Food Manufacturing Africa Nov 2017 - Jan 2018

NOVEMBER 2017 - JANUARY 2018 Vol. 5 • No. 4

A manufacturer of

QUALITY INSULATED TRUCK BODIES and TRAILERS Protein alternatives: from plant to plate SAB and AB InBev celebrate one year of success Manufacturing on the move

ISO 22000 F

Training

SS

C

00 22 0 BR C G F SI

Food safety

Auditing

Implementation

H

CP AC

PRPs

Quality happens through people

Cell: +27 (0)83 440 0460 • Tel: +27 (0)21 871 1563 • Fax: +27 (0)86 275 5678 • Email: anneliec@anneliecoetzee.com www.anneliecoetzee.com 482 Main Road PAARL 7646

CONTENTS NOVEMBER 2017 - JANUARY 2018 Vol. 5 • No. 4

07 NEWS

CCBA transaction concluded Diageo focuses on Africa Seed breeding company launched Ishida wins big at Gulfood

10

EVENT

11

INDUSTRY TALK

16

PROTEIN ALTERNATIVES

18

BEVERAGES

Trends highlighted from Gulfood Manufacturing

Imperial reveals its humanitarian side Sales planning in the digital age

Protein power from plants

25

PAGE

14 “Various manufacturing stages end with a product that is thoroughly and strictly controlled per SABS specifications before being delivered to client…”

18 Beverages

SAB and AB Inbev celebrate their success An end to cold stabilisation in wine Sugar replacement on the rise Sidel’s single smart solution Masking flavours in beverages

“South African Breweries and AB Inbev mark one year since the two global brewers combined their businesses”

PACKAGING

The packaging industry makes huge advancements

Plastic or glass?

Ishida inspection system guarantees quality

Nova offers better versatility PAGE

10 On trend at Gulfood Manufacturing 2017

25 Packaging “More than 60 per cent of consumers agree that glass packaging is better for the environment”

ADVERTISERS’ INDEX ABB South Africa......................................... IBC.............www.abb.com

Omron............................................................ 30..............www.industrial.omron.co.za

Annelie Coetzee.......................................... IFC.............www.anneliecoetzee.com

Polyoak Packaging...................................... 28, OBC....www.polyoakpackaging.co.za

HFH SA............................................................ 24..............www.hfheating.co.za

Protea Chemicals........................................ 22...............www.proteachemicals.co.za

Ice Cold Bodies............................................ OFC...........www.icecoldbodies.co.za

Savannah Fine Chemicals........................ 21...............sfc-info@savannah.co.za

Ishida.............................................................. 29...............www.ishidaeurope.com

Serac............................................................... 27...............www.serac-group.com

Koelnmesse.................................................. 9.................www.anugafoodtec.com

Symrise.......................................................... 19...............www.symrise.com

Krones ........................................................... 23...............www.krones.com

Syspro............................................................ 13...............www.syspro.com

Labotec.......................................................... 15...............www.labotec.co.za

Tromp Group................................................ 5.................www.trompgroup.nl

Nissei ASB..................................................... 26..............www.nisseiasb.co.jp

2017 Quarter 4 | Food Manufacturing Africa

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EDITOR’S COMMENT

EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmediapub.co.za Assistant Editor: Aarifah Nosarka +27 (0) 11 877 6209 aarifah.nosarka@newmediapub.co.za Layout & Design: Kirsty Thomas +27 (0)11 877 6168 kirsty.thomas@newmediapub.co.za

Africa can look forward to

Contributors: Tim Symons ADVERTISING

bigger and better growth T

HE MCKINSEY GLOBAL Institute has identified four groups of consumers that will drive most of Africa’s consumption between now and 2025. These include consumers earning more than US$50 000 per year in North Africa, middle-income earners in East Africa and middle-income consumers in Central and West Africa. This is fantastic news for those playing in the food, beverage and packaging markets. The ability to think out of the box and implement new systems and technologies will assist in driving growth.

On the news front, AB InBev has announced the transition of its 54.4 per cent equity state in Coca-Cola Beverages Africa, while Diageo has increased its commitment to growth over a five-year forecast period. Turn to page 7 for more on how these developments will impact the beverage sector on the continent.

Technological disruption in business is marching relentlessly forward and is a critical business enabler. Without it, no organisation can hope to thrive in today’s competitive markets. Tsar Business Solutions, an ERP solutions provider with an African footprint, benefited from the PartnerUp programme from Syspro by optimising its sales training. To read the full story, turn to page 12 now.

The protein alternatives market has seen a major shift in consumer behaviour, which is causing renewed interest. Soy proteins in particular are making their impact felt in new types of protein. These include peas, rice and chickpeas. On page 16 we look at some of the benefits of plant-based proteins, including lower formulation costs and sustainability.

Changing tastes and preferences are driving the beverage industry. Approximately 30 per cent of the more than 3 900 beverages produced by Coca-Cola globally fall into the low or no-sugar categories, and 18 out of its 20 top brands now feature a low or no-sugar option.

On page 21 we look at how Beneo is tying in with this trend by focusing on the physiological effects of sugar replacement, using ingredients that have a sugar-like indulgent taste and texture and contribute to balanced blood sugar levels.

Our packaging section (page 25) features a wide selection of articles, from radio frequency/dielectric heating systems to inspection systems that guarantee superior quality cheese.

This is the last edition of Food Manufacturing Africa for the year. I look forward to working with you all in 2018 and wish you a happy, safe and prosperous holiday season.

Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmediapub.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmediapub.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmediapub.co.za INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com

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Until then,

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To advertise in Anita Raath

Sales executive +27 (0)82 976 6541

Candida Giambo-Kruger Sales executive +27 (0)71 438 1918

Carla Melless

Sales executive +27 (0)83 260 6060

Food Manufacturing Africa is published by New Media Publishing (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.

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Food Manufacturing Africa | 2017 Quarter 4

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NEWS

Coca-Cola Beverages Africa transition completed AB INBEV HAS announced the transition of its 54.5 per cent equity stake in Coca-Cola Beverages Africa (CCBA) for US$3.15 billion.

CCBA, the largest Coca-Cola bottler in Africa, was formed in 2016 through the combination of the African non-alcohol readyto-drink bottling interests of SABMiller plc, The Coca-Cola Company and Gutsche Family Investments. It includes the following countries: South Africa, Namibia, Kenya, Uganda, Tanzania, Ethiopia, Mozambique, Ghana and the Comoros.

Following completion, CCBA will remain subject to the agreement reached with the South African government and the South African competition authorities on several conditions. Companies continue to work towards finalising the terms and conditions of the agreement for The Coca-Cola Company to acquire AB InBev’s interest in, or the bottling operations of, its businesses in Zambia, Zimbabwe, Botswana, Swaziland, Lesotho, El Salvador and Honduras. These transactions are subject to the relevant regulatory and shareholder approvals in the different jurisdictions.

Diageo increases commitment to Africa ONE OF THE company’s key strengths is its strong presence in Sub-Saharan Africa. Its strategy in Africa is to focus on rolling out affordable beer and to use this as a springboard for the promotion and distribution of spirits as incomes rise and formalisation takes hold. Illustrating the company’s commitment to the region, Diageo announced in June 2017 that it would invest US$144mn in a state-of-theart production facility in Kenya. While there are reasons to challenge the narrative that all consumer sectors will generate real momentum across key African markets, the alcoholic drinks sector continues to offer tremendous growth opportunities by global standards. Diageo’s Africa division has been a key driver of organic growth in recent years, and foresees strong growth ahead.

While Diageo is facing some challenges in the region, including a slowdown in commodity-exporting countries such as Nigeria, it is believed the group is well-positioned to experience robust growth over

a five-year forecast period. Beer, which is more affordable than spirits, accounts for about two thirds of Diageo’s revenue in the region, making it less sensitive to economic volatility. Diageo has built strong relations with local operators, including subsidiaries such as Guinness Nigeria and East African Breweries in the East African Community (EAC). The group has a strong distribution network, which enables it to gradually push the spirits category in the region. Through its local partners and experience, Diageo has strong market knowledge in the region, and the capacity to adapt rapidly to changing circumstances.

