MAY 2022 • JULY 2022 Vol. 11 • No. 2
Making Life Taste Better and Healthier
Intelligent labelling solutions
Natural versus synthetic food colourants
The best in bakery supplies
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CONTENTS MAY 2022 • JULY 2022 Vol. 11 • No. 2
12 T raceability in the face of rising recalls
7
NEWS
South Africa now home to the most advanced taste facility in Africa Bringing chocolate expertise to the growing North African market Tracking food security across Africa IFFA 2022 exceeds expectations
10
COMPANY FOCUS
Symrise – Making life taste better and healthier
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INDUSTRY TALK
The importance of implementing a robust traceability system
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BAKERY
Find the perfect fit for your bakery needs The advantages of choosing a high-quality steel bake oven belt
19
COLOURS & FLAVOURS
Switching to natural food colourants
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WATER PROCESSING TECHNOLOGY
Improve energy usage on your water pumps The optimal sensor for every measuring task
26
LABELLING
Powerful and efficient labelling solutions Combining forces in the labelling industry Labelling innovation in the wine and spirits sector
30
20 Natural versus synthetic food colourants
PACKAGING
Leading packaging supplier achieves new qualification
ADVERTISERS’ INDEX Coperion..........................................................8..............www.coperion.com/food-extruders Endress & Hauser ........................................23............www.endress.com FlavorLogik ....................................................19............info@flavorlogik.com IPCO International .......................................17.............ipco.com/bake Novozymes......................................................9..............www.novozymes.com Polyoak Packaging........................................7...............www.polyoakpackaging.co.za Quantum Colours SA ...................................21.............www.quantumcolours.com Savannah Fine Chemicals...........................15.............www.savannah.co.za
Shanghai Dase-Sing Packaging Technology Co....29..........www.dasesing.com Sidel..................................................................30............www.sidel.com Siyakha Imperial Printing Co.....................28............www.siyaka.net Sollich KG........................................................5..............www.sollich.com Symrise SA .....................................................OFC.........www.symrise.com Syspro...............................................................13.............za.syspro.com Vega Controls SA...........................................25............www.vega.com/vegabar
2022 Quarter 2 | Food Manufacturing Africa
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EDITOR’S COMMENT
EDITORIAL Editor: Tennille Aron +27 (0)73 995 5599 tennille.aron@newmedia.co.za
Have one’s cake and eat it too
Layout & Design: Kirsty Thomas ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541
anita.raath@newmedia.co.za
Sales Executive: Carla Melless +27 (0) 83 260 6060
carla.melless@newmedia.co.za
Sales Executive: 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 Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk
N
EVER HAS THE saying ‘have one’s cake and eat it too’ resonated more than now. Not only do consumers want their cake, but they want it to be vegan with natural flavours and packaged with fully sustainable materials, while still retaining the same delicious flavour. As the trend towards producing natural, healthier food and beverages moves across the African continent, the search is on to find recipes that include healthier ingredients, but still have enhanced flavours that will satisfy consumers. With Kerry recently opening up one of the largest taste facilities in Africa, and Barry Callebaut investing in a chocolate academy in North Africa, there is no doubt that Africa will be upping it’s flavour game over the next year. To help you to up your flavour game, here’s the latest ingredient and equipment innovation in
the F&B manufacturing industry taking place on the continent. Plus a few of my must-reads from this issue of Food Manufacturing Africa. Symrise has repositioned the diana food legacy health actives as a portfolio brand for consumer health products. The diana food portfolio brand consists of a wide range of trusted and sustainable natural health ingredients. Find out more about these ingredients on Page 10. The debate around which is the better option between natural and synthetic colourants has been raging for quite some time. This is particularly true for producers in sub-Saharan Africa, given the complexities of appeal/appearance, stability, affordability, storage, shelf-life and extreme climate impact on foodstuffs produced in Africa. Discover which company is making natural colourants more readily available to the African continent on Page 20. For 40 years, Ceres, the well-known South African fruit juice company, has been growing steadily. Vega sensors have been monitoring the production here for many years. Read about the latest Vega sensor that is helping make activities at the Ceres plant more efficient on Page 24. Industrial labelling machines are an essential component in production lines because they allow, in an automated way, the application of labels and printing data on products. Explore how this equipment can help you apply labels quickly and more accurately on Page 26. Enjoy the read!
Tennille Aron 4
Food Manufacturing Africa | 2022 Quarter 2
CIRCULATION Circulation Manager: Felicity Garbers felicity.garbers@newmedia.co.za PUBLISHING TEAM General Manager: Dev Naidoo Production Manager: Mandy Ackerman Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor 272 Pretoria Avenue, Randburg Tel: +27 11 713 9000 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published by New Media a division of Media24 (Pty) Ltd MANAGEMENT TEAM MANAGING DIRECTOR: Aileen Lamb COMMERCIAL DIRECTOR: Maria Tiganis STRATEGY DIRECTOR: Andrew Nunneley CHIEF FINANCIAL OFFICER: Venette Malone HEAD OF HR: Leone Fouche CEO: MEDIA24: Ishmet Davidson HEAD OFFICE New Media, a division of Media24 (Pty) Ltd 8th floor, Media24 Centre, 40 Heerengracht Cape Town, 8001 Tel: +27 21 406 2002 Email: newmedia@newmedia.co.za PO Box 440, Green Point, Cape Town 8051 www.newmedia.co.za
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. The editor welcomes for publishing consideration news items, press releases, articles and photographs relating to developments in the food and beverage industries. No responsibility is accepted should contributions be lost. Food Manufacturing Africa is printed and bound by CTP Printers. Copyright: all rights reserved. ISSN 2309-5334
Readers are prohibited from using the contact details displayed in any advertisement or editorial within the pages of this publication to generate and/or distribute unsolicited bulk emails or other forms of mass marketing correspondence.
