Food Manufacturing Africa Q4 2021

NOVEMBER 2021 • FEBRUARY 2022 Vol. 10 • No. 4

FOOD Manufacturing Africa

Take a leap into the future Novel beverage processing technology

Food and beverages for a healthier tomorrow

Sustainable rigid packaging solutions

FOOD Manufacturing Africa

CONTENTS

NOVEMBER 2021 • FEBRUARY 2022 Vol. 10 • No. 4

7 NEWS

GEA builds world’s first carbon-neutral juice

production plant

Sundale Schreiber opens cheese processing

plant in South Africa

Heineken to acquire Distell and Namibia Breweries

Castle Lite switches to renewable electricity

Distell launches new vegan Amarula variant

14 “The JNSD line meets

innovation, efficiency and sustainability criteria”

12

INDUSTRY TALK

Smart food choices strengthen the inner defence system An innovative solution for JNSD production The impact of the pandemic on manufacturers

17

MATERIALS HANDLING & COLD CHAIN

Global energy efficiency solutions

18

BEVERAGE PROCESSING TECHNOLOGY

The perfect partner in beverage processing

Dynamic cellular disruption and its benefits

A solution to automatically monitor beverage line performance

24

RIGID PACKAGING

Rapid launch of a new packaging line Embracing a recycling economy with new EPR regulations Introducing juice bottles made of 100% recycled PET A low-density polyolefin sleeve perfect for recycling

ADVERTISERS’ INDEX CCL Label South Africa................................................5............www.ccllabel.com Green Cell Technologies.............................................21...........www.greencelltechnologies.com Ishida South Africa.......................................................IBC........ishidaeurope.com Koel Colours ..................................................................IFC.........www.koelcolours.com Koelnmesse....................................................................7.............www.anugafoodtec.com Krones Southern Africa...............................................9............krones.com Mitas Corporation .......................................................23..........www.tracepack.co.za Omron Electronics .......................................................29..........industrial.omron.co.za

Polyoak Packaging........................................................27..........www.polyoakpackaging.co.za Savannah Fine Chemicals..........................................13..........www.beneo.com Shanghai Dase-Sing Packaging Technology Co...10..........www.dasesing.com Sollich KG.........................................................................11..........www.sollich.com Syspro ..............................................................................8...........www.za.syspro.com Tetra Pak...........................................................................15..........gonature.tetrapak.com Vega Controls SA ...........................................................26.........www.vega.com/vegabar

2021 Quarter 4 | Food Manufacturing Africa

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EDITOR’S COMMENT

EDITORIAL Editor: Tennille Aron +27 (0)73 995 5599 tennille.aron@newmedia.co.za Layout & Design: Andipha Nkoloti ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmedia.co.za Sales Executive: Càndida Giambò-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmedia.co.za

Time flies when you’re having fun

C

AN YOU BELIEVE it is the end of the year already? Like the saying goes, time flies when you’re having fun. It seems like just the other day that we were waving goodbye to 2020 and all its pandemic problems, and hoping that 2021 would be a better, more stable year, for the F&B industry at least. While that was not exactly the case, there were a few good things that came out of the last year.

We can certainly thank the continuing pandemic for bringing to light some of the more pressing issues facing the F&B industry. Fortunately, this has also jump-started the search to find innovations that will help us to cope with these issues.

At the top of the list of issues facing the F&B industry is finding more sustainable food and beverage manufacturing solutions to help conserve the environment and help protect our food sources. Therefore, a large focus this year has been on the three Rs: reduce, reuse and

recycle. Many companies are making tremendous inroads with this such as Tetra Pak, whose innovative solution for juice, nectar and still drinks production combined existing technology in an entirely new configuration to drastically reduce energy and water consumption.

Read more about this on Page 14.

Eckes-Granini is making its packaging portfolio even more environmentallyfriendly with the help of the KHS Group.

The new 1l hohes C juice bottle that they have produced consists entirely of recycled plastic (rPET). Find out about this new technology on Page 28.

When CCL launched their low-density polyolefin sleeve for their PP dairy cups, creating a sleeve that was recyclable was one of their top priorities. Discover more about this thin plastic sleeve label that is made from the same family as the cup and how this has significantly increased its recycling rate on Page 30.

This year has also produced some amazing breakthroughs in food processing technology, like the dynamic cellular disruption process developed

by GCT that processes organic and inorganic matter faster than the speed of sound. Speed on over to learn more about it on Page 20.

From the Food Manufacturing Africa team, we would like to wish all of our readers and advertisers a fantastic festive season. Thanks for all your support this year. We hope that you invest in these three Rs during the holiday period: rest, relaxation and reflection. See you in 2022!

Enjoy the read!

Tennille Aron

INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com

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Food Manufacturing Africa | 2021 Quarter 4

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Food Manufacturing Africa | 2021 Quarter 4

January Interplastica 2022 Expo Centre, Moscow, Russia 25 – 28 January www.interplastica.de International Production & Processing Expo 2022 Georgia World Congress Center, Atlanta, Georgia 25 – 27 January www.ippexpo.org ISM Cologne 2022 Cologne, Germany 30 January – 2 February www.ism-cologne.com

February Fruit Logistica Berlin, Germany 9 – 11 February www.fruitlogistica.com Gulfood World Trade Centre, Dubai 13 – 17 February www.gulfood.com Wine Paris & Vinexpo Paris Paris Expo Porte de Versailles 14 – 16 February www.vinexposium.com Packaging Innovations & Empack Hall 1 NEC Birmingham, UK 16 – 17 February www.packagingbirmingham.com

NEWS

GEA BUILDS WORLD’S FIRST CARBON-NEUTRAL JUICE PRODUCTION PLANT

G

EA GROUP AG has provided innocent, Europe’s leading smoothie and juice brand, with the process technology for the world’s first carbon-neutral juice factory.

The new factory in the Netherlands will lead the way for future plants in the food industry with a truly sustainable approach. Located at the Rotterdam Food Hub, the production facility is scheduled to open officially in spring 2022.

In the new-build project, GEA is responsible for the process, refrigeration and heating technology. Early involvement in the design planning phase enabled the company to develop numerous innovative process changes that significantly help innocent on the path to reaching its climate goals. GEA and innocent recently won gold in the European Heat Pump Association (EHPA) People’s Choice Award for the smart heat pump design.

Energy supply and demand cycle Since much of the energy used in production is for heat, GEA worked intensively on inprocess energy and resource efficiency in the manufacturing process. For innocent, GEA

broke down the entire juice-making process into its component parts and then rebuilt it from the ground up.

The company also applied the sustainable energy solutions (SEnS) approach. This factors heating and cooling requirements into the systems right at the planning stage, instead of after the fact when corrections are virtually no longer possible.

Adapting the process on utilities demand For example, a GEA heat pump will recover waste heat from the refrigeration systems and reuse it in other process steps. The pasteurisation temperatures can be lowered from 95°C to 90°C – improving the energy balance by 3%. This makes it possible to fit a heat pump and thaw frozen juices with warm water instead of steam.

GEA advised innocent to use two separate heating circuits – one set to 65°C for cleaning and the other to 90°C for pasteurisation and sterilisation. What’s more, innocent will only cool the juices as much as is absolutely necessary because every degree that the mercury doesn’t need

to fall, improves energy efficiency by no fewer than 4%.

Showcase for the entire beverage industry “I take my hat off to GEA because they have been at our side every step of the way, helping us challenge conventional design approaches. All the little details add up to a great success,” said Andy Joynson, chief blender (site director) at the new innocent plant.

