Food Manufacturing Africa Quarter 3 2019

AUGUST 2019 - OCTOBER 2019 Vol. 7 • No. 3

For the first time in its corporate history Symrise will set up application labs in Nigeria

Ingredients push boundaries in clean label

Fresh and innovative readyto-drink solutions

Inspection, coding & marking gets to the root of food safety

beverages

dairy farming

dairy processing

utilities

transport

food

core technologies

Milking & Cooling

Seperators

Decanters

Homogenisers

Valves

Spray Drying

Aseptic Filling

Brewery & Dairy

Compressors

Packages & Skids

Ice Machines

Freezers

GEA Southern & Eastern Africa 48 Reedbuck Crescent, Corporate Park South, Midrand 1682, RSA Tel. + 27(0)11 392 7114, Fax. +27(0)11 392 7000 info-sea@gea.com

www.gea.com

engineering for a better world

CONTENTS A U G U S T 2 019 - O C T O B E R 2 019

12 Symrise opens application labs in Nigeria The global fragrance and flavour manufacturer will open its new facilities in Lagos, Nigeria on 4 September 2019. This is the first time in its corporate history that Symrise will set up application labs in Nigeria.

22 Beverage solutions take processing to the next level

Vo l. 7 • N o. 3

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NEWS

R50 million investment for Siyaka Imperial Printing

Nampak to sell Nigerian carton business

Africa Plastics Recycling Alliance launched

10

EVENTS

A stellar line-up for Propak West Africa

Nigerian food event shows excellent growth

11

TECH TALK

Maximise your ERP investment simply

13

BAKERY

Cake emulsifiers for every requirement

Libstar expands par-bake capacity

Hygienic steel for easier cleaning

All your lubrication needs sorted

The perfect container for baked goods

18

INGREDIENTS

Nature-based flavours help pack a punch

Consumers clean up their diets

Serving Africa’s nutritional needs

22

READY TO DRINK

Flexible tech for high-speed production

Innovative packaging for dairy drinks

26

INDUSTRY TALK

The latest in poultry and packaging solutions

28

INSPECTION, CODING & MARKING

Quality control for individual packs

Effective sorting for processing lines

ADVERTISERS’ INDEX ABB South Africa................................................IBC...........www.new.abb.com AMF Bakery Systems........................................5................www.amfbakery.com Courlanders Agencies......................................22..............www.dcnorris.com Emirates SkyCargo............................................OBC..........www.skycargo.com/emiratesfresh Endress & Hauser..............................................7................www.endress.com GEA Africa..............................................................IFC............www.gea.com GNT Group BV......................................................9................www.exberry.com IPCO South Africa...............................................15..............www.ipco.com Ishida.......................................................................29..............www.ishidaeurope.com Kemtek Imaging Systems Holdings..........25..............www.kemtek.co.za

Kluber Lubrication............................................16..............www.klueber.com Krones Southern Africa..................................23..............www.krones.com Omron Electronics ...........................................30.............www.industrial.omron.co.za Polyoak Packaging............................................8................www.polyoakpackaging.co.za Renlaw.....................................................................27..............www.renlaw.co.za Savannah Fine Chemicals.............................19..............www.beneo.com Serac.........................................................................24..............www.serac-group.com Symrise SA ............................................................OFC..........www.symrise.com Syspro......................................................................11..............www.syspro.com Wyda Packaging ................................................17..............www.wyda.co.za

2019 Quarter 3 | 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: David Kyslinger Contributors Doug Hunter, Helen Hook and Thomas Schmidt 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: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmedia.co.za Sales Executive: Daleen Filbey +27 (0) 83 409 3119 daleen.filbey@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

Nutrition becomes personal

T

HE IDEA OF personalised nutrition is generating significant buzz in the food industry. Innovators are seeking new ways to tackle the many and varied demands of the modern consumer. While today’s consumers are more engaged with their food than before, every individual is different, creating challenges for the industry.

Progress is being made when it comes to specific dietary needs or interests.

Plant-based, paleo and vegan diets are growing and there is a corresponding rise in global NPD in these areas. The industry is also starting to recognise that food and beverages can impact mental and emotional wellbeing. Guilt-free and feel-good products are attracting more attention.

Symrise is exploring new territories in Nigeria with the opening of its new application lab in Lagos, Nigeria (page 12). In the facility, company experts will work on flavours for beverages, sweet applications and other ingredients. Your perfect place to start when developing new products!

Manufacturers are also facing new challenges to improve flavour delivery systems across a broader range of food and beverage applications. We look at how nature-based carriers are helping brands to pack a flavour punch. Turn to page 18 now for the full story. Our feature also assesses the impact a youthful population has on new product development and how speciality food ingredients can assist and fuel this exciting trend.

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On page 22, we investigate efficient and flexible processing solutions for products as diverse as baby food, pie fillings and Chibuku. Food Manufacturing Africa spoke to Stuart Rigby of Jet Cook on some of the latest technology innovations impacting the market. Serac’s latest bottle-blow-fill-cap units are also under scrutiny as these are perfect for use in the dairy industry.

We end this edition with some of the latest technology innovation in inspection, coding & marking equipment.

Our feature kicks off on page 28.

I hope you enjoy this edition of Food Manufacturing Africa. Should you have any suggestions or news for us, please don’t hesitate to contact me at maryke.foulds@newmedia.co.za.

Happy reading,

Food Manufacturing Africa | 2019 Quarter 3

CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmedia.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmedia.co.za Production Manager: Mandy Ackerman Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park 2092 Tel: +27 (0)11 877 6111 Fax: +27 (0)11 877 6198 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published by New Media a division of Media24 (Pty) Ltd MANAGEMENT TEAM MANAGING DIRECTOR: Aileen Lamb COMMERCIAL DIRECTOR: Maria Tiganis BRAND STRATEGY DIRECTOR: Andrew Nunneley CHIEF FINANCIAL OFFICER: Venette Malone HEAD OF HR: Camillah West CEO: MEDIA24: Ishmet Davidson HEAD OFFICE New Media House, 19 Bree Street, Cape Town 8001 PO Box 440, Green Point, Cape Town 8051 Tel: +27 (0)21 417 1111, Fax: +27 (0)21 417 1112 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.

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DIARY

September 1 - 3 Speciality & Fine Food Fair London, UK www.specialityandfinefoodfairs.co.uk

4 - 7 WorldFood Istanbul Istanbul, Turkey

2019 SUBSCRIPTION FORM To ensure you receive a copy of Food Manufacturing Africa each quarter, please complete this coupon and return it, together with your payment to: NEW MEDIA a division of Media24 (Pty) Ltd, PO Box 440, Green Point, Cape Town 8051 Tel +27 21 701 1566. Fax 086 529 6468.

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9 - 12 Fine Food Australia Sydney, Australia www.finefoodaustralia.com

12 - 15 World Food Fair Singapore www.singaporefoodshows. com

Full Name:...........................................................................................

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October

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1 - 5 WorldDairyExpo

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Direct Deposit (Fax this form together with a copy of your deposit slip to: +27 086 529 6468 Payee: Bank:

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Cologne, Germany www.anuga.com

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29 – 31 Gulfood Manufacturing

1069321540

Dubai, UAE www.gulfoodmanufacturing.com

Nedbank Seapoint

Branch Code: 10-69-09-00

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5 – 9 Anuga

18 – 22 HostMilano

Method of payment:

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Madison, US www.worlddairyexpo.com

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TAX INVOICE REQUIRED

30 Oct – 1 Nov China Foodtech, Beijing, China www.chinafoodtech.com

30 Oct – 1 Nov RMB WineX, Johannesburg,

(Please tick) SOUTH AFRICA

(PRICES INCLUDE VAT @ 14%)

6

November

FOREIGN

(POSTAGE INCLUDED)

South Africa www.winex.co.za

1 YEAR

R315.00 ❑

R392.00 ❑

31 Oct – 2 Nov

2 YEAR

R514.00 ❑

N/A

Food Japan, Singapore

Food Manufacturing Africa | 2019 Quarter 3

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NEWS

GREEN LIGHT FOR ZAR50 MILLION INVESTMENT Nigeria’s South Africa label manufacturing company, Siyakha Imperial Printing is boosting supplies to the African continent. The company, in operation in South Africa for over 20 years, has announced an investment of R50 million at its Mount Edgecombe operations in Durban, South Africa.

‘The production will serve the domestic market and export to neighbouring countries, thus entrenching its position as one of the leading label producers,’ explains director, Rajesh Lutchman.

AC006.pdf

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The investment will involve the construction of new facilities and the installation of new manufacturing machines. From planning to design, construction and operation, the new facilities’ focus is on green building practice, which expands and complements the modern building’s design.

