AUGUST 2021 • OCTOBER 2021 Vol. 10 • No. 3
FOOD Manufacturing Africa We understand how you strive for constant product quality and optimized costs.
CONSISTENT + CONFIDENT You are poised to meet your safety and quality requirements while optimizing resources and securing process repeatability.
Improve your processes with our comprehensive portfolio of measuring instruments:
Promag H 100: The flow measurement specialist with an ultra-compact transmitter is designed for hygienic applications.
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.
How cleaning processes impact plant productivity Contact us Email: info.za.sc@endress.com Tel: +27 11 262 8000 www.endress.com
Innovative food processing solutions
Top flavour launches of 2021
Embracing automation to boost productivity
FOOD Manufacturing Africa
CONTENTS
AUGUST 2021 • OCTOBER 2021 Vol. 10 • No. 3
7
WHAT'S NEW
Top five flavour launches in 2021
8 NEWS
12 “The Liquitrend QMW43
reliably and continuously measures the thickness of product build-up when it occurs in tanks and pipes”
27 Inspection, coding & marking The benefits of artificial neural networks in inspection processes Preparing for the future with holistic automation approaches A powerful vision system that performs fast, accurate inspections
Novel ingredient for protein bars H.B. Fuller to build new facility in Egypt Huhtamaki’s new acquisition Register now for Propak West Africa
11
INDUSTRY TALK
Creating the brewery of the future
12
COMPANY FOCUS
Endress+Hauser: Minimising cleaning time
14
FOOD PROCESSING TECHNOLOGY
Making food processing more efficient High-pressure processing and its perks Effective sorting solutions for every type of vegetable Facing the challenges of the food processing industry Food processing equipment to reduce your carbon footprint
21
SNACKS & CONFECTIONERY
A sweet collaboration for snack production
Innovation in the chocolate industry
26
READY-TO-DRINK
PET packaging to ensure product integrity and safety Trends to expect in the ready-to-drink beverage category
ADVERTISERS’ INDEX Bühler.............................................................................................OBC......www.buhlergroup.com Capdan and Allied Equipment................................................19..........www.capdan.co.za Coperion........................................................................................10..........www.coperion.com/ foodtransfer Endress & Hauser ......................................................................OFC.......www.endress.com Ishida..............................................................................................21..........ishidaeurope.com Koel Colours.................................................................................IFC.......www.koelcolours.com Krones Southern Africa.............................................................9...........www.krones.com
Omron Electronics........................................................28..........www.industrial.omron.co.za Polyoak Packaging........................................................27..........www.polyoakpackaging.co.za Savannah Fine Chemicals..........................................25..........www.savannah.co.za Sidel..................................................................................8............sidel.com Sollich KG........................................................................5............www.sollich.com Specialised Printing Products..................................29..........www.spproducts.co.za Syspro..............................................................................7.............za.syspro.com
2021 Quarter 3 | Food Manufacturing Africa
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EDITOR’S COMMENT
EDITORIAL Editor: Tennille Aron +27 (0)73 995 5599 tennille.aron@newmedia.co.za Layout & Design: Andipha Nkoloti ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmedia.co.za Sales Executive: Càndida Giambò-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmedia.co.za
INTERNATIONAL SALES
The future likes arriving unannounced
S
O MUCH HAS changed over the last 18 months, here’s just one more thing you can add to that list of changes. After seven years at the publication, Maryke Foulds has decided to hand over the reins to me. We would like to say a big thank you to Maryke, whose expertise has been invaluable to the African F&B industry, and we wish her all the best for her future endeavours! By way of introduction, my name is Tennille Aron and I have been working in magazines for over eight years. Having previously worked as an editor of a B2B publication, I am no stranger to the industry and I am very excited to be back in it. With the ever-evolving landscape of the African F&B industry, particularly in light of the current pandemic, I couldn’t be more excited to explore all the latest industry updates, trends and news with you. Although we have had a rather unpredictable year thus far, the future of the F&B industry still looks bright with a
slew of innovations to help optimise food and beverage production being released onto the African market constantly. Endress+Hauser recently developed a conductivity sensor that can monitor build-up to reduce the time spent on cleaning and ensure maximum safety in a highly regulated industry. Read about this innovation on Page 12. Factory automation is fast becoming the best way to boost productivity, efficiency and quality in this sector, especially post-pandemic. Discover how automation can help you in your business on Page 28. Siemens South Africa recently migrated Maluti Mountain Brewery in Lesotho from an old automation system in the brewing area to a central control and monitoring station. Find out how they are creating the “brewery of the future” on Page 11. Did you know that South Africa’s chocolate industry is valued at over R7bn? With this industry growing so fast, the opportunities to create novel chocolate confection are endless. All you need is the right confectionery partner to help you along. Explore your options on Page 24. If the pandemic has taught us anything, it is that the future is unpredictable. American commentator George Will said it best when he said, “The future has a way of arriving unannounced”. Here’s hoping that my team and I can help get you a little more prepared for that future in the F&B industry. Enjoy the read!
Tennille Aron
Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com
Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk CIRCULATION Circulation Manager: Felicity Garbers 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, 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: 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 - Cape Town. 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.
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Food Manufacturing Africa | 2021 Quarter 3
Diary
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Food Manufacturing Africa | 2021 Quarter 3
November FI Europe Frankfurt, Germany 30 November – 2 December https://www.figlobal.com/ fieurope/en/home.html FI Europe Online 22 November – 2 December https://www.figlobal.com/ fieurope/en/home.html
NEWS
TOP FIVE FLAVOUR LAUNCHES IN 2021 ACCORDING TO GLOBALDATA “Beverage flavours are arguably the most important factor in determining consumer purchasing decisions, with 29% of global consumers stating they would happily try a new drink flavour out of simple curiosity. This highlights huge incentive for beverage producers to launch new product developments – and reinforces soft drinks as a fast-paced, innovative industry,” explains Holly Inglis, beverages analyst at GlobalData.
H
ERE ARE THE top five flavour launches in 2021 so far, which are shaping the global soft drinks landscape:
Going ‘green’ with hemp and CBD Hemp- and CBD-infused drinks are continuing to garner interest, like products such as Trader Joe’s non-dairy hemp beverage in the US and Sonnenstar hemp juice shot in Austria. While hemp and CBD are positively received by a third and fifth of global consumers respectively, GlobalData’s survey indicates that a considerable portion are still unfamiliar with the ingredients – producers must address this to ensure the longevity of their hemp- or CBDinfused launches. Mango, let’s go Mango-flavoured drinks have emerged in Romania and Singapore, while a flurry of
innovations with flavour combinations that incorporate mango have been observed in the US, UK and France. In the US, PepsiCo’s Bubly Bounce product tags no calories or sweeteners and is a carbonated water brand combining grapefruit, mango, orange and passion fruit aromas. Isn’t that just peachy Peach-based products such as Lipton’s peach tea with honey and Badoit’s peach-flavoured sparkling water in France both tag either low calorie or low sugar bases, reinforcing positive brand connotations, and favourable views on peach as a flavour base. Ginger spice and everything nice Ginger, on the other hand, has been integrated across parts of the globe such as Nigeria, South Korea and Peru,
in line with consumers opting for products that promote digestive health and wellness claims. In fact, 78% of global consumers believe that ginger has a positive impact on their health, reinforcing those links to health/wellness, and promoting manufacturer opportunity to innovate in line with consumer trends. It’s ‘grape’ to be back Interestingly, grape-based products have also made an appearance in 2021. These products are fighting off current stereotypes of grapeflavoured beverages being high in sugar and bad for health, especially in parts of Western Europe where they have less-than-favourable links to low quality. •
724474 OSFF
za.syspro.com
2021 Quarter 3 | Food Manufacturing Africa
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NEWS
Raising the bar for tasty snacks ARLA FOODS INGREDIENTS has launched a new concept to help manufacturers create protein bars that offer healthier indulgence without compromising on functionality. The protein bar category is forecast to grow at a CAGR of 6% between 2021 and 2025, largely because of demand for tasty snacks that can quell “carb cravings”. However, there is a growing call on manufacturers to bridge the gap between health and indulgence, with 55% of consumers saying it is hard to find indulgent snacks they believe are healthy. As the bar category becomes more competitive, manufacturers are looking for innovative ways to meet both these needs. One increasingly featured ingredient is peanut butter, which is familiar to consumers and offers indulgent taste as well as melt-in-the-mouth texture. However, the use of a soft nut butter base in protein bars can result in issues such as the risk of hardening over time, which can affect mouthfeel and shelf-life. Arla Foods Ingredients’ newest concept demonstrates how this challenge can be overcome. It combines Lacprodan SoftBar – a dairy and whey protein ingredient, which allows bars to reach up to 37%
protein content as well as delivering a soft texture – with creamy peanut butter. The resulting bar delivers an indulgent eating experience and offers manufacturers opportunities to make claims such as high protein and high in fibre. Lacprodan SoftBar works well in maltitol-free bars and has
performed well in shelf-life stability tests. The new concept can be used by manufacturers as it is or as a basis for recipes with different flavour combinations or nut butter varieties. •
ASEPTIC PET PACKAGING PROVEN PERFORMANCE
Over 46 billion bottles have been sterilised using Sidel Aseptic Combi with dry preform sterilisation saving our customers 7 billion liters of water and over 57,000 tons of PET.