The new solutions implemented go far beyond conventional beverage production processes. •

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19.11.21 13:53

2021 Quarter 4 | Food Manufacturing Africa

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NEWS

Sundale Schreiber opens R97 million cheese processing plant in South Africa THE JOINT VENTURE between local Sundale Dairy and global giant Schreiber Foods in a slice-on-slice (SOS) cheese processing plant at the East London Industrial Development Zone (ELIDZ) is a significant development for the agro-processing sector as a driver of economic reform in the Eastern Cape of South Africa.

The grand opening of the Sundale Schreiber factory was a celebration of the first production off the casting line that will supply processed cheese to quickservice restaurants. The new facility is a game-changer. At present, 70% of SOS cheese slices in South Africa are imported, and the new factory facilitates the supply of local content to the African continent, opening new markets for local business.

The Sundale Schreiber joint venture is an investment in an entire process line from start to finish – from the processing of the product in the cooking process, through the casting line, to case packing

that is done on equipment imported from Italy. The new state-of-the-art facility was designed by Schreiber Foods and represents a R97m investment in the plant and a further R50m in processing equipment. The biggest investment is in people with employment opportunities, secondments to international plants and upskilling of local employees.

The emphasis at the plant is on creating a crazy-clean space in an inherently messy manufacturing environment. The priority is on food and partner safety.

According to Brad McNeely, Schreiber’s operations start-up manager, “The Sundale Schreiber plant is a world-class facility which demonstrates that East London is well-positioned as a global hub for manufacturing. We aim to attract other global investments to the city through our partnership.”

The partnership with Schreiber creates opportunities for skilled labour in the Eastern Cape and is a welcome boost for

Schreiber Foods’ Jason Stephens, Sundale Dairy CEO Pierre van Rensburg, ELSEZ CEO Simphiwe Kondlo, and ELSEZ board member & audit and risk chairperson Ntombentsha Mnconywa

the sector that relies on export opportunities for sustainability. •

Discover how SYSPRO can turn three simple letters into a world of opportunity for your company. Email info@za.syspro.com or call +27 (0) 11 461 1000. Say Yes to Next.

Copyright © 2021 SYSPRO (Pty) Ltd. All rights reserved. All brand and product names are trademarks or registered trademarks of their respective holders.

723425 OSFF

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Food Manufacturing Africa | 2021 Quarter 4

NEWS

HEINEKEN TO ACQUIRE DISTELL AND NAMIBIA BREWERIES HEINEKEN ANNOUNCED THAT it intends to buy Distell and Namibia Breweries to integrate their respective and relevant businesses in Southern Africa into one enlarged company. With Distell currently Africa’s leading producer and marketer of ciders, flavoured alcoholic beverages, wines and spirits; and Namibia Breweries (NBL) the leader in the Namibian beer market, this acquisition bodes extremely well for Heineken.

“We are very excited to bring together three strong businesses to create a regional beverage champion, perfectly positioned to capture significant growth opportunities in Southern Africa.

Distell is a highly regarded, resilient business with leading brands, a talented workforce and a strong track record of innovation and growth in Africa. With NBL, there are exciting opportunities to expand premium beer and cider in Namibia and grow the iconic Windhoek brand beyond its home market. Together we will be able to better serve our consumers and customers through a unique combination of multicategory leading brands and a strengthened route to market.”

The combining of these three

companies will mean that Heineken will be better able to serve consumers and customers with a unique multi-category portfolio, led by iconic brands Heineken, Savanna, Windhoek, 4th Street wine and Amarula.“Together, this partnership has the potential to leverage the strength of Heineken’s global footprint with our leading brands to create a formidable, diverse beverage company for Africa. I am excited for what lies ahead as we look to combine our strong and popular brands and highly complementary geographical footprints to create a world-class African company in the alcohol beverage sector. Our combined entity will grow our Food Manufacturing Africa, 132 x 200 mm, Line com. M, CC-en90-AZ042 10/21 local expertise and insights to better serve consumers across the region,” says Distell CEO Richard Rushton. NBL chairman Sven Thieme said, “What we have achieved with NBL is truly amazing, but the time has come to unleash its full potential by giving NBL

CC-en91-AZ042_10-21.indd 1

25.10.2021 10:48:18

2021 Quarter 4 | Food Manufacturing Africa

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NEWS

Castle Lite switches to renewable electricity

Distell launches new vegan Amarula variant

ELECTRICITY SUPPLY CONSTRAINTS that result in frequent loadshedding mean South Africans are regularly left in the dark. All too often, there is simply not enough electricity to go around.

In order to ensure that it draws less electricity from the national grid, Castle Lite has announced that it is switching to renewable electricity to brew its beer.

With this switch, Africa’s largest premium lite beer is on a journey to make sure that all South Africans are able to enjoy life and their extra cold Castle Lite to the max, without interruption. All seven of its breweries within South Africa contribute to this through solar power, with the Alrode brewery in Johannesburg also making use of bio-gas facilities. From January to August this year they have already generated over 9.7GWh of renewable electricity. This switch has also resulted in 9 443 tonnes of

THE WORLD’S FAVOURITE marulabased cream liqueur, Amarula, has launched a new variant, Amarula Vegan. This is the first and only vegan cream liqueur to use real marula spirit as its base, and stays true to the rich legacy and uniquely exotic taste that Amarula has become known for. This latest edition to Amarula’s easy-drinking and versatile range is a plant-based, dairy-free, better-for-you alternative for conscious consumers.

In addition, it is also free from artificial colourants and flavourings, nuts and gluten.

CO2 emissions reductions since the start of the year.

And this is just the start: the brand is on a journey to be 100% brewed with renewable electricity and to fully switch to renewable sources by 2025.

The move is directly in line with South African Breweries (SAB) and holding company Anheuser-Busch InBev (AB InBev) globally committing to the 2025 Sustainability Goals in climate action by adding renewable electricity capacity to regional grids and reducing CO2 emissions across the globe. •

Our Service

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Food Manufacturing Africa | 2021 Quarter 4

New-look packaging In other news, Amarula has also unveiled new-look packaging for all its variants, which includes Amarula Raspberry Chocolate & Baobab, Ethiopian Coffee and Vanilla Spice iterations.

The packaging brings together a range of design elements that communicate the brand’s

distinctive attributes. They come in a 70cl / 75cl bottle, dressed in shrink sleeve printed in Kings Lynn UK, in collaboration with CCL South Africa.

The vegan design has a special pearl effect while the other designs utilise metallic effects with complex screens and vignettes. The bottles are available for order now in the global travel retail channel.

Brand owner Distell will launch a sampling drive at key international airports to boost awareness of the new range extension. •

PERFECT ASSEMBLY

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U N I Q U E FO R YO U R N EEDS

INDUSTRY TALK

Healthier ageing:

The importance of healthy blood sugar management

In a recent Beneo and Health Focus International survey, 85% of those aged 50 showed a willingness to take charge of their health, realising that their short-term health depends on how well a person takes care of themselves. An important way of doing this is through changing what they eat and drink with 30% of consumers aged 50+ saying that the primary reason for them choosing healthy foods and beverages is to ensure good health in the future, with another 28% choosing these products to enhance their daily health.

SMART FOOD CHOICES STRENGTHEN THE INNER DEFENCE SYSTEM Supporting the immune system is a key part of healthier ageing. A key recommendation to supporting immunity is to manage blood glucose levels as well as sustaining the gut microbiome with gut-friendly foods containing prebiotics. Traditionally, high blood glucose is linked to those with pre-diabetes and Type 2 diabetes, however, blood glucose levels also influence the innate immune system.

