Food Review April 2018

SOUTH AFRICAN

www.foodreview.co.za

Journal for food and beverage manufacturers APRIL 2018 Vol. 45 • No. 4

INSIDE:

Beverage Review & Packaging Review

high volume meat production

Solutions in

Food fraud – a world free of spice adulteration

A fresh look at challenges in

the supply chain

beverages

dairy farming

dairy processing

utilities

transport

food

core technologies

Milking & Cooling

Seperators

Decanters

Homogenisers

Valves

Spray Drying

Aseptic Filling

Brewery & Dairy

Compressors

Packages & Skids

Ice Machines

Freezers

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

www.gea.com

engineering for a better world

CONTENTS APRIL 2018 | Vol. 45 • No. 4

PAGE

18

08 NEWS

ID Logistics records a strong year

First human milk ingredient approved

Afriplex focuses on the benefits of rooibos

10

NEW ON THE SHELF

Latest products to hit the shelves

Keep listeria in check, without

additional sodium

12 EVENTS SAAFFI’s successful 16th annual seminar SIAL presents The Alter’Native Food Sector | Volum April 2018

14

MEAT MATTERS

e 8 | Numb

er 04

BeverageREteria: 33 Beverage Review Lisindustry VIEW

N AFRICA SOUTH

.za review.co www.food

High volume manufacturing for

dairy fights back

formed products Baader’s quality meat press separation technology The many benefits of vacuum stuffing

Niacet keeps listeria in check

20

HERBS & SPICES

Mustard fits industry food trends

g for processin Solutionsproducts sensitive must-have the ics Probiot t for 2018 ingredien

“Taking a stand against Listeria Monocytogenes, the Dairy Standard Agency publishes a bespoke guideline to assist the South African dairy sector”

41 P ackaging

Review

Integrated conveyor and detection systems Global response to spice adulteration

26 LOGISTICS & COLD CHAIN

Robots move with the times

PnP’s competitive edge

Key solutions in handling fresh supply chain products

30 PUMPS & VALVES

A new generation of vacuum pumps

Inoxpa receives 3-A certification

Vac-Cent’s new Vectra range

8 | Volu April 201

In a competitive market, companies are using labels as an extension of their marketing.

Are your labels flexing with these trends?

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April 2018 | Food Review

3

EDITOR’S COMMENT

EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmediapub.co.za

Time to play catch-up T

he food and beverage industry is dynamic and subject to a constantly changing regulatory, quality and safety framework. I recently attended ABB’s Customer World Africa 2018, held in Sandton, Johannesburg. At the show, latest innovations to digitise manufacturing were on display. I chatted to Marcus Brettschneider, general manager of global food and beverage applications at the company. He noted that while challenges vary considerably across the continent, the most critical goal is to drive robotics and automation within manufacturing. This will assist ingredient suppliers, processors and manufacturers to quantify quality and ease traceability. The time is right to invest in technology to control the quality of production lines and leverage opportunities from a raw material perspective. This is the only way of staying competitive with international manufacturers.

In Meat Matters this month, we bring you the latest innovations in high volume production for formed meat and meat replacement products. We also look at Baader Meat (page 15) and how it differs from mechanically separated meat.

Staying with transparent traceability - complexity of detection during spice adulteration makes the condiments industry vulnerable to fraud. This conclusion was drawn from a study published in the Food Control journal. Turn to page 24 now to find out how SSAFE’s food fraud vulnerability tool and The Knowledge Centre for Food Fraud and Quality launched by the EU can assist in ensuring products are safe for consumption. Food Review also spoke to Friedel Spies of ID Logistics about the highly competitive fresh food supply chain and what the company is doing to deliver fresh and quality goods to consumers (page 28).

The listeria outbreak is still dominating headlines. South Africa’s dairy industry is taking robust steps to ensure programmes are in place to offset another occurrence. In addition to reviewing cleaning and sanitation schedules, re-evaluating personal hygiene and maintenance, industry should also implement a listeria environmental monitoring programme. On page 35 Linda Jackson, food safety guru par excellence, highlights some of the most important aspects to consider.

Personalised packaging and tailored labels that resonate with end-users can increase shelf shout and presence. PACKAGING REVIEW brings you the latest trends in the rapidly evolving labels industry and all the latest news to keep you in the loop.