Sidel Aseptic Combi PredisTM FDA approved
Visit Sidel at Gulfood Manufacturing: Booth Z3-C20, Za’abeel Hall 3 November 7th – 9th Dubai World Trade Centre
Sidel, when aseptic matters. sidel.com AdvProvenAsepticPetPackaging_177x130.indd 1
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Food Manufacturing Africa | 2021 Quarter 3
25.08.21 17:04
NEWS
H.B. FULLER TO BUILD NEW FACILITY IN EGYPT H.B. FULLER, a leading global adhesive manufacturer, Food Manufacturing Africa, 132 x has announced that it will build a new facility in Cairo to support customers’ increased demand in the fastgrowing markets of Egypt, Turkey, the Middle East and Africa. The new factory will become a regional supply hub and a center of excellence for manufacturing of adhesives serving the hygiene, packaging, labelling and other industries. “Egypt has naturally become a main gateway to the region and with the new plant we will extend our current leadership in Egypt and Turkey and grow our competitive position across the emerging markets of the Middle East and Africa,” says Harsh Gupta, H.B. Fuller’s managing director for India, the Middle East and Africa. “Our expanded presence in Cairo, with a high-tech site designed with future growth in mind, will allow us to double our production capacity and advance our technologies,” explains Gupta. The world-class production facility will fulfil industryleading sustainability standards. With a gross area of 3700m 2 in a two-story building, the planned site will be built at the well-equipped CPC Industrial Park, in the 6th of October industrial city outside of Cairo, and will commence full production in the last quarter of 2022. H.B. Fuller has had a presence in Egypt since We embrace a holistic approach 2008 and this new strategic to your beverage factory. investment will allow them to grow and create new job opportunities in the region and offer improved quality, capacity to serve increased regional needs, excellent access www.krones.com to transportation and logistics advantages, and technical support to ensure a superior service that can help customers gain business value through their adhesive applications. •
200 mm, CC-en46-AZ440 08/21
Vision. Feasibility. Cost-Efficiency.
CC-en46-AZ440_08-21.indd 1
09.08.2021 07:53:40
2021 Quarter 3 | Food Manufacturing Africa
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NEWS
Huhtamaki acquires flexible packaging supplier Elif
Book your spot at Propak West Africa now
HUHTAMAKI IS SET to acquire Elif Holding A.Ş. (Elif), a major supplier of sustainable flexible packaging to global FMCG brand owners with operations in Turkey and Egypt. In line with Huhtamaki’s 2030 growth strategy, the acquisition will add scale in strategic geographies and support Huhtamaki’s progress towards reaching its high sustainability ambitions. The acquisition will also expand Huhtamaki’s technology capabilities and product range, allowing it to better serve its customers. “I am thrilled to announce this acquisition. With a great portfolio, a strong focus on sustainability and high growth ambitions, Elif is a perfect fit for Huhtamaki,” said Charles Héaulmé, president and CEO of Huhtamaki. Similar to Huhtamaki, sustainability is embedded into
RETURNING TO THE Landmark Centre in Lagos from 14 – 16 September 2021, Propak West Africa promises to re-energise the packaging, printing, plastics and food processing industry, and act as the catalyst to get the manufacturing sector moving once again. With many industry stakeholders expected next month all are eager to meet the over 80 brands from around the globe. Companies that will be showcasing their products this year include Atlas Copco, Bobst, Canon, CIS Buro, Exact Solutions, Fas Agro, Ishida, Miele, Neofyton, Reifenhauser and many more. Alongside the exhibition, the Propak West Africa conference will also be returning. This year the focus is largely on improving the sustainability of the sector, utilising new practices developed in recent years and providing examples of how these can be applied in Nigeria.
Elif’s strategy and it is committed to the areas of sustainability, environmental, social and governance and to enabling its customers to reach their sustainability goals by providing continuous innovation. Specialised in high-quality sustainable flexible packaging, Elif uses both post-industrial and post-consumer recycled polymers as raw materials. It also has an advanced system of collecting and utilising production scrap from both its own as well as from customer locations. More than 90% of Elif’s current product portfolio is recyclable and the product portfolio also includes compostable films. “We are excited to join Huhtamaki, a company that shares our sustainability and growth vision,” said Selçuk Yarangűmelioğlu, CEO of Elif. •
The speaker line-up is as strong as ever, with PwC Nigeria moderating many of the panel sessions and on board as the strategic conference partner. Their insight and knowledge will help to shape the agenda alongside the many industry-leading speakers representing companies including FCMB, Guinness Nigeria, BUA Group, Bobst and Grand Cereals. TetraPak West Africa is sponsoring the event and will be running a notto-be-missed session dedicated to sustainability and innovation. This year for the first time Propak West Africa is launching a networking platform that allows exhibitors and visitors alike to connect with each other digitally ahead of the exhibition, with access to the complete exhibitor and visitor list once registered. Doing so means attendees won’t miss the chance to engage their key targets and be sure that onsite they can have meaningful discussions and close deals. To see more information visit: www.propakwestafrica.com •
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Safe food and ingredient handling. Feeding, weighing and conveying systems provided by Coperion and Coperion-Tron offer the highest in efficiency and safety standards for plant-based food processing applications. www.coperion.com/foodtransfer
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Food Manufacturing Africa | 2021 Quarter 3
08.07.2021 16:43:27
INDUSTRY TALK
On the road to the brewery of the future As a long-standing technology partner to Anheuser-Busch InBev (known as ABInBev), the world’s largest brewer, Siemens South Africa recently migrated Maluti Mountain Brewery in Lesotho from an old automation system in the brewing area to a central control and monitoring station that will combine the brewhouse and cellars.
To watch a video about the Siemens Braumat, visit the digmag.
Siemens Braumat system
M
EETING CURRENT AND future customer requirements quickly and with the highest quality is key to the F&B industry. As a major beer manufacturer, ABInBev and their brewers want to produce beers with consistent
“The Siemens Braumat system enables flexibility and efficiently manages the recipe and the process, minimises human intervention in the process and reduces extract loss”
quality for their customers. The project, in partnership with Process Dynamic- a solution partner to Siemens, features continuous innovation with the Braumat system. The software was required to have virtualisation capability, recipe control and management, trend and alarm management, batch reporting and controlled access Kamohelo Semuli, brewery specialist at Maluti Mountain Brewery (MMB) explains, “MMB is passionate about brewing and has a long tradition of craftsmanship in making superb beer from high quality natural ingredients. Fast changing recipes required us to be skilled with the new process
quickly, which proved challenging. While we are creating the ‘brewery of the future’, it is important for us to deliver according to our customers’ demands, while giving us full transparency of the production process. The Siemens Braumat system enables this flexibility and efficiently manages the recipe and the process, minimises human intervention in the process and reduces extract loss. Graphical recipe management, route control possibility, batch reporting, replay modes, efficiency and mobile working are essential for our ‘brewery of the future’ goals. We are confident that the
partnership with Siemens will be able to achieve this goal.” Siemens is one of leading technology suppliers to ABInBev globally. With our long history of engagement with the brewing world we are not only making it easier for the brewers to manage recipes, but also helping them to optimise on water and energy utilisation in the processes, explains Munish Choudhary, vertical manager for food and beverage at Siemens South Africa. Process Dynamics has been involved with the MMB and understands the requirements for such a system in the brewing area. We have provided a recipe driven system that supports brewing parameter control and monitoring. All user operations are logged so any deviations from the recipe can be easily traced. By being able to analyse batch data, brewers can optimise recipes. We installed the latest Siemens PLC hardware S7-1500, but also utilised existing Siemens PLC with a centralised control room,” explains Process Dynamics, managing director Kobus Van Niekerk. Flexibility, time-to-market, speed and quality are very essential for the brewing industry. Recipe-control is important, especially based on the changing taste of the customers, but also based on the changing raw materials in the process. “For more than 40 years, Braumat has been recognised as the standard for brewing and process automation,” says Sabine Dall’Omo, chief executive officer, Siemens Southern and Eastern Africa. “We are proud to have delivered on this project with ABInBEV. With our digital enterprise solutions and Braumat, Siemens can help beer manufacturers be more flexible and more efficient. Ultimately, digitalisation is ensuring that we can enable our customers to adapt quickly to market situations and demands to expand portfolios with the highest standards. With our leading technology Braumat, we can substantially provide a higher performance and transparency in the brewing and beverage industry,” says Dall’Omo. •
SIEMENS - www.siemens.com/braumat
2021 Quarter 3 | Food Manufacturing Africa
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COMPANY FOCUS
How cleaning process impacts productivity of your plant The automated process for cleaning pipes and tanks in the F&B industry, known as clean-in-place (CIP), is crucial to manufacture safe products. However, it can be time-consuming and an inexact process. To address this challenge, Endress+Hauser has developed a conductivity sensor that can monitor build-up to reduce the time spent on cleaning and ensure maximum safety in a highly regulated industry.