This became very clear during the Covid-19 pandemic when researchers found that high blood glucose was a risk factor independent of diabetes.

Having high blood glucose levels is closely linked with being overweight, obesity, metabolic syndrome, prediabetes, diabetes, coronary heart disease and more. An important way to address this is through a change of diet.

Food choices and ingredients that can reduce the blood glucose response will become increasingly important, and low

12

“The goal for any food producer interested in promoting the long-term health of consumers should be the development of food choices that deliver a lower glycaemic profile”

glycaemic functional ingredients, such as the balanced sugar isomaltulose, are playing a growing part in this process.

BENEO’S LOW GLYCAEMIC FUNCTIONAL INGREDIENTS According to a consumer survey conducted by Insites Consulting on Beneo’s behalf, 78% of 65- to 75-yearolds in Asia, Europe and the US are now paying attention to their sugar intake. However, the key to promoting healthy ageing through blood sugar

Food Manufacturing Africa | 2021 Quarter 4

management is through the right choice of carbohydrate. The ideal carbohydrate provides the necessary energy for a person’s metabolism, it triggers a low and balanced rise in blood glucose and a low increase in insulin as well as encourages fat burning rather than fat storage.

The goal for any food producer interested in promoting the longterm health of consumers should be the development of food choices that deliver a lower glycaemic profile. This is only possible by selecting the right ingredients. A case in point is the increasing popularity of isomaltulose, chicory root fibre (inulin, oligofructose) and isomalt as functional ingredients in product development. With a low glycaemic profile, these ingredients can help in the creation of foods and beverages that promote blood sugar management.

Beneo’s Palatinose (isomaltulose) is a slow-release sugar. It is made from sucrose that is naturally sourced from

INDUSTRY TALK

sugar beet. It is also naturally found in honey. Palatinose is unique in its ability to deliver a lower rise in blood glucose, while delivering full carbohydrate energy (4 kcal/g). Its slow uptake results in a low and balanced blood glucose response, making it an ideal ingredient to help support blood sugar management. No wonder, therefore, that almost two thirds of European 55to 75-year-olds in a consumer survey found Palatinose appealing due to these unique characteristics. Additionally, this unique sugar carries EU health claims for being tooth-friendly and providing a lower blood glucose response.

Beneo’s sugar replacer Isomalt supports a low glycaemic diet by making tasty and enjoyable sugar-free confectionery and other food products possible. It is an almost non-digestible carbohydrate that provides half the calories of sugar, while also having an almost negligible effect on blood sugar and insulin levels. Isomalt also supports dental health and carries an EU health claim for being tooth-friendly as well as an US health claim for not promoting tooth decay.

Chicory root fibres, such as Beneo’s Orafti Inulin and Oligofructose contribute to a low glycaemic diet by replacing available carbohydrates and enriching the food with dietary fibre. At the same time, numerous studies have shown that prebiotic chicory root fibre nourishes the beneficial gut microbiota, supports blood sugar management and weight management together with digestive health and wellbeing.

With Covid-19 driving consumers to boost their long-term health, immunity and mental

stability, manufacturers are increasingly looking to functional ingredients, such as slow-release carbohydrates, to support consumer health goals. Working with food and drink providers worldwide, Beneo can help producers create exciting solutions that promote long-term health, while offering immune support. •

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2021 Quarter 4 | Food Manufacturing Africa

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INDUSTRY TALK

The intersection of beverage processing technology and innovation The global call to reduce CO2 emissions in production processes, including beverage production, has had a significant influence on technology innovations that use less energy and water. This is against a backdrop of an increasingly competitive landscape, growing environmental consciousness among consumers and increasing scarcity and rising cost of water, something of particular importance in waterscarce South Africa.

T

ETRA PAK RESPONDED to this demand from consumers and customers alike by devising an innovative solution for juice, nectar and still drinks (JNSD) production that combines existing technology in an entirely new configuration to drastically reduce energy, water consumption and costs. This ground-breaking solution was recognised by the International Fruit and Vegetable Juice Association and honoured with the IFU 2019 Innovation Award at the annual Juice Summit in Antwerp, Belgium.

To this end, Tetra Pak last year introduced a new JNSD production line that uniquely combines pasteurisation, filtration and UV light to treat beverages in two separate streams, which are aseptically blended together into the final beverage.

“Water is treated separately with filtration and UV light, which uses much less energy. In the new JNSD line, customers reduce energy consumption by up to 67% and water consumption used for cleaning-in-place, sterilisation and product change-over is cut by up to 50%, compared to a normal process” says

14

Hervé Saini, processing director at Tetra Pak Southern Africa.

Tetra Pak’s proven lines for nectars and still drinks offer several major advantages. Starting in the pre-mix area, it offers a choice of different mixers adapted to the customer’s specific product ingredients. It continues with a blending system that, together with its pasteuriser, secures the lowest possible

Food Manufacturing Africa | 2021 Quarter 4

product losses and ends with an aseptic tank from which the product can be safely distributed to the filler.

Such improvements are supplemented by design adjustments to the food manufacturing process to reduce food waste. Manufacture of UHT (ultra-long life) products are the company’s core business and a post-production means of reducing waste is increasing the shelf-

JNSD production line

INDUSTRY TALK

“The JNSD line meets innovation, efficiency and sustainability criteria” life of food. “Product return contributes to CO2 emissions; therefore, food waste reduction is an integral part of our systems.” He explains that shelf-life is governed, not by adding preservatives as it sometimes is believed, but by the UV heating process and aseptic conditions of manufacture.

Saini notes that innovations by Tetra Pak are aimed at assisting customers to achieve their own sustainability goals. Furthermore, they meet growing consumer demand for food quality, safety and sustainability. Covid-19 has shifted consumer behaviours in several ways and

juice consumption is no exception. For instance, an increase in demand has been evident in products that improve people’s immune system, such as vitamin C in fresh juices.

Tetra Pak continues to see much potential for constant innovation. “We see new opportunities on the horizon,

as our customers increasingly search for ways to lead a healthier lifestyle and this trend has accelerated during the spread of Covid-19. The JNSD line meets innovation, efficiency and sustainability criteria. •

Tetra Pak - www.tetrapak.com/za

2021 Quarter 4 | Food Manufacturing Africa

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INDUSTRY TALK

Evolving to meet the factory of the future The Covid-19 pandemic has shaken the manufacturing industry profoundly.

Amid the pandemic, the world could not afford for these industries to grind to a halt. From food to medical supplies, these were some of the sectors that remained at the heart of the economy and needed to operate at all costs. Although the global supply chain is usually a well-oiled machine, the unprecedented crisis forced organisations to not only rethink manufacturing and distribution, but to adapt operations to remain resilient for a postpandemic world.

I

N ORDER TO understand the impact of the pandemic on manufacturers and distributors as well as emerging trends, Syspro conducted a survey in August 2020 that was completed by 144 industry professionals of different managerial levels within the United States, Canada, EMEA and APAC. The study - titled The inflection point for the factory of the future - focused on the rise of the remote workforce and the need for increased collaboration, the impact of supply chain disruptions and emerging trends that will shape the manufacturing and distribution sectors moving forward.

“The pandemic tested the ingenuity, resilience, and flexibility of supply chain leaders globally”

THE VIRTUAL SHIFT Industries needed to change the way they operate and move into digital environments for the first time. The necessary pivot required extensive adjustment.

From the study, 37% of companies were unable to provide the remote work capabilities to employees that were needed. Organisations needed solutions that combine remote collaboration technologies, 73% of businesses stated they would need to invest in technology to facilitate remote working in the future.