Siyakha Imperial Printing is building its third facility on green building principles

plastics subsector to grow substantially Nigeria’s plastics subsector has been projected to grow at seven per cent over the next 10 years.

This is according to a report published by McKinsey & Company. While the Lagos government is set to introduce a long-overdue plastics collection system in the mega city, Nigeria’s commercial capital has a big problem with waste management.

Adebola Shabi, special adviser to the governor on the Cleaner Lagos Initiative says this new development will be implemented in partnership with Visionscape. The government intends to offer an incentive in return for plastic waste. ‘At the end of the day, this initiative is going to help clean up the environment. This will reduce the amount of plastics in our drains, it will reduce the amount of plastic in our canals and other places,’ Shabi points out.

NEWS

NAMPAK TO SELL NIGERIAN CARTON BUSINESS AR Packaging Group (AR) has entered a definitive agreement with South Africa’s Nampak for the acquisition of its Nigerian packaging business, Nampak Cartons Nigeria for an undisclosed amount.

Nampak Limited, the South Africa-based packaging company with footprints in 11 African countries said it reached an agreement with AR, a Swedish cigarette pack maker to sell Nampak Cartons Nigeria, a producer of high quality folding carton products for the tobacco, food and consumer goods segments. According to the company, Nampak Cartons Nigeria based in Ibadan, Oyo State is one of the leading carton packaging companies in the country and serves a broad market of primarily multinational customers in the tobacco and food segments.

The company, which employs 200 people was established in 2004.

André de Ruyter, Nampak’s chief executive, says the disposal of the packaging business in Nigeria is part of the group’s ongoing strategy to sharpen its focus on strategic underlying businesses.

Diageo, Unilever, CocaCola & Nestlé launch Africa plastics recycling alliance Global consumer goods companies operating across Africa have launched the Africa Plastics Recycling Alliance (APRA) to intensify plastic recycling in sub Saharan Africa.

The Alliance covers various plastics and recycling value chains from manufacturing and processing to branding and recycling, a collaborative effort that seeks to improve living conditions by solving the problems associated with plastics. The Alliance is made up of multinational companies Nestlé, Unilever, The Coca-Cola Company and Diageo.

APRA aims to turn the current challenge of plastic waste in sub Saharan Africa into an opportunity to create jobs and commercial activity by improving the collection and recycling of plastics. The Alliance intends to achieve this through an intensive framework, which targets sustainable solutions to achieve its common goal.

The companies will facilitate and support their local subsidiaries to engage proactively in market level public/private partnerships, industry collaboration and alliances. They will share knowledge, encourage innovation and collaborate on technical and other solutions appropriate for sub Saharan Africa as well as participate in local pilot initiatives.

Dougie Brew, Christian Byron and Bruno Witvoet of Unilever Africa, Gavin Pike, Guiness Ghana, Andrew Musingo, CCBA and Gabriel Opoku-Asare, Diageo Africa

2019 Quarter 3 | Food Manufacturing Africa

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EVENTS

NIGERIAN FOOD EVENT 2019 Propak West Africa promises a stellar line-up CONTINUES TO GROW The event will be held at the Landmark Centre in Lagos, Nigeria from 17 to 19 September. Propak West Africa has become the region’s largest exhibition for the packaging, plastics, printing and food processing industries.

THIS YEAR, PROPAK West Africa will feature an additional 25 per cent floor space. Among the brands confirmed to participate are Bobst, Ishida Europe, PanAsia Tech, Sasol, Snetor, SkySat and Windmoeller & Hoelscher.

Sasol has recently been announced as the Gold Sponsor for the upcoming edition. The company is an international integrated chemicals and energy company working in 33 countries. Sasol’s chemicals, polymers, solvents and wax divisions market and supply value-added products and services to the plastics packaging and printing industry globally.

In 2018, Propak West Africa welcomed 4 265 attendees, an increase of 31 per cent from 2017. With 32 countries represented, the show has established itself as a truly global event.

Speaking on Propak West Africa’s growth, regional director for Afrocet Montgomery, George Pearson comments, ‘Additional hall space allocated for 2019 means Propak West Africa has grown by a total of two thirds in just two years. That, coupled with more than 80 per cent of stand space already sold for the upcoming exhibition, is evidence of the market’s growth and opportunity for development.’

WHAT TO EXPECT IN 2019 Several new exhibitors are joining the fold and organisers are confident there will be plenty to see for new and returning visitors. The co-located conference has been tipped to draw in some of the industry’s biggest names. With so much happening in the West African packaging, plastics and printing market, experts from some of the world’s leading brands will be in attendance to share market insights, opportunities and know-how with the audience. •

Propak West Africa has shown consistent year-on-year growth

Propak West Africa - www.propakwestafrica.com

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Food Manufacturing Africa | 2019 Quarter 3

A new show on the international trade calendar, the event is gaining traction amongst global manufacturers, suppliers and buyers from the food, beverage and hospitality sectors.

TO FACILITATE EASY navigation, organisers introduced dedicated pavilions to group together relevant products and regions.

In the country pavilions, top suppliers and manufacturers from selected regions will offer a coherent overview of the region’s primary exports. Current country pavilions include China, Korea, Norway and Turkey.

The Nigerian Enterprise Zone is another innovation.

Specifically designed for SMEs, the zone will provide a great opportunity for companies looking to expand or enhance their existing reach in the West African region from the local market.

This year’s exhibition includes dynamic features such as Drink Lagos as part of the co-located Nigerian Drink Event.

This is a premier pavilion for those that source, buy or serve drinks from sommeliers to bartenders. Chef Skillery will invite leading chefs into a live kitchen demonstration area to provide exclusive tips and tricks from trending ingredient combinations to innovation techniques.

This year’s event includes a dedicated co-located show; the Nigerian Hospitality Event, which serves Hostex West Africa. This well known brand will host leading hospitality suppliers and service providers from the region.

The inaugural edition of the Nigerian Food Event will take place from 22 to 24 October at the Landmark Centre in Lagos, Nigeria. Brought to you by Afrocet Montgomery, the event will provide a pivotal trade platform for those working in the retail, food service, wholesalers and hospitality markets.

With numerous floor events and demonstrations taking place, Afrocet Montgomery hopes to attract over 2 000 visitors to this landmark event. •

Nigerian Food Event – www.nigerianfoodevent.com

TECH TALK

How to maximise your ERP investment Implementing an Enterprise Resource Planning (ERP) system without understanding how it can benefit your business is a bit like owning a gold mine without knowing where to dig. If you’re not experienced in the application of ERP, it can be difficult to pinpoint exactly what solution your business needs. By Doug Hunter.

T

O GET THE most out of your ERP system, you need to draft a predefined list of goals tailored to your business’ specific needs. Align yourself with an ERP services organisation that understands the scope of your business and its processes.

Important features you should be discussing with your consultant include: business processes, relevant functionality, cost of ownership plus qualified consulting resourcing.

The usability of your ERP system also requires significant consideration. For example, mobile options like Syspro Espresso afford employees the ability to access real-time business information anytime, anywhere. If your ERP system currently produces printed reports, consider whether it would make more sense to implement dashboards to give employees greater scope to refine the information they view.

BEYOND BASIC FUNCTIONALITY

It’s important your ERP system grows alongside your company, and an effective ERP partner should help you optimise and innovate across your business.

This means they should be encouraging you to consider new avenues of growth, such as ways to harness the depth of big data, for example. Advanced ERP systems can leverage technology like IoT to broaden data capture throughout your supply chain.

AI coupled to ML (machine learning) analyses and learns from data providing predictive insights before and not after you need them.

Optimisation starts with examining your current processes and identifying operations that could be simplified by enabling and automating them through the ERP. Getting true value from your ERP is about much more than simply enabling more efficient processes and generating transactional data. The data the system produces is the competitive advantage your business needs to grow. You should be assessing elements such as the type of reporting packs your business produces, questioning whether they will ultimately give you the information you need.

PLAN FOR GROWTH

KEEP EMPLOYEES UP TO DATE Optimising the implementation of your ERP system includes making sure employees

understand how it operates. A once-off implementation of the system won’t be enough to help them derive maximum value from it.

The system will be evolving constantly to meet changing business needs, therefore employees’ knowledge of how to operate the system must be updated continuously.

Syspro Professional Services facilitates onsite customised education plus online eLearning (via the SLC - SYSPRO Learning Channel). This allows users to brush up on their current knowledge and investigate what other Syspro ERP functionality is available, which could help them move the business forward.