PERFECT ASSEMBLY
SOLLCOCAP® www.sollich.com
U N I Q U E FO R YO U R N EEDS
2022 DIARY
June 1 – 3 Frigair 2022 Gallagher Convention Centre in Midrand www.frigairexpo.co.za 9 – 11 Food & Kitchen Africa 2022 Nairobi, Kenya www.expogr.com/kenyafood/ 19 – 21 Africa’s Big 7 Gallagher Convention Centre www.africabig7.com 26 – 28 Hostex 2022 Sandton Convention Centre www.hostex.co.za
July 6 – 8 Malaysian International Food and Beverage Trade Fair KLCC Convention Centre, Kuala Lumpur https://mifb.com.my/ 10 – 13 IFT First: Annual Event and Expo McCormick Place, Chicago and Online www.iftevent.org 26 – 29 BIOFACH 2022 Nuremberg and Online https://www.biofach.de/en
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Food Manufacturing Africa | 2022 Quarter 2
NEWS
SOUTH AFRICA NOW HOME TO THE MOST ADVANCED TASTE FACILITY IN AFRICA KERRY, THE WORLD’S leading taste and nutrition company, officially opened the largest and most advanced taste manufacturing facility on the African continent. The new R650m (€38m) facility in KwaZulu-Natal will produce sustainable nutrition solutions that will be consumed across the African continent. Located in Hammarsdale, the new 10 000m 2 facility is one of the company’s most environmentally-efficient manufacturing sites with numerous sustainability features, including low energy usage equipment, solar power generation to reduce consumption from the local grid, waste heat capture, efficient water capture, reuse and reduction. Paul Hewitt, vice president, Sub Saharan Africa Kerry Group, said, “Kerry has had a presence in South Africa since 2011 and our success has been based on our ability to deliver truly authentic African taste by identifying traditional food and flavours and reimagining it into today’s modern context. South Africa is in a unique position to service East, Central as well as West Africa and we look forward to working with food and beverage companies to create products that will be enjoyed across the continent.” PPK029.pdf 1 2022/04/26 15:18
Bringing chocolate expertise to the growing North African market THE BARRY CALLEBAUT Group, the world’s leading manufacturer of high-quality chocolate and cocoa products, officially inaugurated its Chocolate Academy Center in Casablanca, Morocco. This new facility serves as a creative platform where chefs and artisans can showcase and develop their talent and skills, and learn about new trends, techniques and recipes. It is only the second Chocolate Academy Center on the African continent. Through its global network of now 26 Chocolate Academy Centers, Barry Callebaut offers inspiration, training and personalised support for artisans, pastry chefs, confectioners, bakers and caterers, and helps them to explore the infinite world of chocolate indulgence. Amine Mebrouki, general manager Middle East & North Africa, said, “The gourmet chocolate market is growing fast in the North African region. With the Chocolate Academy Center Casablanca, we support local businesses in finding the right chocolate solutions to help them win in the market. In Morocco and beyond, this will be the place to be for artisans and professionals in chocolate.” Rogier van Sligter, president EMEA (Europe, Middle East, Africa) of Barry Callebaut, added,
“This is an important moment for our presence in the North African region. The Chocolate Academy Center Casablanca will strengthen the collaboration with our customers in the North African market and help us to further expand our position in gourmet and specialties in the region.” Chocolate Academy Center in Casablanca, Morocco
Source: The Barry Callebaut Group
2022 Quarter 2 | Food Manufacturing Africa
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NEWS
TRACKING FOOD SECURITY ACROSS AFRICA DURING THE UNITED Nations Security Council’s May 19 session on Conflict and Global Food Security, Gro Intelligence’s CEO, Sara Menker, spoke about the growing global food crisis, the confluence of unprecedented factors contributing to this crisis, and its disproportionate impact on lowerincome countries. As part of a broader response to this crisis, Gro Intelligence is collaborating with The Rockefeller Foundation to make realtime agricultural data on African countries publicly available to all. With support from The Rockefeller Foundation, Gro Intelligence launched the Food Security Tracker for Africa, the first publicly available interactive tool on the key agricultural commodities of 49 African countries. The tool aims to create data transparency for countries to understand the supply and demand of major crops – corn, soy, wheat, and rice – across Africa on a real-time basis. Supply and demand balance sheets, which incorporate monthly historical and forecasted supply and demand of major crops, transform all of the forces that drive a commodity’s price into an actionable end-of-year supply number.
“By combining cutting-edge technology and humanitarian relief efforts, and leveraging the private sector for public use, our collaboration with The Rockefeller Foundation will help strengthen food security initiatives and help build a sustainable world for all,” said Menker. By combining data on drought, crop conditions, prices, supply and demand all in one place, users will be able to develop more effective solutions and emergency response plans to the growing shortages of key agricultural commodities across the continent. “To create a more comprehensive picture, the Gro team, which includes both domain experts and technologists, leveraged our platform and the scaling power of our machine-learning models to quickly and accurately provide needed data,” said Will Osnato, senior research analyst at Gro Intelligence. “With support from The Rockefeller Foundation, we will offer agricultural balance sheets that denote supply and demand of corn, soy, wheat, and rice for the next year. In addition, the tool has been tested and reviewed by our analyst team and methodologies are made available to fully encompass the transparency and objectivity of our platform.”
IFFA 2022 exceeds expectations FOR SIX DAYS, exhibitors presented innovations for sustainable and efficient production and packaging of meat and alternative proteins at IFFA 2022. Around 50 000 trade visitors were more than satisfied with the event. “It was a pleasure to walk through the halls and meet industry participants again. The global family reunion once again set the trends for the coming years – not least due to the expansion to include alternative proteins,” said Wolfgang Marzin, president and CEO of Messe Frankfurt. Automation and digitalisation are the driving topics in meat and protein processing and were at the centre of the innovations. In addition to recyclability, manufacturers focused on renewable raw materials: bio-based packaging as an alternative to plastic made from fossil raw materials points the way to a more environmentally-friendly future. IFFA expanded its product portfolio for the first time and focused on process technology and ingredients for alternative proteins. Visitors showed great interest in plant-based meat alternatives. For the first time, IFFA was also extended into the digital space and the extension recorded 12 661 accesses.
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Coperion`s ZSK Mv PLUS food extruder for plant-based proteins in a hybrid design allows dual use for manufacturing meat substitute products. Both TVP and HMMA can be produced on the same extruder, realizing maximum flexibility and profitably react to changing market demands. www.coperion.com/food-extruders
Coperion_food-extruder-pbp_177x130z3mm_en.indd 1
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Food Manufacturing Africa | 2022 Quarter 2
21.04.2022 10:12:49
ADVERTORIAL
The Russia - Ukraine conflict and how it may impact the baking business in Africa
During the French revolution it’s alleged that the Queen Marie Antoinette, having been informed of the restlessness of the people due to the scarcity of bread in the country, said “If they have no bead, let them eat cake.” . Currently, the world is again facing scarcity of bread, and unlike Marie Antoinette, we need to actively address and try to solve the issue.
With huge dependency on grain imports, African nations have cause for concern.
Global supply shain disruptions and it’s effects on the cost of wheat While the Ukraine-Russia conflict has definitely made the stuation worse, the issues of volatile wheat supply, quality and prices have been there even before and are bound to still be there once the conflict is resolved. Supply chain disruptions exacerbated by the pandemic and harsh droughts, such as those in North America that resulted in a 30% reduction in their production, have also been adding to the surging prices Supply decreased by 5.4% in the 2021 season which in turn initiated a new downtrend. The 2022 season forecast predicts a further 10.0% decrease. If realized, the continued downtrend will induce an upward price pressure (Mintec, 2022). This key global comodity’s quality and supply is also affected by numerous other factors . For example, in Australia, the quality profile of the crop was impacted by a wet harvest. This resulted in a high proportion of the crop being downgraded to low protein and feed grade wheats (ABARESDepartment of Agriculture, Water and the Environment, Australia Government, 2022).
Effects of the Russia-Ukraine Conflict on Wheat Supply Russia and Ukraine are major exporting countries for wheat and together represent 25 % of globally traded wheat. While farmers in Ukraine are currently unable to sow seeds and tractors are used in the war, not only a humanitarian but also an economic catastrophe is looming for Africa. Russia and Ukraine primarily export wheat to Africa, Middle East, and Asian countries. While many scenarios are possible, current estimates indicate that only 50-70% of the wheat will be harvested in 2022. After accounting for domestic consumption, this points to a shortfall of 1-2% of global wheat production or roughly 8-15 MMT. We expect this shortfall to be met by wheat from, among others, India, Australia, Europe, the US, and Canada.
The cost drivers for wheat are currently up-trending which provides an upward price pressure. The shortage in wheat sources aggravated with varying wheat qualities and lower baking performance affects baked products quality, results in difficulties of manufacturing a large range of flour types and managing production costs. This will not the specific application requirements. Beyond the specific baking ingredients, we face an overall high-cost world environment for the coming year. With bread as a staple commodity, this price pressure has economic, social, and political implications. As a key player in the baking community, we see it as both our duty and our privilege to work together with our partners, to help build more across the globe.