In Nigeria, premium products were hit by lower consumer spending on the back of lower oil prices. Net sales still maintained positive growth as the company focused on lower-value products. In Kenya, East African Breweries (majority-owned by Diageo), recorded double-digit growth for its affordable Senator Keg beer in FY16.

East African company diversifies its beverage range PHOENIXBEV, A BREWERY in Mauritius, has installed a hot filling line from KHS. The company opted for one line with two blocks to provide maximum flexibility. Each of these blocks has its own stretch blow moulder and filler so tea, juice and still water can all be run on the line.

‘This means that PhoenixBev doesn’t have to convert the stretch blow moulders when changing over from the 28mm to the new 38mm bottle neck and can switch from a hot fill product to water and vice versa more quickly,’ explains Denise Schneider-Walimohamed, managing director at KHS East Africa. The line

is supplemented by an Innoket 360 labelling machine. An Innopack Kisters PSP pad shrink packer packs both the hot fill products and the water while palletising is still done manually.

The company is already thinking about adding a palletiser to the line.

‘KHS has the right offerings and can give us just the end-to-end systems we need.

Hot filling gives us many options, especially regarding additional products such as energy drinks. This is why we attach such great value to the versatility of the plant engineering,’ says Gerard Merle, senior manager of non-alcoholic beverages and civil engineering at PhoenixBev.

2017 Quarter 4 | Food Manufacturing Africa

7

NEWS

South Africans PRIORITISE RECYCLING THE LATEST PLASTICS recycling figures released by Plastics|SA reveal that South Africans are recycling more plastics than ever before. Anton Hanekom, executive director of Plastics|SA says the results of its annual survey into plastics recycling for the period ending December 2016 reveal there is a growing awareness of recycling and public pressure to recycle. This has resulted in more postconsumer and post-industrial plastics made available for reuse.

‘Last year, 1.144 million tonnes of recyclable plastic entered the waste stream, of which 41.8 per cent was recycled in South Africa based on input tonnages.

This is a year-on-year increase of 5.9 per cent,’ he explains. During this period, a growing number of organisations and consumer groups became actively involved in upstream collection efforts. This resulted in a positive impact on the number of plastics collected and recycled. Recycled tonnages grew by 35 per cent since 2011.

‘The increase in recycling recorded was not because of increased plastic products that entered the market. In fact, 1.518 million tonnes of virgin polymer were converted into products in South Africa during this period – a mere 1.9 per cent increase compared to 2015,’ Hanekom adds.

Plastics manufacturing and recycling industries in South Africa and around the world have been taking strain over the past two years. More end markets had to be developed as a matter of urgency to ensure take off for recycled materials.

‘Toward the end of 2016, South Africa had 204 active recyclers, which mechanically reprocessed plastics materials such as plastic packaging. This provided formal, permanent employment to 6 140 staff and supported the informal employment of 51 500 waste pickers and collectors,’ he concludes.

Arla responds to rise in Africa demand with new Ghana site THE COMPANY IS adding another market to its Sub-Saharan Africa business region by establishing a new sales and packaging facility in Ghana. The new subsidiary will begin selling Arla’s branded dairy products in the country from September 2017 in response to growing demand for dairy products. Based in Accra, the company will supply products from its Dano range, which is also sold in Nigeria, including powdered milk, and butter and cheese from brands like Arla and Lurpak. The subsidiary will manage a repackaging facility close to Accra as well as sales and marketing of the products. Distribution will be carried out through local distributors. The move by Arla is in line with the company’s business strategy Good Growth 2020, which aims to develop new markets for Arla’s products outside the EU to improve the milk price for the 11 200 farmerowners who own the company. As part of its strategy, Arla aims to triple its revenue in SubSaharan Africa by 2020.

Stuart Allen, Jacques Lightfoot, Jeremy Mackintosh and Rowan le Roux

Devoted to

zero pellet loss POLYOAK PACKAGING HAS become part of a worldwide drive by leaders in plastics to reduce the number of plastic pellets ending up in rivers and ultimately the ocean. The company signed a pledge on 24 October, to prevent resin pellet, flake and powder loss as part of Plastics|SA’s Operation Clean Sweep launched earlier this year.

Group managing director of Polyoak Packaging, Jeremy Mackintosh; operations manager, Stuart Allen; sustainability manager, Rowan le Roux and sustainability manager at Plastics|SA, Jacques Lightfoot were among the attendees at the ceremony. The event was held at Polyoak Packaging’s regional head office in Cape Town, South Africa.

Mackintosh says owing to the company’s substantial daily use of pellets and flakes, it is important to adhere to strict environmental standards and take a leading role as a responsible producer.

‘We want to highlight our commitment to making zero pellet loss a priority by ensuring that pellets are kept out of the natural environment, including waterways and oceans,’ he concludes.

US$4 million for tech seed breeding company FORTISSIMO CAPITAL HAS invested US$4 million in Equinom, an Israeli-based technology seed breeding company focused on the development of specialised crops for the food industry.

The company’s advanced breeding technology is based on proprietary algorithms and calculation methods developed by the company. This combines classic breeding with genomic and bioinformatics methods. Its primary products are high-protein legumes and sesame seeds for use in the manufacture of oil and tahini.

Equinom has developed legume seed varieties, namely pea, chickpea and cowpea,

8

containing 50 per cent more protein than any commercial variety available on the market. In a market challenged by the growing worldwide demand for sustainable, non-GMO, plant-based protein sources, an increase in protein levels represents significant financial gain to protein processors and food companies.

Equinom’s second product line, sesame for oil and tahini, transforms the economics of the sesame market by solving a problem that has troubled the world for decades. Despite worldwide sales of sesame exceeding US$8 billion annually, the necessity of manual harvesting has

Food Manufacturing Africa | 2017 Quarter 4

limited the supply of sesame to third world countries where manual labour is available on a large scale.

Addressing this challenge, Equinom developed high-yield sesame varieties suitable for mechanical harvesting, thus opening the supply chain to production anywhere in the world.

‘Using the technology developed by Equinom, we have significantly increased the level of protein in legumes. We are contributing to creating market conditions that will eventually lower the cost of legume based protein, and creating food alternatives based on sustainable, non-GMO, sources,’ says Dr Gil Shalev, Equinom’s founder and CEO.

NEWS A proud team effort

ADM wins most innovative food ingredient

Ishida WINS BIG at Gulfood THE INNOVATIVE ROBOTGRADER was named winner of the Robotics Industrial Vision category at the debut of the Gulfood Manufacturing Industry Excellence Awards held in Dubai recently. The equipment combines weighing and pick and place technologies. It grades protein products of varying weights and packs them to a fixed weight into a tray. The system reduces giveaway to less than one per cent per pack and correctly places and orientates the pieces, at speeds of up to 320 pieces per minute. By comparison, a manual operation can be a very labour intensive with a single operator only able to pack 30 pieces/min, while overfill can be anywhere from five to 10 per cent. The RobotGrader can be incorporated into Ishida fresh food packing lines alongside other Ishida equipment, including X-ray systems, tray sealers, seal testers and checkweighers.

Ishida also secured a Highly Commended Award for its revolutionary leak detector, Ishida Airscan. This helps food manufacturers minimise spoilage in pre-packed retail products. The unit took the highly commended prize in the Production Protection category. The AirScan offers fast, 100 per cent reliable and completely non-destructive identification of leaks of C0 2 . It has been designed to be highly effective in fast moving production environments so that maximum quality can be achieved without compromising on throughput.

‘Winning these prestigious awards at the inaugural event are a testament to the hard work and commitment of our team. They’ve worked hard to protect our customers’ brands and develop innovative solutions for the poultry and meat sectors,’ comments Jeff Say, general manager, Ishida Middle East and Africa.

THE COMPANY HAS been awarded ‘most innovative food ingredient’ for its natural sweetening solution, Fruit Up Fiber, at this year’s Gulfood Manufacturing Industry Excellence Awards. The awards recognise best practices and innovation within the food manufacturing industry value chain. Reduced sugar alternatives are growing in popularity and becoming a necessity for many companies.