I hope you enjoy this edition. As always, we welcome your input and suggestions.

Assistant Editor: Aarifah Nosarka +27 (0)11 877 6209 aarifah.nosarka@newmediapub.co.za

Layout & Design: Kirsty Thomas +27 (0)11 877 6168 kirsty.thomas@newmediapub.co.za Contributors: Bruno Adam, Linda Jackson, Carike van der Merwe ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmediapub.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmediapub.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmediapub.co.za INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmediapub.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmediapub.co.za Production Controller: Rae Morrison 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 on behalf of Media24 by New Media Publishing (PTY) Ltd. MANAGING DIRECTOR

Happy reading!

Aileen Lamb CHIEF EXECUTIVE OFFICER Bridget McCarney EXECUTIVE DIRECTOR John Psillos NON EXECUTIVE DIRECTOR Irna van Zyl

EDITORIAL ADVISORY BOARD Two doctorates in chemistry; leader in the field of palm oil; SAAFoST president 1993-2001 and honorary life member; past president, Society of Cosmetic Chemists SA.

Dr Aubrey Parsons With a PhD in biochemistry, an MBA and a Institute of Brewing and Distilling diploma Heidi also serves on the Innovation Hubs BioPark and UNISA’s Life Science advisory board.

HEAD OFFICE Managing director of Symrise South Africa; chairman of SAAFFI.

Rudy McLean

Head of communications, Tetra Pak Sub-saharan Africa.

Penny Ntuli

Dr Heidi Grimmer Founder, creative director and entrepreneur of Strategic Communications Company (Stratcom).

Gail Angela Macleod

Food Review | April 2018

Postal address PO Box 440, Green Point, Cape Town 8051

Food Review is published by New Media Publishing (Pty) Ltd 11 times a year and circulates to executives in the food and beverage industries. Views expressed in this journal, other than where specifically stated, are not necessarily those of the publisher.

The editor welcomes for publishing consideration news items, press releases, articles and photographs relating to developments in the food and beverage industries. No responsibility is accepted should contributions be lost.

She is a qualified food technologist with an honours in Bachelor of Commerce in Business Management and a PMD at the Gordon Institute of Business Science.

Kerusha Pillay

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Food Review | April 2018

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Innovation In Action

Complete turnkey solutions for Prepared Food Systems

Heat and Control offers the latest value add technology to cook, coat, brand and sear a wide range of meat, seafood and poultry products. Our fryers, overs, branders, searers and breading/batter applications can produce, prepare and cook the highest quality chicken, beef, pork, and fish products, using the most efficient processing and packing technology.

With manufacturing facilities and sales offices worldwide, Heat and Control supports manufacturers with experience, expertise and resources to develop the most value driven and efficient solutions for any food production challenge.

Put our innovation to action in your plant today!

Preparation | Cooking | Coating + Conveying | Inspection | Weighing + Packaging | Controls + Information

www.heatandcontrol.com | info@heatandcontrol.com | Cape Town +27 21 948 5934

NEWS

Strong year for chilled freight ID LOGISTICS SA marked another strong year with high potential new clients. Since the group partnered with its first anchor client, Danone in South Africa in 2012, ID Logistics has become the number two leader in the chilled market.

It has onboarded 18 clients from diverse sectors, with key brands such as Nestlé, Denny, Spar, OK Foods and Sir Fruit amongst others.

Innovation and technology are key differentiators in this highly competitive and commodity-driven market.

Friedel Spies, Eric Hémar, Etienne Juillard ‘With our expertise, strong commitment to quality footprint by 25 per cent; R7.9 million standards and innovation-driven solar investment with 30 per cent culture, we introduce and instill gamereduction off the grid across facilities changing strategies to the benefit of and a centralised control tower. our clients,’ Etienne Juillard, MD of ID This will be a key differentiator and Logistics South Africa comments. potential cost saver for our clients,’ ‘Innovations during 2017 included Juillard enthuses. the successful implementation of our Plans for 2018 are ambitious and secondary transport optimisation include expansion into the perishable programme; reduction of our carbon

distribution sectors and vertical markets where they can add value. ‘We are diversifying our opportunities, and hope to secure other anchor clients.