Connect with us Novozymes’ solutions ensure baking performances that unlock the baking potential of flour. We’re here to help you navigate the volatility and get even more out of your flour. Speak to us today.
Africa is a net importer of wheat, and countries such as Egypt, Sudan, Nigeria, Kenya, large wheat volumes from Ukraine and Russia.
Production volume of wheat in Africa from 2017/2018 to 2021/2022 (in 1,000 metric tons) 35.000
Production in thousand metric tons
30,464
29,286
30.000
26,826
26,652
25,716
8,284
25.000
8,874
8,427
7,407
9,113
20.000 15.000 10.000
19,245
21,590
21,002 18.399
16.603
5.000 0 2017/ 2018
2018 / 2019
2019 / 2020
North Africa
2020 / 2021
2021 / 2022*
Sub-saharan Africa
Africa produced around 25.7 million metric tons of wheat in 2020/2021. The production is forecasted to increase to 30.5 million metric tons in 2021/2022. North Africa accounted for over 60 percent of the African wheat production. In 2020/2021, wheat imports to the continent reached around 54.8 million metric tons.
Edwin Grant Steytler
Ntombi Fikile Nkambule
Asmaa Basha
EGS@novozymes.com
NTFN@novozymes.com
AMBA@novozymes.com
About Novozymes Novozymes is the world leader in biological solutions. Together with customers, partners and the global community, we improve industrial performance while preserving the planet’s resources and helping build better lives. As the world’s largest provider of enzyme and microbial technologies, our bioinnovation ENABLES HIGHER AGRICULTURAL Yields, low-temperature washing, energy-effecient production, renewable fuel and many other benefits that we rely on today and in the future. We call it Rethink Tomorrow. www.novozymes.com Novozymes (biosolutions.novozymes.com)
2022 Quarter 2 | Food Manufacturing Africa
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COMPANY FOCUS
Making life taste better and healthier
Symrise has strengthened the company’s position in the consumer health market. It has repositioned the diana food legacy health actives as a portfolio brand for consumer health products. The diana food portfolio brand consists of a wide range of trusted and sustainable natural health ingredients. They come with proven efficacy to support consumers' specific health conditions and expectations.
“The diana food portfolio supports the Symrise health strategy ‘Delivering everyday health, everywhere’.”
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Food Manufacturing Africa | 2022 Quarter 2
A
CCORDING TO NATHALIE Richer, Global Health business leader, Naturals Business Unit of Symrise Food & Beverage, “The diana food portfolio supports the Symrise health strategy ‘Delivering everyday health, everywhere’. We are targeting ten important areas of health concerns. For this, we have designed our range of natural health solutions to address the current and future needs of consumers around the world.” The list of products in the diana food portfolio brand is growing constantly. It includes solutions for immunity and anti-fatigue, cognitive health, urinary tract health, bone and joint health, cardiovascular health, sports performance, glucose metabolism, detoxification and digestive health, beauty from within, and oral health. Currently, the portfolio includes a diverse collection of health ingredients. They range from fruit polyphenols, vegetable phytoactives to cartilage extracts. Symrise
COMPANY FOCUS
SYMRISE AT A GLANCE Symrise products provide exciting flavour and fragrance experiences, improve food characteristics, and contribute to the health and well-being of consumers in more than 150 countries around the world. A dedicated focus on their customers, a high level of innovation and targeted expansion into new markets represents the basis for their sustainable and profitable growth. Symrise develops, produces and sells flavouring and food ingredients as well as functional ingredients and solutions that enhance the sensory properties and nutrition of various products. The company’s approximately 34 000 products are mainly produced on the basis of natural raw materials like vanilla, citrus fruits, onions, fish, meat, blossoms and plant materials. Their flavours, are often central functional components of their customers’ end products. The company’s origins go back to the year 1874. Symrise has since grown to achieve a current market share of 10% – making it one of the leading suppliers of flavours as well as nutrition in the global market. A high level of innovation and creativity, an exact knowledge of customer needs and various regional
sources them completely Symrise is developing its diana from the highest quality food portfolio brand of natural natural and sustainable health ingredients through raw materials. the sourcing, scientific, Decades of scientific technological and expertise in developing regulatory expertise of Symrise has: and commercialising the Naturals Business • Over 30 000 products natural ingredients Unit of Symrise • Over 6 000 customers back the diana Food & Beverage. It in more than 150 food portfolio brand also leverages the countries products. Manufactured marketing and consumer with proprietary insights expertise of the extraction technologies, diana global Symrise organisation. food actives come with very Symrise invests heavily in R&D high concentration levels. This means, (>100M euros) and puts a company-wide it only takes a very small dosage to emphasis on innovation through science. provide the full efficacy of the bioactive Instead of supplying individual within the finished product. The company ingredients, Symrise alone can supply supports its products with strong clinical the perfect blend of knowledge and study designs to demonstrate proof of expertise required to deliver everyday efficacy and validation of performance health, everywhere, for the consumer functionality. This clinical data helps health market. • customers to define impactful health and structure-function claims for Symrise – www.symrise.com their products.
DID YOU KNOW?
consumer preferences as well as targeted expansion into new and promising market segments contribute to the company’s above-average growth rate. Today, Symrise has over 11 000 employees working at more than 100 sites around the world who serve over 6 000 customers in more than 150 countries. The Taste, Nutrition & Health segment of Symrise uses its combined expertise as well as scientific research to offer customers and partners unique, natural ingredient-based and sustainable solutions in the areas of taste, nutrition and health. With more than 100 sites in over 40 countries, the segment serves the markets of the F&B industry as well as manufacturers of pet food and fish food. The segment is divided into the two core Food & Beverage and Pet Food divisions as well as the two smaller Aqua Feed and Probi units.
2022 Quarter 2 | Food Manufacturing Africa
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INDUSTRY TALK
Traceability in the face of rising recalls Food contamination and product recalls are not a new phenomenon within the F&B industry, with a number of stories making headlines over the years. Doug Hunter, manager: Customer and Ecosystem Enablement at Syspro Africa explains the importance on traceability in preventing this.
J
UST LAST YEAR, Coca-Cola South Africa, the manufacturer of Appletiser, said quality testing revealed that the products were “outside of the acceptable standards,” and six batches of the product were recalled from retailers within South Africa. The reality is food contamination or quality issues mean product recalls are happening more often than most are aware of. The problem is that facing a product recall has the potential to cause long-term damage to organisational and brand reputation of manufacturers and distributors, loss of sales, distribution/listing penalties, and even fines and litigation. With increased regulations around quality and traceability, efforts to ensure food security, plus consumer buying habit changes during the pandemic, innovation is critical for survival in the F&B industry. It’s time for manufacturers to re-examine their facilities and check if they have the right processes and technology in place to handle the challenges they now face. It’s also decision time if inconsistencies are found.