It’s important to make sure your ERP system will continue operating smoothly into the future even when problems occur. You should make sure your business has access to professional consulting and support services via a Contact Centre that can make sure operations continue while complex issues are resolved. You must extend the ERP system to new relevant functions or areas of the business as you grow.

At the end of the day, your ERP system can offer you massive returns on investment, but only if you have a clear roadmap as to how you should implement and leverage your system appropriately. •

Syspro – www.za.syspro.com

Getting Things Done: Our Recipe for Success Food Manufacturing ERP for Movers and Makers of the world.

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It’s why we’re committed to delivering specialist ERP software that can help you track allergens, streamline production across your entire supply chain, improve forecasting and reduce waste.

Because we believe that the Movers and Makers of the world are the ones who move us forward. Learn more at www.syspro.com

2019 Quarter 3 | Food Manufacturing Africa

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COMPANY FOCUS

Symrise expands Nigeria site and opens application labs The global fragrance and flavour manufacturer based in Germany, will open new facilities in Lagos, the largest city in the West African country on 4 September 2019. This is the first time in its corporate history Symrise will set up application labs in Nigeria.

S

YMRISE EXPERTS WILL work on flavours for beverages, sweet applications and other food, as well as cosmetic ingredients. The company wants to meet the preferences of regional customers as closely as possible with this local expansion.

‘With these application labs, we can create products in the market, for the market,’ says Rudy McLean, managing director of Symrise South Africa. ‘We can deepen our understanding of the preferences and needs of local people and, where possible, use local raw materials. This will strengthen our

presence and underpin our growth goals in the region.’

ABOUT SYMRISE: The company is a global supplier of fragrances, flavourings, cosmetic active ingredients, raw materials and functional ingredients for food. Its clients include food and beverage companies, the pharmaceutical industry and producers of nutritional supplements and pet food, amongst others. Sales of approximately €3.2 billion in 2018 makes Symrise a leading global provider. Headquartered in Holzminden, Germany, the group is represented in more than 100 locations in Europe, Africa, the Middle East, Asia, the US and Latin America. Symrise works with its clients to develop new ideas and market-ready concepts for products that form an indispensable part of everyday life. Economic success and corporate responsibility are inextricably linked as part of this process.

AT THE GATEWAY OF AFRICA The history of Symrise is closely connected with Nigeria. With its Scent & Care and Flavour & Nutrition segments, the company has been active in the African country for more than 30 years.

During this time, Symrise has worked intensively to familiarise itself with the local markets. Beyond this, the local team has built close and lasting relationships with customers. The goal of the new

“The goal of the new application lab is to incorporate customer preferences and market requirements in product development”

application labs is to incorporate customer preferences and market requirements in product development. To achieve this, Symrise will employ three new lab specialists at the facility.

With more than 190 million inhabitants, Nigeria is by far the most populous African nation. The country’s economy is growing rapidly. Nigeria overtook South Africa in 2014 to become the largest economy on the African continent. ‘For us, Nigeria is a key African market. With this new investment, we are enhancing our site and are intensifying our commitment to the region,’ McLean concludes. •

Symrise - www.symrise.com

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1, 2, 3, 4 Symrise is growing its footprint on the African continent

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Food Manufacturing Africa | 2019 Quarter 3

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BAKERY

Simply better for you Many cake premix manufacturers currently use shortening as a carrier for emulsifiers, while cake gels are a common choice in long-shelf-life cakes.

P

ALSGAARD’S RANGE OF powdered whipping-active cake emulsifiers are the perfect alternative to both of these formulations.

In a new report, the company highlights the needs of cake consumers globally are changing. There is a demand for a wider variety of cakes, including better-for-you and free-from products, with sustainability becoming increasingly important.

Powdered whipping-active cake emulsifiers can help bakers meet these needs - offering a range of practical advantages over shortening and cake gels.

Their benefits include: • Simplicity: No pre-hydration or preemulsification is needed, reducing the number of production stages • Better-for-you: Can facilitate a switch from saturated fats to unsaturated liquid oils • More with less: Higher emulsifier content than typical shortenings or cake gels • Speed: Act rapidly, allowing acceleration of output • Versatility: Can be used in a wide range of products - high or low-fat, aerated or non-aerated.

The two ranges of powdered whipping-active cake emulsifiers include Emulpals, which is specially designed for premixes, while Palsgaard SA is optimised for long shelflife cakes. Both are suitable for all cake types - from layer cakes and Swiss rolls to cupcakes and muffins. Concepts include a vegan, gluten-free and lean label brownie made from a premix containing Emulpals 130,

Palsgaard’s powdered whippingactive cake emulsifiers

There are huge benefits in powdered whipping active cake emulsifiers

and a matcha, chai and taro tea layer cake featuring Palsgaard SA 6600.

As well as being versatile and easy to use, the powdered whipping-active cake emulsifiers help manufacturers respond to

concerns about sustainability. They are plantbased, and made in 100 per cent CO2 neutral facilities. This is a claim, which to Palsgaard’s knowledge, no other emulsifier manufacturer can make. Where the company uses palm oil ingredients, it relies on RSPO certified raw materials, enabling it to offer its complete product range as MB or SG certified.

Rosa E. Regalado, general manager at Palsgaard concludes, ‘Powdered whippingactive cake emulsifiers are the smart choice in both premixes and long shelf-life cakes. They offer a range of advantages over shortening and cake gels, including stability, simplicity and opportunities for better-for-you cakes.

Industrial bakers and premix manufacturers who work with Palsgaard get all these advantages, as well as meeting consumer demand for sustainably produced products.’ • Palsgaard – www.palsgaard.com

A market for

par-baked goods Libstar expanded one of its plants to meet key client requirements offering par-baked goods by converting a section of the Amaro Foods' facility in Epping, Cape Town into a par-bake facility.

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AR-BAKE IS an economical way of offering freshly baked goods without the need for full in-house baking facilities. The technique involves partially baking the dough and then rapidly cooling it. The retailer then completes the process. It allows producing a range of fresh artisanal bread and rolls.

Andries van Rensburg, CEO of Libstar concludes, ‘We focus on the low-cost manufacture of quality, innovative and value-added products for discerning consumers. These consumers have proven to be more resilient in the everweakening economy. We continue to leverage our long-standing relationships with customers in the retail, wholesale, industrial and export channels to produce innovative products in partnership with them.' •

Amaro Foods' par-bake facility in Epping, Cape Town

Libstar – www.libstar.co.za

2019 Quarter 3 | Food Manufacturing Africa

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BAKERY

Steel makes the case for

hygienic conveying Ipco’s steel belts are used across the food industry in processes as diverse as baking, freezing, cooling, solidifying and conveying. The company is one of the larger manufacturers of steel belt conveyors and serves the African market from its regional base in Johannesburg.

F

OR MANY OF these applications, the thermal properties of steel are a key consideration. Steel belts can be used at temperatures from - 80°C to +750°C. The belt itself acts as a heat transfer medium, whether removing heat from a food product (e.g. chocolate cooling) or enhancing the baking process.

Durability is another factor: steel is more resistant to damage by corrosion, abrasion or impact than any other belt type. This makes it the ideal long-term solution for a whole range of potentially aggressive applications.

For many though, it is the cleanability of a solid steel belt conveyor, which is its most important quality. The hard, flat, smooth surface of a steel belt ensures easy product release at the end of the conveyor and enables faster, easier cleaning so the highest standards of hygiene can be maintained.

REDUCING ACRYLAMIDE LEVELS One challenge faced by all industrial bakeries is ensuring a clean processing medium. It doesn’t matter how clean the operation, a gradual build-up of carbon residues is virtually unavoidable and can be

“The hard, flat, smooth surface of a steel belt ensures easy product release at the end of the conveyor and enables faster, easier cleaning so the highest standards of hygiene can be maintained”

detrimental to the taste and appearance of a baked product.

The negative effect of acrylamide on human health has also made it a health issue and manufacturers are looking to reduce levels of this potentially carcinogenic material. Belt cleaning is a top priority and oven builders now need to consider the cleanability of conveyors.

As well as minimising the risk of harmful acrylamide build-up, the inherent cleanability of a solid or perforated steel

belt also means less water consumption, reduced use of chemicals and depending on the cleaning method, less energy expended on heat.

MAXIMISING CONVEYOR EFFICIENCY As a specialised manufacturer of steel belts, Ipco works closely with machine builders to ensure reliable performance and system efficiency. The success of a steel belt conveyor depends on correct installation. This will ensure smooth, reliable operation and long working life. The initial quality (straightness and flatness) of the belt is central to this. Bake oven belts also require the appropriate tracking and support accessories.

