Food Manufacturing Africa Quarter 4 2019

NOVEMBER 2019 - FEBRUARY 2020 Vol. 7 • No. 4

The right refrigeration system helps extend product life span and reduce energy expenses

Protein alternatives: A nutritional powerhouse

Beverage processing technology: Flexible packaging: Closed loop recycling a must How digitalisation can boost efficiency

CONTENTS N O V E M B E R 2 019 - F E B R U A R Y 2 0 2 0

13 Hot logistics keep products cool Temperature control is an integral part of logistics’ overall products and services. When applied to the cold chain, logistics are subject to even more steps and smarter solutions.

Vo l. 7 • N o. 4

7

INDUSTRY TALK

ew regulations for pathogen control in N meat products

8

NEWS

A healthy boom in enhanced beverages Symrise finalises deal for ADF/IDF Firmenich acquires minority stake in Robertet A new website for Heat and Control Ishida grows its East African presence Nosa's acquisition of Deltamune to go ahead Is graphene the next big thing in packaging?

13

HEATING & REFRIGERATION

Smarter solutions in temperature control

GEA launches new nitrogen freezing plant Save energy with these refrigeration systems

A cooling perspective for the bakery industry

Say no to bottlenecks

A congestion free freeze line

21

PROTEIN ALTERNATIVES

Savannah keeps it green Plant-based proteins are sustainable

23

BEVERAGE PROCESSING TECHNOLOGY

Digitalisation can boost efficiency Bottle integrity on the line Solutions in bottle-to-bottle recycling

26

PACKAGING TECHNOLOGY

Factory harmony will determine future production

24 Sidel introduces the Cermex FlexiPack

28

FLEXIBLE PACKAGING

Understand the art of packaging The way forward in flexible recycling Polyoak is passionate about the planet

This unit improves flexibility and overall ease of operation.

ADVERTISERS’ INDEX Clomark............................................................5............................www.clomark.com Emirates SkyCargo........................................IBC........................www.skycargo.com/emiratesfresh GEA Africa........................................................15...........................www.gea.com KlÜber Lubrication ......................................18..........................www.klueber.com Krones Southern Africa...............................23..........................www.krones.com Polyoak Packaging........................................30..........................www.polyoakpackaging.co.za Roha SA............................................................IFC.........................www.roha.com

Savannah Fine Chemicals..........................21...........................www.savannah.co.za Sollich KG........................................................19..........................www.sollich.com South African Trade Promotions .............11...........................John.t@satp.co.za Syspro .............................................................13...........................www.syspro.com Vivit Foods......................................................12...........................www.vivit.co.za Wild Flavors & Specialty Ingredients.....................................................OBC.......................www.wildflavors.com

2019 Quarter 4 | Food Manufacturing Africa

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EDITOR’S COMMENT

EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmedia.co.za Layout & Design: David Kyslinger ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmedia.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmedia.co.za

INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de

Food trends drive development

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

W

HILE THE FOOD and beverage industry is under pressure, changing trends in packaged goods continue to drive growth.

Urbanisation is picking up and metros on the continent are attracting a younger generation of consumers with changing consumption habits in processed, packaged and liquid food and beverages.

The German-based VDMA Food Processing and Packaging Machinery Association estimates that just over seven million tonnes of packed food was sold in South Africa last year. It is expected that demand will rise by six per cent until 2022. Those segments showing the biggest growth are savoury snacks (an aboveaverage growth of 13 per cent) with rice/ pasta/noodles at 11 per cent. Demand for bakery products will increase by six per cent and dairy products by four per cent.

This is being echoed in other countries in Africa including Mozambique, Angola, Zimbabwe, Zambia, Madagascar, Botswana and Namibia with a corresponding demand for modern processing and packaging technologies. Coupled with SADC trade agreements and the development of the Tripartite Free Trade Agreement, there is every reason to believe that 2020 will be the year for growth!

For our comprehensive feature on heating and refrigeration, turn to page 13 now. We touch on aspects such as temperature control as an integral part of logistics’ overall products and services; sustainable refrigeration practices to reduce energy consumption and the latest in vacuum cooling in the bakery industry. Ever wondered how conveyors keep going in the extreme temperatures of a deep freeze line?

Page 20 reveals all the answers.

Besides fat and carbohydrates, protein is a fundamental nutritional component made up of essential amino acids required for physiological functions. On page 21, we bring you a snapshot of well-known protein alternatives. Flexibility is a key component of manufacturing, more so in the soft drinks market, which is characterised by frequently changing and often short-lived trends.

Siemens (page 23) can now assist soft drink manufacturers to rapidly adapt their production to new requirements. We also investigate the latest solutions in bottle-tobottle recycling from KHS. While the plastics industry has made its journey from innovation to standardisation and widespread recycling, there are certain lessons the flexibles industry can follow to achieve the same success. Be sure not to miss this article on page 29.

I hope you enjoy this edition of Food Manufacturing Africa. If you have any suggestions, news or stories for us, please email me at maryke.foulds@newmedia.co.za.

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

Food Manufacturing Africa is published by New Media, a division of Media24 (Pty) Ltd quarterly and circulates to executives in the food and beverage industries. Views expressed in this journal, other than where specifically stated, are not necessarily those of the publisher.

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Food Manufacturing Africa | 2019 Quarter 4

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INDUSTRY TALK

New regulations put pathogens in its place

The listeriosis threat continues to loom large over food manufacturers and consumers. This was confirmed in October 2019 by South Africa’s National Institute for Communicable Diseases.

'T

HE GOOD NEWS is that this figure is below the projections and historical averages for listeriosis cases in a population,’ Emma Corden, managing director of industrial cleaning company, Industroclean points out. ‘What it also means is there is an expectation that listeriosis remains a threat to consumers, even though the number is statistically small.’

The new Compulsory Specification for Processed Meat Products is important at a time like this. ‘These regulations are a direct result of the listeriosis outbreak and aim to eliminate further food contamination crises by setting out clear checks and balances for processed meat manufacturing,’ Corden explains.

The Compulsory Specification for Processed Meat Products regulations, published by the Department of Trade and Industry, now give effect to the guidelines for the processed meat industry as laid out in SANS 885.

This national standard specifies the handling, preparation, processing, packaging, refrigeration, freezing, chilling and storage of processed meat products.

The new regulations cover all aspects of a manufacturing facility, from its physical structure and equipment to ingredients used, test methods and the handling, preparing, processing, producing,

Pronounced Liss-te-ria mono-cy-to-jeans

Scientific name Listeria monocytogens also known as L.mono

Food recalls between 2008-2017 Products recalled include meat, diary, processed foods, fresh produce and other

6 Facts about Listeria Monocytogenes

High risk foods Ready-to-eat meats eg. ham, chicken) Diary products (eg. eaw milk, ice cream, soft cheese) Fresh produce (eg. raw and frozen fruit & veggies) Cold smoked fishery products

Causes of food-borne illness 2-70 days incubation period makes food poisoning caused by Listeria hard to trace Who is at risk People with a compromised immune system, pregnant women, children and the elderly

packaging, marking, labelling and storage of the product.

Hygiene practices and processes are an important part of the regulations. These apply to the processing facility, equipment and employees, and specify the level of microbiological content allowed. The basic principles of a Hazard Analysis and Critical Control Point (HACCP) food safety

“The Compulsory Specification for Processed Meat Products regulations, published by the Department of Trade and Industry, gives effect to the guidelines for the processed meat industry as laid out in SANS 885”

management system are recommended in the regulations as the model to adopt.

This requires manufacturers to identify potential hazards where they may occur and can be controlled. They should then set limits that allow these hazards to be controlled at each critical point and ensure these limits are properly monitored.

HACCP further recommends producers determine what corrective action is needed if they have failed to control a hazard.

All these steps should become part of any manufacturer’s processes, including the recording, verification and review procedures.

‘Applying the simple steps and covering all the bases outlined in HACCP guidelines for food manufacturing should, at the very least, ensure that bacterial infections are avoided.

‘Hygiene procedures and cleaning schedules are obviously a key part of this process, and in many ways, the low-hanging fruit that producers can grasp to ensure the minimum levels of compliance,’ Corden concludes. •

Industroclean – www.industroclean.co.za

2019 Quarter 4 | Food Manufacturing Africa

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NEWS

HEALTHY LIFESTYLE TRENDS AND THE ENHANCED BEVERAGE MARKET BOOM ENHANCED BEVERAGES ARE gaining a strong market position, especially since consumers are seeking products that benefit their health. GlobalData, a leading data and analytics company indicates that 59 per cent* of consumers in North America say they purchase products that help save them time and effort – but high sugar content is the price to pay.

Holly Inglis, consumer analyst says, ‘With less time in the working day to exercise, beverages that support an on-the-go lifestyle are

therefore likely to prove popular. Healthy lifestyle trends have boosted the industry, with frequent adoption of healthier beverages dominating social media channels and supermarket promotions.’

Research conducted by the National Health and Nutrition Examination Survey found that plain water should be the optimal beverage choice in weight loss.