T
O GUARANTEE THE production of high-quality products that are safe for consumption, a significant amount of time is spent on cleaning to ensure operations meet the hygienic standards defined. To avoid the risk of contamination, many production processes in the food sector take place in closed systems, and this is where CIP is used. In many cases, the duration of the cleaning is determined by evaluating past data rather than looking at what is currently happening in the process, typically in most plants this is based on a set time interval. MINIMISING CLEANING TIME The Endress+Hauser Liquitrend QMW43 minimises the unproductive time of CIP without risking product safety or breaching
12
regulations. The Liquitrend reliably and continuously measures the thickness of product build-up when it occurs in tanks and pipes. The additional conductivity measurement also provides information about the cause of the build-up, i.e., whether it is caused by product residue or cleaning agents. By connecting the device to the control system, the measurement data is available in real time and is automatically documented. If the sensor shows no more build-up, it can be concluded that the critical points have been successfully cleaned. These insights into the process mean that cleaning time can be kept to a minimum and production increased without the concern for poor product quality.
Food Manufacturing Africa | 2021 Quarter 3
WHO ARE ENDRESS+HAUSER Endress+Hauser is a global leader in measurement instrumentation, solutions and services for industrial process engineering with offices in South Africa, where South Africa and sub-equatorial Africa, including Botswana, DRC, Kenya, Malawi, Mozambique, Namibia, Tanzania, Uganda, Zambia and Zimbabwe are supported and serviced. By choosing this company as a partner, customers opt for longterm reliability and a solution provider that has the ability to deliver both instruments and services for a complete solution.
COMPANY FOCUS
The Liquitrend QMW43 can also help to reduce the time spent on laboratory analysis by continuously measuring the products’ conductive and capacitive electrical properties. The use of conductive and capacitive measuring devices has long been adopted by Endress+Hauser. Using the combination of both signals continuously has proven to optimise processes like cleaning. Through these two measuring principals one can accurately determine the build-up height in both conductive and non-conductive processes. Quality parameters can be set in the control system to immediately identify products that don’t meet the required standards without the need for an additional lab test.
“The Liquitrend QMW43 reliably and continuously measures the thickness of product build-up when it occurs in tanks and pipes” The Liquitrend can be used to measure liquids or pastes, whether the media is electrically conductive or not. Due to the unique use of both conductive and capacitive measuring cycles, the device
automatically detects the most accurate measuring mode and uses it automatically. This means that the device can be used without any prior knowledge of the type or strength of the medium and no programming is needed to assist the device to detect any contamination. The Liquitrend meets all food safety regulations and has been constructed by European Hygienic Engineering & Design Group (EHEDG) design standards as well as FDA-compliant materials. In conclusion, with the Liquitrend QMW43 you can reduce cleaning times while maintaining quality and productivity in your plant. •
Phone +27 (0)11 262 8077 | Mobile +27 (0)79 504 6798 Email dhiren.naidoo@endress.com
ENDRESS + HAUSER - www.endress.com
2021 Quarter 3 | Food Manufacturing Africa
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FOOD PROCESSING TECHNOLOGY
Providing the ultimate efficiency
solutions for food production
As the global effort to constantly produce food in more efficient and safer methods continues at pace, BCH rises to meet these challenges by constantly improving their equipment capabilities. BCH has multiple systems installed across the African continent delivering these benefits. COOKING The BCH range of cooking processes allow the user to cook products in atmospheric, vacuum or pressure conditions, all of which can be combined into one system to gain maximum flexibility, if required. The BCH FlexiChef recipe management system can deliver cooking sequences where the heating jacket can automatically switch between surface temperatures on each individual stage, which not only saves energy, but it also allows the user to process more complex recipes in the fastest times. BCH’s clients rely heavily on traceability and that’s where their reporting system assists with recording all times, weights and temperatures by stage as well as showing trends throughout the process. Atmospheric cooking often benefits from steam injection cooking when there is a requirement for rapid heating and/or a need to avoid the risk of damage from a steam jacket. The application of steam directly gives the best heat transfer co-efficient, whereby all the energy is consumed by the product. Vacuum cooking allows the product to be cooked at lower pressure/temperatures and is often used for the preparation of jams, preserves, chutneys, candies and caramels. It is also extensively used when the process requires a reduction cook to a specific solids percentage or weight, such as when
“The combination of BCH cooking and vacuum cooling into one complete system means you can guarantee foods are cooked and cooled rapidly with repeatability and food safety while benefitting from a smaller footprint with reduced labour and energy costs” concentrated stocks are being manufactured. The pressure-cooking process is particularly designed for products such as pie fillings, ragus, stews, curries and ‘long-cook’ vegetable processes. Typically, a four-hour cook can be completed in 75min creating huge savings in time, cost, labour and energy. The adaptability and cooking speed of BCH’s latest range of steam jacketed pressure cookers coupled with their ability to mix and cook simultaneously, enables customers to produce a high-quality finished food product in exceptionally fast times. With methods such as steam jacketed open kettles or steam injection, large amounts of additional water are added to the product and then evaporated off again, which can be costly when energy and water usage are a significant consideration. Pressure cooking retains moisture and locks in the flavour and nutrients, which can sometimes be lost during atmospheric or steam injection cooking. It also guarantees that the entire contents of the kettle have been cooked evenly at the same temperature for the time specified in the recipe. This
pressure method also improves processing times with vegetarian options, such as pulses, beans and chickpeas. BCH systems offer a unique horizontal style agitation that gives exceptional particulate distribution and mixing during the cooking process, keeping the particulates in suspension before and during transfer to the next process. COOLING BCH can offer several types of cooling such as scraped surface units and pouch cooling tumble chillers. However, the addition of a BCH vacuum cooling system ensures a complete high-performance system, providing the fastest and most effective means of heat removal from a batch process. Their vacuum cooling solutions can typically cool products from 90°C down to 5°C within 45min without the need for expensive refrigeration used on scrape surface, pouch and the traditional blast chilling rooms. A vacuum cooling system operates at around 30% of the refrigeration costs and it can be supplied with a seal water recovery system, thus reducing operating costs further. The speed of cooling in a sealed environment offers excellent food safety attributes and swift passage through the temperature danger zone. The combination of BCH cooking and vacuum cooling into one complete system means you can guarantee foods are cooked and cooled rapidly with repeatability and food safety while benefitting from a smaller footprint with reduced labour and energy costs. •
BCH - http://www.bchltd.com
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Food Manufacturing Africa | 2021 Quarter 3
FOOD PROCESSING TECHNOLOGY
High pressure processing: healthier, additive-free and more sustainable products The demand for minimally processed foods has been rapidly increasing around the world, and the continent of Africa is no stranger to this trend. Here’s a closer look at this trend.
C
ONSUMERS ARE LOOKING for natural, nutritious, additive-free ingredients without excessive heating. This trend is motivated by the consumer’s new consciousness, since the consumer is now more aware of the effects of excessive heat in food that can often damage the ingredients and lead to a sensorial and nutritional loss. Therefore, the food industry has been adapting to this challenge, and in recent years, there have been multiples advances in the development of innovative non-thermal preservation techniques. In this context, High Pressure Processing (HPP) stands out as the most efficient technique for food processing. HPP is a food and beverage non-thermal preservation technology that applies highhydrostatic pressure (600MPa) for some seconds or minutes to packaged products. It is synonymous with: • Minimally processed products The nutritional and organoleptic characteristics of food products are kept intact, maintaining the freshness of the original product. • Longer shelf-life From a few days up to weeks or even months, under refrigeration conditions, reducing the use of preservatives such as salt. • Guarantee of food safety The inactivation of spoilage pathogens and microorganisms (lactic acid bacteria,
“High Pressure Processing (HPP) offers producers a solution for the development of clean label foods”
yeasts and moulds) guarantees high sensorial quality. • Wide variety of products It can be applied in traditional sectors such as juices and beverages, avocado products (guacamole), meat (sliced deli meats, dry-cured products) or seafood to more trendy categories like ready-toeat meals, plant-based dips (hummus), baby food or wet pet food. • Development of plant-based products The increased concern for health and for the effects of meat production on the environment and animal welfare has led to the rise of plant-based products, along with HPP technology as its main ally. In addition, since it is a non-thermal preservation method, which inactivates pathogenic and spoilage microorganisms in already packaged products (avoiding the risk of cross-contamination), it offers producers a solution for the development of clean label foods. This technology helps
To watch a video about Hiperbaric High Pressure Processing In-Pack, visit the digmag.