KNOWLEDGE IS POWER In this industry, manufacturers of all sizes must be able to respond quickly and effectively to the recall of products deemed
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unsafe or just unsuitable for the market. Not doing so can have long-term financial or legal consequences. In the age of social media, a company’s reputation is destroyed in an instant should it not respond appropriately to any food safety issue. The pressure is on F&B manufacturers to track and identify all ingredients used in their manufacturing process. From receipt of initial ingredient, seed, foodstuff or raw material, through the entire manufacturing process, to packaging and shipping the end product to the customer is an international trend and imperative. When it comes to traceability, knowledge really is power. Having the information about where your ingredients came from and how they were farmed can give you the upper hand when catastrophes occur, and a full product recall is needed. Full product traceability is required to identify and isolate all possible sources initially, while swiftly withdrawing all potentially affected batches (and items affected by these batches) from sale and customer shelves while investigating the threat – but still allowing the sale of proven unaffected batches. The role of technology is, therefore, vital in managing food traceability in a focused, reliable and cost-effective way.
Food Manufacturing Africa | 2022 Quarter 2
To implement a robust traceability system, different teams must collaborate – procurement, production, quality control, warehouse management and customer service, plus the software supplier and their support. Together they match appropriate processes - and hence initiate transactions - that identify the materials and items that require traceability and to what extent. Along with food safety, food quality is a key consumer concern. Supplying items of consistently high quality is vital to maintaining your reputation and building a sustainable business. Monitoring and analysing all of the variables that can influence product quality and generate streams of valuable data – an ERP system can help you identify critical patterns and help mitigate any issues. Within ERP systems today, continual data collection over time combined with machine learning fuelling prediction through artificial intelligence, offer additional benefits. Benefits not only boosting overall efficiency and productivity through the supply chain, but also minimising loss and food waste throughout the process, and potentially shortening lead times for bringing new products to market.
HAVING THE ABILITY TO RESPOND WHEN A RECALL IS NEEDED To identify, contain and recover from an unexpected occurrence with speed, for example, requires decision-making abilities that only a relevant industry solution can deliver. With recall functionality and built-in controls to preclude product recalls from happening in the first place, industryrelevant ERP solutions enable companies to better prepare for, prevent and minimise product recall effects, limiting potential damage to the business. The ability to manage a recall effectively is only as good as your ability to perform traceability backward and forwards through the supply chain. In the event of a food safety incident, it is also vital to be able to both identify the source of the problem quickly and reassure consumers with facts.
INDUSTRY TALK
“To implement a robust traceability system, different teams must collaborate.” F&B producers who are “emergency ready” and completely in control of their Business IT are not only best positioned to meet the regulations of today, they also gain the trust and confidence of their customers and business partners, turning a seemingly non-productive business activity into a competitive differentiator that contributes to the success of their businesses. With the high stakes of food and beverage recalls, companies can no longer afford to only react to safety issues, but need effective processes in place to prevent contamination from occurring in the first place. An ERP solution can ensure that prevention, control and traceability are central to all operations by improving quality control measures, reducing contamination risks, and documenting the manufacturing process - all while increasing efficiencies in the organisation. •
Syspro – https://za.syspro.com/
From material extraction
to customer satisfaction
and everything in between.
SYSPRO ERP FOR SUPPLY CHAIN MANAGEMENT The well-managed flow of goods, data, information, and finance — from the procurement of raw materials, ingredients, or parts, to the timeous delivery of a completed product — determines a manufacturer’s level of success. Trust SYSPRO’s secure and efficient ERP solution for Supply Chain Management, backed by over 40 years of industry expertise, along every step of your supply chain journey. The control you need. The experience you want.
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V01 Copyright © 2022 SYSPRO. All rights reserved. All brand and product names are trademarks or registered trademarks of their respective holders.
2022 Quarter 2 | Food Manufacturing Africa
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BAKERY
All the solutions to your bakery needs
Savannah has the solutions to all your bakery needs. Explore some of their top ingredients below: widely used in emulsified cake application. It decreases the crumb hardening over time by retarding the staling rate of the cake. It also finds good texture and taste for chocolate bakery products like brownies and devil’s food cake. It is non-GMO, non-hydrogenated and non-lauric providing good economy and functionality benefit to the end product.
BÜNGE LODERS CROKLAAN RANGE OF BAKERY PRODUCTS BREADS, CAKES AND BISCUITS
Carabuta NH The Carabuta NH is a milk fat replacer with flavour precursors creating butter notes during baking similar to dairy butter. It gives the natural buttery flavour to baked goods providing economy in replacing milk fat. The flavour will be developed once the heat is induced and it is stable. Being low in transfats and free from cholesterol, it is also easier to store compared to dairy fat for your convenience.
FROSTINGS, FILLINGS, AERATED CREAM AND TOPPING OF BAKERY GOODS
Icing Short 400 The Icing Short 400 has excellent creaming power with high mechanical tolerance. It is suitable for large production volume of buns and cakes. It gives smooth and light texture to filling creams and improves meltdown sensation. It is able to incorporate a higher quantity of air, giving larger volume of fillings, therefore, saving you money. The Icing Short 400 comes with clean label options and is low in trans fats as well, for better health benefits.
SPONGE AND EMULSIFIED CAKES
Durkex 140 The high stability oil Durkex 140 is specially designed to substitute liquid shortening
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Food Manufacturing Africa | 2022 Quarter 2
For spreads Durkex is a range of spread fats designed to avoid de-oiling at higher storage temperatures or at higher nut (oil) content levels. These give maximum indulgence thanks to a combination of pasty texture and rich mouthfeel, delivering a very pleasant overall experience. Spreadability is a key feature, even out of the refrigerator. Durkex 103 Durkex 103 is the most premium product, delivering maximum indulgence and heat resilience. It also has a high stability with nuts like peanuts, hazelnuts, almonds and pistachios in warm climates. Durkex 105 Durkex 105 contains an emulsifier to further improve the heat resistance without affecting the mouthfeel or flavour. Savannah are also the local distributers of Barry Callebaut’s Bensdorp range of cocoa powders and ingredients, which are the perfect ingredients to help manufacturers adapt to the ever-changing needs of the chocolate industry. These are just a few of the ingredients that they have on offer: • Dark Chocolate Powder Bensdorp’s Dark Chocolate powder is made with no addition of dairy. However, it allows you to claim chocolate on pack and show real pieces of chocolate on the packaging. These powders have a round chocolate flavour with caramel and milky notes. • Defatted Cocoa Powder The Defatted Cocoa Powder contains less than 1% of fat and has a reduced risk of fat blooming because it has a very low cocoa butter content. This powder is ideal for aerated bakery applications. It provides
BAKERY
increased volume of batter (~+20%) and has better baking stability. This powder has a classic balanced cocoa and dark chocolate flavour with a brown colour. • Ebony Black Cocoa Powder This cocoa powder is a fat-reduced highly dutched cocoa powder with distinctive intense black colour. It is one of the blackest cocoa powders on the market and has a strong roasted cocoa flavour with a slightly bitter after-taste. • Croquoa Add Croquoa to your mixture for a delicious multi-textured chewy stracciatella. These crunchy inclusions have a light, aerated texture and a delicious dark chocolate flavour. They show an excellent behaviour at high temperatures (up to 200 °C). The best part is that they are made of cocoa and sugar only. • Callebaut 811 Take on any job with Callebaut 811, which has a full-bodied taste, solid cocoa body and fine, fruity notes. This master in balance pairs perfectly with a wide variety of ingredients and works in all applications
ranging from confectionery to biscuits, sauces and drinks. • Callebaut w2 To create a delightful taste with pronounced milky, creamy, caramelly and vanilla notes that are in perfect balance, Callebaut W2 can be used. It is best used as icing. • Callebaut Gold Callebaut Gold is caramel chocolate that has rich notes of toffee, butter, cream and an exciting dash of salt, which works well in almost all applications. • Sicao hazelnut filling This is a soft filling with a delicious nutty flavour and a velvety sensation that can be added to rolls, croissants and pastries, and it easily resists temperatures up to 200 °C. •
Savannah Fine Chemicals – www.savannah.co.za Barry Callebut Bensdorp – https://www.barry-callebaut.com/en-ZA/ manufacturers/bensdorp Bünge Loders Croklaan https://bungeloders.com/en
2022 Quarter 2 | Food Manufacturing Africa
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BAKERY
Getting the best from your steel bake oven belt IPCO is the world’s largest supplier of steel bake oven belts and has nearly 100 years’ experience of working with the bakery industry. This gives the company an understanding of production issues that goes beyond belts themselves, as IPCO global product manager Marko Leber explains.