This suggests that consuming vitamin and mineral enriched beverages does not actually aid dieting. Inglis adds, ‘Typically drinks that claim they have added vitamins, electrolytes, potassium, antioxidants and fibres often have more sugars than other beverage types. In some cases, these benefits can be obtained by plain water.’

Per GlobalData’s Q2 2019 Quarterly Beverage Forecast, a 5.1 per cent growth in 2019 is forecast for enhanced water,

despite awareness of high sugar content. This supports Minesota State University findings that although individuals know that sugar sweetened beverages are detrimental to health, two per week are still consumed per person.

This indicates the bridged gap between intention and indulgence.

Inglis concludes, ‘If you are looking to hydrate after exercise, or are substituting carbonated soft drinks that are high in sugar, then yes, but if you are consuming it as a food supplement, or are seeking weight loss, enhanced beverages are unlikely to provide an allencompassing benefit.’ •

*GlobalData's 2019 Q3 consumer survey

Symrise completes

acquisition of ADF/IDF The company has announced the successfully completed acquisition of ADF/IDF, a leading US meat and egg-based protein specialist and pioneer in all-natural nutrition ingredients. The acquisition has been cleared by the Antitrust Division of the US Department of Justice (DOJ).

S

YMRISE WILL NOW begin the process of integrating ADF/IDF. With its comprehensive portfolio of solutions for the food and pet food industries, ADF/ IDF will complement the Nutrition portfolio with a highly diversified range of natural based solutions.

‘We very much look forward to teaming up with ADF/IDF given our shared focus on innovation and meeting customer needs.

Together, we will work to continue expanding our

8

diverse solutions portfolio using the highest quality natural ingredients. Our combined reach will allow us to expand our footprint in

Food Manufacturing Africa | 2019 Quarter 4

the marketplace, particularly in the US, and to widen our range of meat and egg-based protein products to our growing customer base’ says Dr Heinz-Jürgen Bertram, CEO of Symrise AG. The integration process will begin immediately and will follow a defined roadmap overseen by cross-divisional teams. Symrise expects the transaction to be fully earnings accretive in the first year after closing.

Symrise announced the acquisition of ADF/IDF which was valued at US$900 million, on 31 January 2019.

The transaction has been financed through a combination of debt and equity. •

NEWS

AZELIS SET TO BECOME A LEADING SPECIALTY CHEMICAL DISTRIBUTOR IN AFRICA AND THE MIDDLE EAST

THE COMPANY, a leading distributor of specialty chemicals and food ingredients has announced its agreement to acquire Orkila, one of the top specialty chemicals and food ingredients distributor throughout Africa and the Middle East.

Headquartered in Beirut, Lebanon, the Orkila Group runs offices in 13 countries and is active in more than 30 countries in the region. They represent several renowned specialty chemicals and food ingredients manufacturers who have a strong strategic fit with Azelis’ principal base.

Orkila serves several thousand customers across Africa and the Middle East, ranging from major multinationals to smaller local producers, all seeking specialty products that bring added value to their brand, and a reliable partner to achieve success in this vibrant and growing marketplace.

Africa has been experiencing economic

acceleration, growing middle class and improved business environment, thus providing Azelis and its principals with the opportunity to accelerate their growth in the region. The specialty chemicals distribution market in Africa and the Middle East is one of the fastest growing in the world, while the blue chip raw material producers are looking for a sizeable distributor in the region.

The acquisition creates a unique combination of Azelis’ innovation and formulation potential, its EcoVadis Gold status and international reach on one side and the strong local presence, regional expertise and excellent reputation of Orkila on the other.

Through this transaction Azelis intends to acquire 100 per cent of Orkila, with over 220 employees joining the Azelis team. Orkila was created in 2005 and grew to become a leading specialty chemicals and food ingredients distributor

in the region, with sales into multiple market segments, including pharmaceuticals, food, agrochemicals, animal nutrition, personal care, paints and construction, oilfield, plastic additives, home care and water treatment.

To ensure business continuity, Audrey Sacy Aris and Christophe Sacy, and other senior managers, will continue to run the operations going forward. Like Azelis, the company is very focused on promoting specialty service offerings and has an application lab in Egypt that serves both food and personal care customers. Orkila also offers accredited laboratory testing coupled with the ability to develop and introduce innovative products, create and enhance formulations and assist the clients’ pursuit of growth and improved performance.

Dr. Hans Joachim Müller, Azelis chief executive officer and president comments, ‘We are very excited that Orkila will become a part of Azelis. They are a well-established company, known in Africa and the Middle East for their high-quality expertise and service. We have been impressed by Orkila’s committed management, the similarity of our business models and excellent cultural fit. We know that many of our principals are currently considering strengthening their activities in Africa. Combining the strength of a leading regional specialty distributor with the strength of Azelis will result in an excellent and unique platform for organic growth.’ •

FIRMENICH ACQUIRES A MINORITY STAKE IN FLAVOURS FIRM ROBERTET FIRMENICH HAS ACQUIRED a 17 per cent minority stake in flavours and fragrance firm Robertet from First Eagle Investment Management, for a price of €683.30 per security.

Robertet produces a wide range of flavours for customers in the food industry and operates 15 manufacturing sites around the world. Firmenich said in a statement that it may consider taking a controlling interest in the company ‘should it be invited to do so’, though also stated that it was willing to be a passive long-term stakeholder in

Robertet for the time being.

Patrick Firmenich, chairman of the board of Firmenich says, ‘Firmenich has the greatest respect for Robertet, with its family values, long term vision of the industry and leading capabilities in natural ingredients. As a long-term oriented shareholder, this investment reflects Firmenich’s commitment to best support Robertet’s continued growth.

Gilbert Ghostine, CEO, Firmenich adds, ‘With its strong naturals portfolio in perfumery, flavours and ingredients, Robertet is well-positioned to benefit

from consumers’ continued demand for authentic natural products. ‘This investment is fully in line with our vision for sustainable and natural solutions.’ •

2019 Quarter 4 | Food Manufacturing Africa

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NEWS

NEW WEBSITE OFFERS IMPROVED VISITOR ENGAGEMENT

COMMITTED TO INNOVATION for nearly 70 years, Heat and Control has launched a new website with Silicon Valley digital agency WebEnertia Inc. The site will offer visitors improved customer engagement, solutions, education and resources. With a modern design and fresh look, visitors will appreciate its intuitive navigation through the broad and deep equipment offering. ‘We are excited about our new website and the product-filled pages of resourceful information it provides for our customers, partners and employees,’ said Amber Crowley, marketing manager at Heat and Control. The website can now grow with the company and it’s ever increasing capability. ‘We wanted our technology expertise on the manufacturing floor to match our technology online and provide helpful information about the comprehensive solutions we provide.’ The site is also mobile responsive to provide the best experience on visitor’s preferred device. Heat and Control is proud to have co-branding with partners and customer success stories showing their commitment to advancing the industry. •

VALIO BRINGS RECYCLED PLASTIC TO FOOD PACKAGING VALIO IS AMONG the first food companies to use recycled plastic. This development is part of a larger goal: the food company wants to cut milk’s carbon footprint to zero by 2035.

Packaging has a vitally important task to prevent the larger environmental hazard of food waste. It’s now possible to use recycled plastic in food packages.

Valio’s range of delicacy cheeses’ new packages are now made from at least 90 per cent recycled plastic.

‘Using recycled plastic reduces the plastic industry’s environmental emissions by 40 to 60 per cent compared to making plastic from fossil oil. Our goal is that in 2020, all Valio sliced cheese packages in Finland are made from at least 50 per cent recycled plastic. In the future, roughly 10 per cent of all our packaging plastic in Finland will be recycled. That matters a lot when it comes to the environment,’ says Juhana Pilkama, package development manager.

In 2015, Valio introduced 100 per cent plant-based cartons to Finland’s stores. These cartons are made from wood and the thin protective plastic film from the sugarcane industry’s waste. The caps are also fully plant-based. In 2019, Valio is discontinuing its use of black-dyed plastic in Finland. Current recycling devices cannot identify the black colour, which means black plastic packages don’t get recycled. •

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Food Manufacturing Africa | 2019 Quarter 4

Ishida strengthens East Africa presence

The Ishida and Heat and Control team

ISHIDA EUROPE IS opening a dedicated office for East Africa to provide localised sales, service and spares support to food processors and packers throughout the region. The new office in Nairobi, Kenya, led by sales manager David Mulwa and service engineer Daniel Ambuka, will include a fully equipped demonstration area, featuring a selection of Ishida’s latest costeffective weighing, packing and inspection solutions. The equipment is suitable for use in a wide variety of markets including snacks, fruit and vegetables, nuts and seeds, confectionery, biscuits and bakery. It will enable the company to provide a fast-response service in the supply and support of individual machines and the design and installation of complete packing lines.

The office is also co-located with international food processing equipment specialist Heat & Control. This will allow snacks companies in the region to benefit from the Ishida/Heat & Control alliance for the devising of comprehensive wall-to-wall snacks processing and packing line solutions that deliver maximum throughput and efficiencies.