We will also continue to improve technologies for visibility and just-in-time information, as well as invest in a fleet of more than 130 trucks. We are also targeting a Level 4 B-BBEE status to actively contribute to the social transformation of the country,’ Juillard notes.

Eric Hémar, CEO and chairman says, ‘We have a clear ambition for South Africa to become a leading player in a market that is in the process of consolidation. South Africa has a strong economy with a sound infrastructure, a large and young population, a skilled workforce with an excellent banking system. It provides a stable gateway into Africa for expansion,’ he concludes.

Africa’s premier food & drink tradeshow

Africa’s Big 7 welcomes thousands of f&b professionals from across the continent and with so much content, features, networking and industry insight it is the essential event for the industry.

What you can look forward to at the show: 200+ Exhibitors From over 25 countries

The food leaders Forum A 70+ speaker conference

Competitions you won’t want to miss The NEW Inter Hotel Culinary Cup The Global Pizza Challenge

Lots of FREE accredited training Barista and mixology classes Farming skills course Food Hygiene workshop

Partners:

Register now for free entry www.africabig7.com AFRICA HOSPITALITY WEEK: Powered by:

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Food Review | April 2018

NEWS

EU regulatory approval of

human milk oligosaccharide DUPONT NUTRITION & HEALTH (DuPont) and Inbiose NV celebrated regulatory approval of the first human milk oligosaccharide (HMO) ingredient for infant formula in the European market. HMO’s, complex carbohydrates found in breast milk, are an important breakthrough innovation in infant formula.

There are more than 100 HMOs found in human breast milk, with 2’-fucosyllactose (2’-FL) being the most abundant. In 2016, Inbiose and DuPont announced a joint development and licensing agreement

for exclusive rights to produce and commercialise 2’-FL and other selected fucosylated HMOs for food applications.

‘After many years of critical research and significant investment, we are delighted to see the first of our range of human milk oligosaccharides becoming commercially available. This addresses a major gap in the nutritional composition of infant formula,’ says Prof. Wim Soetaert, Inbiose executive chairman. ‘Thanks to our successful collaboration with DuPont, our first HMO is now commercialised, with many others to come.’

‘The substantial equivalence dossier for 2’-FL received EU Novel Food approval in December 2017,’ explains Paul Tenning, regulatory affairs manager, EMEA for DuPont.

‘We are excited to be able to bring this important new ingredient for infants and children market.’2’fucosyllactose, will be marketed

by DuPont under the brand name CARE4U. It is already approved for use in dietary supplements, with potential applications related to digestion and immune health.

Rooibos compounds aid healing AFRIPLEX HAS PARTNERED with the South African Medical Research Council (SAMRC) and Agricultural Research Council to develop Afriplex GRT. The ingredient uses naturally occurring flavonoid compounds found in rooibos to target specific metabolic syndrome-related dysfunctions in the body. Afriplex GRT is regarded as the first of its kind to be developed in South Africa.

The focal point of developing the ingredient is the potential health benefit for people managing the symptoms and effects of metabolic syndrome, diabetes, cholesterol and obesity. Apart from it being utilised as an effective anti-oxidant, research conducted by the SAMRC has indicated that flavonoid compounds found in rooibos play a role in cholesterol regulation and points to a positive effect on blood glucose levels as well as a reduction in insulin resistance.

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April 2018 | Food Review

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NEW

ON THE SHELF A guiltfree treat Em-eukal sugar-free sweets are available in four delicious flavours: eucalyptus, gingerorange, lemon and salvia, which features a zesty sage tang. The quality confectionery is manufactured using the finest, natural ingredients and extracts of the highest quality fruit juices and oils. Em-eukal sweets contain no artificial colourants or flavourants and are suitable for diabetics and vegetarians.

These mouth-watering, sugar-free sweets will suit the health conscious and those trying to cut down on their sugar intake.

Elegant effervescence De Grendel toasts the arrival of autumn with the release of Three Spades Cider.

The premium cider is made in limited quantities with freshly pressed apples from Elgin, one of South Africa’s foremost apple growing regions. The cider is pressed from five varieties each playing a part in its flavour: 30 per cent Golden Delicious, 30 per cent Granny Smith, 20 per cent Pink Lady, 10 per cent Braeburn and 10 per cent Fuji.