Moira´s products processed in a Hiperbaric unit
meet the growing demand for cleaner label products. In fact, now, up to 70% of consumers are likely to seek out products that meet clean label requirements: no chemical additives, present a simple and recognisable ingredient list and have been minimally processed. Contact Hiperbaric to know more about the use of HPP to develop healthier foods and the multiple benefits that this technology can provide to companies and products. •
Hiperbaric - www.hiperbaric.com
2021 Quarter 3 | Food Manufacturing Africa
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FOOD PROCESSING TECHNOLOGY
Green beans being sorted in the Tomra 5B
Helping vegetable processors achieve food safety and product quality Guaranteeing food safety. Protecting brand reputations. Complying with product specifications. Minimising food waste. Maximising yields. Protecting profitability. There are too many challenges for the growers, processors and packers of fresh, fresh-cut, canned, frozen and dried vegetables.
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HE CHALLENGES THAT food producers, growers and packers face would be so much easier if foreign materials didn’t get mixed up with freshly harvested vegetables, if every batch of vegetables didn’t contain sub-standard product and if the presence of these unwanted materials on the processing line weren’t sometimes almost impossible to detect. Worse still, these challenges are intensifying because the market is changing. Increasing demand for both fresh and frozen vegetables - a trend accelerated by the Covid-19 pandemic - puts processors under more pressure to handle greater volumes at higher throughputs. It is also increasing demand for organic foods - expected to rise by 50% in the next five years - which means that more vegetables grown without pesticides or herbicides are arriving at processors mixed up with toxic weeds, vermin and insects. The good news is that optical sorting machines can deal with all these challenges. Thanks to ongoing technical developments and innovations by Tomra Food, there are highly effective sorting solutions for every type of vegetable product.
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What’s more, in addition to ensuring food safety and product quality, today’s sorters also deliver a multitude of other benefits. They grade to specification, increase removal efficiency, minimise false rejects, reduce the need for manual intervention, help solve labour problems (scarcity, cost, effectiveness, knowledge and training), reduce line downtime, and - through the Tomra Insight cloud-based data platform provide valuable data about the product sorted. Through all of these capabilities, sorters improve sustainability by cutting food waste while enhancing yields and profits. PRE-SORTING FOR FOREIGN MATERIALS AND CRITICAL DEFECTS You name it, and in a load of freshly harvested vegetables, you’re likely to find it. Clods of earth, rocks, stones, sticks, stalks, vines, toxic weeds, field mice, plastic bottles, fragments of glass - all of these things and others get mixed in with vegetables delivered to processing lines. The extent of this problem varies with crop type and field location, but there’s no getting away from it.
Food Manufacturing Africa | 2021 Quarter 3
This necessitates pre-sorting to remove foreign materials before the vegetables are fed onto the processing line. The more it is possible to sort out at this preliminary stage, the less it will be necessary to do later, enhancing throughputs. Tomra offers four different optical sorters for vegetable presorting: the Sentinel II, Halo, Tomra 3A
“Thanks to ongoing technical developments and innovations by Tomra Food, there are highly effective sorting solutions for every type of vegetable product”
and Tomra 5A. The Tomra 3A is used mostly for unwashed potatoes (and unpeeled onions), which we’re not considering here, but we’ll take a look at the other three machines. The Sentinel II combines Tomra’s pulsed LED/sensor arrays with a simple
FOOD PROCESSING TECHNOLOGY
Tomra 5B processing spinach
user interface to remove a broad range of foreign materials, rodents, defects, discolouration, damage and undersize product. The Sentinel II’s superior technical specification enables it to outperform competitors in sorting efficiency and sorting capacity. With three different sizes giving a wide capacity range, it’s ideal for seasonal and year-round processors. Also popular for pre-sorting many types of whole vegetables is the Halo, a high-performance machine that sorts according to size, shape and quality. The Halo uses top and bottom sensor banks to view each individual object in flight using a combination of LED, CCD camera and near-infrared. This performs targeted spectroscopy to 1mm precision. The Halo is suitable for carrots, beets and onions as well as fresh pack carrots, parsnips, cucumbers and gherkins. Depending on the application, this sorter increases yield by up to 4%, increases throughput by up to 25%, and reduces labour requirements by up to 80%. Another machine often used for presorting and removing foreign material is the Tomra 5A. This belt machine employs top and bottom sensor banks to view each individual object in flight using a combination of pulsed LED, camera and near-infrared. Targeted spectroscopy is precise to 1mm, achieving a superior foreign object removal rate of more than 98%. These high efficiencies combined with low false reject rates are often a key requirement to protect the cutters in the processing line. SORTING NEXT FOR FOREIGN MATERIALS AND QUALITY For IQF processing, removing as many product defects as possible at this stage will save on freezer space and associated electricity costs. However, there will be another opportunity for sorting after the vegetables have
passed through the freezer tunnel. For fresh pack and fresh cut vegetables, though, there are no second chances: it’s now that the product has to be fully sorted to ensure food safety and meet required standards. The Genius, a belt sorter that is lowmaintenance and easy to use, offers different technologies for different inspection zones. High-resolution cameras and lasers can be combined with fluorescent lighting or LED in one area and ultraviolet or infrared in another. This machine is typically used for sorting fresh-cut, blanched or dried/dehydrated vegetables. More sophisticated still is the Tomra 5B. Also a belt machine, this combines 360° surround view camera technology with advanced shape algorithms for object processing and laser technology. Capable of sorting according to colour, shape, structure and biological elements such as chlorophyll and solanine, this sorter is ideal for the targeted identification of individual defects in high-volume production flows. It is typically used for peas, carrots, green beans, spinach, corn and bell peppers, and is capable of detecting and ejecting toxic weeds such as Datura and Nightshade from peas and green beans. It has an unrivalled ability to remove core from Iceberg lettuce. This machine is also exceptionally well designed for fast and efficient cleaning with an open system, which results in fewer unreachable areas and a lower risk of waste material building up. END-OF-LINE QUALITY CHECKS When processing IQF vegetables, there is a final quality check to be made, either immediately after the freezing tunnel, on the mixing line or just before the product is packed. This is an additional opportunity to find and remove unwanted materials that were not visible or were missed when sorting before the product was frozen.