‘Ishida’s success is based not only on the performance and reliability of our equipment but also on the impeccable standards of service and support that we provide to our customers,’ comments Steve Jones, marketing director, Ishida Europe. ‘Our new office will ensure that companies throughout East Africa can experience the same high levels of commitment and maximise the value of owning an Ishida solution.’ •

NEWS

NOSA TO ACQUIRE DELTAMUNE’S LABORATORY BUSINESS GLOBAL OCCUPATIONAL HEALTH and safety (OHS) risk management solutions provider NOSA, has signed an agreement to acquire 100 per cent of the Deltamune Group’s laboratory business (a leader in diagnostic testing and salmonella serotyping). The acquisition remains subject to standard closing conditions, and is expected to close at the end of DEC/JAN 2020.

This acquisition follows NOSA’s 2017 acquisition of the CSIR’s South Africanbased Cape Town and Durban laboratories, and will position NOSA’s laboratory testing business (NOSA Testing) as SA’s largest group of food and agriculture, and occupational health-focused, laboratories.

The combined testing business comprises eight laboratories located across South Africa, all of which are SANAS 17025 accredited, while two are DAFF approved for diagnostic testing within the poultry sector. The acquisition also gives NOSA Testing its first presence in the rest of Africa,

through a laboratory in Zambia.

Pieter Erasmus, NOSA chief financial officer, says the acquisition supports NOSA Testing’s aspirations of becoming South Africa’s leading food and agriculture and occupational health laboratory group, and over the medium term, extending testing services across the African continent in support of NOSA’s existing regional audit and certification business.

NOSA’s Testing, Inspection and Certification (TIC) business offers unmatched technical expertise with regards to microbiological and chemical analysis, process and retail safety audits and ISO 22000/FSSC 22000 certification.

‘Post-acquisition, the laboratories will operate as usual. Over time we will enhance efficiencies across the testing network to better meet the stated needs of our clients,’ Erasmus explains. ‘Through this acquisition

and the combined portfolio of services it delivers, NOSA TIC can now bring increased scale and reach, an expanded range of technical solutions and become a regional partner for all our clients who are looking to improve and minimise their risk exposure across the food and agriculture value chain and employee occupational health.’

‘This business combination allows us to better serve and understand our customers’ needs, while creating growth opportunities for our people,’ says Andre Munian, general manager of the Deltamune laboratory business. The Deltamune Group will continue to serve its customers and their industries as a dedicated vaccine development and manufacturing company. •

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2019 Quarter 4 | Food Manufacturing Africa

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NEWS

IS GRAPHENE THE NEXT BIG THING IN FOOD PACKAGING?

Professor Konstantin Novoselov

Tetra Pak has joined the European Commission Graphene Flagship project as the exclusive representative from the packaging industry to explore possible future applications of graphene in food and beverage manufacturing.

Graphene is a carbon-based material, one of the thinnest known to human kind, one atom thick, while also around 200 times stronger than steel. It is an excellent conductor of heat, electricity and has a wide range of light absorption abilities. Graphene material could bring breakthrough innovations with unlimited potential for integration in almost any industry.

Professor Konstantin Novoselov, physicist and Nobel Prize winner says, ‘Graphene has the potential

to revolutionise a range of processes and industries.

Since its first isolation in 2004, we have seen tremendous success and marketplace application of the material within the electronics and automotive industries. I’m looking forward to the next phase of the Graphene Flagship and exploring potential innovations in the packaging industry.’

Tetra Pak is leading research and development in the packaging sector, exploring the potential graphene holds to unlock a range of new and revolutionary innovations for the food and beverage industry. In terms of packaging material innovation, the product is being examined to see how graphene could offer coatings to reduce carbon footprint in the packaging supply chain.

The material can also enhance the performance of current packaging materials, enable new functionality and increase recyclability. With the development of smart packaging, graphene’s ultrathin flexible sensors can be integrated to packages as data carriers for producers, retailers and consumers. Graphene sensors can also be smaller, lighter and less expensive than traditional sensors.

Next generation equipment – exploring how graphene composites can be used to make equipment lighter and more energy efficient has the potential to reduce costs and energy consumption. With only modifications needed to equipment over additional purchases, both time and money are saved. •

Family range of yoghurt tubs launched ASTRAPAK IS AMONG South Africa’s leading suppliers of rigid dairy packaging. Its yoghurt cup range includes an assortment of sizes including 80ml, 125ml, 150g, 175g, 250ml, 500g and one kilogramme tubs. It also offers six-unit multipacks to provide packaging solutions that are tailored to suit varying customer needs. The sleek tub design ensures protective packaging that is lightweight yet durable, and the multipack yoghurt cups are userfriendly as they can be simply snapped-off for snacking.

Made from versatile polypropylene (PP), the yoghurt cups are recyclable and offer a sustainable packaging solution. Berry Astrapak presents customers with a variety of moulding options

12

that include blow moulding, thin-wall injectionmoulding and thermoforming - a cost effective production method. To ensure food grade hygiene standards are met throughout production processes, plants extrude all sheeting used for thermoformed packaging.

Brand owners can choose from a range of modern decorative techniques. In-mould labelling (IML), which creates precise labelling without compromising on high-end graphics, is ideal for dairy products because IML can withstand the cold chain. Berry Astrapak also offers full-length sleeving for dairy products – this award-winning technique gives products the branding edge. Other labelling techniques include offset printing, hot and

Food Manufacturing Africa | 2019 Quarter 4

cold foiling, silk screen and flexographic printing.

These top-quality decorative options ensure polished products that exude a sleek shelf presence. •

HEATING & REFRIGERATION

Hot logistics keep products cool

Temperature control is an integral part of logistics’ overall products and services. When applied to the cold chain, logistics are subject to even more steps and smarter solutions.

F

OOD, WHETHER FRESH, canned, dry or vacuum packed has a shelf life.

The longer it takes to distribute these products to retailers, the less time and probability exist to sell it, while still leaving time for it to be consumed.

There are two important lead times at play. The first is the time from factory to shelf or distribution lead time. The second is from shelf to consumption - also referred to as consumption lead time.

Logistics must manage the following: • Manage the storage and movement of food to deliver appropriate/best customer service • Deliver a brand promise in line with consumer expectation.

Lead time contains both elements.

Activities must be planned and coordinated to prevent eating up usable shelf life. This is not as easy as it sounds.

CONTROL AND MEASURE

Let’s look at a manufacturer of yoghurtbased desserts. The processor can control the time a manufacturer holds raw materials and manufactures, packs, stores and crossdocks to vehicles. Software can also control the environment by ensuring temperatures stay constant at four degrees Celcius or lower if required.

Truck temperature can also be monitored when offloading to mainstream retailers into temperature controlled receiving areas.

It is then up to merchandisers to pack cold shelves quickly in an ambient environment.

What about difficult to reach mall-located or garage forecourt retailers? It’s challenging to monitor broken cold chain activities such as slow offloading. Even if these second-tier outlets are efficient at logistics - planning and coordination could be problematic.

A broken cold chain is often the result of having to wait to fill shelves, resulting in additional cost to check systems that maintain the cold chain. It can also cost your brand by reducing available lead time.

“Software can also control the environment by ensuring temperatures stay constant at four degrees Celcius or lower if required”

TECHNOLOGY CAN HELP

Lateral thinking and technology may come to the rescue through innovations such as temperature sensitive strips on food

Logistics must manage the movement of food

packaging. These items discolour when the cold chain is broken allowing merchandisers or category managers to backtrack and analyse where the breakdown occurred.

RFID tags on pallet covers or boxes can record the logistics activity, route planning and temperature. This can facilitate a call to action when needed to optimise shelf life and measure and select LSPs and outlets for yoghurt-based desserts.

‘Syspro provides enterprise resource planning systems to plan manufacturing and distribution better by collecting RFID tags or other IoT device data. We can feed built-in artificial intelligence, which over time and multiple data cycles is boosted by machine learning,’ explains Doug Hunter of Syspro Africa.

This continuously improves the prediction of which LSPs routes, activities, products or customers will likely be affected by cold chain problems before they happen. •

Syspro – www.syspro.com

Enabling Your Business To Box Clever Packaging Manufacturing ERP for Movers and Makers of the world.

At SYSPRO we support people who get things done – people like you.

It’s why we’re committed to providing specialist ERP software that enables intelligent forecasting and faster delivery while helping you reduce waste materials and support sustainable practices.

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

2019 Quarter 4 | Food Manufacturing Africa

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HEATING & REFRIGERATION

Process test

before you invest GEA has launched its new nitrogen freezing pilot plant for bacteria, giving food and dairy processors the opportunity to trial this new technology in their own plants before investing in production-scale equipment.

B

Y FREEZING BACTERIA into pellets before drying, the technology innovator can now provide processors with greater flexibility, a higher active cell count and reduced costs through better utilisation of their fermentation lines and freeze dryers.

Many dairy and food processors, as well as suppliers of probiotic products, use live bacteria as part of their production process (e.g., yoghurt or cheese).

“Freeze-dried bacteria have become popular because they can be transported and stored at ambient temperature and rehydrated as required”

Traditionally, they have kept their own strains of bacteria and transferred them from one batch to the next.

As more specialised strains of bacteria have emerged, so too the need to distribute them more widely.

This is typically done by freezing them to -50°C and then storing them under temperature-controlled conditions until they are required. This requires a continuous cold chain, which may be no problem in developed countries, but more challenging elsewhere.