Fruit Up Fiber is a source of soluble fibre that provides sweetness with 30 per cent less sugar on a dry basis relative to nutritive sweeteners, such as sucrose or glucose. Based on naturally occurring carbohydrates (sugars, sweetening ingredients, polyols and soluble fibers), Fruit Up Fiber can provide developers with a lower sugar, clean label solution for a wide range of food and beverage applications.

It has a glycemic index Fruit Up Fiber of 40, is also nonfrom ADM GMO, and Halal and Kosher certified.

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23.11.17 12:43

2017 Quarter 4 | Food Manufacturing Africa

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EVENT

On trend at

Gulfood Manufacturing 2017 It is the biggest event for the region’s food and beverage processing industry. It connects suppliers from 60 countries and showcases the latest manufacturing business improvement tools. We look at some key trends identified that could help you formulate new products to grow your bottom line.

CEREALS AND GRAINS SAVOURY SNACKS Globally, breakfast cereals are forecast to grow at 1.1 per cent over the next five years in constant retail value terms. In contrast, the MENA region will account for three per cent of the total global retail value by 2021, growing at 4.4 per cent over the same period. South Africa is the largest market, accounting for 32 per cent of the region’s sales in 2016, while Saudi Arabia was among the largest remaining markets, generating 11 per cent of sales.

In Saudi Arabia, volume sales of breakfast cereals rose by seven per cent CAGR between 2011 and 2016, while constant value sales increased by 12 per cent CAGR. Sorghum-based brands are affordable options, especially for low-income consumers as they attempt to seek more affordable breakfast options. Commodity price increases make other types of breakfast cereals less affordable.

Hot cereals remain a Ramadanspecific product as it largely consists of oats, and is often used in Shorba, a popular meal item during Ramadan.

10

PULSES These products remain an underdeveloped category in the Middle East and Africa, which accounted for four per cent of the world’s value sales in 2017. The Middle East and Africa records stronger growth than the global average, with an 11 per cent CAGR between 2012 and 2017 in value sales, compared to a six per cent CAGR globally. Saudi Arabia, the largest market, generated 22 per cent of the region’s value sales in 2017. Iran was among the region’s largest markets, accounting for 11 per cent of total sales. The increase in on-the-go consumption, growing demand for convenience and greater awareness of healthy eating practices were the main trends supporting growth of savoury snacks in 2016 in the UAE. Manufacturers responded to these trends by offering more packaging choices to consumers through the introduction of smaller pack formats for many of their popular products, as well as economy and familysize packs and bundles.

Food Manufacturing Africa | 2017 Quarter 4

Globally pulses are set to record a CAGR of 3.2 per cent over the next five years, which is in line with the 3.5 per cent CAGR seen for the Middle East and Africa region. Within fresh food, pulses were the best performer, increasing by seven per cent in volume terms over the past year. They provide an affordable source of protein and are particularly important across developing and emerging markets. The global success of pulses is largely attributed to four per cent growth in India, where some 360 million vegetarians rely heavily on pulses for dietary protein. The growth of pulses in the Middle East and Africa region is supported by the popularity of pulses within the region as well as steady influx of South Asian expatriates.

As health-conscious consumers are interested in these ingredients, premium varieties, especially organic products are expected to grow. •

INDUSTRY TALK Much needed food aid has been sent to Malawi

Imperial

saves lives in Malawi

Working in partnership with a leading humanitarian aid agency, Imperial Managed Solutions leveraged its unique, asset-light business model to successfully deliver food aid to drought stricken communities in rural Malawi.

I

MPERIAL LOGISTICS’ INVOLVEMENT in this significant humanitarian project started when the Southern African Development Community (SADC) Secretariat called for an urgent meeting with heads of industry, state representatives, logistics partners, global aid organisations and donors. This was revealed

by Imperial Managed Solutions, chief executive officer, Johan Truter.

‘At this meeting, the impact of southern Africa’s worst drought in 20 years was discussed, together with the challenges that would have to be overcome to move the required volumes of food aid. The biggest problem was that within six months, nine million metric tonnes of food aid had to be received through various ports into the SADC region. It was then transported to various hubs in almost all the SADC countries. Last mile distribution would take place within the different regions. This had to happen while already congested ports dealt with normal day to day operations and trade,’ Truter notes.

Imperial’s response to these challenges was that if governments actively engage the private sector on the undertaking, the end target was achievable.

‘The successful completion of the Malawi food aid distribution project has borne this out,’ he stresses.

Considered one of the poorest countries in Africa, with the lowest GDP per capita, Malawi has a predominantly agricultural economy, and was especially hard-hit by the drought. ‘Lives were at stake. Consequently, focus was placed on Malawi with food aid imported via the ports of Durban, Nacala, Beira, Dar Es Salaam and Lusaka,’ Truter explains.

Imperial Managed Solutions’ flexible, asset-light model proved the optimal approach to the delivery challenges in the country.

It offers a temporary logistics solution that could quickly provide the required capacity for the vast volumes, but could be disbanded at the end of the project. In just three weeks, Imperial was ready to help Malawi’s desperate communities, with a solution that included 15 Samil vehicles, which have been developed by

“The biggest problem was that within six months, nine million metric tonnes of food aid had to be received through various ports into the SADC region”

the South African military to operate in harsh African terrain. Drivers were trained for these specific vehicles, stand-by vehicles were arranged, permits were secured for five months’ operation in Malawi, a mechanic was trained specifically on the Samils, and controllers were upskilled to manage the project from in-country.

Imperial Logistics initially established a base of operations in Blantyre. The site had to be mobile in order to travel, with the product, to rural areas in southern Malawi. Managed transport solutions capable of reporting on daily operations and executing deliveries regardless of the weather or the terrain were also organised.

‘We worked in areas with few roads, no infrastructure, accommodation, or other services,’ Truter elaborates. ‘We provided a solution that was completely self-supportive, but extremely effective in getting the job done. In remote, mountainous areas, we dealt with vehicle breakdowns, driver care, the changing of personnel at short notice due to Malaria and other health hazards, and quick load transhipment where needed.

‘Capable of carrying between seven and 13 tonnes, each Imperial Samil delivered more food aid into normally unreachable areas, than any other vehicle used on the project. When the rain started in Malawi, many of the much lighter vehicles were stuck at certain points. The Samils under load could continue and make sure the vital food aid reached the recipients, and the project was a success,’ Truter concludes. •

Imperial Managed Solutions – www.imperial.co.za

2017 Quarter 4 | Food Manufacturing Africa

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INDUSTRY TALK

Rethinking sales planning for the digital age

Technological disruption in business continues to march forward. No longer optional or just nice-to-have, technological disruption is a critical business enabler. Without it, no organisation can hope to thrive in today’s increasingly competitive markets.

I

T HAS BEEN estimated that up to 60 per cent

of sales failure can be chalked up to poor sales planning and a lack of sales cycle optimisation.

In an age with limitless digital tools available, that’s 60 per cent too much.

Ivan Naidoo, CEO of Tsar Business Solutions, a national ERP solutions provider with an African footprint, knows the struggle first-hand. With sales planning becoming more critical to his growing business, he implemented Syspro’s PartnerUP solution in his own operations to such great effect that Tsar Business Solutions decided to pass the benefits on to its own clients, by becoming a premium PartnerUP solutions provider. Naidoo explains, ‘My business is based on customised software solutions that fit in with the specific needs of each client. We pride ourselves on working closely with clients to deliver the best possible outcomes. Through my own experience, I knew that an emphasis on good sales Ivan Naidoo planning and ERP could deliver that and more.’

The PartnerUP programme actively encourages knowledge enhancement and ongoing sales optimisation training for every user. It focuses on breaking new ground in previously untapped target markets and adding value to the customer lifecycle for The company is a global, independent provider of long-term viability. industry-built ERP software designed to simplify It encompasses business complexity for manufacturers and distributors. Focused on delivering optimised training, tools and performance and complete business visibility, the enablement solutions Syspro solution is highly scalable, and can be deployed for sales and on-premise, in the cloud, or accessed via a mobile implementation, as well device. Syspro’s strengths lie in a simplified approach as business analysis to technology, expertise in a range of industries, and marketing tools. and a commitment to future-proofing customer and PartnerUP also enables partner success. users to react quickly to

ABOUT SYSPRO

12

Food Manufacturing Africa | 2017 Quarter 4

fast-changing conditions, penetrate global markets and remain competitive, efficient, agile and dedicated to their core competencies. This can only be achieved within an ecosystem of trusted partnerships.