In response, 56% of businesses investigated dual sourcing and other initiatives to reduce supply-chain risk, and 37% were looking at planning tools that could actually incorporate visibility into the supply chain. For decades, supply chains have been heavily integrated and increasingly reliant on foreign raw material, in particular from Asia. Industries experienced increasing shortages of parts and started to find alternative supply sources and establish more resilient supply chains. In the study, 42% of businesses stated that they would transfer business operations that was moved overseas back to the country from which it was originally relocated. Organisations also started to explore industry-built technology solutions to deliver functionality to optimise, control and simplify operations.

SUPPLY CHAIN AGILITY The pandemic tested the ingenuity, resilience and flexibility of supply chain leaders globally. The survey showed 60% of businesses were impacted by supply chain disruptions during the pandemic.

THE FACTORY OF THE FUTURE The study mainly revealed that business systems lacked the necessary accessibility, availability, insights and basic planning tools needed by the industry to react to the pandemic.

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Food Manufacturing Africa | 2021 Quarter 4

From the research, 37% of businesses agreed that their business systems lacked those basic planning tools that could adjust to day-to-day changes in the environment. In fact, 29% of businesses stated that their systems lacked in responsiveness during the pandemic and they would be pursuing cloud-based business systems to address immediate needs and accelerate digital transformation.

THINKING FORWARD WITH DIGITAL TRANSFORMATION Digital adoption has taken a quantum leap in the manufacturing and distribution industry due to the pandemic.

The study revealed that manufacturers and distributors needed to increase agility in operations by continuing to invest in digital initiatives across their production process and supply networks. Benefits of transforming digitally have been farreaching. This includes the ability to innovate rapidly, the ability to offer a shorter time to market and a capability to prevent wastage by storing less inventory. Long-term results include more efficient supply chains and higher capital efficiency.

As these businesses attempt to stabilise, the challenge for many is understanding which technologies to adopt and how to pursue this transformation. •

Syspro - www.syspro.com

MATERIALS HANDLING & COLD CHAIN

Danfoss offers global energy efficiency solutions After two weeks of global talks at the United Nations COP26 summit in Glasgow, Scotland, nearly 200 nations finally agreed to a deal to try to contain the world’s climate crisis. Danish multi-national engineering company Danfoss, a leading provider of solutions enabling the green transition, has put forward thoughts on how improving energy efficiencies in buildings and infrastructure can offer some hope to the climate crisis

D

ANFOSS HAS BEEN involved in engineering solutions since 1933 and was a participant at COP26. The company hosted a virtual side event on 10 November, in which experts from Danfoss and other organisations including the United Nations (UN) Environment Programme discussed the topic of decarbonising buildings and their construction.

Danfoss highlights that energy efficiency is the most cost-effective way to achieve economic growth, decarbonise economies and meet the goals of the Paris Climate Agreement, namely the limiting of global warming to 1.5°C since pre-industrial times1.

“The greenest energy is the energy that we don’t use” During the course of the online panel discussion, Danfoss noted that energy efficiency is able to deliver more than 40% of the reduction in energy-related emissions that the world needs to fully achieve international climate and energy goals.

Ziad Al Bawaliz, Danfoss Turkey, Middle East & Africa regional president, clarifies, “Being able to deliver more than 40% of the required energy-related emissions is a phenomenally positive figure. The Danfoss COP26 virtual side-event focused on the opportunity that is presented by infrastructure plans to create ways to fasttrack the green transition. When we look at South Africa, we know that, as an emerging economy, and as with India, there are also

concerns and practical realities around the phasing out of coal within the national energy mix.

“Indeed, COP26 also saw – for the first time – the granting of an historic partnership in which South Africa received a R131 billion financial package from other countries, including the United States, United Kingdom, France and Germany to help the country transition away from coal to cleaner forms of energy 2.”

South Africa presently emits the most greenhouse gases on the continent, because of its reliance on coal for almost all of its electricity 3.

Al Bawaliz continues, “And so, if we are to be open to the sensitivities around coal in the energy mix in emerging countries, it is necessary to be aware of other ways in which nations can work together to achieve a reduction in greenhouse gas emission – and, most importantly, using technology that is already available today. This is why Danfoss is so strongly focused on the energy efficient heating and cooling of buildings and sector integration in urban areas.” The Danfoss COP26 virtual side event noted that urban areas can reach this 1.5°C target with technologies that already exist today. The live event discussed concrete measures that can be taken to make the world’s cities more energy efficient as well as solutions available for making construction sites more sustainable and allow for the reduction of CO2 emissions.

Two highlighted case stories also discussed the following: • A 30% energy savings in excavators on building construction sites: Through Danfoss Digital Displacement technology,

we can save 30% of the energy from excavators and 40 million tonnes of CO2, simply by reducing waste heat in excavators.

• A Danish supermarket becomes its own heat supplier: The supermarket fulfills 95% of its heating demand from its own cooling display cases: by installing Danfoss heat recovery units, it has halved its CO2 footprint in five years.

Essentially, the heat is recovered from the refrigeration systems and can be used within the store itself or perhaps within a microgrid such as a shopping centre.

Taking this one step further, surplus heat can be fed into the district heating network to additionally heat a small number of homes in the neighbourhood.

“The greenest energy is the energy that we don’t use,” comments Al Bawaliz.

“There are multiple energy efficient solutions available today that are proven to be able to decarbonise our global economy. As the world continues to ponder the aftermath of COP26, I believe that there are practical ways to continue the conversation, including from the perspective of implementing the changes that we can already make today, using technologies that are already in existence and proven to work.” •

1. https://www.aljazeera.com/news/2021/11/13/cop26-countriesstrike-deal-with-coal-compromise 2. https://www.timeslive.co.za/politics/2021-11-02-cyril-ramaphosa-secures-historic-cop26-green-finance-deal/ 3. https://www.iol.co.za/weekend-argus/news/r130-billion-fundingonly-the-first-step-for-eskom-93fd3e5f-e0e5-4434-b336-1e95cfe7aafd

Danfoss - www.danfoss.com

2021 Quarter 4 | Food Manufacturing Africa

17

BEVERAGE PROCESSING TECHNOLOGY

Your perfect partner in beverage processing technology In 2019, Vitaqua GmbH put its 7th PET line into operation at its plant in Breuna, Germany – and like all of its predecessors, it’s a turnkey line from Krones. Besides the installation of Line 7, the company also needed to restructure all the plant’s peripherals since everything was configured for the existing six lines. That, too, was handled by Krones.

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HEN THE VITAQUA plant in Breuna was completed in 2007, it was considered one of Europe’s most state-of-the-art beverage production and logistics facilities. Krones served as general contractor and planned, built, and installed everything (except the building itself) in just under a year. The project included the turnkey delivery of the entire process technology, a high-bay warehouse with 51 000 pallet slots, internal logistics, the digital connectivity of the entire plant and four PET bottling lines, each rated at 43 200 containers per hour.

That enabled the newly established plant to fill around four million containers per day.

But that wasn’t the end of it. As planned from the outset, Vitaqua continued to expand its capacities in the years that followed, adding two further Krones PET bottling lines that would be used exclusively for water. In 2014 and 2018, respectively, Krones updated Lines 1 and 2, increasing their individual capacities from 43 200 to 63 000 0.5l containers per hour.