Freeze-dried bacteria have become popular because they can be transported and stored at ambient temperature and rehydrated as required. On the other hand, freeze-drying bacteria is a long process requiring several hours to freeze, then an additional 48 to 72 hours for the lyophilisation process to be completed. This ties up expensive freeze-drying equipment and limits production.

With its new pilot plant, GEA has taken a different approach, freezing the bacteria in

GEA's new pilot plant

droplets using a liquid nitrogen bath outside the freeze dryer, then drying the pellets via the normal procedure.

This method has many significant advantages: • Rather than freezing all the bacteria in a single batch, it can be collected from a continuous stream improving flexibility and equipment utilisation • Fermentation and freeze-drying are separate so the freeze dryer does not need to be available when the product is frozen • B acteria can be stored at -50°C until it is required • The bacteria cell count resulting from this process is nearly double that of traditional freeze-drying techniques • Frozen pellets dry much quicker than bacteria in slab form • Lyophilisation process is also faster, typically 24 to 36 hours compared to up to 72 hours.

‘Although there is a cost for the liquid nitrogen, this is more than offset by the optimised utilisation of the freeze dryer,’ explains Morten Pedersen, area sales manager for GEA Process Engineering. ‘Freeze dryers are expensive, so we need to make sure customers are getting the best possible output from them.’

Regarding the higher cell count from this technique, Pedersen states, ‘Bacteria that is frozen quickly via liquid nitrogen and dried in this way, retains twice as many viable cells than other techniques. This product is more effective than other options and ultimately, reduces the customer’s costs.’

The new pilot plant has a simple design, is easy to use and can be cleaned in place. ‘We are absolutely committed to this technology and want our customers to have the opportunity of trying it out for themselves in their own factories,’ Pederson enthuses.

‘The results seen with this new pilot plant are impressive and we’re confident that our customers will also be delighted with the results.’ •

GEA – www.gea.com

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Food Manufacturing Africa | 2019 Quarter 4

beverages

dairy farming

dairy processing

utilities

transport

food

core technologies

Milking & Cooling

Seperators

Decanters

Homogenisers

Valves

Spray Drying

Aseptic Filling

Brewery & Dairy

Compressors

Packages & Skids

Ice Machines

Freezers

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

www.gea.com

engineering for a better world

HEATING & REFRIGERATION

Sustainable refrigeration reduces energy consumption Tna has introduced a new energy-efficient fan design for its Ferguson ener-freeze FFV 3 (ener-freeze).

The technology will assist in reducing energy consumption by just over 30 per cent and can provide French fry manufacturers with a cost-effective and sustainable freezing solution.

“By upgrading equipment to the new fan, manufacturers can expect a return on investment in one to two years”

F

EATURING THE LATEST airflow technology, the unit can evenly freeze a variety of potato products in different shapes, including sticks, cubes and wedges. The technology also assists in reducing operating costs and increasing production cycles, while

ensuring high quality and uniformly frozen product.

Centrifugal fans with curved blades optimise airflow underneath the belt.

This results in even air velocity over the product for a high heat transfer rate and fluidisation across the entire width of

SHAPE REFRIGERATION WITH INNOVATIVE SOLUTIONS

E

MBRACO IS A multinational supplier of hermetic compressors and cooling solutions for the refrigeration industry.

The company offers innovative and low energy solutions to food and beverage manufacturers and processors. the company annually invests between three to four per cent of its nett revenue in research and development. It aims to transform technology into innovation with a focus on energy management, refrigeration and food preservation.

‘The level of quality, performance and reliability is a huge asset for our customers and the end user,’ says Marcio Schissatti, vice-president of business and marketing.

Growing demand for refrigeration systems with higher energy efficiency, lower noise and longer preservation of food, means the market is moving towards variable speed compressors. Embraco’s Fullmotion

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consumes 40 per cent less energy compared to conventional technologies.

Another invention is its Plug n’ Cool technology. This is a simple and compact sealed unit for commercial refrigeration, which aims to optimise resource installation and maintenance for manufacturers and contractors.

The technology allows the use of R290 natural refrigerant, making it possible for customers to comply with global efficiency standards in refrigerant gases.

To simplify the production and replacement process with robust and durable solutions, Embraco provides condensing units for commercial and aftermarket segments with high quality and efficient compressors with low energy consumption.

Embraco – www.embraco.com

Food Manufacturing Africa | 2019 Quarter 4

the belt. As airspeed is near the product's fluidisation velocity, the appearance of clusters is eliminated. Each French fry is frozen individually, quickly and to perfection.

The specific impeller construction ensures the fan curve has almost 100 per cent spare static pressure to minimise the effects of production fluctuations.

This offers a stable fan curve over an increased period. Power consumption is reduced by 30 per cent compared to previous technology. It also works for a longer period before defrosting is required. This can have a significant impact on production cycles.

‘Pre-coolers and freezers are some of the biggest power consumers in any French fry line,’ comments Henk Boon, group solutions manager for processing at tna. ‘These systems often require high volumes of electric power to operate and cool down the heat they release in exchange.

‘Reducing the power consumption of this type of equipment results in immediate energy savings, and has a significant influence on the overall operational costs of the entire production line. By upgrading equipment to the new fan, manufacturers can expect a return on investment in one to two years. This, in combination with shorter cleaning periods, reduced maintenance and superior equipment reliability, make the unit a valuable addition to any French fry production line.’

Ferguson, a tna brand, has been supplying the French fry industry for over 30 years by developing some of the industry’s most innovative designs. Renowned for its performance, reliability and low energy consumption, these cooling and freezing tunnels are the ideal solution for a wide variety of potato products. •

Tna Solutions – www.tna.com

HEATING & REFRIGERATION

A cooling perspective for the bakery industry

of 60 to 90 minutes. At the production of Zwieback Toast, the maturing time of up to 24 hours can be completely abolished.

The operating system is the heart of the process and system. Product quality can be The concept of industrial vacuum cooling in the food industry is maximised as well as an increase in volume not new, but the technology has opened a new perspective in food due to a substantial reduction of the baking production. Used in conjunction with vacuum baking it can shorten time. While the product is still dynamic, product quality is influenced and the baking time. capacity of the oven can be increased by 25 to 40 per cent.

When vacuum cells are closed, heat loss, which occurs in the conventional cooling process, can be efficiently regained DID through heat exchangers. The YOU KNOW? existing temperature and condition of the production Next to the production of batch chambers for the bakery industry, room is less influenced by vacuum cooling solutions can be the baking process. used for products like sauces, The baked product is also soups and fillings. stabilised due to the vacuum cooling process. It will lose practically no moisture (less than four per cent sometimes down to 2.5 per cent) compared to conventional products.

The 25m2 system could replace a traditional 250m2 spiral cooler

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LOBALLY, SEVERAL CONTINUOUS vacuum cooling systems have been installed at major industrial bakeries.

By integrating this technique in the bakery production environment, the average production capacity can be raised by 30 to 50 per cent. This is due to a reduction in production time.

“The baker steers the process in a detailed way, resulting in a better product with less acrylamide and other unwanted compounds”

Industrial vacuum cooling has been applied to standard baked products such as toast, biscuits and apple pies, but also for special products like gluten-free. The implementation of this technology can result in substantial cost reduction and quality

improvements. Space saving is guaranteed as the system is smaller than a conventional cooling system. There is a significant saving on ingredients as product volume increases with vacuum cooling. A reduction in energy consumption is also noted - an important consideration and one of the biggest challenges for future bakeries.

The continuous vacuum cooling process consumes less time than conventional methods and the modular designed installation is compact. Cells are stackable and can be swiftly loaded and unloaded.

The operating system allows a rapid, pulsed increase and a controlled decrease of the vacuum. The vacuum cooling process enables a high capacity of production and room capacity is customised and modified to conventional oven production requirements.

The system can be scaled up to quantities of 45 000 cakes, 54 000 croissants or 12 000 toast pieces of bread per hour, depending on the capacity of the preceding production line, its recipes and baking processes.

The average cooling time for products is now reduced to two to three minutes instead

Product comparison: Conventional versus vaccum cooling and baking

Vacuum cooling influences the distribution of moisture, which leads to energy saving.

On freezing time, a 30 per cent saving can be realised and the physical characteristics like crust can be improved and controlled.

The baker steers the process in a detailed way, resulting in a better product with less acrylamide and other unwanted compounds.

The technology forms part of the extensive product range on offer from Verhoeven Baking Company in the Netherlands. •

Verhoeven Baking Company – www.vehoevenoss.nl

2019 Quarter 4 | Food Manufacturing Africa

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HEATING & REFRIGERATION

Insulated impact

traffic can boost efficiency Bottlenecks often occur in a facility when there is an increase in the volume of pedestrian, cart and man-ridden traffic. This can lead to a decrease in functionality and productivity.

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IM DESSING, sales executive of Apex Strip Curtains & Doors, says that it is critical to ensure that traffic is allowed to pass through openings in an unhindered manner to alleviate these issues.

‘One of the first steps is to eliminate the stop, open, move through and manual actions that traditional single, one-way swing doors require,’ he explains.