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HE PRIMARY ROLE of an IPCO steel bake oven belt is to convey goods through a continuously operating oven. The high thermal conductivity of this type of belt, whether solid or perforated, concentrates heat onto the product to achieve the desired crisp base, and the smooth, flat surface ensures a clean discharge at the end of the line with minimal risk of damage to fragile products. A high-quality bake oven belt will have key mechanical properties – flatness, straightness – ‘engineered in’ at the production stage to ensure that it runs through the oven as it should. Consistency of colour is important too; dark areas absorb heat while light, shiny areas reflect it, so uneven belt colour could result in an uneven bake. This has to be engineered into the belt too. In short, the quality of the manufacturing process – the transformation of a length of cold rolled carbon steel band into a high precision component – determines the long-term
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reliability of a bake oven belt and, in turn, the productivity, quality and profitability of the overall bake oven line. A steel belt that has been manufactured to the highest standards is a highly efficient tool, one that with the right maintenance will deliver reliable service for longer than any other conveying medium; a belt life of 20 or more years is not unusual, some can last two or even three times that long.
MAINTENANCE PROCEDURES Maintenance requirements are relatively low compared with other belt materials. Solid and perforated steel belts are by their very nature highly durable and resistant to stretching and this alone keeps downtime to a minimum. A premium quality belt will also display good tension and tracking characteristics, again key to reliable, trouble-free operation. So, what maintenance does a steel belt need? Aside from regular checks, more of which in a moment, lubrication and cleaning are the two most important maintenance tasks.
Food Manufacturing Africa | 2022 Quarter 2
IPCO Global Product Manager, Marko Leber
Lubricant is essential. As well as reducing friction, it helps eliminate the risk of rust caused by condensation, it reduces wear, prevents belt distortion, and ultimately leads to a longer belt life. It also helps to maintain a regular belt colour for an even bake. The easiest way to apply a lubricant is via graphite skid bars, which deliver a gradual deposit of graphite to the inside of the belt. IPCO graphite skid bars are available for all standard belt widths. If for any reason a skid bar cannot be used, graphite should generally be applied to the inside of the belt once a month for the first three months after installation, then every three to six months. If graphite is not permitted, specially selected oils can be used instead.
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. • • • • •
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. See us at IBIE Las Vegas · 18-21 Sept · Booth 2971
ipco.com/bake
BAKERY
Cleaning is usually carried out using rotating brushes, with the application of scrapers as necessary. The brushes should be adjusted to apply gentle cleaning of the belt surface. Ineffective cleaning will result in a buildup of carbon deposits on the baking side of the belt, leading to less than perfect products and, ultimately, a risk to health due to the presence of hazardous acrylamide. A range of factors including belt type, end product, oven type and personal preference will determine the most effective approach to the removal of carbon deposits and will usually involve the application of chemicals, dry ice or detergents and a great deal of manual input. But it’s a task that cannot be ignored if an oven is to produce high quality goods. Of course, some issues go beyond what could be termed ‘everyday’ maintenance and this is where our service support operation comes in.
IPCO SERVICE SUPPORT One of the unique strengths of IPCO is our ability to offer maintenance support that looks beyond the belt. For some customers, belt supply is all that’s needed, but for others we support the OEM or end user with a full range of conveyor components, from drums, sheaves and shafts to tracking systems, break points and graphite stations. We understand how a belt interacts with the other components that make up the system as a whole. For our service teams, analysis of belt condition can paint a clear picture of how that system is performing. It’s almost always the case that any issue with belt condition is the symptom of another problem, not one in its own right. Once the cause has been identified and rectified, we can return our attention to the
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“The primary role of an IPCO steel bake oven belt is to convey goods through a continuously operating oven.” belt itself and take whatever remedial action may be necessary to make sure that it’s in a condition to perform reliably for years to come. For example, if side wandering is occurring, this can often cause the belt to come into contact with the structure or another rigid object, resulting in burrs. Wavy belt edges could be another indication of side wandering or of uneven temperature in the oven. It can also indicate uneven pressure from the belt cleaner or scraper, or a belt scraper that is wider than the belt itself. We look for deformations in the belt, which could suggest problems with drums, belt supports or other parts coming into contact with the belt. Remedial actions include cleaning the drums, cleaning or replacing belt supports and checking scrapers, rollers, and belt tensioning. We also inspect the underside of the belt, as any scratches could indicate worn or damaged belt supports or safety scrapers. In one recent case, a customer asked us to look at belt tracking problems they were experiencing. They believed they’d probably need a new belt, but wanted us to identify the root cause of the problem first. As it turned out, the condition of the belt itself was not a concern, but it was clear to our engineers that certain components were incapable of providing the reliability and performance that could be expected of modern conveyor equipment. The surfaces of the drums, for example, were no longer suitable for effective belt tracking. We were able to retrofit a range of new components including inlet and outlet drums, tracking devices, a graphite station and a cleaning brush and scrapers, and retain the existing belt. The customer ended up with a state-of-the-art conveyor system capable of delivering significantly improved productivity,
Food Manufacturing Africa | 2022 Quarter 2
at a cost 25% less than it would have been for a new belt.
PREVENTATIVE MAINTENANCE AGREEMENTS While trouble-shooting is a great way of supporting customers, prevention is obviously better than cure. By offering Preventative Maintenance Agreements, we aim to identify risks of failure before they have chance to disrupt production. Inspection work will cover all major system components. We check that terminal drums, rollers and skid bars are aligned horizontally and at right angles to the center line of the longitudinal axis of the oven line. We check that terminal drums and rollers are rotating freely and that tension devices are functioning correctly. And we ensure that tracking devices are operating as they should be. As a company we have fully trained and equipped service teams on the ground in all key markets, including Africa. This means we can provide a quick response to any service or repair needs, and that work is carried out by qualified people with a real understanding of customers’ needs and values. Local teams can call on the support of IPCO’s Special Engineering team, experts who can be sent anywhere in the world to troubleshoot issues and provide specialist support. We also support customers in the form of technician training, either on-site or at our regional headquarters in Johannesburg. Subjects can be tailored to requirements but will typically focus on best practices in belt maintenance, repair techniques and use of the QuickTools range, all specially designed to make repair work as efficient as possible. •
IPCO – www.ipco.com/bake
COLOURS & FLAVOURS
Natural versus synthetic food colourants The debate around which is the better option between natural and synthetic colourants has been raging for quite some time, with most food manufacturers still opting for more stable synthetic solutions. This is particularly true for producers in sub-Saharan Africa, given the complexities of appeal/appearance, stability, affordability, storage, shelf-life and extreme climate impact on foodstuffs produced in Africa and consumed on the continent, explains David Kruger, sales representative at Quantum Colours CC.