And yet, even that wasn’t enough to keep up with demand. So, Vitaqua decided to add another PET line – now its seventh and again from Krones. Designed to handle four different bottle formats ranging from 0.75l to 1.5l at a

A multifunctional PET line

speed of 40 000 bottles per hour, this new line is the first to be used as a multipurpose line. “Strictly speaking, if we include the two upgrades, Krones has now installed nine turnkey lines in our plant,” says plant manager Stefan Thöne. “In addition, in 2020, we also retrofitted all of the lines with new Contiroll

In 2020, Vitaqua retrofitted all of the lines with new Contiroll labelers

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Food Manufacturing Africa | 2021 Quarter 4

labellers, so they now all use the same gluing system.” But even so, he explains, the contract award wasn’t a done deal. “We’re almost an entirely Krones-built operation, but Krones still has to prove itself with each bid,” explains Thöne.

The new turnkey line bottles, both still and carbonated water as well as carbonated soft drink, went into operation in mid-2019.

At Vitaqua, the blow-molder on each line is linked to the filler via an air conveyor. “It’s our ‘house philosophy’ and it has worked well for us so far,” explains Thöne. Besides trouble-free operation, flexibility is a priority. “Since we run four different containers on this line, it was important that the Contiform blow-molder be equipped with quick-change capability. We can now change over from the smallest bottle size to the largest in just 75min.”

The cleanroom that houses the filler also has three integrated cap supply systems that feed into the screw capper. Switching between normal screw caps, flat caps and sports caps is done automatically. “This is the first line on which we’ve been able to handle sports caps at all,” says Thöne. The company buys the sports caps, while the normal screw caps and flat caps are produced on-site in Breuna and even

BEVERAGE PROCESSING TECHNOLOGY

Based on experience from past orders, the SitePilot Planning module creates a production plan for each line and machine, using a specific algorithm to take into account the needs and thus generating a list of planned orders

So, when the operator starts production, the system already knows exactly which raw materials and supplies are needed and makes them available, fully automatically, by way of the electric overhead conveyor. When the operator scans the barcode on the machines, another validation takes place. Likewise, it is also possible to precisely trace which product was produced and packaged when and with which raw materials and supplies. “It practically eliminates the risk of production errors,” says Thöne.

This high level of digitalisation is also necessary for smooth operation. “Our production is configured for round-the-clock operation on seven days a week. Depending on the season, though, we sometimes only work five days a week. We always have to be able to deliver, because we’ve only got two days from

supplied to the group’s other plants.

In addition, Altmühltaler Mineralbrunnen has been producing its own PET preforms for all four plants at the Baruth location since 2004. The company has a dedicated container design and development team. All in all, the group is pretty self-sufficient. “Basically, we are a plastics processing operation,” explains Thöne.

MAJOR MODIFICATIONS WERE NEEDED Although the plant offered enough space not only for the seventh, but even an 8th line from the start, the entire periphery was laid out for six lines. “As a result, this project was not simply about installing another filling line. Rather, the new line had to be embedded, and our plant’s entire structure had to be adjusted,” says Thöne. In other words, the installation of Line 7 required some major modifications to the plant.

An existing carbonator was moved to make room for the Contiflow mixer in the centralised syrup room. In addition, a new CIP system and a high-capacity compressor were needed. A new pallet inspection unit for Düsseldorfer pallets was installed. The material flow technology was adjusted, with eight new electric overhead conveyor vehicles and fitted into the existing structure.

The electric overhead conveyor serves the entire Vitaqua plant. Finally, the production planning and control (PPC) system for the entire plant was also upgraded to the latest version.

“Krones had to do all of this in a timeframe that kept production stoppage to a minimum. In the end, we only had to shut down for three weeks. It was really a great accomplishment on the part of everyone involved. Krones sent 70 welders alone, who laid new piping and every one of them deserves a great deal of praise,” says Thöne.

The material flow technology was adjusted with eight new electric overhead conveyor vehicles fitted into the existing structure

HIGHLY DIGITALISED The new line is, like all of the other lines, highly digitalised and therefore equipped with a variety of solutions from the SitePilot suite.

The Line Management order management system, Line Diagnostics for production data acquisition and analysis, and the Asset Management maintenance tool. A barcode is affixed to each machine that helps coordinate the raw materials and supplies needed for each respective order.

Suppliers of raw materials, labels or films affix barcodes that are defined by Vitaqua to their products.

These barcodes contain information like batch numbers and best before dates. Based on experience from past orders, the SitePilot Planning module creates a production plan for each line and machine, using a specific algorithm to take into account the needs and thus, generating a list of planned orders. This complete production plan then goes into the Line Management System.

receipt of an order until the product leaves the plant. That’s a logistical challenge, especially with regard to getting the raw materials and supplies ordered in time,” explains Thöne.

The plant manager sums up the project positively. “Initially, the commissioning was delayed by a couple of weeks, but in the end we have been extremely satisfied with the new line. We were able to run the final acceptance at 98.5%. All guaranteed performance criteria were either met or exceeded. For the 1.5l bottle, we had agreed on a rated capacity of 38 000 containers per hour and we are actually able to run the line at between 40 000 and 41 000 containers per hour for all container sizes,” says Thöne, adding this summary of his experience from nearly one and a half decades. “Krones always brings its orders to a good conclusion.” •

Krones - www.krones.com

2021 Quarter 4 | Food Manufacturing Africa

19

BEVERAGE PROCESSING TECHNOLOGY

Beverage processing takes a ‘sound’ leap forward into 4IR Getting the most out of our planet’s available harvest is essential. Particularly with a growing population and a shrinking agricultural footprint also challenged by climate change and environmental pressures. In cavalierly tossing aside overripe or blemished produce or failing to use the entire fruit, vegetable or plant, we have also created a mountain of waste and reduced the level of meaningful nutrition we consume accordingly.

DCD is a solution to achieving net-zero

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ANUFACTURING METHODS HAVE not changed much since the initial industrial revolution. “For the main part, the boxes have just got shinier, the conveyor belts faster, a new computer and several zeroes have been added to the price, reducing the bottom line – the industry has not really changed,” comments Roy Henderson, CEO and co-founder of technology company Green Cell Technologies (GCT).

Manufacturers are, however, quickly realising that it’s time for a new approach, one that not necessarily replaces everything they already have, but one that certainly complements and advances their need to achieve net-zero, while retaining and even increasing profitability and product nutrition and efficacy.

Bringing food and beverage processing firmly into the Fourth Industrial Revolution (4IR), GCT has developed a process – Dynamic Cellular Disruption – and a solid piece of disruptor technology that processes organic and inorganic matter faster than the speed of sound.

Stopping the process in a nanosecond, cell structures are snapped, releasing all the available active molecule components. Whole

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To access the video for this article, visit the digimag

“While more automation can make processes in our industry faster and reduce expensive labour, we must not forget the human element” fruits and vegetables are utilised in the process. There is no need for harmful heat or chemicals, therefore there is little to no denaturing of the original resource.

Food Manufacturing Africa | 2021 Quarter 4

WHY IS THIS IMPORTANT? In trials conducted at GCT’s centre of excellence in Cape Town, South Africa, and in commercial facilities such as Citrosuco in Brazil (one of the world’s largest orange juice manufacturers), DCD and disruptor technology have been shown to dramatically increase yield, while reducing/eradicating waste, enhancing bioavailability of active ingredients and reducing pathogens.

Commenting on the technology, Alex Scheurmans, product

BEVERAGE PROCESSING TECHNOLOGY

development and applications general manager at Citrosuco, remarks that, “It took some time for our mindsets to fully embrace the opportunities that disruptor technology can provide us, but four years down the line, we have not looked back. Our previous ‘waste’ is now an integral part of some of our product lines and DCD has opened up several new avenues for product enhancement and development for us.”