The Apex SR 9000 insulated impact traffic door combines functionality with longevity and opens with a simple hand push or on impact from a cart or man-ridden vehicle such as a forklift truck. The door then 1 & 2: The Apex SR 9000 insulated impact traffic door combines functionality with longevity

automatically closes after traffic has passed through.

In spite of its lightweight construction, the Apex SR 9000 door is engineered and manufactured to be robust. Adding to its durability and low maintenance requirements, the perimeter edges on the door panels are bull-nosed with a minimum radius of eight millimetres. This prevents excessive wear on the edges.

High bumpers are also fitted to the door panel to further absorb impact from manridden vehicles and carts, as well as reduce stress on hardware and mount assemblies.

The patented honeycomb framework and flexible urethane foam insulation give the door optimum stability and superior soundproofing qualities. This characteristic makes the Apex SR 9000 the perfect choice for use in noise-sensitive areas.

The three millimetre ABS skin retains its physical properties down to temperatures

1

of minus 40°C, making it ideal for walk-in cold rooms. The low maintenance skin is impervious to moisture, acids, petroleum products, animal fats, rodent, insects and salt solutions and is easily and quickly cleaned for rapid turnaround time.

High volumes of traffic can lead to accidents occurring. This is mitigated by the inclusion of standard vision panels in the Apex SR 9000 doors.

Constructed from three-millimetre clear polycarbonate sheeting, these panels are available in several custom sizes and are scratch-resistance and UBC compatible.

Determination of the optimum mounting position of the windows allows for enhanced visibility, following safe operational requirements. For refrigerated areas, double panel vision panels can be installed.

‘As with all applications, it is important to ascertain the optimum design elements for each customer’s specific needs.

Our extended team of agents can offer technical and installation support that ensures longevity combined with productivity within any workplace environment,’ Dessing concludes. •

2

Apex Strip Curtains & Doors www.apexstrip.co.za

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

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Food Manufacturing Africa | 2019 Quarter 4

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B4 R5 CONBAR ® T H E K E Y T O “PERFEC T BARS”

Please come and see us at: Düsseldorf, Germany 07.05.– 13.05.2020 Hall 3 Booth F 20

www.sollich.com

HEATING & REFRIGERATION

Congestion-free on the deep freeze line Interroll has designed its MCP modular conveyor platform with decentrally-controlled RollerDrive drive technology. Units can operate in environments as low as -30 degrees Celsius.

The advantages of efficient material flow with zero pressure accumulation are now available for deep freeze logistics. are located in each individual conveyor.

This design allows each conveyor zone to be switched on or off individually and automatically. The advantage is there is only movement in the conveyor system when the material conveyed is present. To optimise energy savings, only the unit needed for the optimum flow of the conveyed goods is driven. This results in potential energy savings of up to 50 per cent and a significant reduction in noise and wear.

MATERIAL FLOW WITHOUT DYNAMIC PRESSURE AT LOW TEMPERATURES

The MCP modular conveyor platform

S

INCE ITS MARKET launch in 2014, Interroll's modular conveyor platform (MCP) has been used by system integrators and plant builders for demanding material handling solutions.

An important reason for the success of this conveyor is its modularity. The MCP is a modular solution that can be flexibly assembled and expanded from plug-and-play standard components in the same way as the Lego brick principle.

This not only facilitates planning, installation and maintenance, but also ensures short delivery times. The conveyor platform is connected to higher-level IT systems through consistent standardisation of the interface technology. Modules are prewired and can be configured at the push of a button for the desired Fieldbus technologies, such as EtherCat, Profinet or EtherNet/IP. In conventional conveyor lines, central 400V geared motors drive long flat belts around the clock - regardless of the material being conveyed. With the RollerDrive there is no central drive station and compact drives

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The advantages of this modern solution can now be used for conveyor solutions in the deep freeze sector. Kerr Walker, managing director of Interroll South Africa explains: ‘For decades, conventional continuous conveyors have determined and limited the possibilities of material flow in deep freeze logistics. Interroll solved this issue in 2018 when we designed the most important components of our modern conveyor platform for use at temperatures as low as -30 degrees Celsius.

‘With these specially modified curved and straight conveyor lines and their highly efficient drive, it is now possible to achieve a uniform material flow without accumulation pressure in deep-freeze logistics as well,’ he enthuses.

As with Interroll's proven conveyor platform, a high-performance material flow solution for the deep freeze sector can be flexibly assembled from plug-andplay standard components and extended as required. This not only increases work productivity under extreme environmental conditions, but also provides system integrators with decisive advantages during the planning phase. Thanks to user-friendly planning software, which Interroll provides free of charge, it is possible to simplify work steps during the project planning phase.

Food Manufacturing Africa | 2019 Quarter 4

TESTED UNDER EXTREME OPERATING CONDITIONS

To ensure the modified conveyor platform could be used without any problems in the deep freeze sector, engineers at the Interroll Research Centre carried out endurance and start-up tests at very low temperatures.

The expansion behaviour of the metals and plastics used at different temperatures can lead to functional impairments. It is also critical when unsuitable oil and grease become more viscous as temperatures fall.

HYGIENIC DRIVE TECHNOLOGY OF THE NEXT GENERATION

The introduction of its latest drum motor platform can provide customers with significant added value. All asynchronous and synchronous drum motors now fit in the same mounting due to identical axes. An even greater range of speeds can be operated via an extended number of gear stages. This makes it easier for system integrators to meet individual throughput requirements for a conveyor solution. All options such as encoders, brakes or backstops are available for motor variants of the new platform and can be freely combined.

All drive solutions feature Class I certification from the European Hygienic Engineering & Design Group (EHEDG) and meet the material requirements of the USDA/FDA and EU Regulation EG 1935/2004 for use in the food industry. Motors can easily be provided with a special rubber coating for special applications i.e. for use with form-fit driven thermoplastic belts.

The new drum motor platform’s installation, assembly and maintenance have been simplified. As a true plug-andplay solution, the pluggable connection ensures faster and easier initial installation, maintenance and repair. This enables noticeable time and cost savings and reduces possible system downtimes. •

Interroll – www.interroll.co.za

PROTEIN ALTERNATIVES

Lead the scene and keep it green Besides fat and carbohydrates, protein is a fundamental nutritional component made up of essential amino acids required for physiological functions.

T

HE FOCUS ON wellbeing and sustainability within the food industry is pathing the way for plant-based alternatives. Demand for high protein and lower carbohydrate food is challenging developers to source alternative proteins suitable for the desired application.

Soy, pea and chickpea are some examples enjoying the limelight.

Nutritional profile, allergen status, flavour, functionality and cost-in-use are important considerations for a specific application when choosing a protein. The ingredient’s ability to disperse, solubilise or bind water are key factors to assist manufacturers in creating final products that provide consumers with more options.

The challenge lies in creating plant-based alternatives that mimic the nutritional profile, taste and texture of conventional dairy-based proteins.

A SNAPSHOT OF WELL-KNOWN PROTEIN ALTERNATIVES

Soy protein: These concentrates offer a complete amino acid profile and economical cost-in-use benefits. Defatted soy proteins exclude anti-nutritionals, such as soluble sugars and anti-nutritional factors, assisting with the improved flavour profile and shelflife duration. The ability of soy protein to deliver the desired characteristics in extruded applications makes it the preferred protein alternative.

Pea protein: A cost-effective alternative to allergen based proteins used in food and nutritional applications. It lends itself to combination with other proteins i.e. with rice protein to achieve a complete amino acid profile.

Chickpea protein: Its neutral taste and white colour aid in formulating a favourable appearance and flavour profile especially

when replacing dairy proteins. The small and uniform particle size offers interesting benefits including faster processing and less waste during production.

Rice protein: Contributing to the environmentally conscious trend, rice protein is a sustainable and smart protein alternative used in several cereals and bakery applications. The ability to not influence the final product structure/expansion rate assists in formulating a consistent product with improved crispiness and bowl-life.

Fortifying with protein has several functional benefits and offers different claims such as dairy-free, soy-free, glutenfree, clean label, high in- and source of protein claims.

Savannah Fine Chemicals represents several leading global manufacturers and specialists. The supplier offers quality ingredients, support systems and a proven product development capability. •

Savannah Fine Chemicals – www.savannah.co.za

2019 Quarter 4 | Food Manufacturing Africa

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PROTEIN ALTERNATIVES

The latest food trend

is sustainability Consumers are food smart, evaluate food production methods and are asking questions about transparency and how their food is sourced.

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WARENESS CONTINUES TO grow around the huge amount of land, food, energy and water required to raise animals for human consumption. An animalbased diet is not enough to meet the protein demands of a growing world population - leading many to seek plant-based alternatives. This trend reflects an increased focus on health, wellness, food safety and diet, coupled to concerns about animal welfare and environmental sustainability.

One of the best plant-based alternatives is pulses. Nutritional and biological attributes of pulses play a huge role in reducing poverty, hunger and improving the sustainability of agro-ecosystems. All this contributes to achieving the United Nations Sustainable Development Goals. In 2012, pulses were recognised by the United Nations for their role in improving the environmental

sustainability of farming practices.