Herald the Le Chocolat Pinotage A new angel has taken flight at Grande Provence Heritage Wine Estate with the launch of Angels Tears Le Chocolat Pinotage.

This easy drinking red wine is blessed with a heavenly twist of chocolate and generous splashes of ripe plums and red berry fruits.

The newest addition to the Angels Tears’ range, the cultivar is a smooth, medium bodied wine that allures with its appealing ripe fruitiness enhanced by hints of chocolate.

When two worlds come together Set the stage for

premium spirits Fitch & Leedes, the bespoke range of authentic mixers, is taking cola enjoyment to another level with the launch of its new craft cola. Products are made in small batches using quadruple filtered water for purity and only the finest ingredients are used. The new Fitch & Leedes Craft Cola is the perfect accompaniment to premium spirits.

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Food Review | April 2018

Be

carb clever Woolworths has launched its Carb Clever Ayrshire full cream plain yoghurt with spiced granola.

Simply tip the granola into the yoghurt, stir, and enjoy. The product is free from hormones, is sweetened, features no added preservatives and has live bifidobacterium cultures.

The new 12-year-old single malt The Macallan Double Cask has just been launched. Exclusively aged in sherry seasoned casks, the 12 year old delivers a distinct American oak style, reflecting a perfect harmony of flavours and natural colour. The delicate flavour of American oak – vanilla, citrus and light oak – rises in prominence as the traditional Macallan character of rich fruit, sherry and wood spice affords a familiar backdrop.

Entries now open for the 2018 New Product Competition

Contact Natalie Da Silva: natalie.dasilva@newmediapub.co.za | +27 (0)11 877 6281

EVENTS

A confident nod to African flavours SAAFFI’s 16th annual seminar and workshop took place on 6 March at the Bytes Conference Centre in Midrand. The event focused on unique African flavours and fragrances and how to harness these to maintain brand vitality and differentiation.

N

ick Tandi of Strategic Water Partners Network offered a sober look at water stress in the sub-Saharan region and its impact on doing business. He noted that currently a 17 per cent gap between water supply and demand exists. This could have fatal consequences for the manufacturing industry. ‘Water scarcity is a supply chain risk,’ he explained. ‘About 93 per cent of South African companies identify a direct operational risk linked to water shortages.

Municipalities lose up to 36 per cent of their water in systems due to leaking pipes and other forms of physical losses. Combined Pinchas Goldberg, Selwyn Blieden, Joseph Mohohoma and Jane Granger took part in the first ever panel discussion

with water theft and revenue not collected, this is a R10 billion financial loss annually.’

TRENDS TO WATCH The latest trends impacting product launches was a highlight during the seminar. Gary Boast of Nicola-J Flavours and Fragrances offered an overview of regional flavours with a specific emphasis on sweet and spicy for the snacks category. His prediction for 2018 includes peanuts, hot and spicy, cinnamon and melon. Chris Slabbert, business and development manager of IFF unpacked the latest data on clean-eating, reconnecting with nature, ancient ingredients and its impact on consumer choice.

DOING BUSINESS IN AFRICA A much anticipated presentation was delivered by Ibikunle Olatunji, senior manager at PWC’s Africa Desk. He noted that the current rate of innovation on the continent is staggering, which offers prime opportunities for home grown brands.

Africans are also doing more business with neighbouring countries due to the many trade blocks on the continent. He concluded on a positive note, ‘World Bank statistics are looking good in terms of economic growth and it is expected that it will improve in the next 12 months.’ •

SIAL’s focus on alternative food A major phenomenon is underway in the food industry. This mini-revolution is throwing new light on what we put on our plates by reinventing the way we feed ourselves. Alternative food is healthy, respectful of nature and mindful of animal wellbeing. The Alter’Native Food Sector, a show within a show at SIAL Paris, will be held from 21 to 25 October 2018.

A

rtisans and manufacturers the creators and inventors of the food of tomorrow, are brimming with ideas and notions around the concept of alternative food.