At a recent international technology conference, Henderson was asked to contribute to a panel on the Internet of Things (IoT). Now what, you may well ask, does the F&B manufacturing sector have to do with IoT? Henderson explains, “The world around us is fast becoming an interconnected, homogenous singularity. This will have implications as to how we grow, manufacture and consume our sustenance in the future. While more automation can make processes in our industry faster and reduce expensive labour, we must not forget the human element – we need to remember that 4IR should be about working for humans and not about replacing us. The need for food remains, and even more so, foods and beverages that can deliver better quality nutrition and more intelligently.”

Henderson shares that disruptor technology can deliver emulsions at a molecular level as they are heavily concentrated. Thus, he says, they pack a concentrated punch of goodness too. Less is needed for better nourishment while there’s more to go round to those who need it. While this may sound like pie in the sky, there has been a rapid development of “smart” products across the industry. Smart products, however, need equally smart tools to optimise them.

4IR juice making in the now: Whole oranges to concentrate to juice using DCD

The F&B sector could well lead the charge on delivering the opportunity for ultimate health – we are, after all, the products of what we eat and drink – and with a ‘sound’ strategy at its fingertips, it might well do this. •

Green Cell Technologies - www.greencelltechnologies.com

Faster than the speed of sound…

DCD and Disruptor Technology is the beverage industry’s answer to net zero.

And it won’t cost you the earth!

 Processes whole fruit, whole vegetables, etc.  Creates endless opportunities of value and NPD.  One machine, multiple benefits. www.greencelltechnologies.com

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2021/11/11 17:06 2021 Quarter 4 | Food Manufacturing Africa

BEVERAGE PROCESSING TECHNOLOGY

Taking inspections to the next level Robo-QCS is a single solution that can automatically monitor your beverage line performances [CP and CPK], improving and automating your quality control process.

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ARRYING OUT SEVERAL nondestructive quality control operations at any one-time during production can optimise the production process and prevent non-conformities, which ensures complete product quality.

These are some of the results that can be obtained by inserting an automatic robotic system in line.

The system allows monitoring of the efficiency of the whole filling and capping process in real-time. Its advanced data analysis system crosses all acquired values by its stations and from all other installed inspectors allowing the optimisation of line performance and the product’s quality protection.

Reduce your costs through predictive maintenance, manage claims thanks to the historical database and plan production improvements using all the stored information with the advantages of improved productivity and quality.

Let’s analyse its full potential below:

HOW IS THE LINE EFFICIENCY IMPROVED? The inspections and quality controls on the samples are performed in real-time in the automatic analysis station next to the production line and this replaces the manual checks carried out on the line.

The data is automatically correlated to a production date and time, and aligned with the efficiency of the filler and the correct operation of the capper.

It is, therefore, possible to recalibrate the equipment instantly in the event of deviation from specifications, monitor trends over time and plan targeted and punctual preventive maintenance.

The controls of the ROBO-QCS allows for: • Recalibrating filling valves that do not fill properly - On average, the standard

WHICH NON-DESTRUCTIVE INSPECTIONS CAN BE CARRIED OUT SIMULTANEOUSLY IN A SINGLE ANALYSIS PLATFORM? Usually, four types of controls or measurements are identified: • Weight and volume control.

• Checking correct cap application by measuring torque and application angle.

• Measuring the concentration of gases in the headspace (e.g. CO2, N2, etc.)

• Measuring micro leaks between cap and preform.

HOW CAN THESE INSPECTIONS BE DONE SIMULTANEOUSLY? A robotic arm picks up samples from the production line and inspects them in an automatic analysis station through nondestructive tests. These controls are required by law or necessary to optimise and satisfy internal processes and procedures.

Compliant samples are automatically reinserted in line. It is not necessary to change the production speed of the line and there is no operator intervention.

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Food Manufacturing Africa | 2021 Quarter 4

procedure involves a random manual weighing of 20 bottles every 4 hours. If a deviation occurs to the filling valve during this time, overfilled bottles are produced. With ROBO-QCS, there is a real-time level control preventing large non-compliant productions. The correlation of the sampled bottles to the specific filling valve provides additional important information enabling other controls and dedicated adjustment. This is extremely important information that with manual sampling is difficult to have.

• Evaluating the correct application of the cap - The standard manual procedure involves checking the torque on a random sampling of 20 bottles every 4 hours. With ROBO-QCS, continuous

The ROBO-QCS

BEVERAGE PROCESSING TECHNOLOGY

“With ROBO-QCS there is a real-time level control preventing large non-compliant productions.”

checks for the correct application of the cap through removal torque and application angle. Automation allows specific monitoring of the individual capping heads without the need for operator intervention and eliminating the randomness of sampling as per the filling valves.

• Checking the filler and the capper at the same time with immediate possibility of maintenance - With ROBO-QCS, it is possible to control two or more parameters at once. This means being able to set the equipment very close to the correct setpoint, allowing for planned interventions and maintenance.

Automatically monitor your beverage processing line with the ROBO-QCS

• Reducing the production loss The checks carried out with ROBO-QCS are all non-destructive and therefore the samples used for the inspections can be placed back into the packaging line.

• Digitising the data - ROBO-QCS produces date and time reports that can be shared digitally and used retrospectively during an audit to optimise internal processes or recover data from a specific batch.

• No variability due to operator when making measurements - With ROBO-QCS, no operator is needed on the line. Inspections and records take place automatically, eliminating the possible influences of manual verification. •

TracePack - www.tracepack.co.za

Machine vision systems that offer powerful solutions.

TracePack’s machine vision systems and industrial barcode readers offer powerful solutions to protect product quality and safety, ensure package integrity, manage allergens and maintain traceability.

Contact TracePack to find out about our machine vision systems.

+27 10 020 7221 www.tracepack.co.za A Division of MITAS Corporation (Pty) Ltd

2021 Quarter 4 | Food Manufacturing Africa

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RIGID PACKAGING

Rapid launch of a new 1l bottle on a Guinean line To expand its carbonated soft drink (CSD) brands Planet, Bubble Up and American Cola, and meet market needs for home consumption with larger formats, Nouvelle Brasserie de Guinée (Braguinée) reached out to Sidel for help with the remote tuning of its packaging line to produce 1l bottles. In just three days, Sidel’s multi-expertise team from around the world were mobilised to guide and empower the customer, using Sidel’s latest remote line-adaptation technologies and leveraging effective digital solutions for quick set-up of larger formats.

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RAGUINÉE IS A family-owned company and part of the Gaselia Group. It opened its plant, equipped with a Sidel PET packaging line, in 2018 in Conakry, capital of Guinea. Braguinée is one of the top three players on the Guinean CSD market with growing demand for its products. Its bestknown products are Planet, available in six flavours, Bubble Up, in three flavours and American Cola. It also manufactures other beverages such as energy drinks, juices and bottled water.

As Gaselia Group had already experienced successful collaboration with Sidel since 2009, Braguinée once again turned to its trusted partner to align with market demand. The company was previously producing beverages in small, on-the-go formats (300ml and 350ml) and needed to adapt its production for home consumption with a larger format (1l).

With travel restrictions due to Covid and to ensure a fast launch of the new 1l bottle, line tuning was carried out remotely thanks to Sidel remote video assistance and remote access solutions. The complete packaging line with a Combi SF300 for CSD, installed in 2018, can now manage not only on-the-go formats but

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“A fast release of our new product on the market with minimum line downtime was possible thanks to strong collaboration and excellent project management by Sidel”

Food Manufacturing Africa | 2021 Quarter 4

RIGID PACKAGING

Packaging line for the new 1l bottles

also 1l bottles for three of its flagship brands with high efficiency, running at 22 000 bottles per hour.

