones can access to online information on ingredients, production chain and packaging recyclability,” advises Jacobs. “These tools empower the consumer to have visibility across the supply chain, from the raw materials used down to how they can be recycled.”

Digitally printing unique QR codes integrated with blockchain technology can provide a digital certificate of authenticity, designed to assure buyers that their product is genuine and not counterfeited. “This points to a coming future when tamperproof labels with digital authentication attached will become a new standard in offering consumers full traceability, while offering brands protection against counterfeiting,” he concludes. •

Lebone Paarl Label - www.lpaarllabels.co.za

2021 Quarter 2 | Food Manufacturing Africa

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LABELLING

Hybrid polyolefin film facilitates easy separation of labels from PET

FAST FACT EcoFloat helps consumer goods companies to reach recycling targets in the US.

CCL Label, the global converter of pressure sensitive and extruded film materials for decorative, functional and information labels, can now supply a sustainable sleeve solution for plastic packaging.

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CL DEVELOPED ECOFLOAT - a floatable polyolefin shrink film with high shrinkage - to meet new market demands and to assist brand owners to reach their sustainability and recycling targets.

This hybrid polyolefin film facilitates easy separation of labels from PET bottles and other types of plastic containers in the recycling process to enable bottle-to-bottle circularity, an important goal for global consumer goods brand owners.

“We see EcoFloat as the sustainable decoration solution of the future – for a whole range of packaging in the beverage, dairy, home care and other industries,” says Guenther Birkner, president of Innovia and CCL’s food & beverage business. “We are proud that this has been verified by receiving the recognition of APR.” EcoFloat shrinksleeves have been engineered to perform

ideally in the sink/float separation process of PET recycling plants for PET containers. This enables smooth bottle-to-bottle recycling to achieve high yields of high quality PET flakes.

The products has also been endorsed by the European PET Bottle Platform EPBP in their evaluation earlier this year. As it is a polyolefin film, the material is also an ideal match for HDPE bottles and PP cups as certified by recycling organisation Interseroh with their ‘Made for Recycling’ accreditation.

“Our investment is part of our commitment to boost plastic recycling and take steps towards a circular economy as stated when we signed the Global Commitment of the New Plastics Economy led by the Ellen MacArthur foundation last year.

“In future we expect more regulations to set a target for the recycling rate in municipal waste, for example. Reaching these will

not be feasible without investing in new technologies for packaging materials that support design for recycling. As a floatable, low density polyolefin film, EcoFloat fulfils the requirements for sleeves as defined in packaging design guidelines,” Birkner concludes. • CCL reaches next milestone for EcoFloat sleeve material in the US market

CCL – www.ccl.com

SUPERCHARGE YOUR BRAND WITH

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+27 (11)-314 5444

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CLOMARK’S DIVERSE PACKAGING RANGE

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Across industries and applications, we design specialised solutions.

Bringing together leading brands in processing and packaging equipment for the Value-added industry. Our fryers, ovens, branders, searers and breading/batter applications can prepare and cook the highest quality meat, poultry and seafood products. Whatever your product needs, we can meet it with precision and passion.

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