‘Our PartnerUP programme was developed around strategic sales planning and enablement to optimise sales cycles and sell more profitably. The Syspro T90 rapid partner set-up programme quickly registers, equips and educates our partners with all the tools they need to grow their businesses and service and expand the Syspro customer base,’ says Syspro CEO, Phil Duff.

As part of the on boarding process, the portal provides a single access point for the primary contact, sales people and pre-sales people to upskill through a combination of online training and sales tools to use after the training course and coaching.

‘We make our partners’ learning experience as comprehensive and accessible as possible through the Syspro Learning Channel (SLC). We also offer several services to help them make the most of their partnership with the company. Partners can select product and technical support via phone and email – remotely and on-site. They can also access our world of knowledge online via our PartnerUP portal.

This contains a wealth of information in the form of case studies, whitepapers, blog posts and thought leadership articles.

In conclusion and in agreement with Duff, Naidoo says, ‘PartnerUP provides partners with all the marketing and ERP assets they need to pitch for new business, along with the tools, techniques and training necessary to accelerate sales with clarity and confidence.’ •

Syspro – www.syspro.co.za

COMPANY FOCUS

REFRIGERATION SOLUTIONS in a challenging climate

Established in 1993, the logistics and cold-chain expert is a well-respected and proudly South African body and trailer manufacturer.

Burt Gildenhuys

T

HE COMPANY PRIDES itself on implementing a flexible and responsive business model. ‘Our product range includes insulated and semi-insulated bodies and trailers. These units can be adapted and customised – without affecting production time,’ enthuses managing director, Burt Gildenhuys. ‘Our system approach allows us to implement lean initiatives throughout our operations. Just-intime production and continuous in-line development through line balancing and product optimisation is a key focus area.

Our reputation as a best in class body and trailer manufacturer has evolved from our relationships with customers from various industries. This ensures an ever-growing market share from the first contact through to after sales service.’

Icecold Bodies is synonymous with providing solutions to the food and beverage industry. ‘We pride ourselves on supplying only superior quality insulated and semiinsulated bodies to this challenging market segment. We have over 24 years of customer satisfaction to back our statement,’ concurs manager Burt Gildenhuys. ‘Our focus has always been on fostering great relationships and can be vouched for by many of our long-standing clients and suppliers, who are giants in the food and beverage industry in their own right.’

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BEHIND THE SCENES The factory in Heidelberg covers a floor space of over 7 500m2 and employs just over 135 people. The area under roof includes a glass re-enforced plastic and panel section with a sheet shop and vacuum section, steel factory, spray and repair bays, assembly line and finishing department.

The trailer line is solely for the refrigerated and non-refrigerated industry.

After manufacture all units are sent to an independent contractor for final installation.

Expansion plans are also on the cards in 2018. ‘We are in the planning stages of commissioning a new factory in Denver, Johannesburg next year. Our intention is to become the preferred refrigerated manufacturer in our industry. We opened an additional four service centers in the Gauteng area in 2017 alone. This speaks volumes about our future,’ Gildenhuys points out.

Icecold Bodies is currently in discussions to secure additional service centres in KwaZuluNatal and the Eastern and Western Cape. This will enlarge the company’s footprint within the South African region. Facilities include a dynamic design office, highly productive machine, repair and finishing shops.

‘The manufacturing process starts in the drawing office where the product is planned on paper. There are numerous consultations and site meetings before any production can be signed off and accepted into the factory for the initiation phase, which includes a job card and bill of materials. The final drawing is then completed and submitted to the factory so the raw material can be ordered. Various

Food Manufacturing Africa | 2017 Quarter 4

manufacturing stages end with a product that is thoroughly and strictly controlled per SABS specifications before being delivered to client,’ Gildenhuys concludes. •

FOCUS ON AFRICA We believe that by improving our business relationships with current clients in neighbouring countries we are not only enlarging our company footprint but also encouraging internal development and future business opportunities for our cross border clients and their specific suppliers. We currently build for clients currently in the following African countries - Botswana, Mozambique, Zambia, Zimbabwe and Swaziland.

- Burt Gildenhuys

Icecold Bodies – www.icecoldbodies.co.za

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PROTEIN ALTERNATIVES

From plant to plate The protein alternatives market accounted for US$4.2 billion in 2016. It is expected to witness a CAGR of 6.8 per cent during a 2017 to 2022 forecast period. A major shift in the consumer behaviour is causing renewed interest in alternative protein sources.

G

ROWING HEALTH CONCERNS demand alternative proteins. In 2014, more than 1.9 billion adults were overweight, and about 600 million were obese. Markets observed a steep decline in meat consumption and other traditional proteins. Many food processing companies are adding protein substitutes in their product portfolio. Soy-based schnitzels, for example, have been introduced in many developed markets and these products are registering around 20 per cent higher sales. Increasingly, food manufacturers are looking at producing alternative, clean and GMOfree protein products.

By 2022, global demand for alternative protein is expected to be 20 to 25 per cent higher than current levels. Main growth is expected in Asia-Pacific and the African continent. These ingredients are derived from various sources, ie seeds, pulses, nuts, bacteria or mycoprotein, microalgae and insects.

The difficult question is then, how do we meet the protein needs of nine billion people in a way that is affordable, healthy and good for the environment?

THE NEW 90 PER CENT PROTEIN NUGGETS DuPont Nutrition & Health has announced an expansion of its 90 per cent protein nugget product range. The new Supro 90 protein nuggets are unique for their exceptionally high level of protein. The product is also label friendly.

Vegetarian soya burger patty

“For brands seeking to capitalise on the popularity of plant protein while desiring a crunchy texture, Trupro Nuggets are a perfect solution”

Nutritionally robust with a neutral flavour and crispy, crunchy texture, these plant-based nuggets are ideal for use in snacks, cereals and nutrition bars. The nuggets can help formulators achieve desired protein levels while using liberal amounts of nuts, seeds and fruit to add visual appeal. Available in a range of textures, shapes and sizes, the nuggets offer endless possibilities for the creation of innovative and greattasting products.

‘Consumers want products with simple ingredient statements and high protein content,’ says Jean Heggie, strategic marketing lead, protein solutions business unit, DuPont Nutrition & Health. ‘These new additions to our nugget portfolio deliver on those promises.’ DuPont was the first supplier to offer a 90 per cent protein nugget with the initial introduction of Supro Nuggets 570, a light, crispy textured nugget with a barrel shape. Three new nuggets have now been added to the portfolio, each featuring a unique shape, size and texture: •S upro Nuggets 580 – The firmer texture of this ovalshaped nugget delivers a crunchier texture and better piece integrity during processing, resulting in more appealing bars and snacks

GLOBALLY SIGNIFICANT SOURCES OF PROTEIN Animal proteins

Plant proteins

Alternative proteins

• Red and white meat

• Pulses

• Microalgae

• Diary

• Nuts

• Bacteria

• Eggs

• Seeds

• Mycoprotein

• Farmed and wild-caught fish

• Beans

• Insects.

• Legumes and grains.

• Future ingredients i.e. synthetic or lab grown meat.

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Food Manufacturing Africa | 2017 Quarter 4

PROTEIN ALTERNATIVES

SIX AREAS DRIVING SIGNIFICANT CHANGE IN PROTEIN

Increasing the proportion of plantbased protein consumption with consumers

Scaling up sustainable animal feed innovation to meet demand for animal protein

• Supro Nuggets 583 – The unstructured shape of this nugget creates visual appeal in clustered cereals, yoghurt topping, muesli and bars, while adding crispy, crunchy texture • Supro Nuggets 585 – This larger roundshaped nugget offers a unique appearance and crunchy texture, making it ideal for novel snack formats, nutrition bars and cereals.