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HILE QUANTUM COLOURS primarily supplies synthetic colours to the food industry, they have also recognised the value in offering a wider selection of solutions to our customer base. Realising the advantages in making the change to natural colours, and managing this change, is often a challenge. Vivid bright colours, achieved through the use of synthetics, are often not possible or at least not easily achieved by using natural colourants. There are various factors to consider when using natural colours to replace more stable synthetics in a food system. Factors such as background colour, the food matrix itself (the micro- and macro ingredient impacts), as well as packaging and processing conditions are just some of the elements to consider when choosing an appropriate colour source. Quantum Colours is among the top colour suppliers, and they can assist food processors and producers to navigate a minefield of information in
making the change to a natural or natureidentical solution, while still offering a wide variety of synthetic colourants to suit your customers’ needs. For yellow shades, beta-carotene is offered in various sources and in varying strengths to cater to a variety of customer requirements for naturality and depth of shade. This versatile colour is naturally oil soluble and is offered in emulsified watersoluble variants, often encapsulated to make it a more robust alternative to Sunset yellow and/or Quinoline yellow (depending on strength). It is also stabilised further by the complimentary use of ascorbic acid (vitamin C) and can be used in acidic environments, making it perfect for use in beverages. It is also used in confectionery, snacks and dairy products as well as fats and oils. Depending on the specific hue desired, turmeric (which is also naturally oil soluble) can be a great alternative for an even brighter shade of yellow. Turmeric is significantly more
sensitive to light and, therefore, great care must be taken in choosing the appropriately processed and/or treated colour for specific applications. Special packaging requirements may also be required for the specific endproduct due to the colour photosensitivity and product shelf-life. Red shades have been dominated by the use of carmine (cochineal) offerings in the past, given the stability, versatility and bright pinkish red to bright-red shade (or bright to deeper orange shade from carminic acid) these colours offer. The source albeit natural, not being a vegetable source, has seen this colour fall out of favour with food developers and consumers alike. To find such a versatile and stable offering remains somewhat of a challenge given religious and vegan objections, though there are few alternative options to consider. One such offering is anthocyanins, with the vegetable varieties from black carrot and/or sweet potato being more common alternatives to red radish and
“Quantum Colours is among the top colour suppliers.”
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Food Manufacturing Africa | 2022 Quarter 2
COLOURS & FLAVOURS
elderberry for example, and various options for blending for increased stability. The shade provided by anthocyanin is often impacted by the pH of the final product and especially over its shelf-life, so it is critical to evaluate the most suitable option given the various factors that can impact product stability. There are also solutions such as beetroot red (betanin pigment) for a more pinkish-red offering, lacking in stability for higher heat application areas and a lot more sensitive to light sources, with lycopene (a carotenoid pigment) being a more stable red on offer in certain application areas. As titanium dioxide is falling out of favour as a whitening or opacifying agent/colour
option, the need for suitable alternatives beyond calcium carbonate, which has its own challenges in application, has grown. Offerings based on starch has proliferated and proven to be worthy solutions with numerous blends being offered. Quantum Colours has sourced viable solutions for various application areas and has also developed their own offering called Glacier for use beyond coating systems for pharmaceutical applications into the food industry. Quantum Colours are continuously looking at various technologies to improve the effective use of natural colours and to bring increased stability to these products. An improved encapsulation technique is just one of the solutions being explored at present. With an increased demand for natural colours and the continued growth of synthetic colours, it is evident that synthetic and natural colours will continue to co-exist and may not necessarily be pitted against each other. Quantum Colours is, therefore, suitably placed to meet customers’ growing demand for these items. As noted, blends of similar (or different) colour sources can be considered to assist in giving an improved balance of each individual colour’s strength in the end application. This is another area where they will be focusing their attention on, with some colour blends already on offer, either for improved shade differentiation or improved performance, while colouring foodstuffs such as orange carrot or redbeet concentrate will continue to be of value for improved clean label requirements. •
Quantum Colours – https://quantumcolours.com/
2022 Quarter 2 | Food Manufacturing Africa
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WATER PROCESSING TECHNOLOGY
Energy efficient water pumps save costs and planet With water pumps consuming a significant portion of the energy needs of most buildings, plants or industrial facilities, South African businesses still have plenty of opportunity to save costs and cut carbon emissions. Grundfos senior service sales specialist Nicolette Gomes explains that it all starts with an energy check.
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NERGY COSTS CONTINUE to rise, and the pressure is on for the private sector to create a more sustainable, low-carbon economy. What better time for companies to optimise energy usage on their water pumps? “Original equipment manufacturers like Grundfos have been working hard for many years to make our pumps more energy efficient,” says Nicolette Gomes, senior service sales specialist at Grundfos. “I am still surprised that few pump users take advantage of the opportunity to improve their bottom line by cutting energy costs and at the same time, reducing their carbon footprint.” Doing this requires firstly a clear picture of a company’s current energy costs, says Gomes, so Grundfos offers an Energy Check service to help establish the foundation for a considered solution. This involves a service engineer visiting the site and collecting data from pumps and motors as well as basic energy consumption indicators. “From this data, we produce an analytical report that shows where improvements can be made,” she says. “Knowing exactly what our energy-efficient Grundfos systems can achieve, we can compare these expectations to the current situation; in our experience, the savings can be up to 30%.”
The information contained in these reports also includes the new system’s life cycle costs and its return on investment. She highlights that some customers’ energy savings have paid off the new equipment in less than two years, after which the system provides ongoing and substantial savings in operational costs. “A useful rule of thumb is to look at the age of the pumps in your existing arrangement – and if they are older than six or seven years, then an upgrade invariably makes perfect financial sense,” she says. “Where the capital outlay can be recouped in three years or less, it is usually an easy decision to make.” Where data is more difficult to gather – for instance, where nameplates have been removed or are not legible – Grundfos can also conduct a more intensive Pump Audit. Using a range of equipment from a specialised audit kit, the service engineer will install flow meters and pressure transducers, and measure kilowatt ratings of pumps. “This will log data for five to seven days, to create a detailed load profile for the customer,”
Nicolette Gomes, Senior Sales Specialist at Grundfos.
she said. “An added benefit is that the cost of this audit is deducted should they decide to go ahead with our Grundfos solution.” This intervention is of particular interest to the head of engineering in a plant or facilities manager in a building, whose key performance indicators (KPIs) are often linked to the cost-effectiveness of their operations – as well as the carbon emissions generated. “With services like our Energy Check and our Energy Audit, we can help key personnel to achieve their KPIs in relation to energy consumption,” she concludes. •
Grundfos – www.grundfos.com/za
Grundfos offers an Energy Check service to help establish the foundation for a considered solution.
Skilled technicians use the correct equipment to undertake comprehensive pump audits on installations.
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Food Manufacturing Africa | 2022 Quarter 2
We understand how you strive for constant product quality and optimized costs.
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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.
WATER PROCESSING TECHNOLOGY
Stopping the flow at the right time For 40 years, Ceres, the well-known South African fruit juice company, has been growing steadily. Vega sensors have been monitoring the production here for many years – the latest one in use is a level switch of the new VegaPoint series. It is deployed in a pulp residue container that is extremely problematic when it comes to level measurement explains, Claudia Homburg, from Vega Grieshaber KG.