Ipco offers a range of active and passive belt alignment solutions. These include the Compact Belt Tracker (CBT), which works with virtually any belt edge detector system. This device manages tracking by tilting the belt using a linear actuator and is available with a choice of control options. Easy to install with self-supporting construction, the CBT can be used on belt widths from 600mm to 3 000mm.

Belt support needs to be provided by means of cast iron skid bars and Ipco recommends that a minimum of 10 per cent of the skid bars should be graphite. As the conveyor moves, a deposit of graphite is delivered onto the inside of the belt. This reduces friction for optimum performance and increased belt life and protects against rust caused by condensation or general humidity. •

Ipco – www.ipco.com

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Food Manufacturing Africa | 2019 Quarter 3

Solid and perforated steel belt conveyors for the food industry IPCO is a world leader in the manufacture and supply of solid/perforated steel belts and associated process systems for the food industry, with application-specific expertise that extends across baking, cooling, forming, freezing, drying, casting, meat cutting, conveying and more.

Our belts and systems are used to handle literally hundreds of different food types, from cookies, chocolate and coffee to strawberries, sugar and seafood. And in every area they offer efficient, reliable and durable operation together with fast, easy cleaning for maximum hygiene.

Whatever your requirement – belt-only, process support or system solution – our global coverage and technical expertise means we deliver the level of service that’s right for your business, whatever its size or location.

• W orld leading steel belt technology: solid/perforated, carbon/stainless, wide belts, choice of grades.

• Process solutions including our proven Rotoform FD pastillation system.

• G lobal service and spare parts support, new installations, upgrades, planned maintenance, belt replacements.

• Experienced engineers offer consultancy on all aspects of process design.

ipco.com

BAKERY

All your

lubrication from one expert Lubricants for the food & beverage industry are subject to a multitude of requirements. Food Manufacturing Africa spoke to Demelza Mulligan of Klüber Lubrication on what constitutes a good lubricant and some of the unique challenges faced by local processors.

Q: WHAT ARE THE BIGGEST CHALLENGES FACING THE F&B INDUSTRY IN SOUTH AFRICA AND ON THE CONTINENT? Avoiding contamination of food products during manufacturing while making production processes as efficient as possible. The main challenge concerns food-grade quality, safety and compliance. Under - and over-lubrication can also be problematic. This could be a lack of skill, training, or automation.

Q: HOW CAN YOUR COMPANY ASSIST IN OVERCOMING THESE CHALLENGES? Klüber Lubrication complies with the stringent registration of the ISO 21469 standard for the hygiene requirements for the formulation, manufacture and use of H1 lubricants used in the food-processing industries. The entire manufacturing process of our H1 lubricants is certified.

All Klüber Lubrication manufacturing plants are certified to quality standards (DIN/ISO/TS 16949 or DIN EN ISO 9001); environmental standards (DIN EN ISO 14001 or eco-audit) and occupational safety standard (OHSAS 18001).

Automatic lubricating systems ensure reliable, clean and accurate lubrication 24 hours a day. Machine reliability is safeguarded - there is always fresh lubricant at the friction point, which assists in reducing energy costs. Our solutions on offer include freely selectable lubrication intervals, incrementally

from one to 12 months; a variety of (food grade) lubricants to choose from; selfcontrolled or PLC-controlled lubrication systems. Our units are flexible and compact for use in demanding applications and can be used for applications subject to strong temperature fluctuations. They are also suitable for precise lubricant metering under strongly ambient temperatures and single or multiple lubrication points.

•

•

•

Q: WHY SHOULD CLIENTS CHOOSE YOUR PRODUCTS? WHAT MAKES THEM UNIQUE? We offer a combination of personal consultation and a comprehensive lubricant range. The right lubricant carries considerable potential to reduce energy, savings on spare parts and labour costs while increasing productivity. We never recommend a product without the appropriate technical and consultative site visit. We offer more than 100 different lubricants with halaal and kosher certification that are H1-registered, enabling Klüber Lubrication to support compliance across the complete production line.

Q: HOW CAN THESE PRODUCTS OPTIMISE PRODUCTION? • Special gear oils ensure long maintenance intervals, high efficiency and lasting component protection, even at the gear’s performance limits.

• Prolonged service life of synthetic lubricants and the consequent longer oil

•

•

•

change intervals can reduce equipment downtime and save resources.

Klüber Summit FG series range of products reduce oxidation in pistons and valves for an extended compressor lifetime.

Sprayable greases have good wear and corrosion protection, good hot and cold water resistance and provide ease of application on open gears and slideways.

Lubricants for drinking water valves need to meet country-specific guidelines, be resistant to media, provide good sealing effect and offer good tactile properties at all temperatures.

Machines susceptible to water washdown must be given protection against corrosion and water accumulation on metal surfaces.

Our products can displace a higher amount of water when compared to those without H1 approval.

High-temperature chain oils show 22 to 37 per cent lower evaporation losses when compared to the best competitor product.

The use of high-performance compressor oils allows our customers to reduce their energy costs and increase general reliability. Products are manufactured with less sulphur content; produce a smaller gas reaction; cleaner filters and coalescers and offer greater heat transfer efficiency with low oil carryover. •

Klüber Lubricants – www.klueber.co.za

Greater efficiency for your filling line A new conveyor lubrication solution for the Food Industry Contact us for more information: sales@za.klueber.com 011 908 2457/8/9 or vist us: www.klueber.com

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Food Manufacturing Africa | 2019 Quarter 3

BAKERY

The perfect container for baked goods

Wyda South Africa’s range of aluminium trays, dishes and forms are suitable for oven baking, freezing and reheating.

B

RIGHT AND REFLECTIVE alufoil containers can withstand extremes of all types of baking: grilling, fan and convection oven, barbecue griddle, microwave oven and reheating. The characteristics of foil can satisfy the many demands of chilled or frozen bakery products. Its formability and robustness means aluminium foil is available in a large variety of standard shapes and sizes.

DID YOU KNOW? Wyda South Africa is solutions oriented and committed to delivering top quality aluminium foil products and services to the southern and western African food industries.

MOST POPULAR TRAYS AND DISHES WP20-100: Medium sized aluminium foil dish with 198mm diameter and 550ml capacity.

Perfect for small pies, whether sweet or savoury.

W3001: A light-duty, medium sized milk tart aluminium foil dish with 400ml capacity. Perfect for baking tarts. The rim style is full curl. The pack size consists of 250 and there is an optional lid to go with this dish. For heavy duty choose the WHD3001. This is a heavy-duty, medium sized milk tart aluminium foil dish with 400ml capacity.

W4191: Small aluminium foil loaf pan with 550ml capacity. This smaller pan is ideal for Madeira loaves. With a dimension of 200L x 87W x 48H, it is great to stack and store.

W4041: A new Swiss strudel tray, which may also be used for baklava, pizza bread and various mini rolls.

W1081: Perfect for Christmas mince pies with 40ml capacity and three holes.

Wyda also supplies special colourful aluminium products for special occasions during Easter or Christmas season. The WHRTRED is a red coloured aluminium cupcake in a heart shape with optional clip-on PET lid.

Adding even more versatility is a range of purpose designed lidding materials. This includes straightforward foil/board laminates to more sophisticated coated or laminated alufoil lids that can be sealed to the container rim yet peel off easily. •

Wyda South Africa - www.wyda.co.za

2019 Quarter 3 | Food Manufacturing Africa

17

INGREDIENTS

Delivering flavour through nature

Manufacturers are facing new challenges to improve flavour delivery systems across a broader range of food and beverage applications. Helen Hook, marketing manager at Ingredion EMEA, looks at how nature-based flavour carriers are helping brands to pack the flavour punch.

P

EKING DUCK AND hoisin sauce.

Lemon, ginger and honey. Fennel and cardamom. Stracciatella and salted caramel. These are just some of the new and interesting flavour fusions to hit the food and grocery store shelves over the past twelve months.

With global travel now possible at the click of a button and the rise of the Instagram effect, exposure to new cultures, cuisines and flavours is increasing consumer demand and expectation for foreign food and tastes to be available at home too. The emergence of the adventurous consumer has seen a 17 per cent average annual growth in global food and beverage launches with ethnic flavours over the 2013 to 2017 period1.

As the use of fresh and new flavour combinations continues to grow manufacturers must be aware of these new trends before they quickly burst onto the culinary scene. They should also know how to preserve these flavours as they carry them into final production.

PROCESSING SOLUTIONS To meet demand for these bold and interesting flavours in a way that delivers product consistency, and balances the cost of production, ingredient formulations and processes must advance. This is particularly important in the process where liquid-based flavour is converted into powder.

The most common and traditional technique used to encapsulate a flavour is spray drying, with plating onto maltodextrin the other key flavour carrying process.