DuPont also offers Supro Soy Protein products ranging from 60 to 90 per cent

Closing the protein nutrient loop

Developing indigenous plants and protein sources from local communities

protein. Fiber Nuggets delivers a minimum of 55 per cent dietary fibre from soy. Trupro Pea Protein Nuggets, soy protein and fibre nuggets provide high-quality, plant-based protein and/or fibre nutrition, and a crispy, crunchy texture. They are excellent choices for nutrition bars (extruded, sheeted and baked), clustered cereals and toppings, and a great way to deliver a nutrition boost to a variety of snack and confection formats. Trupro 1614

Scaling up sustainable aquaculture for food and animal feed

Restoring soil health

provides plant-based protein derived from Canadian yellow peas. Pea protein is not required to be labeled as an allergen and is non-GMO. For brands seeking to capitalise on the popularity of plant protein while desiring a crunchy texture, Trupro Nuggets are a perfect solution. •

Du Pont – www.food.dupont.com

Plant PROTEIN POWER Soy proteins are making their impact felt in the “new types of proteins” category.

These include peas, rice and chickpeas amongst others. Plant-based proteins offer a range of benefits, including reduction in total and saturated fats, lowered formulation costs and are more sustainable. Many work well in combination with traditional animal proteins. By Tim Symons

S

OY IS WIDELY used around the world to enhance the nutritional profile of a multitude of food and beverage products. Ingredients are available in a wide variety of formats. These include textured and concentrated protein, with high protein content and fibre. Soy proteins offer enhanced functionality for a wide range of applications. In its role as a nutrition enhancer, soy adds value for formulators as a low-cost gelling and emulsifying agent. This makes it ideally positioned to improve texture in place of meat proteins.

With formulation advancements, different soy protein ingredients can be used in combination with animal proteins to create a variety of meat profiles. This allows manufacturers to mimic a specific meat reference. Ingredient product development advisors, like ADM, are experimenting with different processing techniques to develop on-trend applications from vegetable proteins. An innovative example of this is using and extrusion process to create a

pulled-pork analogue made from 100 per cent fibrous soy.

Soya in its raw form

FROM ADM’S EXTENSIVE PRODUCT RANGE

NEW FORMS AND SOURCES OF PROTEIN A wide variety of plant protein options are entering the market. Wholefood ingredients such as legumes, nuts, seeds; and grains such as quinoa and pea are becoming popular.

These ingredients are gluten-free, clean label and high in protein and fibre, meeting consumer demand for more wholesome and closer-to-nature foods.

Beans are incorporated into recipes to up the nutritional value. Varieties, including pinto, black, small red, navy, great northern and chickpeas can contain 20 to 27 per cent protein and nine to 29 per cent fibre. Available in a range of formats, beans can be used to create different sensory characteristics in the end application. Grits for example provide a crunchy bite, while powder formats help manufacturers achieve a creamier, pastelike texture.

As product development challenges become more complex and multi-faceted, ADM’s wide-ranging plant protein offering and knowhow can support food and drink brands in bringing differentiated, on-trend products to market. ADM has a broad portfolio of plantbased ingredients, including soy protein concentrates and textured concentrates, isolated soy proteins, customisable protein crisps, edible bean ingredients, a range of wheat proteins and several organic options. •

TIM SYMONS is sales director -

Meats & Meals EMEAI at Wild Flavors and Specialty Ingredients, ADM.

ADM – www.adm.com

2017 Quarter 4 | Food Manufacturing Africa

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BEVERAGES

Celebrating

one year of success!

South African Breweries (SAB) and AB InBev marks one year since the two global brewers combined their businesses. The combination has brought together significant intellectual synergies, enabling the sharing and integration of best practices of both companies.

I

N AFRICA, THE business has three key priorities: job creation promoting nutrition and health and reducing harm caused by the misuse of alcohol.

‘We are proud of what we’ve been able to achieve in South Africa and across Africa in just one year, thanks to the remarkable work of our team. Their efforts showcase what we have been able to achieve by bringing together two great companies to create one team, with one dream: to bring people together for a better world,’ says Ricardo Tadeu, zone president for SAB and AB InBev Africa.

The organisation has worked hard over the past year on its Public Interest Commitments (PIC’s) made to government and regulatory authorities during the business combination in late 2016. The PIC’s include a R1 billion investment over five years in the areas of agriculture (R610 million), enterprise and supplier development (R200 million) and societal benefits (R190 million) – reinforcing a transformation agenda across its business.

SAB has implemented programmes that are over and above the PIC’s and which complement them. These include the goal of creating 10 000 jobs in South Africa by 2022 through the launch of SAB’s entrepreneurship programme and a R2.8 billion investment in two of its breweries in Gauteng.

Efforts have been made to grow agricultural sectors by strengthening rural employment and job creation, as well as accelerating the development of emerging farmers. Several societal investments are planned such as disability learnerships, bursaries, water, waste, solar, school sports programmes and environmental education projects.

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Job creation is embedded in the company’s business strategy. It focuses on fostering a better world where everyone has an opportunity to improve their livelihoods.

“Efforts have been made to grow agricultural sectors by strengthening rural employment and job creation” ‘We recognise that job creation is top of mind amongst South Africans.

As one of the country’s leading corporates with a deep sense of pride, and a belief in the future of our country, we not only have a responsibility to help, but a duty to improve the lives of people in communities. We will do this through a range of initiatives, including providing real, authentic and sustainable jobs that we can measure going forward,’ Tadeu says.

10 000 JOBS BY 2022 The SAB Entrepreneurship Programme encompasses four entrepreneurship programmes – SAB KickStart, SAB Foundation, SAB Accelerator and SA Thrive. These which provide support to entrepreneurs and opportunities for them to become part of the SAB supply chain.

Collectively, they offer a comprehensive and holistic package of entrepreneurship support to develop small businesses from

Food Manufacturing Africa | 2017 Quarter 4

ideation to growth, transforming the supply chain, as well as investing in the potential of entrepreneurs in the broader community.

Using these programmes, SAB is targeting the creation of 10 000 jobs in South Africa by 2022.

GROWING AGRICULTURE SAB and AB InBev Africa have committed to establishing thriving barley, hops, maize and malt industries that strengthen rural employment and job creation, accelerate the development of emerging farmers and enable South Africa to become a net exporter of hops and malt by 2022. In addition, South Africa’s technological and innovation base will be strengthened to improve the productivity of emerging and commercial farmers and create new business opportunities. The company will invest R610 million, during this period, towards developing the capacity of new emerging and commercial farmers and increase the amount of local barley that is malted. The strategic intent is to create at least 2 600 new farming jobs in South Africa. •

BEVERAGES

A REVOLUTION in

wine stabilisation Enartis has announced the introduction of Zenith, a range of revolutionary products based on potassium polyaspartate (A-5D K/SD) for tartrate and colour stabilisation at every level of instability during the wine-making process. The new product hits a milestone in environmental sustainability, putting an end to cold stabilisation – an important factor in drought stricken wine producing areas.

T

HE PRODUCT WAS authorised on 28 October by the European Union. This follows the approval

by EFSA-European Food Safety Authority and OIV International Organization of Vine and Wine. Zenith enters the market with a diversified range aimed at red, rosé, white and sparkling wines.

The intrinsic properties of potassium polyaspartate, a polyaminoacid produced from L-aspartic acid, an amino acid naturally present in grapes, makes it possible for Zenith to maintain total tartrate and colour stability over time.

It allows wine to withstand thermal stress and inhibits the formation of tartrate crystals, without altering the organoleptic properties of wines. Zenith requires minimal use of energy, drinking water and manpower thanks to its simplicity and rapid application.

‘In addition to ensuring more stable wines and allowing wineries to remain competitive, Zenith is a milestone in environmental sustainability,’ says Samuele Benelli, business director, Enartis International. ‘We have

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calculated that wineries can save up to 80 per cent of energy and drinking water. Greenhouse gas emissions can also be cut by 90 per cent by simply using this product.’