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EGA SENSORS HAVE been used for many years in the entire production process of Ceres juice, for example in the numerous water and chemical tanks, in wastewater treatment as well as in the pasteurisation process. During all this time, the company has always appreciated the reliability of the Schiltach-based sensor manufacturer and the close, uncomplicated relationship it has had with it. One special challenge was a measuring point in a tank where the residues from production are collected. This aqueous pulp contains a mixture of cellulose and other solid materials. The mixture is dewatered, and the remaining sludge ends up in another tank. In the past, this tank overflowed now and then, and the pulpy substance spilled onto the plant floor. This happened because the vibrating level switches used at that time often failed to function properly. The accumulation of cellulose on the tuning forks caused them to malfunction, not switching properly when the tank was emptied. What is more, the fruit acid caused further difficulties. The result was an overfilling of the tank, as the pumps did not start in time or even switched off too early. Cleaning the floor and the whole area around the tank was very time-consuming. A new sensor from Vega for capacitive point level measurement sounded promising, but it wasn’t yet officially on the market. Nevertheless, the fruit juice company offered to be a tester of the sensor even before the official product launch. The new Vegapoint 21 is a level switch with adjustable switching
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“By introducing the new Vegapoint series, Vega is now able to offer the optimal instrument for every measuring task.” point for detection of water-based liquids. The sensor and the tank form the two electrodes of a capacitor. Any change in capacitance due to a level change is converted into a switching signal. Florian Burgert, product manager at Vega explains more about the new Vegapoint 21. Q: WHY WAS THE NEW VEGAPOINT SERIES INTRODUCED? Vega is known for the high quality and accuracy of its measuring instruments, which are often used for complex and challenging measuring tasks. However, there are many applications, in auxiliary systems in particular, that require sensor technology that is especially easy to install and reduced to the bare essentials. By introducing the new Vegapoint series, Vega has completed its portfolio for the entire range of existing point level applications and is now able to offer the optimal instrument for every measuring task – whether highly complex or standard. Q: WHAT SETS THE SERIES APART FROM PREVIOUS MODELS? The new Vegapoint instrument series includes IO-Link as a communication platform. The advantage of IO-Link is that the technology can be flexibly implemented in almost any application – whether new or already
Food Manufacturing Africa | 2022 Quarter 2
Florian Burgert, Product Manager at Vega
existent. With the option of bidirectional communication, device data and status information can be called up on demand, in addition to mere process data. The all-round, 360° switching status display is also new. Switching states can be easily discerned from any direction. The display remains perfectly visible even under difficult lighting conditions or at great distances; not least because its colour can be freely selected from a palette of 256 colours. At first glance you can clearly see if the measuring result is what it should be or if there is a malfunction in the production process. Q: FOR WHOM OR FOR WHAT APPLICATIONS IS THE SERIES BEST SUITED? We’ve reduced point level detection to the absolute basics in the new Vegapoint instrument series. With the usual Vega quality, it reliably meets all standard requirements without the extras that extreme ambient conditions or highly specialised applications would require. The new instruments can optimally cover all important aspects including, plant safety and reproducible product quality, efficiency and economy. •
Vega – www.vega.com
We bring colour into view! Compact pressure sensors and switches with 360° custom-colour status display
256 colours Individually selectable: Measurement in progress Sensor switching Process malfunction
15 cm
Compact design
Hygienic adapter system
Adjustment via smartphone
www.vega.com/vegabar
LABELLING
Tracepack’s deep learning OCR solutions ensure overall label legibility and compliance
Labelling with a difference Industrial labelling machines are an essential component in production lines because they allow, in an automated way, the application of labels and printing data on products. Moreover, these machines apply labels quickly and accurately. Meet TracePack’s new S series line of industrial labellers.
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RACEPACK’S LATEST S SERIES line of industrial labellers is very versatile, including seven models for every need and every market, even where large label formats need to be applied and can be equipped with devices for printing and marking using four different technologies. Each industrial labeller in this range has the following unique features: • Small size for maximum adaptability • M odularity • Optimal efficiency performance • Network connectivity for Industry 4.0 • Remote control TracePack’s Performance 4.0 label applicators are fast and will keep up with almost any production line, including the fast-paced lines in the beverage industry. It features intuitive control, even remotely with even more advanced features and is very high performance in terms of frequency, speed, accuracy, autonomy as well as motorised rewinder and control technology that allows the perfect synchronisation of the two motors while the label roll housing has a diameter of up to 400mm for exceptional autonomy. Considering that
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“Tracepack’s machine vision systems and industrial barcode readers offer powerful solutions to protect product quality and safety” time is precious, the Performance 4.0 labeller constantly updates you on its residual autonomy expressed in pieces informing you through the mobile app, wherever you are and whatever you are doing. Architecture, mechanics and the engines’ latest generation electric (step, step and brushless) ensure performance unattainable in each market segment: from 20m/min to 200m/min with up to 1 800 labels dispensed per minute. It also has maximum energy efficiency and lower noise than that of a refrigerator. Successful food and beverage operations embrace innovations in product quality inspection, packaging inspection, assembly verification, allergen management, traceability, and food safety to minimise downtime and deliver consistently high
Food Manufacturing Africa | 2022 Quarter 2
quality, safe products with fewer defects and less waste. Tracepack’s machine vision systems and industrial barcode readers offer powerful solutions to protect product quality and safety, ensure package integrity, manage allergens, and maintain traceability. Food and beverage product labels contain product-specific data such as origin, date, expiry, amount or class. In many factories, machine vision controls the alignment and placement of brands and the inspection. Smudged ink and lowcontrast printing commonly affect print and apply inkjet labels, jeopardising the readability of many barcodes. Barcode printing errors and poor label quality require manual intervention, slowing down production and presenting challenges to vendors and partners. In addition, many defects are hard to detect during the label application process due to the belt’s orientation and the curved surfaces of items. However, quality inspections ensure product labelling is defect- and error-free. Machine vision systems with surface detection technology ensure labels are applied cleanly and squarely without
LABELLING
TracePack’s Performance 4.0 label applicators
TracePack’s vision systems inspect for the presence or absence of allergen labels
To access video, check out the Food Review Digimag.