Plating refers to the physical blending of liquid substances onto a solid carrier - most commonly maltodextrin. This creates a free-flowing powder, which can be used to develop dry-mix seasoning blends, powdered sauces and teas.

With the emergence of new flavour combinations, manufacturers are looking to transform additional liquid and oil-based flavours, to deliver a free flowing and homogenous powder. Even a small amount of these ingredients can often be expensive and delicate. Maximising plating capacity, while carrying a consistent flavour with good shelf-life is a top concern for food producers.

Using traditional plating agents and techniques like spray drying can prove a challenge, particularly for thick and syruplike liquids. Due to the viscosity of such ingredients, processing conditions need to be adapted, often adding cost and time.

HIGH EFFICIENCY PLATING TECHNOLOGY An alternative solution that has emerged in recent years, is a processing technique that produces a porous starch. Derived from nature, this versatile ingredient requires no special equipment and can be used in existing mixers and blenders. Due to the nongelatinised and unique granular structure of porous corn-based plating agents, they can be used to carry high-flavour concentrations that flow freely through processing equipment. They also mix evenly into food and beverage recipes, even when using thick liquids such as honey and chocolate syrup.

Naturally sourced from waxy corn, plating agents such as Ingredion’s N-Zorbit 2144 DG, enable food producers to create uniformly blended, flowable powders, which streamline the formulation process. The unique,

porous structure increases the surface area exposed to liquids, facilitating and improving absorption, and delivering a plating capacity as high as 40 per cent. This means 100g of N-Zorbit 2144 DG plating agent can plate up to 70g of liquid, delivering far more than traditional carriers such as maltodextrin.

Manufacturers can produce highly concentrated, active and vibrant flavours in small volumes of powder, leading to lower cost-in-use and reduced packaging costs.

Coupled with this is a desire for a move towards natural versus synthetic extracts, to reduce the number of chemicals used within food production. The more widely known maltodextrin, often requires the addition of silica dioxide to produce a good flow of powder. With consumers demanding more natural, simple and recognisable ingredients, there has been a trend in flavour houses and manufacturers seeking to move away from using silica dioxide.

Incorporating ingredients such as N-Zorbit 2144 DG plating agent, which does not require the addition of silica dioxide to optimise the flow of the powder, manufacturers can meet consumers desire for a simple and clean label declaration. The product can be simply listed as glucose syrup on food labels across Europe, the Middle East and Africa, making it much more appealing to retailers and customers alike.

A BURST OF FLAVOUR The rising need for efficient flavour encapsulation of high value-added ingredients looks likely to continue in line with the trend for different wide-ranging flavours of foods. Consumer and market preferences now lean towards simple labelling and minimal processing, while delivering that all important intensive flavour burst. The selection of an appropriate and effective process, will depend on the compounds, storage and onward processing techniques to be used. Working with a partner that can help you navigate the different methods and ingredients available, will help manufacturers to capitalise on this growing market opportunity. •

Ingredion – www.ingredion.com 1. Innova Market Insights: Top 10 Trends 2019

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Food Manufacturing Africa | 2019 Quarter 3

INGREDIENTS

Consumers continue to

clean up their diets International research indicates that clean claims such as "no artificial ingredients" and "no preservatives" are getting high scores from shoppers.

Thomas Schmidt talks about changing consumer attitudes and how functional ingredients can assist manufacturers to meet these needs.

S

OCIAL MEDIA’S OBSESSION with clean and healthy eating has moved many consumers from focusing purely on calories to looking at the level of processing, additives and/or preservatives.

Consumers are starting to link the term clean label with healthier products. This has helped drive growth in clean-label product launches. According to Mintel GNPD , in the last four years Europe has launched the newest products with clean label-related claims: Europe 47 per cent; Asia Pacific 26 per cent; and North America 16 per cent.

As part of Beneo’s clean label consumer research, the ingredient list for a clean label

tomato sauce (containing Beneo’s Remypure S52 functional native rice starch) was compared with one containing an E-number and another with modified corn starch. Over 70 per cent of 3 000 respondents opting for the recipe containing the natural rice starch.

THE POWER OF A LABEL With no standard global definition, consumer perceptions are shaping what the food and drink industry considers to be clean label.

Products are generally deemed to be clean label if they contain only simple, recognisable ingredients (e.g. no E-numbers or food additives). They must be made from natural

(non-chemical sounding) ingredients, undergo minimal processing, inform consumers about the production process (e.g. provenance and transparency) and have a perceived healthier nutrient profile.

Worldwide 64 per cent of consumers read the labels on food packages, and one in three consumers around the globe are said to have increased their research on ingredients over the last year.

To put the power of the label to the test, Beneo included five label options in its consumer research. The one carrying a “no preservatives and made with natural ingredients” text was by far the most

Label-friendly texturising solutions.

A natural, sensorial experience.

Our Sales Network Partner in South Africa:

Go for clean plates with BENEO’s label-friendly texturising solutions. Full, smooth, creamy, crispy… Taste is pivotal, as well as recognisable, natural ingredients. A short and sweet label requires versatile solutions that are big on impact. BENEO offers the application expertise to enhance the sensorial value and the process performance of your recipe. We help cutting back on the number of artificial ingredients, while maximising your options and improving the consumer’s eating experience.

Follow us on:

sfc-info@savannah.co.za

www.beneo.com

2019 Quarter 3 | Food Manufacturing Africa

19

INGREDIENTS

preferred label (by 49 per cent of all the consumers surveyed), compared to ‘non-GMO/ contains no artificial ingredients’ (21 per cent preferred), ‘vegetarian/with plant-based ingredients' (12 per cent preferred), ‘no claim’ (11 per cent preferred) and ‘free from allergens/free from modified starch’ (seven per cent preferred). When asked why they liked that particular label, consumers replied that it showed the product was natural (56 per cent) and it had a clear, understandable label (55 per cent).

PUSHING THE BOUNDARIES OF CLEAN LABEL More ‘natural’ product launches have attained a world average annual growth rate of 15 per cent. With 55 per cent of UK consumers taking a stance of ‘the fewer ingredients the better’, it is no real surprise these preferences are challenging manufacturers and retailers alike to make transparency and traceability accessible.

In response to consumer demand, manufacturers are taking clean label new product reformulation further. Due to developments in functional ingredients, Beneo’s Technology Center has been working with customers on a wide range of recipe concepts, including cream cheese, bakery creams, ice creams and tomato-based sauces, through to spoonable dressings and ketchup.

Adding a clean label texturiser, whilst reducing fat and/or sugar and maintaining taste and texture, is no mean feat with many technical challenges to be overcome. A range of functional ingredients has been proving their worth in even the most difficult clean label applications.

CLEAN LABEL FAT REPLACEMENT Manufacturers interested in producing cleaner label products are looking to natural alternatives that can provide the required creamy sensation and maintain a great taste normally achieved through fat. The ideal clean-label fat replacer should bring a level of indulgence to fat-reduced products through a variety of different technical characteristics, yet be non-GMO to qualify as ‘natural’ for consumers. It should also create a fat-like texture and a creamy mouthfeel, be process stable, have no off-taste, deliver in terms of volume and have fewer calories. Beneo has solutions available that support producers to meet these high expectations and rise to the challenge; using either Beneo’s chicory fibre inulin or native rice starch, or combining both ingredients in optimal quantities.

Beneo’s Orafti Inulin is ideal for replacing fat in water-based products due to its longchain molecular structure. Its low solubility enables it to form fat-like granules under high shear. With its neutral and balanced flavour, it does not affect the taste of the product, yet delivers in terms of a similar mouthfeel, texture and creaminess. The ingredient is a natural, non-GMO, clean label prebiotic fibre that is derived from chicory root via a gentle hot water extraction method, unlike some other fibres that are artificially or chemically made.

CLEAN LABEL FAT REPLACER IN ICE CREAM – USING ORAFTI INULIN INGREDIENTS (%w/w)

Reference

Fat reduced

Water

55

58

Cream

23

15

Sugars

11

11

Skimmed milk powder

10

10

Orafti Inulin

-

5

q.s.

q.s.

Minor ingredients (e.g. emulsifier, stabiliser, flavours)

Beneo’s clean label rice starches assist in reducing fat in products, yet convey a creamy texture and mouthfeel. Depending on the used rice variety, rice starch obtains textures ranging from short to long, making it ideal for use as a texturiser for short texture recipes such as puddings, flans and mousses, as well as longer texture yoghurts and creamier desserts.