The product enters the family of Enartis stabilisers after metatartaric acid, gum arabic, resins, mannoproteins and CMC. It is the result of complex and meticulous work that started in 2011 with research on potassium polyaspartate and evolved into the StabiWine project. This involved the collaboration of prestigious research institutes, universities and international winemaking industries, including the University of Milan, University of Turin, University of Zaragoza, Council for Agricultural Research and Economics, the Italian Association for Organic Agriculture, Australian Wine Research Institute, Institut Rhodanien, Vinidea and the Institut Francais de la Vigne et du Vin. •

TOP EMERGING AFRICAN WINE PRODUCERS

TANZANIA IS LEADING by sheer volume of production. Dodoma is the prominent wine making region where major wine producers such as Tanzania Distillers Ltd, Dodoma Wine Company and Cetawico are based. These companies have given rise to brands such as Dodoma, Imagi, Presidential and Altar Wine.

In Kenya, wine is being produced in Naivasha, Yatta Plateau and along the Great Rift Valley Escarpments. Two big names in the trade are Rift Valley Winery and Kenya Wine Agencies; with Leleshwa Wines and Yatta Wines respectively. Uganda produces wine in Lira District and Mbarara, in the south. It is exciting to note that producers continue to increase investment in these ventures as they work with producers from more established wine regions to increase quality. Rarely cited as a wine region of note, Zimbabwe’s wine industry Enartis – www.enartis.com is gradually growing and evolving. Despite its relative immaturity, Zimbabwe’s wine culture has progressed as far as establishing a basic appellation system, although there are few wine production laws to complement these. It is standard procedure to employ foreign “flying Sample after winemakers”, particularly from neighboring treatment with Zenith Color South Africa, as well as Australia. Off-dry wine styles are prevalent, mostly white wines made from Chenin Blanc, Colombard and Cape Riesling DID (Crouchen).

Red wines are YOU KNOW? Pinotage is a red wine grape typically round, developed in South Africa soft styles in 1925. Originally a cross based on between Pinot Noir and Cinsaut, Pinotage naturally produces deep Pinotage, red varietal wines and has Cabernet a vast range of blending varieties that has brought Sauvignon, the taste of South Africa Merlot and Syrah. to the world.

Food Manufacturing Africa | 2017 Quarter 4

BEVERAGES

DELIVER JOINT HEALTH IN FORMULATIONS WHERE TASTE MATTERS

B

ENEO IS FOCUSING on the physiological effects of sugar replacement and the importance of looking beyond the label. In keeping with this theme, the company is taking sugar replacement to the next level, using ingredients that have a sugar-like indulgent taste and texture that consumers expect, but contribute to balanced blood sugar levels.

Food and beverage products that feature less sugar are a major focus for many producers at present. The current discussion about sugar reduction often ignores the fact that blood sugar management plays a key role in weight management. Whilst high glycaemic ingredients, such as maltodextrin, help to reduce the sugar because they are oligo- or polysaccharides (and not monoor disaccharides) they nevertheless have a significant negative impact on a person’s metabolism. Over time, the human blood glucose regulation system can become imbalanced, leading to prediabetes and diabetes, accompanied by overweight conditions.

Beneo’s naturally sourced chicory fibres and functional carbohydrates can replace commonly known sugars and maltodextrin, while also lowering blood glucose responses (a benefit that has been confirmed by the European Commission with a respective EU health claim) and providing a natural taste with the mild sweetness consumers are looking for.

SUGAR-LIKE TASTE AND TEXTURE Replacing sugar brings with it a range of technical challenges, as sugar (sucrose) is regarded as the gold standard in formulations due to its body, texture and taste. Sensorial evaluations have shown that the use of chicory root fibres and functional carbohydrates also result in maximised taste. Technical trials have demonstrated, to food and drink producers, how the company’s range of ingredients can replace sugar in recipes, whilst maintaining great texture and improving the physiological quality of the product. •

Savannah Fine Chemicals – sfc-info@savannah.co.za

JOINT HEALTH

Sugar replacement shines

Water-Soluble, Neutral Tasting Version of 5-LOXIN®is Great for Chewables, Gummies, Beverages and Other Taste-Sensitive Formulations Clinically demonstrated to improve joint comfort and reduce a key cartilage-degrading enzyme, 5-LOXIN®, a potent Boswellia serrata extract, has become one of the best known ingredients in the joint health category.

AquaLOX™, a newly developed extract – documented to have a similar pharmacokinetic profile to 5-LOXIN – opens up new formulation opportunities never before available.

Produced using a specialized process, AquaLOX is lowdosage and water-soluble with a neutral organoleptic profile making it ideal for taste-sensitive formulations.

• • • •

Water soluble Neutral taste Low dosage Patent-pending

• Kosher, Halal, Gluten-Free • Non-GMO

sfc-info@savannah.co.za THESE STATEMENTS HAVE NOT BEEN EVALUATED BY THE FOOD AND DRUG ADMINISTRATION. THIS PRODUCT IS NOT INTENDED TO DIAGNOSE, TREAT, CURE, OR PREVENT ANY DISEASE.

Contact PLT Health Solutions for samples and more information.

+1.844.PLTHEALTH www.PLTHealth.com

2017 Quarter 4 | Food Manufacturing Africa

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BEVERAGES

Intelligent production makes its mark S

IDEL’S SUPER COMBI is designed and engineered as a single smart solution for beverage processing. It is ideally used in CSD and water production.

The system uses integrated data-driven intelligence, making optimum performance continuously achievable across the entire production process.

Integrated data driven intelligence

22

The next generation solution integrates five process steps: preform feeder, blower, labeller, filler/capper and cap feeder into one smart system. It combines intelligent automation with connected machines and data-analytics management, leading to optimised production and maintenance services.

Beverage producers want solutions that think for them and act on their behalf.

Autonomous regulation is achieved via Sidel Intelli-adjust, which controls the system’s performance. It automatically applies adjustments where needed. Longterm enhancement without compromising on simplified operation, reduced maintenance time and minimal downtime are all possible thanks to intuitive interfaces such as augmented reality guidance and GPS localisation.

The Super Combi blower operates at high oven efficiency and minimal environmental footprint. This pushes the boundaries of

Food Manufacturing Africa | 2017 Quarter 4

ultra-lightweight bottle production and handling. Consumption of electrical power is reduced by up to 45 per cent and preformheating time is lowered by up to 15 per cent.

With the option of AirEco2 double airrecovery a 35 per cent reduction in the use of compressed air is also achieved.

A strict focus on hygiene, packaging quality and beverage integrity ensures maximum food safety. Gentle handling of preforms by the preform feeder ensure that original quality is retained. Positive handling of the bottles by the neck throughout the whole system and across a safe environment - from blowing to capping - guarantees optimal care. This enables higher bottle quality overall and maximises lightweighting opportunities. The integrated vision/rejection systems from preform to caps saves raw materials and reduces consumption. •

Sidel – www.sidel.com

BEVERAGES

A dazzling array of solutions

S

ensient Flavors showcased masking solutions for proteins and sugar reduction at FIE Europe held in November in Frankfurt, Germany.

The company supports sugar reduction concepts in various beverage, bakery and dairy applications. The range helps to maintain the full sensorial perception in products, even if sugar is significantly reduced. There is no need to change labelling.

A major trend in the food and beverage industry, protein has many benefits and helps to enhance the nutritional profile of products. The main challenge in product development is to mask the unpleasant taste many proteins deliver.

Sensient’s innovative protein masking solutions work with all protein sources and blends. Manufacturers can improve the taste profile of products by eliminating off-notes, improving the unpleasant mouthfeel some proteins display. Proprietary masking technologies allow for natural, nonGMO, allergen-free and kosher labelling.

Natural Origins is a comprehensive range of authentic true to nature extracts. The botanicals collection includes herbs such as hops, basil and sage; spices such as cardamom, saffron and pink pepper and a broad variety of dazzling floral notes such as cherry blossom, lavender and chrysanthemum.

A highlight is the ginger collection and powerful extracts add to the richness of different ginger profiles, perfect for the ready to drink beverage industry.