Three machines are typically assigned to handle these checks: the Ixus Bulk, Blizzard, and Nimbus BSI+. The Ixus Bulk scans product in bulk to detect dangerous foreign materials, such as metal, glass and small rocks that may be free-flowing in the product stream or embedded in the product. This machine has been engineered around the best performing x-ray detector for unmatched image resolution, resulting in the ability to find the smallest defects at high throughputs. The Blizzard, a free-fall sorter with a small footprint, does its detection work with pulsed LEDs and a combination of cameras. Optimally positioned after IQF tunnels or on packaging lines, this machine’s lighting system generates little or no heat in the cold environment and needs very little calibration or maintenance. The LEDs’ different wavelengths detect unwanted foreign material, misshapen product and discoloured product. The Nimbus BSI+ is used in applications where it will do an even better job than the Blizzard in sorting-out some types of difficult-to-detect foreign materials or extraneous vegetable material. This machine’s way of ‘seeing’ combines multiple high-resolution lasers with unique Biometric Signature Identification (BSI) technology. In addition to seeing the colour of objects it scans, this machine also detects their biometric characteristics. It instantly compares these characteristics with features stored in its database to determine whether the objects should be accepted or rejected. Thanks to the various tasks performed by all of these sorters, all major operational challenges are addressed. Processors can assure food safety and product quality with total confidence. •
Tomra - www.tomra.com/en
2021 Quarter 3 | Food Manufacturing Africa
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FOOD PROCESSING TECHNOLOGY
Uncovering the latest trends and challenges facing the food processing industry The challenges facing food producers are always evolving, but with resource management, food safety and rising to the demand of an expanding population all now top-of-mind, the need for flexible, efficient food processing equipment has never been greater. Food Manufacturing Africa sat down with Magdy El Dessouky, tna solutions’ newly appointed general manager for Algeria, Libya, Morocco and Tunisia, to get his perspective on the issues dominating today’s food processing market. Magdy El Dessouky, tna solutions’ General Manager for Algeria, Libya, Morocco and Tunisia
Q TAKING INTO ACCOUNT THE CURRENT CLIMATE, HOW IMPORTANT IS SUSTAINABILITY AND RESOURCE MANAGEMENT FOR THE FOOD PROCESSING INDUSTRY? As one of Africa’s largest and most economically significant sectors, the food processing industry has a vital role to play in helping safeguard the continent’s natural resources. Manufacturing the products that fuel people, businesses and entire nations can be a very energy and raw-material intensive process. However, with the effects of climate change becoming more and more pertinent, and the region’s population rising at a rapid rate, we’re all acutely aware of the need to make processes more efficient – both to meet consumer demand and protect the planet. Improving the sustainable credentials of their offering can also help businesses boost consumer appeal, as research demonstrates that almost half of global shoppers say that reducing their environmental footprint is more important to them post-pandemic. Q WHICH TECHNOLOGIES CAN HELP MAKE FOOD PRODUCTION MORE ENERGY AND RESOURCE EFFICIENT? When it comes to resource management, tna always recommends brands focus on making small, incremental changes that add up to meaningful improvements in waste reduction and efficiency. The tna florigo conti-pro PC 3
The sophisticated software featured with the latest processing and packaging equipment can be helpful here. The tna
“As one of Africa’s largest and most economically significant sectors, the food processing industry has a vital role to play in helping safeguard the continent’s natural resources” robag® FX 3ci packaging system, for example, delivers energy savings of up to 20% through its intuitive power saving modes. Advanced control and monitoring systems, which are often included as standard with today’s food processing equipment, also help minimise energy and material usage. For instance, they can help tightly control the temperature and oil levels within frying machines or automatically adapt conveying equipment performance to reduce product breakage. Q WHAT ARE THE MAIN CHALLENGES TO FOOD SAFETY DURING THE PRODUCTION PROCESS, AND HOW CAN ADVANCED EQUIPMENT SOLUTIONS HELP OVERCOME THEM? Today, hygienic food production is as pressing an issue for global consumers as it has always been for site managers, with 57% citing food safety concerns as a major influence on their purchasing decisions. The main challenge facing food producers in this area is keeping processing equipment scrupulously clean to prevent crossThe tna intelli-flav OMS 5.1
The tna robag® FX series-high performance VFFS System
contamination. To ensure food safety, producers should look for hygienicallydesigned processing equipment with minimal moving parts and features that make it easy to sanitise between product runs. tna solutions’ range of vibratory and horizontal distribution conveyers is constructed using food grade stainless-steel with a 2B natural finish that can withstand aggressive fats, oils and flavours, but is also resilient to caustic cleaning materials. Meanwhile, the leading tna intelli-flav OMS 5.1 on-machine seasoning system and portfolio of Florigo frying equipment are similarly designed to be thoroughly, yet quickly sanitised day after day, batch after batch for complete safety and optimal food quality. Q HOW CAN PRODUCERS IMPROVE EFFICIENCY AND THROUGHPUT ACROSS THEIR PRODUCTION LINES? In my opinion, the single most effective step producers can take to boost efficiency is to focus on line integration. Every one of our processing and packaging solutions is designed to work in harmony with one another, both physically and through smart connected operating systems. This has a profound effect because it minimises all the factors that can slow down production. For example, with complete line integration, blockages or errors in the conveying system can be automatically communicated to the seasoning, frying or weighing equipment, preventing product waste and alerting operators to the issue before it can cause costly delays. •
tna solutions - www.tnasolutions.com
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Food Manufacturing Africa | 2021 Quarter 3
SOUTH AFRICAN MANUFACTURER OF
SPECIALISED FOOD PROCESSING EQUIPMENT
With our experienced design team and Paarl based factory, our production capabilities are endless.
With over 45 years experience in the production of Industrial Cooking Equipment, we have extensive expertise to custom design and manufacture quality, highend equipment to meet your food production needs.
2000Ltr Cooker/Mixer pot in production
Our range is not limited to: • Steam Jacketed Kettles ranging from 20-2000 litres
• Pressure Kettles • Bin Hoists
available in various configurations • Vacuum Cookers
• Combi-Ovens
• Sauce / Jam Pots
• Conveyor Ovens
• Mayonnaise Plants
• Homogenisers
• Continuous Conveyor Fryers
• Confectionery Cutting Tables
• Transfer Vessels
• Foot Operated Wash Hand Basins
• Holding Tanks
• High Shear Blenders and more….
• Steam / Electric Tilt Frying Pans
CAPDAN AND ALLIED EQUIPMENT (PTY) LTD Benoni Office: +27 (0) 11 969 3407 Paarl Office:
+27 (0) 21 862 6110
sales@capdan.co.za Soup Plant with Hoist
www.capdan.co.za Jam Plant
FOOD PROCESSING TECHNOLOGY
Reduce your carbon footprint with this new equipment Reduce your carbon footprint with the Cook Quench Chill ‘Adapt’ series. This cooking and cooling system for rice, pasta and vegetables gives food manufacturers optimum performance, while using the minimum amount of energy and water.
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C NORRIS’ RESEARCH and development team have been busy during the pandemic, using the time to develop fresh ideas and re-design existing equipment to streamline processes and improve efficiency for their customers. The company have paid particular attention to helping customers minimise their carbon footprint by reducing the amount of water and energy required to run their equipment. The Cook Quench Chill ‘Adapt’ system is just one of these new launches. This versatile, user-friendly machine is manufactured to suit the highest demands of the food industry. All areas of the process are designed with optimum performance in mind without compromising on product quality, hygiene and maintenance. The Cook Quench Chill process uses a series of vessels arranged in-line, which can have a low-to high-risk divide. The product is contained in baskets that tip into each other and ultimately, into a suitable receptacle at the end of the line. The standard Cook Quench Chill is made up of three main parts, namely, cook, quench and chill. However, the versatility of the ‘Adapt' series means that modules can be added or removed according to throughput, which allows manufacturers greater flexibility for expansion. It is also streamlined in construction and is simple to install. ENERGY EFFICIENT Products such as pasta, rice, potatoes and vegetables are cooked or blanched continuously at faster speeds due to the addition of two patented jet heat direct steam heat systems. The use of DCN’s patented Jet Cook technology allows manufacturers to speed up cooking and cleaning times. It operates by collapsing steam into the product at high velocity through a specially designed nozzle. As the steam collapses it pulls the product (liquid) through, creating a recirculating effect (partial vacuum) in the recirculating pipe. 99.5% of the steam is utilised and then collapsed into the product
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“The Cook Quench Chill ‘Adapt’ System is a versatile, user-friendly machine created to suit the highest demands of the food industry”
ensuring huge energy savings. Jet Cook also replaces tube and tube type heat exchangers that are inefficient and take up valuable space. Recent trials in DCN’s product development kitchen showed the ‘Adapt’ producing 195Kg of cooked and cooled basmati rice in 23min (65kg dry weight), 50kg of diced carrots in just 18.5min and 110kg of cooked and cooled spaghetti in just 15.5min. WATER-SAVING DESIGN The ‘Adapt' is designed to achieve maximum water savings with smaller tank capacities and variable water levels to suit different batch sizes. A Weir starch removal system means the same water can be re-used for a new batch. Internal heat exchangers continuously chill and control the Quench and Chill water temperature, saving more water as it recirculates through the stainlesssteel heat exchangers. HIGH QUALITY PRODUCT Product quality is assured with the variable wave agitation system, which ensures that the product is always kept in suspension producing a damage-free product and preventing product clumping. The rapid heating and cooling of products such as rice, pasta, vegetables and pulses is critical to maintain nutritional values and both visual and taste quality. Rapid and even heat treatment reduces the loss of nutritional values of certain foods and reduces the damage in plant cell wall structure, which effects eating quality and shelf-life. Cooling the product at speed is just as important so that bacteria can’t grow and
Food Manufacturing Africa | 2021 Quarter 3
To watch a video about the Cook Quench Chill ‘Adapt’ series, visit the digmag.
cause illness. It is critical that products pass through the temperature danger zone quickly to reduce the growth of pathogens. LOADING/UNLOADING A DCN designed hydraulic tipper makes loading of the product easier and quicker, tipping directly from the floor. A stainless-steel trough vibrating conveyor drains water from the product before discharging into a standard tote bin or customer product trays. FULL TRACEABILITY WITH DCN PROCESS MANAGEMENT SOFTWARE DCN’s process management software controls the entire system. The user-friendly system allows customers to create a step–by–step cooking and cooling process with individual basket agitation speed control and useraccess security with all processes stored to a relational database. Each product has its own unique cooking and cooling parameters written in to give precise repeatable times and temperatures. These can then be recorded for full traceability using the virtual chart recorder. DCN has a product development kitchen in South Africa at the Cape Town Peninsula University and can also assist African manufacturers remotely. •
DC Norris - www.dcnorris.com Courlanders - www.courlanders.co.za
SNACKS & CONFECTIONERY
The natural choice for artisan potato chips The collaboration between Belsia, a high-quality artisan French potato chip manufacturer, and Ishida, world leader in weighing and packing line solutions for the food industry, underlines the care and support that the company can provide to help small start-up companies achieve a foothold in the market and build a foundation for sustained growth.