wrinkles, air bubbles, rips or other raised errors. TracePack’s vision systems with feature extraction technology use lighting and software algorithms to create high-contrast images that enhance the 3D features. It catches errors and defects such as torn, ripped or warped labels. Monochrome and colour models identify colour errors and inspect labels for consistency and quality in size, shape and texture. This quality control measure reduces the incidence of error, helps meet label quality standards and guarantees customer satisfaction. During the food and beverage industry manufacturing process, labels can be applied to products through several methods, such as print, and use laser marking and thermal inkjet printing. When manufacturing at high speeds or on small, hard to mark products, labels can drift and change orientation over time. Poorly applied labels can lead to misaligned text, overprint and other issues impacting a product’s legibility, and label alignment. Without visual inspection to ensure alignment, food and beverage manufacturers can incur unwanted waste, costly rework, chargebacks, and non-compliance penalties related to industry and retailer marking and label regulations. By using TracePack’s vision systems, food and beverage manufacturers can ensure labels are correctly positioned on the product and avoid product quality
recalls or brand damage. Likewise, automated inspections identify errors before a misaligned label creates issues further along the supply chain. In addition, the label alignment inspection can be coupled with our optical character recognition (OCR) and other vision tools to ensure overall label legibility and compliance. Mislabelled allergens threaten public health and can result in expensive and damaging recalls. Strict rules established by government agencies worldwide require manufacturers to label and trace common allergens such as peanuts, soybeans, milk, eggs, shellfish, tree nuts and wheat. To ensure product safety and efficient recalls, manufacturers must be able to quickly identify and locate non-compliant products in the supply chain, posing hazards to consumers. Therefore, manufacturers need to ensure the correct label is on the right package. TracePack’s vision systems inspect for the presence or absence of allergen labels and ensure they are printed. In addition, pattern-matching technology locates allergen labels on packages, bottles and other items, and verifies that they are
correct to ensure customer safety and limit a product recall. Food and beverage manufacturers take great measures to avoid labelling mix-ups that, at best, damage brand reputation and, at worst, can lead to expensive recalls and liability. Many companies print and scan 1D and 2D barcodes or text on items to ensure they are labelled accurately and advertise the correct contents. These barcodes or alphanumeric values verify that multi-part packaging components match like a top lid and bottom container. Tracepack’s vision systems and deep learning OCR solutions can check that lids and containers match each other, accurately reflect the package contents, and confirm that labels comply with regulatory bodies’ in-house procedures and quality standards. In addition, this technology ensures codes and text can be read and decoded at high speeds in the most challenging environments. •
TracePack – www.tracepack.co.za
TracePack’s vision systems with feature extraction technology can catch errors and defects such as torn, ripped or warped labels.
2022 Quarter 2 | Food Manufacturing Africa
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LABELLING
Canon acquires Edale Canon Production Printing and Canon Inc. announced the acquisition of UK-based packaging converting equipment manufacturer Edale, with the aim of strengthening Canon’s label and packaging business, and creating opportunities for future developments.
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HROUGH THE ACQUISITION of Edale, Canon is intensifying its long-term strategy to provide turn-key solutions for the label and packaging sectors. The move will enable Canon Production Printing to further develop its LabelStream 4000 product line, as well as provide expertise and technology for future products. Mick Asada, CEO, Canon Production Printing said, “Edale has been a supplier of the web transport, conventional printing and embellishment modules for our LabelStream 4000 series since 2018. Through this close collaboration, we have a very high regard for the Edale team’s capabilities and specialist expertise in printing and converting for the label and packaging industry. We’re excited by the enormous potential that will come from far closer co-operation, and confident that this will help to realise Canon’s ambition to become a major force for digital innovation in the packaging arena.” Based in Hampshire, UK, Edale engineers and manufactures world-class printing and converting solutions for the label and packaging industry, including digital and hybrid presses, carton and label production lines, flatbed diecutters, and finishing and converting equipment. The company has a long history in the flexo-label industry and
Mick Asada, CEO, Canon Production Printing
a strong reputation for its web transport and converting solutions for digital label production. Edale owner and chairman Grahame Barker said, “We’ve experienced a period of exciting growth, and I believe that the support of a strong global player is vital to enable us to continue that trajectory in the future, so I’m delighted that Canon will be that partner for the next stage of Edale’s development. We’re confident that
the combined force of Edale and Canon will deliver tangible advantages for both companies’ customers.” Edale, continuing to trade under the Edale brand, will remain an independently managed company, pursuing its established strategy to provide printing and finishing solutions, focused on the label, folding carton and flexible packaging segments. Grahame Barker will retire and the business will be led by the existing Edale management team under managing director James Boughton, reporting into Canon Production Printing through Walter Vogelsberger, VP, Digital Packaging Printing. •
WE WILL HELP YOU MAKE THE SMART MOVES Experts in Flexibles, Shrink Sleeves and Pressure Sensitive Labels For further information on how we can help build your brand contact our Project Development team on Tel +27 31 502 5050
T: +27 31 502 5050 E: info@siyaka.net www.siyaka.net
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Food Manufacturing Africa | 2022 Quarter 2
LABELLING The Modular CM 480
A star is born The Modular CM from P.E. Labellers is the new rotary labelling machine that is bewitching the wine and spirits sectors. It is completely ergonomic and flexible with a layout that can be reconfigured quicky and easily.
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HE MODULAR CM is a compact and solid machine available in four sizes (from small to medium). It has up to six labelling stations and is perfect for glass and plastic bottles, cylindrical and shaped formats, and for partial/wraparound labels – front/back, neck labels, wraparound labels, plastic I/L/U shape tax stamps. This solution has all the features loved by many sectors that need a small to medium-sized labelling machine that is super flexible thanks to its complete modularity with a layout that can be reconfigured easily and quickly. This ergonomic labelling machine meets the needs of many producers and bottlers in the wine and spirits’ sector. In addition to wine and spirits, the Modular CM also
satisfies the production needs of the oil, beer, food and dairy industries. This innovative machine features labelling stations with pressure sensitive technology and cold glue, reciprocally interchangeable; they are replaceable in a few steps according to any production needs. The Modular CM is a machine that provides the highest standards of safety for the operators. It has up/down protections that, when raised, instantly stop the machine’s operation. •
P.E. Labellers – www.PELabellers.com USS Pactech – www.usspactech.co.za
Drone image of the P.E. Labellers headquarters
2022 Quarter 2 | Food Manufacturing Africa
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PACKAGING
Sidel recognised as provider of high-quality vocational training The leading packaging solution provider recently received French Qualiopi Certification for its global training methodology, reinforcing Sidel’s commitment to provide additional value to customers through long-term support programmes.
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IDEL’S COMMITMENT TO providing high-quality specialist training for its customers around the world was recently reinforced with the award of the French Qualiopi certification. This independently assessed mark of quality for vocational training and skills development, provides assurance that a training provider has rigorous quality management processes in place, while enabling customers in France to access funding that covers part of the training cost. “We are committed to offering customised training programmes to every single one of our customers, working in partnership with them to assess existing skills, to identify gaps and needs, and to propose specific training to ensure
continued safety, product quality and line efficiency,” said Olivier Cocheril, VP Asset Performance & Maintenance Services. “By attaining Qualiopi certification, we are assured that the rigorous methodology used by our teams across the world is ensuring consistent high-quality training for all course participants.” Sidel delivers customised training options to more than 5 000 trainees per year, providing over 350 different courses to meet the specific needs of individual customers around the world. Recognising that every production line and operational job profile is different, courses can be tailored to ensure that customers achieve maximum operational efficiency in their facility.
In addition to virtual and onsite training, Sidel operates a global network of specialist training centres, led by teams of expert trainers with extensive knowledge of PET, can and glass production processes. Training centres are equipped with facilities with both physical and virtual learning environments set up to replicate some production conditions. This avoids interruption to a customer’s operations. Based on over 50 years of proven experience, Sidel’s training offering, provided for customers around the world, helps shape the factory of tomorrow. •
Sidel – www.sidel.com
SIDEL EAST AFRICA IS MOVING CLOSER TO YOU With a new office soon to open in the heart of Nairobi, Kenya, we’re looking forward to serving our East African customers with on the ground support and tailor-made solutions and services!
Sidel Services East Africa West Wing, 1st Floor, Riverside Park ICEA Lion Centre, Chiromo Road Parklands/Highridge Nairobi, Kenya
sidel.com
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