The premise is simple: The product basket is exciting and focused on plant proteins i.e. wheat, soya, pulse proteins. The key lies in marrying the desire for healthy eating with eating pleasure. The number of innovations based on meat substitutes exceeds the number of meat-based innovations.

Fermented food such as kombucha, kefir and kimchi are seeing renewed popularity for their perceived natural properties and health halo.

Health concerns are at the heart of success in alternative food. After the major food crises of the 1990s and early 2000s, consumers are turning toward food that is perceived

12

Food Review | April 2018

as healthy and ethical. The success of products with original flavours and textures; plant-based milks or yoghurts, free-from products (enriched with super fruits or super vegetables) and natural energy drinks are in the spotlight. ‘SIAL will be welcoming many alternative food producers and suppliers. It is a unique potpourri of experiences we propose for 2018,’ explains an enthusiastic Nicolas Trentesaux, director of the SIAL network. ‘The show is the The full programme of vanguard conferences, roundtables of the food and guided visits will be industry. available in June 2018, This year from sialparis.com. we go even further.’ •

DID YOU KNOW?

Full Serv ce SA’s business magazine for the restaurant & catering industry

Full Service will target decision makers in the restaurant business. Restaurant owners, restaurant managers and caterers will be informed about new machinery; ready-to-make meals; bakery goods; utensils; furniture; trends and editorial, which will help save costs and increase profits.

The magazine will provide solutions to restaurant owners and caterers who are facing challenges within the market. It will provide tips and advice, training and compliance and even legislative updates for the restaurant and catering market.

www.fullservice.co.za For more information or advertising opportunities contact: CHARLENE GONCALVES Tel +27 82 873 2687 | charlene.goncalves@newmediapub.co.za

launching

May 2018

M E AT M AT T E R S

RAISE THE BAR in high volume drum forming GEA has launched its new MaxiFormer rotary drum former for high-volume production of formed chicken, pork and meat replacement products. The technology offers increased production capacity, better consistency, improved filling accuracy, less product waste and significantly lowers operating costs when compared with alternative forming systems.

A

key feature is its innovative stepfilling system, which manages communication between the Handtmann vacuum filler and former.

Pressure used to fill each cavity is minimised, resulting in less waste, improved filling accuracy, a higher quality formed product and excellent shape retention. It also reduces downtime for cleaning. The unit is available in widths of 1 000mm and 600mm.

FILLING ACCURACY MaxiFormer’s unique drum design creates a more rigid structure that ensures consistent filling pressure across the entire width of the drum.

This ensures a standard weight deviation that is 50 per cent less than its nearest competitor.

The drum also features a unique knock-out system.

Technology uses dry air at high pressure applied to relevant cavities, not the whole drum.

This significantly reduces air usage and energy costs.

Paul Verbruggen, product manager further processing explains, ‘Better weight control results in less product giveaway and the knock-out system uses up to 40 per cent less air. This means we can be confident in achieving the lowest total cost of ownership in drum forming.’

Size and new features make the GEA MaxiFormer the next big thing in drum forming. For 1 000mm wide lines, running one GEA MaxiFormer 1000 (compared with two 600 wide formers), is cost-efficient and space saving. It also delivers optimal belt loading, resulting in a much higher line throughput with fewer doubles down the line. Direct loading conveyors

“It is essential that meat is chilled to exactly the right level to achieve an optimum crystalline state, binding in required levels of water with minimum use of salt and phosphates”

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Food Review | April 2018

also eliminate the need for ‘Y’ conveyors and can therefore achieve much denser loading without compromising quality.

EFFICIENT CLEANING MaxiFormer is complemented by the MaxiClean automated drum cleaner.

Unlike ordinary drum cleaners this unit continually monitors temperature, flow and pressure of fluid during cleaning and compares it with data from a clean drum.

This minimises cleaning time for each drum allowing faster product changeover and greater productivity.