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ASED IN BEAUCE in northern France, Belsia was established in 2015 when Matthieu and Clémence Maisons decided to devote 10 hectares of the family’s 160-hectare farm to growing the Lady Claire potato variety, whose intrinsic qualities are ideal to produce high-end potato chips. First marketed in 2016 to local supermarkets, the potato chips, which are hand produced using 100% natural ingredients in four tasty varieties, quickly became a great success, reflected by ever-increasing volumes – 50 tons of potatoes processed in 2016, 150 tons in 2017, 300 tons in 2018 and 500 tons planned for 2019. AN ON-GOING COLLABORATION The first contact between Matthieu Maisons and Stéphane Woigt, regional sales manager at Ishida, took place during an exhibition in Paris and a dialogue was maintained during Belsia’s early years, during which time the company relied on second-hand packing equipment to process around 400kg of potatoes per day. “At Ishida, we do not have large or small customers,” explains Woigt. “Instead, we have companies seeking the most suitable and reliable solution for their specific application. In the
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“We appreciated that an international company like Ishida was willing to give equal consideration to the needs of a young company like ours” case of Belsia, when the company first approached us, it was not yet producing a significant enough volume to warrant the purchase of new equipment. However, we remained in regular contact, providing advice and establishing and maintaining a relationship of trust so that, when ready, Matthieu Maisons turned to Ishida to invest in a new potato chip packing line." As Maisons confirms, "We appreciated that an international company like Ishida was willing to give equal consideration to the needs of a young company like ours." COMPLETE RESPONSIBILITY In 2018, after an assessment of three manufacturers, Belsia chose Ishida to devise a complete turnkey line with a small footprint with Ishida assuming full responsibility for the entire installation and its performance. During the 1990s, Ishida devised an integrated snacks packing solution, featuring a weigher mounted directly over
Food Manufacturing Africa | 2021 Quarter 3
a VFFS bagmaker to deliver valuable space savings. The multihead and bagmaker work in perfect harmony to deliver the highest speeds, efficiency and pack quality, without compromising Ishida’s proven precision and accuracy. A FULLY INTEGRATED SOLUTION At Belsia, the line comprises a 10-head Ishida CCW-SE series multihead weigher with polished stainless-steel hoppers and an Astro bagmaker equipped with special stripping plates that clear the seal area
SNACKS & CONFECTIONERY
before sealing to ensure excellent pack quality and close to zero film waste. In addition, Ishida has supplied a bucket elevator that feeds the potato chips to the weigher and a throat metal detector, positioned between the weigher and the bagmaker to identify and reject any metal contamination before the potato chips are bagged. Belsia is packing both 150g and 40g bags on its Astro bagmaker. The new Ishida installation, which is operating at 30 packs per minute for the 150g bag format, has enabled Belsia to increase production to 800kg per day of processed potatoes, combining excellent equipment reliability and minimum downtime for product changeovers with accuracy to within one gram of the target weight, thus avoiding overfills. All these benefits combine to provide substantial savings for the company and a short investment payback. Equally important, the line is scalable and therefore will be able to support Belsia’s ongoing development of its potato chip range to deliver ‘a new flavour each year’, according to Clémence Maisons.
The Ishida Astro The Ishida Astro
CUSTOMER SATISFACTION Maisons concludes, "In addition to the reliability and speed of the line, we also appreciate its ease-of-use thanks to the intuitive touchscreens. Changing the bagmaker film reel takes only a few minutes and daily cleaning is easy. In our business where a production stoppage can very quickly cause problems, we are able to work with confidence because we know we can not only rely on the Ishida equipment, but also on their fastresponse after-sales service." •
Ishida - www.ishida.com Ishida machinery at Belsia
2021 Quarter 3 | Food Manufacturing Africa
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SNACKS & CONFECTIONERY
Take your chocolate confectionary to the next level! The chocolate industry is a dynamic and innovative segment that is ever-changing. South Africa’s chocolate market is valued over R7 billion and demand for sugar-free, premium and artisan chocolates is driving the way to new markets. The innovation is endless especially with great quality products, writes Carien Schoeman and Carina Mendes.
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AVANNAH FINE CHEMICALS knows well in fat-reduced chocolate and compound how to assist you with all your chocolate formulations. PGPR reduces chocolate solution needs from chocolate yield value efficiently allowing for nutrition to indulgence and from luxury to better coating of inclusions, removal of air low-cost alternatives. bubbles during vibration process and optimal Chocolate is one of the most consumed for moulding applications. products on the globe. Barry Callebaut Group Consumer's lifestyles are evolving with is one of the world's most prominent an increased trend toward healthy snacking. manufacturers of high-quality chocolate Chocolate manufacturers are continuously and cocoa products. looking for new and exciting ways to answer Savannah’s proud partnership with the call of this global demand. Barry Callebaut includes the complete In addition, there is a trend towards cocoa derivative portfolio- cocoa butter, consumers not only wanting something mass/liquor and powders ensuring our healthy and good for the planet, but also customers have the highest quality indulgent. That is why manufactures are chocolate at their fingertips. answering this request with sugarConsumers want brands to own their commitment on sustainability. Its DID exclusive Cocoa Horizons YOU KNOW? programme answers this question and helps The global chocolate position your chocolate market is expected to confection above the grow at 4.78% over the next four years to reach rest. On the other hand, a total market size of the partnership with Bunge US$ 182.090 billion Lodgers Croklaan ensures by 2025. Savannah can also offer cocoa butter substitutes to the confectionary industry. The CLSP range has become an international standard for lauric-based fats, which offer great value and technical functionality with giving a good snap, excellent moulding, quick meltdown and is also low in trans fats. Discover how to The flow behaviour and viscosity of innovate your chocolate are important parameters for next innovation moulding, enrobing, panning, dipping and hollow figure application. Here, Savannah Fine Chemicals can offer lecithin and PGPR as the two emulsifiers applied in chocolate to control viscosity behaviour. Bungemaxx sunflower lecithins have high purity and clean taste. In addition, it helps improve blending and stabilisation, decreases viscosity and yield value in chocolate. Masemul PGPR 9090 (polyglycerol polyricinoleate) works
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Food Manufacturing Africa | 2021 Quarter 3
reduced and sugar-free chocolates. However, producers are not only looking for ingredients that will replace sugar, but will also add a health benefit. Beneo offers a clean-label solution with the Orafti HSI and P95 (Inulin and oligofructose) for sugar reduction and Orafti HP and Isomalt LM PF for sugar-free options. The Orafti products not only replace sugar, but improve mouthfeel, aid in digestive health (with prebiotic benefits) and reduce the glycaemic response. Beneo's Isomalt LM PF is a polyol derived from sugar beet and has a clean sugar-like taste with no cooling effect or
SNACKS & CONFECTIONERY
“The flow behaviour and viscosity of chocolate are important parameters for moulding, enrobing, panning, dipping and hollow figure application”
after taste. In addition to having a very low glycaemic index where it hardly affects blood sugar and insulin levels, it is also low in calories. Added to that, it also has a technical advantage of a good snap and mouthfeel in chocolate. For children, Beneo’s Palatinose is a toothfriendly, low GI option. Other sugar replacers on offer is maltitol, erythritol, xylitol and stevia. The concept of health and wellness is changing where consumers are looking more for brands that offer health solutions and added benefits. There are many options to give your confection that added health value while maintaining the indulgence. How about we jumpstart the creative process with these three options? Fortification with Acerola
from Diana Foods which is a natural vitamin C, adding Probiocab (microencapsulated probiotics) from Lallemand for optimum gut health or even Veri-te Resveratrol from Evolva which improves blood glucose support, cardiovascular health and cognitive function. Next level indulgence can be achieved through adding flavour, crunch and colour to your chocolate. If you are looking at adding vanilla to your confections why not go the next step and use ‘Green Vanillin’? Borregard is the only producer of natural and sustainable vanillins
made from wood. EuroVanillin Supreme has the lowest CO2 footprint in the Vanillin range, which has superior taste closest to natural vanilla. Borregard can also compete with low-cost alternatives with the Vanillin SB18, which is equal strength to oil-based vanillin. Even at lower levels, it can be used to mask off notes and add the extra boost of flavour. Everyone also likes a bit of crunch and eye-catching colour with their confections. Diana foods has a wide range of clean label solutions from fruit and vegetables such a minis, crunchies and crunch’flakes used in different sizes and forms for that memorable multi-sensory experience. The opportunities are endless in this ever-growing market. What will your next confection look like? If you are interested in knowing more for your chocolate solution needs, all products are supplied locally through Savannah Fine Chemicals. Contact them for the appropriate recommendation for each specific application. •
Bungemaxx sunflower lecithins have high purity and clean taste
Savannah Fine Chemicals – www.savannah.com
INGREDIENT INNOVATION THAT’S VALUE DRIVEN
BASIC FOOD INGREDIENTS FOR EVERYDAY SOLUTIONS
We supply food manufacturers with quality ingredients and a wide range of additives to help create the taste, texture, performance and appearance you need for your food nutritional products. We represent leading global manufacturers & our specialists can provide you with unrivalled sales support bringing the highest quality products to market: Bakery ingredients: flavour, texture and fortification - Beverage ingredients for innovation - Confectionary: healthier & tastier alternatives to enhance your brand - Culinary solutions for sauces, dressings and prepared meals that will innovate - Dairy & Desserts: texture & functionality - Flavour & fragrance creation - Health & Sports nutrition. Johannesburg: +27 11 856 4500 Cape Town: +27 21 551 5353
Durban: +27 31 202 0794 Email: info@savannah.co.za
www.savannah.co.za
2021 Quarter 3 | Food Manufacturing Africa
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READY-TO-DRINK
COVAP’s first complete aseptic PET line Thanks to Sidel’s end-to-end complete aseptic PET line, UHT liquid dairy products (LDPs) from Spanish milk producer COVAP are now also available in PET bottles for the very first time. This new PET bottle opens the door to meet changing market demand and ensures product integrity and safety.