A FAST LAUNCH TOGETHER WITH GREATER EQUIPMENT KNOWLEDGE The main objective of the intervention by Sidel experts was to empower Braguinée’s employees with in-depth equipment expertise to ensure a safe and efficient line adjustment to the new format. To do so, an international team of high-level Sidel experts from Pakistan, Italy, Portugal and the United Arab Emirates were mobilised to ensure flawless line conversion. Remote collaboration, continuous availability of Sidel experts, accurate and clear communication between both parties as well as specific documentation facilitated the successful installation of the new equipment parts required to run the new 1l bottle format.

“A fast release of our new product on the market with minimum line downtime was possible thanks to strong collaboration and excellent project management by Sidel.

Everything was planned in detail, from parts installation to line start-up, and we could count on the expert team at every step of the project. They also showed great teaching skills and, thanks to the digital solutions they used, they quickly transferred Sidel's expertise to our team. Learning by doing was a great way to develop our operators’ technical skills even further,” remembers Amadou Ndiaye, technical director at Braguinée.

RIGHT COMBINATION OF DIGITAL TOOLS FOR EFFICIENT REMOTE SUPPORT Line tuning for the new format involved a combination of complementary digital remote

solutions: Remote Video Assistance (RVA) and remote access to customer equipment.

Braguinée’s team could successfully check all mechanical aspects: correct installation and adjustment of parts, validation of machine operations and optimisation of line efficiency. In addition to live chat and drawingover functionalities, the video-supported augmented reality feature accurately guided the customer.

With Sidel’s expert hands showing the movements and pointing to details in real time on the equipment, seamless exchanges were possible. This resulted in Sidel experts having complete situational awareness and in accurate corresponding actions from the customer’s operators. Also, during

line adaptation, Sidel experts checked all settings and set the correct ones for the new format to ensure its quality and maintain optimal line efficiency.

“Despite the distance and Covid-19 restrictions, Sidel was able to provide the same high quality of line conversion services to the customer with the help of our digital solutions, thus enabling greater flexibility in the whole process. The remote services also gave an additional advantage for Braguinée by saving on travel-related project time and costs for the Sidel team,” says Hannes Oeschger, lead customer care manager at Sidel. •

Sidel - www.sidel.com

2021 Quarter 4 | Food Manufacturing Africa

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RIGID PACKAGING

EPR regulations can make a zero-waste South Africa a reality Under new Extended Producer Responsibility (EPR) regulations, producers, manufacturers, importers and brand owners of everything from paper to lightbulbs must establish their own EPR scheme. These schemes had to be submitted to the Department of Environment, Forestry and Fisheries by 5 November 2021, and, as responsible corporate citizens, it’s crucial to get on board, says Terry van der Walt, new business development manager at Nampak Liquid Cartons.

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OUTH AFRICA HAS a significant waste problem. According to the 2018 State of Waste Report, in 2017 we generated 55 million tonnes of general waste, with only 11% diverted from landfills. Yet, according to a 2016 National Pricing Strategy for Waste Management report, South Africa disposes of R25 billion worth of recoverable resources each year.

That’s, quite literally, throwing away money.

Most of the country’s landfill sites are now at critical capacity and to reach the end-goal of a zerowaste and circular economy, drastic measures are needed. Before realising a zero-waste world – where materials are designed to be repeatedly re-used instead of dumped in the bin – South African consumers and producers alike must embrace a recycling

“Before realising a zero-waste world, South African consumers and producers alike must embrace a recycling economy”

economy. The Extended Producer Responsibility (EPR) regulations are a crucial step towards achieving this.

WHAT ARE THE EPR REGULATIONS, AND HOW DO THEY IMPACT ME? The amended EPR regulations for paper and packaging, e-waste and lighting were published on 5 May 2021. For now, this new legislation is broad in scope and will mostly impact manufacturers, producers, retailers, importers and brand owners as they will need to ensure that the bulk of their products are recycled or

256 colours Individually selectable: Measurement in progress Sensor switching Process malfunction

returned after being sold and used.

With only 12.9% of South African households in metros recycling waste, the EPR regulations shift the responsibility to recycle from consumers to the producers – and formalise industry self-regulation through strict targets. For the paper and packaging industry, this means that responsibility will also lie with the manufacturers of the packaging for the products, like Nampak Liquid Cartons.

PARTNERSHIPS WITH PROS In line with the new regulations that have been gazetted, producers must set up collection and recycling schemes, whether through waste management companies or the informal sector. They’ll have to meet collection targets within

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Food Manufacturing Africa | 2021 Quarter 4

03.02.2020 11:50:36

RIGID PACKAGING

their scheme, comply with cleaner production rules and reduced waste targets, and they’ll need to reuse existing materials. All of this will be monitored by government. The amended EPR regulations also make it mandatory for producers to belong to an EPR scheme and pay an EPR fee.

Taking on this responsibility will be a significant challenge for individual producers and manufacturers, so

it’s important for stakeholders to register with a licensed Producer Responsibility Organisation (PRO). The PRO oversees compliance with these new regulations, and as a responsible corporate citizen, Nampak Liquid Cartons has partnered with Fibre Circle, a PRO that represents the paper and packaging sector.

Fibre Circle facilitates EPR programmes for paper producers, which includes everyone from manufacturers of paper packaging to brand owners and retailers. Fibre Circle’s aim is to help companies adhere to the legislation as well as to support its members to embrace recycling – and, ultimately, to make zero waste a reality.

THE NEXT STEP TO A SUSTAINABLE FUTURE IS HERE Under the new regulations, producers must establish their own EPR scheme (or join a registered PRO like Fibre Circle) that works on the behalf of its members. Nampak Liquid Cartons has made a commitment to environmental sustainability, and we strongly encourage our customers and stakeholders to register with the government and Fibre Circle.

At Nampak Liquid Cartons, we also believe that these amended regulations will propel much-needed change by compelling producers and manufactures – from glass to plastic, and polystyrene to paper – to take responsibility for the reuse of their waste, and to make it easier for their consumers to recycle.

To ease the burden on South Africa’s landfills and to reach the end-goal of a zero-waste, circular economy, drastic measures are certainly needed. This is a critical step in the right direction. •

Nampak - www.nampak.com PP024 (hi-res).pdf

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RIGID PACKAGING

Introducing bottles made of 100% rPET Eckes-Granini is making its packaging portfolio even more environmentally-friendly with the help of the KHS Group. Since the middle of May its 1l hohes C juice bottle has consisted entirely of recycled plastic (rPET). KHS’ Bottles & Shapes experts in Hamburg were responsible for optimisation of the bottle.

An InnoPET FreshSafe block from KHS has been in operation at EckesGranini since 2017

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CKES-GRANINI HAS BEEN using 25% rPET in its hohes C PET juice bottles since 2018.

“Bearing the EU’s plastic strategy in mind and the increase in recyclate quotas this prescribes, we’ve now decided to switch to using recycled PET only.

We want to be a pioneer with regards to the circular economy and set a good example for the beverage industry,” states Hermann Naumann, plant manager for Eckes-Granini in Bad Fallingbostel in Lower Saxony.

Europe’s leading producer of fruit juice beverages has pursued an ambitious sustainability strategy for years, Naumann continues. “We aim to continue steadily reducing our carbon footprint in production

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“We want to be a pioneer with regards to the circular economy and set a good example for the beverage industry” and in our packaging. This means not only cutting down on the amount of material used but also closing the recycling loop.”