Barbara Lezzer, Sensient’s director of marketing Europe for sweet and beverage concludes, ‘Visitors to the stand discovered how to partner with Sensient in the development of new and unexpected taste profiles based on key market and consumer insight. With our holistic approach, our

experts help customers to develop integrated natural product concepts including flavouring, colouring and balanced sweetness that hit the right note with consumers.’ •

Sensient Flavors – www.sensientflavors.com

2017 Quarter 4 | Food Manufacturing Africa

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ADVERTORIAL

CELEBRATING remarkable milestones High Frequency Heating (HFH), an internationally recognised and certified company, is celebrating its 31st anniversary.

The South African company specialises in radio frequency/ dielectric heating systems, which assist in the provision of cost-effective solutions.

R

ICHARD BAYLEY ESTABLISHED the company in 1986. HFH initially targeted the timber industry, a fast growing

market at the time, before progressing to the manufacture of radio frequency (RF) tarpaulin welding machines.

After commissioning its Twin Shuttle RF Welding machines, which according to Bayley, provide a variety of application

A vacuum former creates moulds

solutions for different markets, the company set its sights on the food and beverage industries.

‘We started building machines for manufacturing plants. These include vacuum formers, twin shuttles and roller cutters,’ he explains. ‘Our range of vacuum formers enable clients to form packaging such as punnets and cups in a number of different shapes. Roller cutters assists clients in

Roller cutters designed to cut out moulds

removing excess material around these punnets and cups while twin shuttle RF welding machines help pack products and seal them in blisters.’

The company’s rapid expansion and great staff complement are the two main reasons it is able to effectively service so many markets.

How do you speed up a production line when the deadline is extremely tight?

With the technology currently available,

Twin shuttle welders for sealing moulds

nothing is impossible. ‘Our vacuum formers are PLC Controlled. The complete machine is controlled via the Human Machine Interface on a control panel. This means the machine

features a complete CAD/CAM installation.

The facility is resourced by qualified engineers and technicians, who ensure the most up-to-date knowledge is at the company’s disposal.

HFH’s comprehensive tooling area is complete with a CNC machining centre and software for the manufacture of vacuum-forming moulds and engineered components. It stocks tool-rules, aluminium plates, Euro slot weld-outs and all the necessary components. Its engraving facility allows the manufacture of RF Welding dies for all industries, including packaging and other specialist applications.

Highly trained technicians conversant with all makes of RF equipment, factory automation and industrial electronics can be found in its service department. This division has a complete factory backup for the manufacture, modification and conversion of redundant parts.

‘We stock a comprehensive range of spares, accessories and consumables for our equipment to ensure that we minimise downtime of your equipment. Your machine or production line will not be left standing with HFH’s impressive range of stock coupled with years of experience,’ Bayley adds. ‘Our footprint extends to Zambia, Zimbabwe, Botswana, New Zealand and Australasia amongst others. Why import when you can have a proudly African manufactured plant with full support at your fingertips?’

HFH offers a comprehensive service, from the design stage, tooling and manufacture to the supply of capital equipment. A lot of time is saved, owing to the in-house manufacture of all tooling. •

WHAT’S ON OFFER?

can be set to perfection with minimal physical labour. It is a promise of perfect moulds every time,’ Bayley explains.

A ONE-STOP SHOP Situated in Boksburg, HFH is home to a 1500m² facility equipped with a machine shop, tool room, electronics workshop and

HFH SELLS A wide range of shuttle welders. The 220V single-phase smaller shuttle welders start at 1.5 to three kilowatts, while the three-phase 380V machines range from four to 12kW. All machines require a six bar air supply with the exception of the roller cutters.

a fully supported design facility. The latter

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Food Manufacturing Africa | 2017 Quarter 4

High Frequency Heating Tel: +27 11 918 4370 Email: sales@hfheating.co.za www.hfheating.co.za

PACKAGING

Packaging industry SET TO ADVANCE The national statistical service of South Africa, StatsSA, indicates an uptick in manufacturing data. This offers the packaging industry an opportunity to ramp up production digitisation in preparation for further growth.

F

IGURES RELEASED BY StatsSA in October indicate manufacturing production increased by 1.5 per cent in August 2017 compared with August 2016.

Bruce Peters, regional manager for manufacturing at Cisco Southern Africa believes that because the increase was mainly due to higher production in the basic iron and steel, non-ferrous metal products, metal products and machinery division (11.3 per cent and contributing 2.0 percentage points), downstream manufacturers will take up this increased production and provide the packaging industry with slightly increased upstream demand.

‘Meeting this demand will require the packaging Bruce Peters industry to take advantage of the window to reduce downtime by bringing internal processes up to speed and improving services,’ he says.

In a Cisco survey of more than 600 senior executives in 13 countries – from both industrial machine builders and end user manufacturers – 86 per cent said the transition In 2015, Deloitte from product-centric to predicted the African service-oriented revenue continent would become models are a core part of their a high growth region growth strategies. for the packaging industry.

StatsSA announced that seasonally adjusted manufacturing production increased by 1.3 per cent in the three months ended August 2017 compared to the previous three months. Six of the 10 manufacturing divisions reported positive growth rates over this period.

DID YOU KNOW?

definition, packaged – I believe that the packaging industry can therefore expect an uptick as well,’ Peters explains.

The McKinsey Global Institute has identified four groups of consumers that will drive much of Africa’s consumption growth between now and 2025. Those earning more than US$50 000 per year in North Africa and South Africa, Nigerian consumers, middleincome consumers in East Africa and middle-income consumers in Central and West Africa.

These figures come in the wake of recently announced investments in the African packaging market. These include: • A B InBev investing in two new packaging lines for returnable glass bottles • Mpact announcing a new liquid packaging recycling plant • G olden Era partnering with a Nigerian beverage can manufacturer to build a large scale beverage can plant

PROS AND CONS IN AFRICA StatsSA’s latest figures underscore findings in McKinsey’s research released in October points to consumer spending in Africa reaching US$2.1 trillion by 2025 in real 2015 prices. ‘Consumer goods are by

2017 Quarter 4 | Food Manufacturing Africa

25

PACKAGING “Complexity and a lack of digital capabilities are holding firms back”

THE BIGGEST CONTRIBUTORS TO THE UPSWING THE FOLLOWING DIVISIONS of the manufacturing sector have made the largest contributions, resulting in the 1.3 per cent increase: •b asic iron and steel, non-ferrous metal products, metal products and machinery (2.5 per cent and contributing 0.5 of a percentage point) •p etroleum, chemical products, rubber and plastic products (1.6 per cent and contributing 0.4 of a percentage point) •m otor vehicles, parts and accessories and other transport equipment (3.9 per cent and contributing 0.3 of a percentage point) • f urniture and other manufacturing (7.1 per cent and contributing 0.2 of a percentage point).

26

Food Manufacturing Africa | 2017 Quarter 4

• Nampak’s investments in recent years both locally, in Angola and Nigeria.

In 2015, Deloitte predicted the demand for packaging would be driven by a number of factors. These were identified as increased markets for consumer products, burgeoning individual incomes, an expanding population of youthful consumers and growing domestic economies, particularly those in East and West Africa.

Peters warns the packaging industry will be negatively affected if it doesn’t address digital transformation to reduce downtime.

‘Complexity and a lack of digital capabilities are holding firms back. The top inhibitor to transitioning to a service model is the difficulty of managing a “two-front war” –products and services simultaneously. However, their ability to capture significant value and leapfrog competitors, hinges on accelerating to a service model,’ he says.

To resolve this service dilemma, the services and digital journeys must converge.

‘To unlock the full potential of the service model, while still improving products, industrial machine manufacturers and end-user manufacturers need to digitally transform their businesses,’ he concludes. •

Cisco Southern Africa – www.cisco.com

PACKAGING

Where do you stand in the

glass vs carton debate?

More than 60 per cent of consumers agree glass packaging is better for the environment than other types of packaging. Tetra Pak believes this is erroneous as life cycle assessments (LCA) on carton indicate it is environmentally friendlier than glass.