CLEAN LABEL IN HIGH SHEAR APPLICATIONS One of the biggest advances in clean-label ingredient technology

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Food Manufacturing Africa | 2019 Quarter 3

comes from the use of functional native starches to replace chemically modified starches. With 72 per cent of Beneo’s survey respondents regarding rice starch as ‘familiar’ and 66 per cent as ‘natural’, this is an ideal ingredient for clean label applications.

Beneo’s new grade of functional native rice starch, Remypure S52, creates a window of opportunity for manufacturers wanting to create cleaner label sauces and dressings.

It is characterised by its high tolerance to severe processing conditions, overcoming low pH, high temperature and high shear. Due to Beneo’s unique thermal inhibition process, the functional properties of Remypure rice starches are obtained without using chemicals. Remypure S52’s performance level is comparable to modified food starches, due to its reduced granule breakdown during processing.

CLEAN LABEL TOMATO SAUCE PERFORMANCE Thanks to Remypure’s clean label credentials, the Beneo Technology Center has created a retorted tomato sauce ingredient list that features water, tomato paste concentrate, tomato passata, rice starch, sugar, olive oil, salt and pepper. The technical challenges of creating a clean label retorted tomato sauce is significant, due to the sauce’s low pH and severe temperature processing conditions.

When put to the test, Beneo’s tomato sauce containing Remypure S52, gave viscosity results with good stability over time, results which are difficult to obtain with native rice starch.

From clean label fat replacement to high shear applications, consumers want alternatives with ingredients lists they recognise. With the latest developments in functional ingredients, food and drink producers can now bring cleaner label solutions to even the most processed products. With continuous global growth for clean label related new product development (+16 per cent in Western Europe . There is significant market demand for those manufacturers who aim to make the switch to cleaner options. •

www.beneo.com 1 Innova Market Insights (CAGR of 15% based on new product launches monitored worldwide with a “clean label” between 20122017) 2 FMCG Gurus, Understanding consumer attitudes towards the clean label, 2017 i Source: BENEO Clean Label Consumer research 2018 (UK | Germany | USA, Apr-May 2018, N=3000 (1000/country)) ii Source: GNPD (clean label claims: no additives/preservatives, natural, organic or GMO-free) where Claims matches one or more of [No Additives/Preservatives, All Natural Product, Organic, GMO-Free] as the claim and Date Published is between Jan 2012 and Dec 2017 iii Source: HealthFocus International Global Trend Study 2018 OR BENEO clean label consumer research 2018 – not clear which - slide 3 of SC2 2018 webex doc iv Source: FMCG Gurus 2016 v Source: Innova Market Insights Jan 2012 – Dec 2017 (clean label claims: no additives/preservatives, natural, organic or GMO-free)

INGREDIENTS

Serving Africa's nutritional needs Africa is a continent of contrasts. A variety of climates, landscapes, populations and cultures, lifestyles, preferences and different diets constitute its demographic. It is also the continent with the youngest population in the world with a median age of just 19 years and seven months.

I

T IS THIS burgeoning youthful population that industry experts believe is behind the growing clean label trend in Africa.

The number of product launches with claims such as natural, organic, GMO-free, and no additives increased by nine per cent (CAGR) from 2014 to 20181. Consumers in Africa and particularly South Africa are shifting to a plant-based diet, thus benefiting human health and the health of our planet.

‘Younger consumer groups like Millennials and Generation Z have different perceptions of what their food, lifestyle and dietary needs are about. They are looking for healthier and more sustainable products. This is a global trend, and we are now seeing it in Africa too,' explains Murat Orhon, general manager, Europe, Middle East and Africa, food and beverage solutions, Tate & Lyle.

The strong growth of the company's speciality food ingredients business has been fuelled by the global drive to reduce sugar and calories. Rising obesity and diabetes rates, along with consumer desire for more natural food are leading food manufacturers around the world to reduce the level of salt, sugar and fat in recipes.

In Africa, nutrition ranges from overconsumption of calories, which drives up obesity rates to undernutrition. This results

in people not getting enough key nutrients such as fibre and missing out on important health benefits. In South Africa, more than half of adults are overweight or obese and close to 10 per cent are thought to have diabetes. The statistic includes many people who are undiagnosed with the condition2.

Orhon adds, ‘This unique set of challenges presents us with an opportunity to make an impact in two ways.

Firstly, to provide healthier choices by developing the ideal sugar and calorie reduction solutions for our customers.

This is especially true in the light of stringent sugar tax regulations, such as the one introduced in South Africa last year. Secondly, by offering costeffective ingredients, this will make food more affordable for a larger number of people.'

Cooperation with Long Life Dairy, a leading dairy company in South Africa is a recent example of a partnership making a difference to local consumers. Developed for families in South Africa with limited access to refrigeration, a new range of dairy products including bottled milkshakes, yoghurt-style drinks and custard pouches were made using Tate & Lyle's stabilisers and functional systems allowing shelf stability for up to one year.

Thanks to the solutions used, the new products were also low cost.

This enabled more families in South Africa to access the nutritional benefits of dairy. ‘This product innovation demonstrates how we are providing

Murat Orhon

access to nutritious and affordable foods and delivering on Tate & Lyle's purpose of ‘Improving Lives for Generations.' These products can now reach very isolated rural areas of the continent, with its quality unchanged. This contributes to the nutrition of the people living in those hard-to-reach places,' Orhon explains.

There are huge opportunities for purposeled food and beverage companies to positively impact the continent.

These include: • Africa's rapid population growth, (predictions place the continent's population at 2.4 billion by 2050); • Fast urbanisation rates are driving even higher demand for prepared and packaged food; • GDP growth is predicted at 3.9 per cent annually until 2022.

‘Africa is one of our key emerging geographies.

It's the second-fastest-growing region in the world. As we grow our presence on the ground we can support increasing demand. The continent has an impressive growth trajectory and we are keen to leave our mark, helping existing and new customers feed Africa's growing population in a healthy, sustainable and affordable way,' Orhon concludes. •

Tate & Lyle – www.tateandlyle.com Sources 1. Mintel 2. International Diabetes Federation

2019 Quarter 3 | Food Manufacturing Africa

21

READY TO DRINK

Beverage solutions take processing

to the next level DC Norris works with food and beverage producers across the African continent. The company focuses on supplying efficient and flexible processing solutions.

Food Manufacturing Africa spoke to Stuart Rigby, Jet Cook product and process manager about some of the latest trends developing in the market.

WHAT IS MOST IMPORTANT TO YOUR CUSTOMERS? We have worked with many companies throughout Africa on a variety of products.

These range from baby food and pie fillings to beverages such as Maheu, Mabele, milkshakes and Chibuku. We can adapt each system to suit the customer's individual needs and flexibility.

We're often asked if we can reduce a customer's processing times while improving product quality. Our new, all-in-one Jet Process System addresses process areas such as cooking, cleaning, entraining and sterilising. Traditionally, African producers use multiple processing vessels. This can result in uneven heating and poor finished

Take 5's Jet Cook vessel

New continuous processing solution for the high speed production of beverages & liquid foods Jet Cook

Jet Entrain

Jet Sterilise

Jet Clean

Jet In-Line

Jet Heat

TM

“After nearly 40 years of using steam pots, it was time to move onto the next generation of cooking. We were up and running within 4 days – it worked as promised, and more.”

world leaders in industrial food & beverage processing equipment www.dcnorris.com | jetcook.dcnorris.com

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Food Manufacturing Africa | 2019 Quarter 3

Courlanders Agencies (Pty) Ltd  +27 43 722 5513  c.tucker@courlanders.co.za

READY TO DRINK

products due to inconsistent gelatinisation caustic solution. We've replaced this with in full confidentiality to identify of maize. Burn-on can, coupled with poor a single six tonne vessel, which requires ways of reducing processing times, agitation in the vessel resulting in hot spots. cleaning only once at the end of the day. It product quality, particulate integrity This year we developed a solution for local uses less than 4 000l per day. The system can or to reduce fat, starch, salt and beverage producer Take 5 to produce 18 000 pay for itself in 16 months, based on the cost other spices. The information can kilos/ph of fully hydrated and cooked maize of water saved. be relayed to the Recipe Manager for Maheu and Mabela. This is the world's Software on-site. With our product fastest producing Maheu system, capable of YOU HAVE SYSTEMS ALL OVER THE development kitchen in South producing 6 000l in 20 minutes with a single WORLD. HOW DO YOU MANAGE Africa at the Cape Town Peninsula vessel and operated by a single person.