AGT Food and Ingredients is a large supplier of value-added pulses, staple foods and food ingredients. The company produces a full range of pulses and speciality crops, including lentils, peas, chickpeas, beans and canary seeds and ingredients such as pulse flours, proteins, starches and fibres.

DID YOU KNOW? AGT is a value-added pulse, staple food and ingredient processor for the export and domestic markets. Through its offices and processing facilities located in some of the best agricultural growing regions in Canada, the US, Turkey, China, Australia and South Africa, AGT produces a full range of pulses and speciality crops and food ingredients.

Some consumers feel that food production must go back to traditional processing technologies

‘To meet consumers’ nutritional needs with fewer resources, we must use more pulses,’ explains George Tomazos, AGT Foods Retail and Food Ingredients, South Africa. ‘Pulses have a lower carbon footprint in production than most animal sources of protein.

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Food Manufacturing Africa | 2019 Quarter 4

In 2012, pulses were recognised by the United Nations for their role in improving the environmental sustainability of farming practices

One kilogramme of legume only emits 0.5kg in CO2 equivalent, whereas one kilogramme of beef produces 9.5kg in CO2 equivalent. People see food as being intimately connected with wellness and their broader value system.’

While a whole food plant-based diet will always be the best option, plant-based processed foodstuffs are appearing on the shelves. A whole food plant-based diet is one that includes whole, unrefined and unprocessed food. It is made up of fruits, vegetables, whole grains, beans, legumes, nuts and seeds.

Plant-based eating is becoming accessible and convenient. Demand for lentil pasta, chickpea pasta, pea protein smoothies and veggie burgers are on the rise. Even though processed plant-based food is not necessarily healthy like whole-food, consumers are happy there is no animal cruelty and that they are helping decrease their environmental impact.

AGT Foods also produces pulse flours and pea protein for inclusion in the manufacture of a variety of food, such as cereals, bread, protein powders and bars. Pea protein is non-genetically modified (GMO-free) and a hormone-free alternative to soya in the baking and food manufacturing industries.

‘Sustainability is a positive step in improving our planet and world,’ Tomazos concludes. ‘We must continue educating consumers on the benefits of pulses, which play an important role in food security in the developing world and are a cornerstone ingredient in humanitarian food aid.’ •

AGT Foods – www.agt.co.za

BEVERAGE PROCESSING TECHOLOGY

Digitalisation boosts efficiency The Nairobi Bottler’s Embakasi plant, based in Nairobi, Kenya is a fully owned subsidiary by Coca-Cola Beverages Africa (CCBA).

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HE FACILITY received a Totally Integrated Automation Training (TIA) rig from Siemens Digital Industries South Africa to enable skills development in digitalisation technologies.

The training rig will serve a pivotal role in training apprentices, trainees and employees to understand the current and future value of food and beverage manufacturing plant operations.

Engineers and technicians can now take the complete value of the latest automation solution and develop their team to carry out technical activities related to migration and management of S7-1500 PLC, HMIs, servo drives etc. This rig was configured and supplied in conjunction with International Energy Technik (IET), a local Kenyan Company and Siemens partner.

Eric Nyakundi, an electrical engineer at CCBA’s Embakasi plant explains, ‘It perfectly fits into our business goals and overall strategy of capability development and asset care strategies. The bulk of our control systems are based on Siemens products, hence the direct transfer of skills and knowledge acquired in training to our manufacturing facilities. This is in line with the new supply chain philosophy of growing and developing engineering capacity in our manufacturing facilities and the overall asset care strategy.’

Automation teams, machine specialists, electrical artisans and apprentices at CCBA will be trained on this rig. These teams are responsible for supporting the manufacturing facilities in realising the company business goals in manufacturing.

‘The soft drink market is characterised by frequently changing and often short-lived trends. Soft drink manufacturers must always be able to rapidly adapt their production to new

requirements – and to always work efficiently and produce optimal quality. Digitalisation gives them the flexibility they need to accomplish this while also boosting energy efficiency, states Ralf Leinen, senior vice president for

Siemens Digital Industries, Southern and Eastern Africa. • Siemens –www.siemens.co.za

2019 Quarter 4 | Food Manufacturing Africa

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BEVERAGE PROCESSING TECHNOLOGY

Sidel introduces the Cermex FlexiPack This unit improves flexibility and overall ease of operation.

It offers total protection of the primary packaging by enabling 10 minute changeovers and enhanced bottle flow management.

N

EW FORMATS AND a growing number of SKUs are pushing the boundaries of production scalability in the wine and spirits industries.

‘The wine and spirits market presents a very fragmented product offering,’ explains Olivier Goffin, vice president global accounts beer, wine and spirits at Sidel.

‘While this leads to shorter production runs, it can’t be at the expense of brand equity and product integrity. These aspects are key components for the attractiveness and differentiation of products. Consumers expect to try new packaging and tastes, which blurs boundaries across drink categories quickly. Brand owners are responding to this development by expanding their portfolio.’

At production level, this trend creates a clear set of consequences. The brand image relies on the container’s look and feel, while changeovers are expected to be frequent and smooth. Product integrity becomes critical at the secondary packaging stage. Bottles must be handled with care when conveyed to the infeed of the packing system, selected, gripped and inserted into the case. New formats must be easily and autonomously managed. Bottling operators want a great level of agility with automated changeovers and easy operability to manage current and future packaging operations,’ Olivier adds.

QUICKER CHANGEOVERS

Cermex FlexiPack is a new pick and place case packing solution for glass bottles. It combines robotic technology and market expertise, accumulated over 45 years of serving the alcoholic drinks industry.

This piece of equipment is particularly suited to handle between 10 000 and 18 000 bottles per hour. It has been designed with a high dose of flexibility and operability in mind for each of its sub-modules.

This consists of a bottle channel infeed, a numerical-axis gantry manipulator and its regular slotted container (RSC) case conveying part (i.e. the case infeed, loading and outfeed). The system can be complemented by an upstream DiviArm. This is a positive bottle distribution system allowing limited pressure and zero shocks when the bottles are divided into the packer infeed channels - for maximum product integrity.

The solution’s improved agility and ease of operations are felt in several features.

These include a high level of automatic adjustments and lighter redesigned parts.

This enables ergonomic, reliable, repeatable and toolless changeovers in less than ten minutes.

Didier Saussereau, packing product manager at Sidel explains, ‘Cermex FlexiPack handles a wide variety of bottle diameters and heights. The system pays the utmost attention to product integrity and different bottlenecks or cap designs pose no challenge as end grippers are quickly and easily changed.

The product flows effortlessly at all times and allows for fully automatic adjustments for changeovers.’ A single servo-driven auto-adjustable gripping head ensures frictionless The equipment can handle between 10 000 and 18 000 bottles per hour and precise batch

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Food Manufacturing Africa | 2019 Quarter 4

The Cermex FlexiPack

gripping. It can transfer between 24 to 48 bottles simultaneously.

‘For greater accessibility and ease-of-use, the solution comes with the latest version human machine interface (HMI). This assists the operator with statistics, diagnostic and maintenance procedures - available through tablet-based navigation,’ Saussereau highlights. The HMI also guides the operator step-by-step for any new format creation, while automatically generating the respective changeover settings. This increases autonomy and maximises uptime.

BOTTLE INTEGRITY TO DECORATION

The innovative flow and speed management at every step of the packing process protects the glass bottle and its label.

Noise reduction is achieved by limiting the pressure and shock bottles are subjected to at every step of production. There is no friction when bottles are positively distributed in either three or four lanes via the DiviArm divider.

FlexiPack features a unique batch collation through each of the four conveying zones. Each zone operates at a different speed and the batch is created at the fourth conveying section by an accompanying endstop bar. This smoothly transfers the bottles to the picking station and assists with minimising shock.

INCREASED ENERGY EFFICIENCY AND COMPACTNESS

Sidel’s new auto-adjustable pick and place case packer saves energy. The technology employs lighter materials for the gripping head, thereby reducing weight and energy consumed by the manipulator. The Cermex FlexiPack significantly limits the usage of compressed air thanks to the replacement of all pneumatic actuators with electrical ones. Projected for a production run of five years, the generated savings could reach up to 10 000kWh, which is equal to 3.5 tonnes of CO2. •

Cermex FlexiPack: - ww.sidel.com

BEVERAGE PROCESSING TECHNOLOGY

A wafer-thin layer of glass on the inside wall of the PET bottle combines product protection with the option of full bottle-to-bottle recycling

Solutions in bottle-tobottle recycling Public demand for sustainability is growing stronger and the industry is concentrating on the recyclability of PET bottles. This type of packaging often contains composite materials, which can hamper pure-grade recycling.

K

HS’ FRESHSAFE PET technology offers food and beverage industries a unique alternative. A wafer-thin protective layer of chemically pure glass on the inside wall of the PET container combines product protection with full bottle-to-bottle recycling.

‘Plastics are subject to critical questioning and consumers want more sustainable solutions from the industry,’ says Jon Elward, head of plastic packaging at KHS. PET bottles, coated with the Plasmax barrier technology, are now classed as 100 per cent recyclable by the Association of Plastic Recyclers (APR).