MONITORING SYSTEMS FOR THE PERFECT MIXTURE In any forming machine the quality of the final product is determined by the

MaxiFormer rotary drum former

mix. It is essential that meat is chilled to exactly the right level to achieve an optimum crystalline state, binding in required levels of water with minimum use of salt and phosphates. Get it wrong and the forming drum can quickly clog, which requires immediate cleaning. This creates unnecessary and unacceptable downtime for processors. Built into the mixer is a unique monitoring system that can detect exactly when the mix is in the ideal state for forming. If customers have difficulties in achieving the optimum mix or product quality, GEA’s support team can assist. Unique competences form a bridge between meat preparation, vacuum portioning and drum forming. •

GEA – www.gea.com

M E AT M AT T E R S

How to ensure

excellent meat recovery Baader low pressure meat recovery systems offer a unique and proven method for separating soft and solid components for a wide range of applications. This includes desinewing from pre-cut red meat and poultry.

A

variety of raw product can be refined using this method. During the desinewing process, a squeezing belt feeds the product to a perforated drum and presses soft components through the holes of the drum.

Solid components such as sinews, gristle and skin remain outside the drum. Ratios between yield and quality can be influenced by means of adjusting the pressure roller.

When sinews and gristle are removed, the desinewed meat is richer in protein. It also contains less connective tissue than ground only meat.

Baader soft separators are available in five size ranges, each with various options suitable for different applications and capacities.

Throughput values vary, depending on the hole size in the perforated drum, type of feeding, product and its pre-treatment (e. g. degree of pre-grinding), feeding temperature and selected pressure. Values for each application must be determined individually between customers of the machine and suppliers.

WHAT EXACTLY IS BAADER MEAT? In 1969 Baader developed a press-separation process for the separation of soft and hard components. It is used for desinewing and meat recovery of pre-cut red meat and poultry.

Baader meat is a fixed term of quality today, but can only be gained by using original 1396_DFS ADVERT.pdf 1 12/03/2018 machines. The company has mandated an

independent institution to consider the technology from a food regulatory point of view. Press-separation methods separate meat from connective tissue and sinews. Meat obtained is not separated and therefore does not have to be declared as separator meat.

HIGH PRESSURE TECHNOLOGY Lima is a specialist in the manufacture of meat-bone separators, deboning and desinewing machines for the poultry, pork, fish, lamb, rabbit and beef industries. High pressure meat recovery systems provide high yield and fine textured meat suitable for emulsion type products.

small temperature increase. This enables the production of high quality meat - ideally textured for further processing.

The profile of the hopper and the head body allows 100 per cent access for quick and easy cleaning and disinfection. All models can be supplied with a special dismantling table to ease cleaning operations. The head adjusts to allow for optimum yield to cope with variations in the raw product. Separated meat is transferred and protected in a pipe without the need for an extra pump.

Lima offers complete equipment such as automatic feeding and weighing systems. It also supplies two-step D+S operations. Lima and Baader equipment are supplied locally through DFS Process Solutions. •

DFS Process Solutions – www.dfs.za.com Meat is ideally textured for further processing

Lima’s main advantages are: • High product quality • Hygienic design • Easy operation maintenance • Quick cleaning •N o pre-breaker needed • Very low increase in temperature.

Due to the design of the Lima equipment range, raw product is handled very gently with minimum pressure. Low rotation speeds of the 09:09 auger ensures a very

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PROCESSING SOLUTIONS FOR POULTRY, MEAT, FISH, PROTEIN RECOVERY AND EFFLUENT WATER. +27 (0)87 238 1873 • sales@dfs.za.com • www.dfs.za.com

April 2018 | Food Review

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M E AT M AT T E R S

Developments in further meat processing Dutch company DJM specialises in the manufacture of forming and extrusion equipment. It combines the benefits of vacuum stuffing technology and integrates it with various attachments for perfectly formed products.

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he company produces its own vacuum stuffer, but attachments are easily integrated to other vacuum stuffing machines. Using a vacuum stuffer as a basis for air removal results in a consistent product density. It is then possible to pump raw material at a specific rate, which ensures accurate portion control. The entire system can handle a wide variety of input products from whole mussels to emulsified products.

Exiting the stuffer, the product is pumped to one of the various attachments. Using a unique distribution system, the product is divided into the number of forms or extrusions required.

Low pressure and shear are maintained through the entire system. Units can

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Food Review | April 2018

pump whole cooked vegetables like peas, corn, cooked potato squares and soft meat cubes.