THE DEMAND FOR YOUR SERVICES, University, we can assist African Food Manufacturing Africa, 132 x 200 mm, Hydronomic, CC-en34-AZ231 05/19 The system has a footprint of 4x7m, which SYSTEMS AND TIME? manufacturers remotely. • consists of four patented Multi In-Line Jet I work from our test kitchen in the Courlanders – www.courlanders.co.za Cook units. The specially designed 1 000l Jet UK. I can analyse customers' recipes Entrain powder induction system can entrain 6 000kg of maize flour in just two minutes.

HOW DO YOU ENSURE PRODUCT QUALITY? Ingredients’ flavours are improved due to the reduced thermal impact of rapid heating and mixing. The total system is controlled by the DC Norris recipe manager software. African producers want the flexibility to produce smooth or coarse Maheu and other beverages using ingredients such as cassava, sorghum and milk powders. The Jet Cook's product flexibility is critical, coupled with its ability to maintain and improve product quality consistently.

We can vary the texture of the finished product by controlling the amount of shear we create inside the Jet Cook chamber. The same system has the flexibility to make different beverages including milkshakes, condensed milk and fruit juices.

WHAT IS DC NORRIS' REACTION TO DEMANDS FOR EFFICIENT, ENVIRONMENTALLYFRIENDLY SYSTEMS? Certain locations are suffering severe drought issues and we must reduce water usage during cleaning. We've addressed this by designing a jet clean function, which heats, atomises and accelerates water through the patented jet unit. This high pressure, high flow cleaning system removes grease and debris in the vessel and only uses a minimum amount of water.

In a recent installation, a customer used 13 one tonne vessels to produce its Maheu base. Each one used 1 300l to clean with the addition of a

Hydronomic #GermanBlingBling #Hydronomic

We do more.

CC-en34-AZ231_05-19.indd 1

06.05.2019 14:00:08

2019 Quarter 3 | Food Manufacturing Africa

23

READY TO DRINK

Serac helps produce fresh and innovative products Dairy processor Greenfields, opened its second processing factory in South Asia in 2017. The factory produces spoonable and ready-to-drink yoghurts.

P

ACKAGING EQUIPMENT MANUFACTURER Serac, provided the industrial solutions that Greenfields was looking for supplying two cup filling lines and a cuttingedge bottle blow-fill-cap unit. ‘Serac has proven itself as a real partner. We can rely on their dairy expertise to ensure efficiency and quality,’ enthuses Darmanto Setyawan, head of manufacturing at Greenfields.

HIGH PRODUCTIVITY, FILLING ACCURACY AND EXTENDED SHELF-LIFE With tens of millions of litres expected each year for the new factory, productivity and overall line efficiency were the main issues.

On such volumes, a single drop wasted in each cup or bottle can lead to considerable product losses. This is unacceptable for

Inside and around the rotary cup filler

any manufacturer. Filling accuracy and cleanliness were discriminating criteria in equipment choice.

TWO ROTARY CUP FILLERS FOR STIRRED YOGHURT The efficiency and reliability of Serac’s cup fillers are attested to by global manufacturers Chobani, Lactalis and Nestlé. The two rotary machines used by Greenfields can handle polypropylene (PP) cups and offer a standard deviation of 0.5 per cent. This results in the high precision filling.

RTD WITH EXTENDED SHELF-LIFE IN PET BOTTLES Serac has also come with a cutting-edge solution for Greenfields' latest innovation: a single block blow-fill-cap. This unit produces ready-to-drink yoghurt packed in 250ml bottles made of transparent PET. The idea of blowing the bottles inside the factory came out of a discussion on how to offer an extended shelf-life without using large quantities of chemicals. The on-site blown bottles only need chemical-free decontamination of the neck and the cap to ensure required hygiene levels. An additional benefit of on-site blowing is empty packaging storage. A processor can store more preforms than bottles in the same space: logistics are reduced and simplified.

The highly hygienic filler of Serac’s Combox H2F benefits from the OEM’s knowhow in aseptic machine design. It meets the hygiene requirements for chilled dairy

SMART BLOW-FILL-CAP SOLUTIONS For your aseptic and chilled drinks

www.serac-group.com

24

Food Manufacturing Africa | 2019 Quarter 3

products and guarantees there will be no recontamination issue in production.

The standard clean in place (CIP) systems provided on Serac’s Combox H2F have been completed with clean/sterilise out of place (COP/SOP) to ensure required extended shelf-life.

Serac’s Combox H2F has been specially designed to meet the needs of dairy companies entering the market of PET bottles. It combines a high precision linear blowing unit. Benefit include options such as preferential heating to blow innovative shapes, with a very accurate rotary filler using weight filling technology.

The efficiency of the Combox is guaranteed by a unique, patented transfer system designed by Serac. This converts the sequential motion of the linear blower into a continuous motion adapted to the rotary filler. It is associated with a special filling mode to ensure quick adjustment of the fillercapper to the blowing unit output.

At the end of each production batch, both machines communicate with each other to ensure all remaining preforms in the blowing unit are used and properly filled and capped. The Combox also keeps downtime to a minimum. This is due to quick mould changeovers that require only a few minutes of one operator. Simplified maintenance operations and the avoidance of starts and stops potentially associated with accumulation systems, are also eliminated. • Serac – www.serac-group.com

Aseptic Combox

Combox H2F

INDUSTRY TALK

Innovative poultry processing and packaging solutions The poultry industry plays a huge role in the economy in Africa. Cheaper and healthier than red meat, chicken remains an incredibly popular meat from Cape to Cairo.

F

OOD MANUFACTURING AFRICA spoke to Mikko Brunner of Renlaw, a Cape townbased engineering firm specialising in industrial food-processing and packaging blades.

‘Africa has seen huge growth in poultry consumption over the last few years. In South Africa alone, nineteen million chickens are slaughtered each week,’ Brunner explains. ‘About twenty per cent of that is destined for fast food outlets.

‘We have been in the engineering field for thirty-five years. Over the last ten years, we have seen a massive surge in demand for poultry blades, with customers ordering from across Africa. Keep in mind that Africa’s growing population is projected to double within the next thirty years. Poultry is big business in Africa and it is growing at an astounding rate.’

We asked Brunner to explain the sequence of processing and a few of the different industrial blades that are used in poultry processing, which relies on sharp, highquality knives. ‘Our business manufactures a wide range of blades that are used in the poultry industry, from processing to packaging. The bulk of cutting for processing begins once plucking is completed by automated machines,’ Brunner notes. ‘First, the less commonly consumed parts are removed using knives such as neck cutters

Wishbone blade

and tail cutters that remove heads and feet.

Other knives are used to remove internal organs, which are set aside for further processing.’

Poultry is then washed and chilled to prevent microbial growth and weighed and graded for quality.

More cutting takes place and deboning, if applicable. ‘Depending on the desired endproduct, the carcass may be left whole or cut in half using halving slicer knives,’ Brunner continues. From there, poultry is cut up into sections such as thighs, breasts, drumsticks and wings.

‘There are specific knives designed for each segment of the chicken such as breast cutters, leg cutters, wing slicers of various sizes, vent cutters, and thigh cutters. We also manufacture wishbone blades and slicer blades which are used to make chicken strips, as well as mincer blades and bowl chopper blades for the processing of chicken burger patties, nuggets, steaklets and cold cuts. We work closely with customers to optimise blade designs and ensure minimal wastage and optimal yield.’

The poultry industry needs to be very carefully controlled for hygiene purposes.

It is highly automated to ensure low levels of human contact with the product, making high-quality knives even more essential.

Poultry producers try to avoid downtime at any cost as it has a significant impact on the overall cost. A sharp knife keeps the whole production line moving.

Sharper knives also preserve more meat during processing, adding more value.

‘We pride ourselves on the quality of our cutting tooling and manufacture to OEM specifications,' says Brunner. ‘With our inhouse built CNC machines, we can produce European quality tooling right here on the African continent which enables us to offer African companies great solutions at very competitive prices.'

There are many options available when it comes to poultry packaging and once again industrial

Large hook blade

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Food Manufacturing Africa | 2019 Quarter 3

machine blades are needed. Poultry can be packaged in a variety of ways, depending on the style and size of the end-product.

‘At the moment the vast majority of poultry packaging makes use of plastics,’ says Brunner. ‘As consumers and producers become more conscious of the pollution crisis, I’m sure we will see more bioplastics and other more sustainable materials being used in the poultry packaging industry, and Renlaw is already producing blades suitable for a wide range of packaging materials.’

Vacuum sealing is the most common form of packaging for poultry products that are intended for sale to butchers or grocery stores as opposed to end-user consumers. Vacuum sealing uses advanced plastic materials and specialised equipment to eliminate air from poultry products – enhancing freshness and shelf life and industrial blades are used to trim the bags.