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CA IS A common method used to compare the total climate impact of different kinds of packaging. Climate impact varies between different types of glass packaging and carton packs. Overall, these assessments show carton packaging is better for the environment. There are a number of reasons for this: • The weight of cartons are lighter than glass. This leads to cost saving when cartons are transported as they are made primarily of renewable materials, which glass packaging is not.

• C arton pack production is a less energy intensive process than glass packaging. A recent LCA conducted by a non-profit ecological research institute, the Institute for Energy and Environmental Research (IFEU) indicates glass packaging had a climate impact about nine times higher than cartons.

THE ADDED BENEFITS Cartons are based on renewable resources and have less climate impact than traditional plastic usually made from fossil materials. Their square shape allows more packs to be packed onto one vehicle, thereby reducing emissions from transportation.

Aseptic packs can be stored without the need for refrigeration or any preservatives for up to six months. These packs are also strong, resealable, stackable, light, durable and portable.

An aseptic pack has six layers protecting a product’s contents from light, oxygen, flavour loss and odour intake.

All products in the pack are heated to over 135°C from two to 15 seconds.

This maximises the destruction of microorganisms while minimising the chemical changes in the product. The technology sterilises both the product and packaging materials using rapid heating and cooling techniques.

Owing to aseptic technology and package structure, carton packs protect food and drink without the need for additives or preservatives.

No harmful substances are released. When compared to transparent packaging, Tetra Pak says cartons offer better protection against light, which otherwise breaks down vitamins and other nutrients. •

Tetra Pak – www.tetrapak.com

SMART PACKAGING SOLUTIONS For your dairy product innovation

SIMPLIFIED CONVERTING CARTON PACKAGING RECYCLING entails the collection of packs, which are then agitated in a hydro pulper. This process involves the separation of the six layers of paper fibre, plastic and foil constituting carton packs. These materials are used to make new products. Recycled paper fibres are used to produce products such as cereal and pizza boxes as well as printing paper.

Meet us at

2017 Quarter 4 | Food Manufacturing Africa

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PACKAGING

Inspection system guarantees

superior quality cheese

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PECIALIST SOUTH AFRICAN cheese supplier, the Famous Brands Cheese Company, managed by Coega Dairy in the Eastern Cape enhanced its stringent quality control standards with the adoption of an Ishida x-ray inspection technology.

The company installed the Ishida IXGN-4044 inspection system to identify potential foreign bodies in three-kilogramme packs of diced mozzarella cheese supplied for pizza toppings. The flexibility of this system has enabled the company to use the machine for weight estimation as well.

Prior to the installation, the organisation used metal detection for its quality inspection process but was attracted by the much wider capabilities of the x-ray technology.

‘With the IX-GN-4044 we can also search for glass as well as different metals. This means we can make our products even safer for our customers,’ says Richard Rudman, operations manager of the Famous Brands Cheese Company.

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TAILORED FOR FLEXIBILITY

Elastos Mudzamatira, a Coega machine operator setting up the machine

The equipment is in operation 24 hours a day, seven days a week. It handles 20t diced cheese daily and approximately 18 bags per minute. The line speed is currently governed by the capabilities of the bagmaker. The system has the capacity to operate at much higher speeds, providing a valuable element of future-proofing the company’s continued growth. The device is user-friendly, easy to operate, quick and easy to clean.

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Food Manufacturing Africa | 2017 Quarter 4

Installation and training the company’s operators to work on the system took a total of three days. The machine was immediately up and running for production and has been operating reliably since. The Famous Brands Cheese Company is an existing user of Ishida’s multhihead weighers.

‘We were familiar with the technical sophistication and reliability of the company’s equipment. The production detection levels and consistency of the IX-GN-4044 are much higher than x-ray solutions offered by other suppliers.

The system’s weight estimation feature is an additional and interesting feature,’ Rudman explains.

He says the company is delighted with the enhancements the system has made to its quality control of cheese products. •

Ishida – www.ishida.com

Proven to deliver productivity

High speeds are a given with Ishida snacks packaging technology. Our lines are consistently fast, and you’ll experience high levels of operational effectiveness and efficiency too. Delivering only the highest quality packs, in a fraction of the time.

Work in harmony with Ishida.

ishidaeurope.com

PACKAGING

Versatility

is the name of the game Nova, a company in the Serac group, has designed the latest version and addition to its Neo cup filling line, which can efficiently fill up to 12 000 cups per hour. The solution matches the continuous need for faster speeds and bigger batches and is less labour intensive to operate.

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HE NEO RANGE is designed to fill pre-formed cups at low and medium speeds. Defined as compact, these complete solutions comprise cup de-stacking, filling, lid placing, sealing, coding and over-lid placing units. The range’s compact and ergonomic design reduces its footprint on cup packaging lines, especially when compared to linear solutions.

These machines have been designed with Nova’s expertise in dosing and volumetric filling, making them easy to install, operate and maintain. The technology can be used to fill cups with yoghurt, dairy desserts, food and beverage products.

An illustration of the Neo cup filling line

SMARTER APPROACH TO FILLING

Achieve flexible production with integrated robotics solutions

There are two filling stations, which offer options of producing single or two-layer products. The supplementary layer can be either pre- or post-filled. The range for cup packaging can process several different cup sizes of cylindrical or rectangular cups. No tools are required for changeovers, which can be carried out within 15 minutes. A specific version of the range is available for the automatic filling of non-de-stackable containers such as glass or carton cups.

With the newly developed Neo machine, indexed rotary cup filling is no longer limited to low speed filling. The rise in speed allows manufacturers to target markets that report an increase in dairy products consumption with new product formulations and packs.

The latest version of the Neo filler also addresses cost optimisation.

EQUIPPED TO DECONTAMINATE Capitalising on its aseptic filling experience and packaging decontamination, Serac’s indexed rotary machines can be equipped with a dry H2O2 decontamination system. This type of cup treatment meets the hygiene and food safety requirements of dairy and food manufacturers developing products with more natural ingredients and fewer preservatives. • Delta Parallel robot Quattro and Hornet

Articulated robot Viper

SCARA robot eCobra

A MARKET LED BY PRODUCT INNOVATION

Mobile robot LD Series

The new Omron Robotic Automation enhances the most demanding manufacturing lines. Realize faster line start-up & change-over, implement easier to use technology & vertical line integration, and facilitate faster data capture & analysis to increase your in-line efficiency.

DRIVEN BY TRADITIONAL and modern consumption trends, yoghurt, processed cheeses and dairy desserts are some of the most popular dairy foods consumed worldwide. Dairy companies cherish these market segments and look for any opportunity to add value to existing lines. Competition is harsh and differentiation through continuous innovation is an obligation for any manufacturer looking to grow its business. To facilitate this trend, Serac strives to find smart packaging solutions that emphasise product innovation.

Our industrial robotics range from articulated, SCARA, and DELTA to collaborative (mobile) robots that optimize the handling of varying lot sizes and diverse products, formats and qualities. Achieve flexible production with integrated robotics solutions that give you a competitive edge!

Discover how to improve your flexible production, contact us: +27 (0)11 579 2600 info.sa@eu.omron.com industrial.omron.co.za

Serac – www.serac-group.com, www.dairy-packaging-machines.com

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Solutions for the food and beverage industry.

Reducing energy costs and plant downtime.

Food and beverage manufacturers as well as ingredient processing industries like sugar, grain, starch and edible oils are challenged by rising costs. ABB is working with customers across the food and beverage industry in Southern Africa who are looking for the best sustainable technology solutions for present market conditions.

ABB microgrid technology addresses unreliable grid supply through renewable energy. High efficiency and reliable solutions improve operational energy, water efficiency and reduce total cost of ownership with reliable power preventing costly downtime. http://new.abb.com/food-beverage http://new.abb.com/power-generation/microgrids-solutions

ABB South Africa (Pty) Ltd Tel. +27 10 202 6995 E-mail: contact.center@za.abb.com

We speak dairy It may all come from the same place, but when it comes to the packaging there’s no one-size-fits-all.

Our diverse range of award-winning dairy containers and aseptic carton systems is specially designed to fulfill your complex dairy processing needs. We know, because we speak your language. Let’s talk.