‘Equipment is seeing interest from customers in the meat, poultry, seafood, vegetables, dairy and convenience food sectors. Units are capable of forming, depositing, extruding and co-extrusion,’ enthuses Gary Clack, managing director of Albrecht Machinery. ‘Recent sales of onion ring extruders, high capacity hamburger forming machines, snack food options with varying outer and inner products, accurate depositors and co-extruded snack lines have been concluded.’

DJM is represented by Albrecht Machinery in South Africa. •

LOW PRESSURE SYSTEM DELIVERS THE FOLLOWING BENEFITS: • Maintains raw product integrity • Optimum weight control • One to 1.5 per cent yield increase • Reduced cooking loss • E xcellent bite and mouthfeel • Proteins and spices are not overworked • E xtreme low cost of ownership compared to other traditional systems.

Albrecht Machinery www.albrechtmachinery.co.za

M E AT M AT T E R S

Keep listeria in check,

without additional sodium At a recent Listeria symposium held by industry watchdogs SAAFost and FoodFocus, organic-salt specialist Niacet presented its Provian product line.

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iacet’s latest product development within this range, Provian K, is specifically designed to prevent the outgrowth of Listeria monocytogenes and other pathogens. This will assist in ensuring protection of processed meat and ready-toeat meals.

Produced in The Netherlands using Niacet’s advanced, unique, co-spray drying technologies, Provian K is a unique, patented, powder alternative to conventional liquid preservative systems.

It is widely used in Europe and the US due, in part, to its proven efficacy in university studies and large scale production facilities.

This highly concentrated acetate based blend’s recommended dosage level is as low as 0.5 per cent w/w, due to the high preservation effect of acetates, making it a cost-effective solution.

The addition of Provian K in processed food products also controls the outgrowth of Listeria monocytogenes and other pathogens, without the addition of sodium.

This assists food manufacturers in reaching 2019 sodium reduction targets, without compromising food safety.

The superior bacteriostatic effect of Provian K in comparison to other preservative systems can be predicted using

an independent model - developed by the Technical University of Denmark. The Food Safety and Shelf Life Predictor (FSSP) is freely available for download at http://fssp.food. dtu.dk. This model predicts the efficacy of Provian K in processed food products where Listeria monocytogenes might be an issue and can be used to show authorities a control point, within listeria control programmes.

Niacet’s technical experts, in conjunction with local supplier CJP Chemicals, are available to provide application support. •

CJP Chemicals – www.cjpchemicals.co.za

PROVIAN® K - Listeria control Niacet.com |

Niacet.tiel |

Niacet

www.cjpchemicals.co.za | lisadk@cjpchemicals.co.za CJP Chemicals.indd 1

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2018/04/12 1:36 PM

FOOD AND NUTRITION YOUR STRATEGIC ALLY IN FIGHTING LISTERIA As the global market leader in lactic acid, lactic acid derivatives and lactides, our supplier Corbion creates highperformance, biobased ingredient solutions for the world’s leading food manufacturers in bakery, meat, culinary, confectionery, dairy and beverage.

Corbion’s long history and proficiency in helping meat and poultry processors combat Listeria, has led to the development of highly effective, natural ingredient solutions.

With more than 80 years of experience in meat preservation and food safety, Corbion has both the expertise and the strong ingredient portfolio to help the South African food industry respond effectivelyto the current Listeria outbreak.

•

Opti.Form® Powder Ace S61, an easy-to-use, cost-effective blend of sodium lactate, sodium acetate and sodium diacetate for use in cured and uncured ready-to-eat meats. The lactate/acetate/diacetate combination is proven to be highly effective in inhibiting Listeria growth for up to 100 days of shelf life in most product formulations.

It’s powdered format also offers advantages in transport, storage and production.

•

Opti.Form® PPA Plus, a highly concentrated blend of potassium lactate and food grade potassium acetate which can be used in cured and uncured cooked meat products, as well as in fresh meat products, to inhibit Listeria growth throughout shelf life and the manufacturer’s supply chain. In fresh meats, Opti.Form inhibits the growth of both spoilage and pathogenic microorganisms and can be useful in reducing sodium levels and increasing fresh meat color.