Overwrap knives are extensively used to package fresh chicken portions such as breast fillets that are sold on styrofoam trays wrapped in plastic.

When it comes to frozen poultry products, usually sold in plastic bags, cardboard freezer boxes or plastic tubs, tray-form knives, sharp bagger knives and boxer knives are used to produce the packaging. Good seals help to ensure quality and freshness.

Regardless of the style of packaging, today’s poultry packaging is an automated process that is conducted at high speed. High quality, reliable blades with excellent cutting performance and sharp-lives are essential for avoiding slowdowns and stoppages which can cause a loss of this fresh product. •

Renlaw - www.renlaw.co.za

Renlaw CUTTING-EDGE TECHNOLOGY With 35 years of blade manufacturing experience, Renlaw offers top quality knives, blades, punches and dies for the food-processing and packaging industries.

Africa’s leading supplier of industrial cutting tools Made in South Africa Offering blade customization Key stock holding saves customers time and money We use only the finest quality German toolsteels Extremely competitive prices

www.renlaw.co.za +27 (0)21 701 7917 (C.T.) +27 (0)79 155 7358 (JHB)

sales@renlaw.com

INSPECTION, CODING & MARKING

Custom weighing and quality control for individual packs A customised multihead weigher and X-ray inspection system from Ishida are major components of a new packing line for instant dried soups.

The linear multihead weigher was developed for the highperformance handling of freeflowing products

T

HE LINE INSTALLED at leading Swiss manufacturer Haco includes an Ishida linear multihead weigher and IX-GA X-ray inspection system. The 12-head linear weigher processes the soup ingredients at a speed of up to 170 weighments per minute with a weighing accuracy of 0.1g. The X-ray system uses Ishida’s patented genetic algorithm technology to detect foreign bodies with a very low density and a size of as little as 0.5mm.

The main reason for Haco’s investment in the new line was the desire for greater flexibility during end-of-line packing to meet growing retail demand for shelf-ready transportation containers. The manufacturer also wanted to increase output and ensure maximum availability. A major challenge for the installation was the limited floor space and room height.

Haco packs the dry soups in bags. During filling, pasta or vegetable ingredients are mixed with a soup powder with the fill weight of the ingredients between 10 and 80g. The linear multihead weigher was specially developed for high performance handling of free flowing products with small target weights. Even the top-of-the range CCW-R-112P, which features 12 weighing heads, has extremely compact dimensions.

This allows it to be seamlessly integrated into the new line.

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TECHNOLOGY FOR ACCURATE TARGET WEIGHTS Soup ingredients such as pasta, croutons or peas are fed into the multihead weigher via two vibrating channels. The feeder system then distributes the product evenly onto 12 vibratory feeder troughs, which transport it to the hoppers. Loadcells and sensors are used to ensure the product is fed consistently. The 12 pool hoppers (used for weight stabilisation) are followed by 24 weigh hoppers, which provide tens of thousands of weight combinations to get as close as possible to the target weight.

Accurately weighed product is then released in a double dose via two discharge chutes into two sachets at a time, which are taken to a carousel. The tilt angle of the chutes was specifically designed so ingredients drop into the sachets at maximum efficiency. Due to a lack of space, the chutes on the filling system had to be staggered.

Food Manufacturing Africa | 2019 Quarter 3

As well as its speed and accuracy, the linear design of the CCW-R-112 ensures gentle product handling, with the low drop heights particularly beneficial for fragile ingredients like alphabet pasta shapes.

Employees at Haco also appreciate the machine's fully enclosed hygienic design, which curbs the amount of dust generated and protects the lightweight product from air turbulence.

Product changes are carried out speedily by selecting from up to 200 presets. All feeder troughs and hoppers have quick release mechanisms for tool-free removal and replacement.

Once the ingredients are in the bag, soup powder is added using auger fillers. The sealed pre-printed bags are then conveyed for quality control in the Ishida X-ray, which can handle the commonly used aluminiumcoated bags.

Haco places great importance on foreign body detection. The Ishida IX-GA’s Genetic Algorithm technology, which uses image data analysis over several generations, was adapted specifically to match the requirements of Haco. This carefully checks the product against the entire spectrum of potential foreign bodies including glass, metal, stone or plastic.

Sachets pass through the X-ray inspection system in two lanes at a belt speed of up to 60m/m. Faulty packs are not rejected using the standard methods of a swivel arm or a compressed air nozzle, because the flat bags are transported horizontally on the conveyor belt. If a contaminated sachet needs to be removed from the process, the conveyor belt quickly retracts at the outlet and the bag falls through a slit at the transfer point to the downstream conveyor belt.

The easy-to-use IX-GA features an automatic setup function and is ready to operate within 90 seconds. Adjustments can be made on the machine without interrupting production. A data log collects valuable visual and numerical information to demonstrate that production and packing processes are properly and correctly performed. • Ishida – www.ishida.com

Retail ready. Smarter, faster, together.

Every business has challenges; ours is to help you overcome yours. Ishida can help you get your product to market quicker, without compromising quality or compliance. From foreign body and leak detection through to checkweighing, working smarter, faster, together, we can achieve higher standards at every stage of your quality control process.

Smarter Faster Together

To set the wheels in motion visit ishidaeurope.com

INSPECTION, CODING & MARKING

Getting to the root of the safety issue Potato farmers encounter an increasing spectrum of hazardous foreign material in the field such as sticks and stones, plastic bottles and golf balls. This makes effective sorting a critical element in the processing line.

W

HILE LARGE FOREIGN objects such as rodents, insects, stones, soil, wood and plastic might be easier to spot, public safety relies on food being free from microscopic contaminants and transparent items like glass - usually invisible to the human eye.

Undetected foreign material such as glass carries a potentially fatal risk to consumers.

It can also trigger a breakdown of trust. This can have an irreparable impact on a brand's reputation and in the digital age, this is difficult to repair.

CAN YOUR BUSINESS SURVIVE A RECALL? Product recalls create a domino effect negatively impacting every single stage of the food supply chain. They are costly in terms of business, brand awareness and the environment. Unnecessary stoppages in production result in increased energy consumption, while the recalled product has nowhere to go. This further contributes to waste in landfills.

When things go wrong, a product recall can be truly devastating for a potato manufacturer in terms of financial loss and status. Automated sorting is not just good for business, it's vital.

MANUAL SORTING: INEFFECTIVE AND UNAVAILABLE While foreign materials pose a significant threat to the quality and safety of a product, manual labour opens the potential for human error, which can result in other objects making their way into the food stream.

Within the context of food safety, the limitations of manual sorting are clear.

Farmers no longer have the same access to labour as they once did due to sociological factors such as rural depopulation and an increasingly educated workforce. As food demand continues to rise in line with a growing global population, optical sorting is no longer seen as optional, but rather as the industry benchmark for maintaining operational efficiency, product quality and food safety.

LED illumination and multispectral cameras facilitate the identification of very small foreign materials and contaminants

IMPROVING PRODUCTIVITY, QUALITY AND VALUE As a partner with some of the world's most influential potato suppliers, Tomra developed a unique insight into some of the biggest challenges facing potato producers and processors today. The company is using these findings to drive innovation to continue to deliver advanced grading, sorting and peeling technology. From whole potatoes to French fries, chips, crisps and speciality potato products, the range of potato sorters guarantees the removal of foreign materials such as stones, plastic, wood and glass.

Equipped with innovative technology, Tomra's potato sorting solutions can detect and reject product defects based on biological characteristics, shape and size, structure, colour and density. Recovery sorting ensures no good product goes to waste. Sophisticated LED illumination and multispectral cameras facilitate the identification of very small foreign materials and contaminants. It also picks up on abnormal solanine (greening)/chlorophyll

The Tomra range of potato sorters can guarantee the removal of foreign materials

content, which can be time-consuming to inspect and remove.

The benefits of having efficient sorting and quality analysis systems in place are farreaching. Not only is this a means of ensuring food safety and preventing product recalls further down the line, but this also goes a long way in preventing machine damage, reducing product waste and minimising production costs. •

Tomra Sorting Food – www.tomra.com

Superior image sensing speed and precision FH Series

• High-precision object detection • Ultra-high-speed searching • Flexible functionalities to provide high compatibility with manufacturing machines

Would you like to know more? +27 (0)11 579 2600 info.sa@eu.omron.com industrial.omron.co.za fh_series_177x65_ad_enza_01.indd 1

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Are you constantly striving to improve food safety, eliminate contaminants, and ensure full traceability? Our comprehensive portfolio and consultative approach runs from power to palletizing. So whether you need total traceability or reliable washdown solutions, we have the answer. Discover the infinite possibilities at new.abb.com/food-beverage