4 000 TONNES OF NEW PLASTIC AND 8 000 TONNES OF CO2 SAVED These are the exact issues KHS addressed first when implementing

Food Manufacturing Africa | 2021 Quarter 4

the current project. With its holistic Bottles & Shapes consultancy programme customers benefit from over 40 years of expertise in container design and production.

Here, beverage producers state their preferences regarding the weight, shape or stability of the container, for instance, upon which the systems supplier assesses the feasibility of the design with the help of laboratory tests and simulation.

In the case of Eckes-Granini, the specifications were clear: switch to 100% rPET while maintaining the homogeneous quality of the container. According to Eckes-Granini, the changeover of the 1l hohes C bottle to rPET will save over 4 000 metric tonnes of new PET per annum.

RIGID PACKAGING

ABOUT THE KHS GROUP The KHS Group is one of the world’s leading manufacturers of filling and packaging systems for the beverage and liquid food industries. With over 150 years' experience in the development of filling and packaging systems, they have the expertise to create innovative and sustainable solutions for the future. In particular, KHS is one of the world's leading suppliers in the area of developing PET containers and perfectly matched filling lines. Besides the parent company (KHS GmbH) the group includes various subsidiaries outside Germany, with production sites in Ahmedabad (India), Waukesha (USA), Zinacantepec (Mexico), São Paulo (Brazil) and Suzhou (China). It also operates numerous sales and service centers worldwide. KHS manufactures modern filling and packaging systems for the high-capacity range at its headquarters in Dortmund, Germany, and at its factories in Bad Kreuznach, Kleve, Worms and Hamburg.

The KHS Group is a wholly owned subsidiary of the SDAX-listed Salzgitter AG corporation.

In 2020, the KHS Group and its 5 085 employees achieved a turnover of around €1.130 billion.

This, in turn, means that the bottler will cut its carbon emissions by about 8 000 tonnes a year.

EFFICIENT AND SUSTAINABLE: THE INNOPET FRESHSAFE BLOCK Finding ways of saving on resources was not the only focus of the ambitious project. The ability to do so on the KHS InnoPET FreshSafe block in operation at Eckes-Granini since 2017 also had to be investigated. “One

of the concerns was whether either the preforms or machine needed adapting,” explains Dr Matthias Kruse, head of PET Technology at KHS. “We thus assessed the quality of the recycled PET material.

This is crucial, for large variances in colour, molecular length and inhomogeneity quickly reduce the efficiency of production.”

The fact that Eckes-Granini procures its preforms from two different suppliers presented an added challenge, Kruse adds. The

“The changeover of the 1l hohes C bottle to rPET will save over 4 000 metric tonnes of new PET per annum” geometry of the preform is essential for efficient processing, especially when a high percentage of rPET is used. Through extensive testing it was established that both makes of preform function soundly on the block system.

All that was needed for optimum bottle production were minor adjustments to the heater on the stretch blow molder. KHS’ near infrared technology provides a wide processing window for rPET, allowing preforms to be heated prior to the stretch blow molding process with pinpoint accuracy.

No major changes to the machinery or geometrical properties of the preforms were required. “This enabled us to achieve a very high level of process efficiency while retaining the container quality, thus fully meeting our customer’s requirements,” Kruse smiles. rPET BOTTLE ALSO HAS BARRIER PROPERTIES Eckes-Granini will continue to benefit from FreshSafe PET barrier protection also after converting to 100% rPET. The company has relied on the environmentally friendly system from KHS since 2006. The oxygen barrier of chemically pure glass, a waferthin coating on the inside of the PET bottle, not only effectively protects the juice from oxygen pickup, but is also fully recyclable.

The coating can be easily washed off Eckes-Granini bottles during the recycling process. The sustainable packaging alternative therefore permits pure-grade bottle-to-bottle recycling. “By combining rPET and future-proof product protection Eckes-Granini and KHS are again demonstrating their pioneering role for the circular economy,” claims Kruse.

Furthermore, by the end of 2022 Eckes-Granini Deutschland intends to only use PET bottles made entirely of rPET for all brands, saving approximately 9 000 metric tonnes of new plastic per year by doing so. •

KHS - www.khs.com

Flexible Production Integrated Robotic Solutions

• Autonomous teach and go and self-recharging • Automated can fit within a line or factory to achieve end to end automation and traceability • Intelligent can optimize travelling path and work within a fleet of up to 100 robots • Safe fully collaborative and operate along people Would you like to know more? +27 (0)11 579 2600 info_sa@omron.com industrial.omron.co.za

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07-09-21 13:57

2021 Quarter 4 | Food Manufacturing Africa

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RIGID PACKAGING

Dairy packaging: A match made in recycling heaven CCL introduces certified EcoFloat polyolefin sleeves for PP dairy cups to boost recycling rates.

P

P CUPS ARE mostly the packaging of choice when it comes to dairy packaging. CCL has launched the perfect product decoration match – a low density polyolefin sleeve that has an ideal performance when it comes to recycling.

“Using a thin plastic sleeve label that is made from the same family as the cup increases the recycling rate.

First of all it is detected as the material it is on the sorting lines and can be successfully recycled afterwards. Most sleeves tend to be removed due to natural friction and de-sleeving during the recycling process, but if it stays on it can also be efficiently recycled,” says Norbert Fenkart, head of development at CCL Label’s Dairy Packaging Hub in Hohenems, Austria.

FULLY RECYCLABLE: CERTIFIED BY CYCLOS-HTP The renowned cyclos-HTP institute conducted a test that showed that 92% – 100% of the sleeve could efficiently be recycled with the PP cup, depending on other factors like ink coverage. This earns the EcoFloat polyolefin material the classification “highly to fully recyclable” according to the cyclos-HTP rating system.

Additionally, the sleeve material is very thin with a density <1, which means that it is

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“The EcoFloat polyolefin material is classified as “highly to fully recyclable” according to the cyclos-HTP rating systems” very resource efficient and creates less CO2 emissions during transport.

Use sleeves from the same plastic family to avoid composite materials that can hardly be recycled.

Paper banderoles have become increasingly popular in recent years because paper seems a natural sustainable choice to the customers, but is a multimaterial composition: paper, plastic and the aluminium lid. These are not very often recycled as it is up to the consumer to separate those materials, which can be a challenge and obstacle.

Food Manufacturing Africa | 2021 Quarter 4

POLYOLEFIN SLEEVES ARE A GREAT CUP DECORATION First of all it shows great shrinkage, which means that all cup shapes can be covered. It is suitable for highquality printing and offers great possibilities for 360° graphics to make the product stand out in the sales shelves. •

CCL - https://ccllabel.com/

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Review Ishida Europe has extended its range of QX Flex tray sealers with the launch of a new model, which meets market demands for a compact, high-performance solution. The innovative model also maximises output, capacity and flexibility for medium- to high-volume production lines.

Sustainability is an integral part of Multivac’s strategy. For 60 years, the company’s packaging solutions have ensured that sensitive products globally can be processed efficiently, as well as being packed hygienically, reliably and attractively.

Rotolabel is passionate about the environment and focuses on minimising any negative ecological impact of its products. The company subscribes to the four Rs of packaging sustainability: responsible sourcing; reduction of materials; recyclability and increased recycled content

Read more in the latest issue of Packaging Review Out Now! ADVERTISING

Interested in advertising in PACKAGING REVIEW? If you are a supplier to the packaging industry, this will be an ideal opportunity to showcase your product offering and create additional brand awareness within the food, beverage, pharmaceutical, cosmetics, personal care, and home care manufacturing sectors.

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