The gradual ousting of mixed material PET bottles, which are hard to recycle is opening the market to packaging systems, which are easy to recycle. In this context, KHS' FreshSafe PET technology provides a suitable alternative and has been classified as meeting APR’s 1 most stringent critical guidance criteria for recycling.

The wafer-thin glass coating applied to the inside wall of the bottle is washed off during the recycling process, producing pure PET.

‘We've fully satisfied the strict specifications and critical demands of the recognition process,' Elward states. ‘This proves that FreshSafe PET is a sustainable technology and a reference for the recyclability of PET bottles without composite materials.'

Sensitive products such as juice, wine, sauce and liquid food are protected from oxidation and carbonated beverages from carbon dioxide loss. Compared to standard composite materials, the coating process provides a better barrier quality and a longer product shelf life.

‘This technology considerably facilitates recycling and at the same time improves barrier properties of PET bottles,' confirms Steve Alexander, executive director of the APR. Through its recognition programme, the organisation aims to improve the recycling quality of plastic bottles. Interest among bottlers is growing in the system, which has already been tried and tested on the market.

These quickly pay off as the overall operating costs at the plant are reduced. When they use this system, bottlers can switch to less expensive standard PET preforms, relieving them of the obligation to source preforms from a specific manufacturer. KHS offers plant operators an individual consideration of the total costs accrued when using its barrier coating technology. Measured against the benefit of additional product protection and a longer product shelf life, the cost per bottle is lower than when conventional composite materials are used.

1. The Association of Plastic Recyclers is a North American trade association which strongly advocates the recycling of all post-consumer plastic packaging.

The association draws up design guidelines and recognises packaging design innovations that meet its most stringent guidance criteria for recyclability.

KHS CALCULATES INDIVIDUAL TCO

Beverage producers will incur additional overheads when they invest in FreshSafe PET.

KHS - www.khs.com

2019 Quarter 4 | Food Manufacturing Africa

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PACKAGING TECHNOLOGY

Working in harmony in the factory of tomorrow Exports are a key indicator of the economic performance of an industrialised country. With an export volume of US$1.44 trillion, Germany ranked third behind the US (US$1.54 trillion) and China (US$2.26 trillion) in a global comparison in 2017.

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O ENSURE THE German economy does not lose out in the long term, new concepts are needed to optimise the efficiency of industrial production. Given the progress made in automation and artificial intelligence, a well-established and improved interaction between man and machine could help to ensure high economic standards and productivity.

“Digitalisation provides companies in the manufacturing industry with an enormous inventory of technological options for implementing the factory of the future�

Many still believe man and robot can only work against each other or if need be, side by side. There is still a real fear that machines will replace human workers. The coexistence of human workers and automated machine solutions and robots has become commonplace in companies.

Digitalisation provides companies in the manufacturing industry with an enormous inventory of technological options for implementing the factory of the future. Smart networking using artificial intelligence offers the opportunity to convert manufacturing data into strategic information. It also enables the smooth integration of high-precision robotics technologies that work at high speed.

This is supplemented by methodically safe and simple interaction between man and machine.

A NEW ERA OF INTELLIGENT, INTEGRATED AND INTERACTIVE PRODUCTION

The ability to increase efficiency, reduce costs and strengthen competitiveness is necessary to secure your market position

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in a competitive global market. It can be implemented with innovative solutions for flexible and efficient production. An impressive example of the potential of a technology that can revolutionise the factory floor of the future, while promoting harmony between human and machine, is a new collaborative robot that emerged from the partnership between Omron and Techman.

It offers an innovative solution for the simple automation of applications traditionally carried out by humans and where automation has been very difficult.

The robot can be seamlessly integrated into an autonomous mobile robot and enables the automation of complex tasks using a 3D camera.

One example of a futuristic solution is bin picking. The robot quickly and precisely sorts different articles and deposits them where they are needed. The 3D camera locates the items and sends their coordinates to the robot, while the software, supported

by AI algorithms, performs the advanced calculations required for optimised goods picking, for customised orders. Meanwhile, a mobile robot is responsible for the subsequent transportation of goods. In this respect, the efficient combination of different production processes forms the basis for particularly flexible and reliable production and material handling. It also gives a foretaste of what will be possible in the future with "Factory Harmony", where integrated, mobile and collaborative robots work in harmony with humans, to ensure flexible manufacturing and customisation.

SYSTEMATICALLY AVOIDING MALFUNCTIONS AND BREAKDOWNS

Operational excellence is an important basis for investment security - especially because of the current changes in the industrial production organisation. Changing consumer behaviours are forcing manufacturers to flexibly produce smaller quantities in a larger number of variants, saving as much time as possible. The factory of the future must become more flexible and convert production more quickly and produce smaller runs. The goal is to be able to deliver

Food Manufacturing Africa | 2019 Quarter 4

personalised products from an agile and networked production line. In an automation model that meets this requirement, all devices, machines and solutions should operate in an integrated manner.

Effective quality control is essential in all production and packaging lines. Those who can identify defective products before they leave the factory, or even before they are produced, benefit from considerable time and cost savings. They also avoid costly product recalls, loss of productions and possible damage to brand reputation.

Equally important is the quality control of packaging for products such as food or medicines. An illegible barcode or a wrong expiration date can lead to the need to dispose of faultless products. There is a trend towards stricter legislation, which gives top priority to unambiguous labelling for all types of products. The EU has introduced new regulations in 2019, requiring production lines to meet even higher quality control standards.

Because of the increasing degree of automation in production lines, the need for automated processes in quality control has also been amplified. It pays off if the machines can collect data to optimise predictive maintenance. The more data that is collected and processed, the

FACTORY HARMONY DETERMINES FUTURE PRODUCTION The networking of humans and machines is more than just a trend towards the efficient organisation of processes and the distribution of tasks in manufacturing plants. The tangible benefits of tomorrow's high-performance factory are already showing how the systematic harmonisation of human and machine-based capabilities is revolutionising production with the help of artificial intelligence and robotics and is breaking new ground for the production methods of the future.

PACKAGING TECHNOLOGY

more "intelligent" the machine can be to help extend production line life, reduce downtime, and increase productivity.

Omron's Sysmac AI controller includes a predictive maintenance library based on AI and collects, analyses and uses data on Edge devices to extend their life, detect anomalies and prevent failures. No internet connection is required: users are no longer dependent on cloud computing and can leverage the AI potential for their business advantage.

IMAGE PROCESSING SUPPORTS ERROR DETECTION

An important factor in quality control on production lines is smart image processing - technically implemented either as a completely new solution or by partially retrofitting an existing system.

Very compact image processing systems monitor production in real-time and react immediately to any error. The data transmitted by an image processing system is processed on-site and made available centrally via the cloud for detailed analyses.

For an inspection system to make intelligent decisions, data must be captured by a sensor, such as a camera for image processing. These cameras can be set up to monitor various aspects of a product, such as detecting defects or checking labels for printing errors or missing information. The data is analysed with high computing power to compare the process with the actual and target results. When problems are detected, the system responds per programmed rules. Sometimes it can automatically correct the errors, but even then, the operator is always informed to ensure correct processes and in case additional action is required.

Since this system is fully networked, it provides a better link between the machines on a production line. This results in precise quality control and greater efficiency. When an error is detected, the system can often automatically compensate for it and production is not affected. Intelligent automation solutions of the latest generation work fast, offer high computing power, are easy to operate and thus ensure transparent quality control in the factory of tomorrow.

FLEXIBILITY IS THE ENGINE FOR CUSTOMER SATISFACTION

Flexibility in the organisation and arrangement of production resources is one of the key success factors for efficient production. This includes the mobility of the robots used and their adaptability to concrete requirements in practical use.

By combining image processing, motion, control, functional safety and robotics in a single management system, production lines can be easily adapted to short production runs. The line layout can be quickly redesigned and the recognition pattern for quality control can be easily updated in the software. This ensures different product variants or even different products are produced and packaged flawlessly. Such a system brings the benefits of futureproof orientation because it can be easily adapted to new regulations. Manufacturers do not have to worry about changing their production lines but can simply initiate a firmware update for the existing solution if necessary. •

Omron – www.omron.co.za

2019 Quarter 4 | Food Manufacturing Africa

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FLEXIBLE PACKAGING

Passion for the art of packaging Clomark has been serving the South African market since the 1970s. The company prides itself on its extensive range of printing and packaging equipment, which is in line with European specifications. Food Manufacturing Africa spoke to Shyam Chirkoot on what sets this company apart from competitors.

THE VOICE OF CLOMARK CUSTOMERS

A sample of packaging from Clomark

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AVING PRODUCED SOME of the most complex and challenging packaging designs, Clomark serves a wide market from food and beverages to the automotive market. Designs have won the confidence of many of its customers such as Tiger Brands, Shoprite, Dischem, Checkers and PnP.

PACKAGING ADDS VALUE

Clomark has now turned its attention to the rest of the African continent, forging relationships in many African countries.

‘People judge the quality of food products in part from the impact made by the packaging and its quality,’ Chirkoot explains. ‘Our goal is to help the rest of Africa uplift its packaging quality to a world-class standard.'