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OVAP, A SPANISH cooperative, is one of the major milk producers in Spain. The company has one of the most technically advanced dairy plants in the whole of Europe and has been a family of farmers for over 60 years. COVAP also produces ready-todrink dairy products for other retailer brands in Spain. Although LDPs are dominated by carton packaging, major supermarket players have decided to sell them in PET bottles as well based on market preference. To meet demand, COVAP partnered with Sidel for the first time on a complete aseptic PET line with the Sidel Aseptic Combi Predis at its heart, after visiting various dairy plants using Sidel’s equipment in Spain and Italy. Sidel experts worked in close collaboration with COVAP from bottle design to line startup. The new PET bottles were designed with a sleek shape, providing a similar look and feel to glass bottles. Thanks to the PET barrier properties, the shelf-life of milk drinks has
been extended by 4 months to retain their fresh taste. All three bottle formats – 225ml, 1l and 1.5l – can be labelled with sleeve or roll-fed labels based on different brand positioning. Thanks to 40 years of aseptic packaging expertise, the safe and simple aseptic PET line requires only a few operators and thus facilitates a smooth and efficient production, running at up to 13 200 bottles per hour. As a result, COVAP is now producing 30 million
PET bottles annually. Furthermore, Sidel provided intense training for operators to ensure successful production on the line. “Since PET packaging is a new territory for us, Sidel is the right long-term partner to advise us in every phase and to provide end-to-end solutions,” commented Vidal Madrid, director of operations and digital strategy at COVAP. •
Sidel – www.sidel.com
Ready-to-drink category on the rise With more people looking for convenient, on-the-go beverages to keep up with their fast-paced lifestyles, it is not surprising that the ready-to-drink (RTD) beverage category is growing rapidly in Africa. Tennille Aron looks at what we can expect from this category in the future.
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LOBALLY, THE READY-to-drink (RTD) market is gaining increasing popularity. According to the IWSR (the leading source for beverage alcohol trends in the world), the RTD market grew by approximately 26.4% in 2020 and was the only beverage alcohol category to grow during the pandemic. If the popularity of these types of drinks continues to increase, the IWSR projects the RTD volume to increase by 26.6% in 2021. What makes this beverage category so popular? Whether it is RTD cocktails, coffee or tea, these drinks have taken the world by storm and this is largely due to the convenience factor that these drinks offer. RTD beverages fit in perfectly with the current global grab-and-go culture as they are packaged in single-use containers and are meant for immediate consumption. Grabbing a RTD iced coffee that you can consume on your way to work, aligns with the fast-paced lifestyle that people now lead. RTD beverages such as energy drinks and coffee have also become a favourite as more people look for something quick and easy to consume
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to boost their energy levels during a busy day. AS THIS CATEGORY CONTINUES TO GROW, THESE ARE SOME OF THE TRENDS TO EXPECT: Let’s keep it healthy FMCG Gurus’ consumer insights 2021 found that 60% of global consumers would like to improve their general health over the next 12 months. Therefore, one of the biggest trends throughout the beverage industry, and especially for the RTD market, would be producing healthier drinks with more nutritional value. RTD beverages with no added sugars or calories, but that are infused with natural ingredients such as vitamins or plant extracts is becoming increasingly popular in this drinks category. As the world moves towards finding plant-based alternatives to dairy products, RTD beverages that contain these plant-based alternatives are also becoming more trendy. What’s your flavour? Another trend that is on the rise in the
Food Manufacturing Africa | 2021 Quarter 3
beverage industry is the need for flavour innovation. Research from FMCG Gurus found that 74% of global consumers said they like products with new and unusual flavours. Experimenting with new flavours and exotic flavour combinations is essential for those in the RTD industry, especially when it comes to alcoholic RTD drinks like hard seltzers. What’s in the box? Packaging forms a crucial part of RTD beverages as it adds to the overall convenience factor of these products. Finding packaging that is sleek and easy to use on-the-go, but that is also sustainable and environmentally-friendly is a key area that beverage manufacturers will have to consider as RTD beverage popularity rises. This beverage category arose to suit consumers’ needs and their changing lifestyle, and has become extremely popular as a result. One thing that is certain is that this is a beverage category that is here to stay. •
INSPECTION, CODING & MARKING
Deep learning in inspection technology Anyone who works with empty-bottle inspectors knows that not every bottle that the inspector rejects has a defect. In some cases, it might be water droplets still clinging to the bottle after cleaning, but conventional systems can’t always distinguish these from contaminants. Krones has taken the evolution of its inspection technology to the next level with the Linatronic AI. It employs deep learning software to automatically detect and classify anomalies, making it much smarter than its conventional peers. THE NEXT RUNG ON THE EVOLUTIONARY LADDER: ARTIFICIAL NEURAL NETWORKS Deep learning is a technology that enables machines to do what humans do naturally: learn from example. However, the one big difference is that a machine can use this ability more efficiently than humans can. The foundation for deep learning is an artificial neural network (ANN). The ANN can be described as a complex system of multiple consecutive filters. The images captured during the inspection process are fed through these filter layers, one after the other. Each layer extracts a different characteristic of the image. Since one filter’s output becomes the input for the subsequent filter, the complexity of an image’s characteristics can be increased almost infinitely. The chain ranges from simply identifying darker or lighter pixels all the way to classifying very specific objects such as beads of water.
The new Linatronic AI uses deep learning technology for automated image recognition for the first time.
TRAINED USING THOUSANDS OF IMAGES To ensure that the Linatronic AI applies these filters with the necessary precision in practice, it is trained ahead of time with pre-classified example images. In this way, its neural network learns to filter out and interpret the relevant image characteristics. The same is true for machines that is true for humans: the more intensively you train, the better the results. Therefore, Linatronic AI’s neural network was continually fine-tuned using thousands of example images until it
“Linatronic AI’s neural network was continually fine-tuned so that it could accurately distinguish water droplets from other anomalies with a reliability rate of over 99.9%” could accurately distinguish water droplets from other anomalies with a reliability rate of over 99.9%. Therefore, waste due to false rejects is no longer an issue. The time-consuming process of configuring the inspector during commissioning is also a thing of the past. The neural network doesn’t require manual calibration to local conditions. Instead, the Linatronic AI is delivered fully trained and ready to start work. •
Krones - www.krones.com
INSPECTION, CODING & MARKING
Addressing the “new normal” of factory automation in food manufacturing Food and beverage companies can now set the course for the time after the Covid-19 pandemic using automation to boost competitiveness and productivity. Manufacturers should focus their resources on four market driven perspectives: workforce, product quality, flexibility and sustainability.