The company offers turnkey solutions to the market. This service offering includes packaging design and stunning artwork from its dynamic design team to technical considerations. The team can assist a customer from concept to delivered product at a quick turnaround time. ‘Making the correct choice of material is not a simple matter. It has a direct impact on the perception of the consumer. Its look and feel must reach out to the customer while

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providing outstanding functionality,’ adds Jocelyn Munsami, Clomark’s sales manager and packaging technologist. ‘We have a very diverse product offering including self-adhesive labels, bar wrappers, shrink sleeves, complex laminates, printed and folded cartons amongst others. This offers convenience for a customer who wants to find a product range from one source and assists in colour matching and consistency throughout the range.’

Dhiraj Chirkoot, operations director of Clomark is proud of their manufacturing plant and equipment. ‘We have installed state of the art printing presses, finishing equipment and application equipment. The latter is used to assist some of the smaller food and beverage packing companies with shrink sleeve application on their containers.

We can print up to nine colours at a time, as well as adding decorative foils and embossing onto labels and cartons. This brings about a wide consumer appeal.

Some of our products are designed in Europe, with the final product being sold in the UK and US. We are proud to be up there with the best.’

Food Manufacturing Africa | 2019 Quarter 4

Quinton Jonathan is the packaging technologist at Clicks: Our primary aim is to get our products to stores on a tight and regular schedule. We rely on dependable service providers like Clomark to keep us on track. We are very pleased with the quality of service and appreciate the team’s responsiveness and the way it conducts business.

Craig Kaminsky, director of FitChef: Our packaging appeal is as important as our innovative meal solutions. Our brand is growing incredibly quickly. This means that FitChef needs the best of everything.

The Clomark team provides great quality, service and pricing.

Diego de Radigues, director and brand owner of Bakali Foodstuffs: We can offer our customers an attractive and competitive healthy snacking solution. We often receive compliments about the product’s freshness.

Service delivery is excellent - a key factor if you want to be successful and lead times are probably one of the best in the market.

The team’s response rate, availability and knowledge of our products are excellent.

UNDERSTANDING AFRICA’S PACKAGING CHALLENGES

Clomark understands that many countries in sub Saharan Africa must radically improve the quality of its packaging to capture or recapture market share. Access to good quality packaging has been a challenge to many African manufacturers and Clomark’s focus is to improve access to their offering and improving distribution channels. It is looking to expand its manufacturing footprint and is in discussion with packaging suppliers in several countries to understand how they may assist.

Clomark strives to maintain its identity and appeal to African brand owners. ‘Our team is getting this right by adopting a fresh perspective and focus on the African market,’ Chirkoot concludes. •

Clomark – www.clomark.com

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FLEXIBLE PACKAGING

Lessons flexible packaging can acquire from PET

The plastics industry has made a journey from innovation to standardisation and widespread recycling. This is very true for PET bottles. There are lessons that flexible packaging can follow to achieve the same success.

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N THE 1970s beverage companies sold their products in plastic bottles, composed of a mixture of materials.

This featured a combination of aluminium screw cap, plastic (either polyethylene terephthalate, PET or acrylonitrile) and a hard-black plastic base glued to the body of the bottle. This made recycling difficult.

When acrylonitrile was thought to be carcinogenic, PET became the frontrunner as the most favourable material. With the industry using the same materials, the widespread collection and recycling of PET bottles was established. The journey to PET bottle recycling took many years and involved every part of the supply chain.

WHAT CAN FLEXIBLE PLASTIC PACKAGING LEARN TO SPEED UP THE RECYCLING JOURNEY? STEP 1: INNOVATION

The first plastic bottles for carbonated soft drinks were developed by Coca-Cola in 1975. Six “Easy-Goer” lightweight plastic bottles were lighter than one glass bottle of comparable size. The material used for these bottles, acrylonitrile, was not recyclable and produced toxic fumes when burned. DuPont field engineer Nathaniel Wyeth was busy trying to create a plastic bottle for carbonated drinks that wouldn’t explode. Replacing acrylonitrile versions and the original glass bottle with PET was the solution, and in 1973 he patented the process in the US. This new, clean, easily recycled material could be injection-moulded into test tube shaped ‘preforms’ and then stretched to form bottles. The footed base was created, which helped PET bottles withstand the pressure of carbonation.

Lesson learnt for flexible packaging: The PET equivalent for flexible packaging is polyolefin. This works better for flexibles because of its high puncture resistance and strength, which allows for a variety

of irregular-shaped items to move through the supply-chain life cycle without being damaged. Most flexible plastic packaging is made up of a range of different materials (including PET, polypropylene, polyethylene (PE), aluminium, and paper). In 2018, Amcor Flexibles achieved an innovation breakthrough: it developed a recyclable PE film that also provides high barrier protection.

STEP 2: STANDARDISATION

PET quickly became the most commonly used material across the beverages industry. Its unique combination of properties contributed to its global growth and universal acceptance.

These include transparency, strength and toughness, low gas permeation rate, nontoxicity, a wide range of usage temperatures and the ability to be easily depolymerised and repolymerised. To be successful, the transition from two- to one-piece bottle technology required an industry-wide effort.

The entire supply chain had to be educated to maintain the conditions (up to 45°C degrees and internal pressures exceeding 90 psig (six-bar) necessary to avoid product failure.

That effort has paid off in the form of an extraordinarily safe, efficient and recyclable bottle that is used by beverage companies around the world.

Lesson learnt for flexible packaging: Flexible high barrier and retort packaging are popular. Since its launch in April 2019 customers started using Amcor’s new recyclable flexible laminate on their machines. One of Amcor’s tasks is educating customers on the benefits of this new breakthrough film. Its lighter weight reduces carbon footprint and cuts shipping costs. It can also be recycled.

By growing awareness and adoption, polyolefin films for flexible plastic packaging will gradually become the industry standard.

STEP 3: MASS RECYCLING

The expanded market for PET-based packaging increased the mandate for companies, together with the government to develop means of recycling it. By the end of the 1970s, in a consumer culture that craved convenience, people starting paying attention to the landfill crisis and the problem of nonreturnable containers. Companies including Pepsi-Cola and Coca-Cola campaigned for municipal recycling systems; testifying before the US Congress to secure more support from the federal government.

Curbside recycling programs became more widespread. By 1992 there were over 4 000 such programmes across the US. In the same year, Johnson Controls (the world’s largest manufacturer and recycler of batteries) engineers with Coca-Cola pioneered the first ‘bottle to bottle’, closed loop recycling technology. This could recover PET from post-consumer use packaging and clean it sufficiently to be reused with virgin materials in new packaging.

Lesson learnt for flexible packaging: Designing for recycling means nothing if the infrastructure isn’t in place to collect and recycle the packaging. For widespread flexible plastic packaging recycling to become a reality, we need to engage with industry, policymakers and cross-value chain organisations. Forthcoming guidelines from organisations such as the Ellen MacArthur Foundation and Ceflex are also important.

These will align raw material suppliers, converters, brand owners, retailers, sorting and recycling facilities and regulators on how to realise a circular economy for flexibles. * This is an abbreviated article from the original found on the Amcor website.

Amcor – www.amcor.com

2019 Quarter 4 | Food Manufacturing Africa

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FLEXIBLE PACKAGING

Passionate about the planet Polyoak Packaging is intensifying its commitment to extended producer responsibility. The company is now partnering with customers to optimise packaging recyclability. Design, functionality, material choice, decoration, closures and on-pack communications must be taken into careful consideration, to deliver a truly recyclable pack.

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OLYOAK HAS SPENT the last few months, running workshops with reclaimers, buy-back centres and recyclers and visiting landfill sites including Africa’s largest waste material recovery facility in Cape Town, South Africa to better understand what else can be done to optimise their packaging for recycling.

Alan Caldwell, regional director for Western Cape says, ‘We must provide our customers with the most accurate and up to date information. We must assist them in making informed and responsible packaging decisions that will optimise recycling and help eliminate waste in the environment.’

Whilst it’s essential that brand owners and their packaging partners get this first step right, it is no guarantee that even the most recyclable packaging won’t end up as litter,

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polluting rivers and oceans. Consumers must understand how to recycle and have the means to do so. Polyoak has implemented inhouse sustainability training and awareness through its business school, to educate employees about their role in protecting the planet and the importance of recycling.

Another step for all businesses is to ensure that they implement sustainable practices throughout their own operations.

Polyoak Packaging focuses on continuous improvements in operational efficiency and utilisation of raw materials to create packaging solutions that maximise product and environmental performance without compromising customer satisfaction. Its targeted programmes aim to optimise energy and water consumption and eliminate waste generated on-site from going to landfill.

The company has installed bespoke recycling bins in all green areas of its production sites across South Africa and has trained almost 2 000 employees on how to separate waste at source to maximise recycling. That means almost 2 000 households are starting to understand the importance of environmental stewardship.

Caldwell concludes, ‘It’s such a complex issue, so we need to unpack it piece by piece. Behaviour change starts with changing attitudes and perceptions, and unfortunately, there is a great deal of misinformation in the public domain that we need to set right.’ •

Polyoak Packaging www.polyoakpackaging.co.za.

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