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HE PANDEMIC HAS posed immense challenges to companies of all sizes. According to Deloitte Global, food and beverage (F&B) companies are facing significantly reduced consumption as well as disrupted supply chains. But how can manufacturers adapt their business strategies and production processes, factories and machinery to the new circumstances. The current crisis offers a chance to rethink outdated procedures and to use automation with the aim to boost productivity, efficiency and quality. F&B companies that want to prepare for the future should be appraising the opportunities that innovative robotics, sensor technology and holistic automation approaches provide. 1. Collaboration and factory harmony are key The first aspect to be considered in this respect are the employees, the workforce perspective of factory automation. Robert Brooks, Omron Europe’s industry manager for Food and Beverage, said, “At the moment, there are millions of people employed in these sectors. This number has an enormous impact on producers in terms of costs, but also primarily in terms of the health
and safety of human resources. The pandemic has led to developments such as social distancing and tighter safety regulations that companies need to adhere to. Automation can help in overcoming this challenge while also improving security and efficiency in the longer term. An example is a cobot or mobile robot solution that can relieve employees from challenging and repetitive tasks so they can focus on more value-added and fulfilling roles.” Daniela Moles, communication expert at Omron Solution Partner LCS Group, explains it as follows, “We carried out a project where we implemented a fully automatic system for the handling of heavy rolls of fabric that weigh up to 30kg. These rolls were previously handled by humans. Automating this exhausting task meant that the company could support its employees while also boosting efficiency and productivity. The value of automation is in the mix of humans plus machines, robots and artificial intelligence. Collaboration is key. While robots show their advantages when it comes to speed and accuracy, human colleagues can take care of business-critical issues, customer communication and daily individual tasks. Collaborative and mobile robots working alongside their
human colleagues assisting in lifting or transporting goods, material and fulfilling tasks employees can’t do because of distance or safety rules.” 2. Product quality and traceability play an increasingly important role Product and production quality as well as traceability are further aspects that are increasingly important for both manufacturers and customers alike. Barcode quality is one example that is a key element in many applications. Regulations from international organisations like ISO or GS1 are widely adopted, but in addition there may be further project specific specifications driven by suppliers and customers. This leads to a need for reliable systems and tools that ensure a barcode is correct and readable. Solutions can be adapted so they can also check pack design aspects and package integrity and completeness. Alberto Giordani,
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@omron.com industrial.omron.co.za fh_series_177x65_ad_enza_02_d01.indd 1
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Food Manufacturing Africa | 2021 Quarter 3
09-06-20 10:22
INSPECTION, CODING & MARKING
“Automation is a well-thought-out overall structure of fixed, collaborative and mobile robotics; monitoring and control technology; sensors and vision technology tailored to the respective production requirements” product and project manager at Omron Solution Partner Alfacod, explains, “Moreover, innovative solutions can understand the quality grade and if it's decreasing before it's too late. They can, therefore, plan preventive maintenance actions to avoid potentially costly errors. In the food industry, it is useful to check labels while they are printed by a thermal transfer machine with an integrated barcode verifier on the printer. Customers, especially large distribution companies, want to receive only products with the correct information, labelling and barcodes. If this information is wrong or incomplete, they might return the goods or levy a fine on the supplier. “ Information taken from the packaging in the form of codes is also becoming increasingly useful for consumers at the point of purchase. When reading the code at a self-scanning system or the retailer, as seen at larger retail stores, they can get information about allergens or other specific ingredients such as gluten. Consumers are taking an interest in information such as country of origin. 3. Flexibility as the engine of future food manufacturing Mobile robots and flexible production lines provide companies with valuable support. Moles describes a LCS customer producing coffee pods, “Our customer
receives requests for very different pods, such as normal plastic or reusable, ecofriendly, different colours and different sizes. By implementing a fleet of Omron’s mobile robots that can manage the fluctuating demand across periods of time or two entirely different requests, we were able to help them to achieve a more flexible environment within the plant. Being able to adapt and evolve will become even more relevant and important in the future.“ Many solutions still rely on inflexible conveyor systems, whereas mobile robots provide the manufacturer with the flexibility to move stock and consumables to the required locations at the right time. Cobots are very easy to train, easy to deploy and transportable, making them a useful companion in achieving more flexibility. Omron mobile robots can change routes quickly, dynamically avoiding obstacles or working on different priorities. They can be customised with special accessories that allow for even more flexibility. The latest solution from Omron combines cobot and mobile technology to offer a mobile manipulator or MoMa solution.
4. On the way to sustainable food manufacturing Automation is closely connected with sustainability. It can control temperature and pressures, ensuring a product is correctly packaged and reducing waste and scrap. A more detailed example could be one where a producer must consider multiple variables such as packaging thickness, ambient temperature and packaging film speeds. This approach requires a system to capture data in real-time, analyse it and make decisions. “If we are able to process and read through this data, we have all the guidelines in order to work better, implement sustainable actions to achieve a sustainable future,” says Brooks. One good example for innovative technology is the Omron Sysmac AI Controller, a smart artificial intelligence solution that collects, analyses and utilises data on Edge devices within a controller to prolong equipment longevity. It also detects abnormalities to prevent failures. It combines control functions of manufacturing lines and equipment with AI processing at manufacturing sites in real-time. •
Omron - www.industrial.omron.co.za
2021 Quarter 3 | Food Manufacturing Africa
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INSPECTION, CODING & MARKING
Powerful solutions to protect product quality and safety 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 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.
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ATE AND LOT codes, batch codes and expiration dates are required on food and beverage products to identify when and where a product was made. These codes often combine 1D symbologies and plain text to encode information about the batch and manufacturing date. Optical character recognition (OCR) is used for reliable process control, helping manufacturers meet labelling requirements and ensuring consumer safety. Quality inspections must verify that the codes are present and printed correctly to ensure traceability and more easily manage product recalls.
“The In-Sight 7000 series is a powerful vision system that performs fast, accurate inspections of a wide range of parts across all industries” In-Sight vision systems with OCRMax technology detects the presence or absence of date and lot codes and verifies that its chain of numbers and letters is correct. Deep learning solutions ensure codes are accurately read and verified, and deciphers deformed, skewed, and poorly etched characters using OCR and optical character verification (OCV). The pretrained, omni-font library identifies most text without additional programming or font training. The In-Sight 7000 series is a powerful vision system that performs fast, accurate inspections of a wide range of parts across all industries. Its compact footprint easily fits into space-constrained production lines and the unique, modular design is highly field-customisable to application requirements. Along with the internal and external power/control lighting options, this series also has a highly visible pass/fail LED indicator light ring around the camera body, making it easy to see the inspection status no matter where the system is installed. OCRMax is a font-trainable Optical Character Recognition (OCR) and Verification (OCV) tool that offers 99% accuracy on difficult-to-read characters. It prevents misreads, handles process variations and provides easy font
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management with minimal training. OCRMax achieves unprecedented read rates for OCR and OCV applications even under the most challenging conditions, while giving the customer the flexibility to optimise their system for speed, read rate or a combination of the two. This gives users the chance to optimise the OCR/OCV for To watch a video millisecond character reads, about the OCRMax, visit the digmag. 99.99% read rates or anywhere in between. Unlike other OCR reading tools, OCRMax technology includes an auto-tune capability. With a few clicks, auto-tune dramatically decreases the time it takes to set up the tool by acquiring a sample image and automatically training fonts and adjusting the tool to its optimal segmentation parameters. Packaging traceability is critically important for the overall safety of food and beverage products, which must be continuously monitored and occasionally recalled. It is also important for the security speed and accuracy to ensure packages of of products that are increasingly threatened all shapes and sizes are properly sorted, by counterfeiting and theft. Finally, there picked, stored or shipped and can be easily are also global regulations that must be identified and located in the event of a met to provide a trail of information that product recall. In-Sight vision systems with follows each item through the supply chain. OCRMax technology read alphanumeric To ensure proper packaging traceability, date/lot codes and store the information in food and beverage producers must be able a central database that can track and trace to quickly identify and locate products in goods throughout the supply chain. the supply chain. To achieve this, many Industries are increasingly turning to companies use 2D barcodes, vision systems product security solutions to safeguard their and image-based barcode readers as products and meet industry requirements. key components in a simple yet robust In-Sight industrial barcode readers and traceability system. Data Matrix codes machine vision systems address these have been adopted as standard in many concerns head-on by delivering the applications because they allow the storage industry’s highest read rates, superior of information such as manufacturer, product quality and assembly inspections and supply ID, lot number, expiry and even a unique chain protection. This technology reads, serial number. Track and trace solutions inspects and authenticates products at the assure full compliance with food safety unit and package level, easily exchanging and traceability laws by capturing an image security data with third party software and of a code at each scan point and storing hardware systems to verify the safe and its encoded data in a central database. accurate movement of products. • Tracepack’s barcode readers reliably read 1D and 2D codes at read rates of 99.9% regardless of barcode quality or orientation. Tracepack - www.tracepack.co.za Image-based barcode readers have the
Food Manufacturing Africa | 2021 Quarter 3
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