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Verdad® Powder N4, a vinegar-based solution that is extremely effective in helping to control the growth of Listeria monocytogenes in ready-to-eat meat and poultry products, which are particularly susceptible to pathogens. It is also useful in reducing sodium levels without adversely affecting flavor.

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Verdad® Powder N6, also based on vinegar, a rich source of acetic acid and a wellknown inhibitor of microbes and pathogens. In readyto-eat meats, Verdad Powder N6 can inhibit the growth of Listeria for more than 100 days.

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Verdad® Avanta® Y100, a proprietary blend of vinegar and citrus flour, which provides Listeria control while improving cook yield, controlling purge and enhancing the texture of processed meats.

•

The Corbion Listeria Control Model (CLCM) helps calculate antimicrobial dosage levels required to effectively retard the growth of Listeria monocytogenes in a food system. Based on data from more than a decade of Listeria studies, this online tool helps project Listeria growth over time based on specific food characteristics such as moisture level; pH; sodium, potassium and nitrite levels; and water activity.

Corbion’s long history and proficiency in helping meat and poultry processors combat Listeria has led to the development of highly effective, natural ingredient solutions available in the region, such as: Meat, poultry and fish products are highly susceptible to microbiological contamination, including food-borne pathogens.

Listeria monocytogenes is a major concern for food regulators and meat processors because it is able to grow at refrigerated temperatures and in products with low water activity.

While Listeria is inactivated at high temperatures, it can often re-enter the food supply following heat treatment.

Brenntag South Africa (Pty) Ltd 11 Mansell Road Killarney Gardens Cape Town, 7441 Cape Town +27 (0) 21 556 1920 Johannesburg/KwaZulu-Natal +27 (0) 11 396 3733 info@brenntag.co.za

www.brenntag.com

FOOD AND NUTRITION | NUTRACEUTICAL | PHARMACEUTICAL FLAVOURS | STABILISERS | PRESERVATIVES | EMULSIFIERS SODIUM AND SUGAR REDUCTION | SHELF LIFE EXTENDERS

HERBS & SPICES

The wonders of mustard

The spice is one of the world’s oldest ingredients to be worked into a condiment. Romans were the first to make prepared mustard, by mixing wine and freshly ground mustard seeds to make a tasty paste to spice up meals, writes Carike van der Merwe.

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ustard plants are derived from several plant species of the genera Brassica and Sinapis.

The most common types of mustard are Sinapis alba (also called Brassica alba, yellow mustard or white mustard) and Brassica juncea (also called brown mustard or Indian mustard). Black mustard (Brassica nigra) fell out of use in commercial products in the 1950s.

Traditionally, mustard or mustard oil would have been used as a treatment for stomach and intestinal disorders, diabetes, as a natural antibacterial agent, stimulant for vomiting and

massage oil to improve blood circulation, muscular development and skin texture.

Its primary use today is as a condiment. Whole, ground, cracked or bruised mustard seeds are mixed with water, salt, vinegar, lemon juice, white wine or other liquids, flavourings and spices to create a paste or sauce that ranges from sweet to spicy - bright yellow to dark brown. Mustard becomes the pungent condiment we know when seeds are cracked and mixed with a liquid to activate the volatile oils that give its distinctive taste. It remains one

of the most popular and widely used spices in the world. There is also a whole world of functional benefits of mustard ingredients in the food industry.

REPLACEMENT TO EGG YOLK The Avian Bird Flu outbreak hit the food industry hard in South Africa during 2017.

Egg suppliers were often unable to meet the demand of the food industry. This had a tremendous impact on condiment/ sauce manufacturers. While shutting down production lines was not an option, many manufacturers opted to take the mustard route.

We are Frutarom South Africa (Pty) Ltd We combine flexibility, simplicity, speed, quality, leading pricing and most of all, the right personality to become your preffered partner for tasty and healthy success.

Frutarom South Africa develops and manufactures customised solutions for the beverage, sweets, snack, meat and convenience industry.

We strive for long-term relationships with you in order to address the needs of your business, both locally and globally.

Frutarom South Africa (Pty) Ltd 70 Lechwe Road, Corporate Park South, Midrand Private Bag X2025, Isando, 1600 Phone: +27 11 974 7822 www.frutarom.com

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2018/04/16 11:55 AM

HERBS & SPICES

Mustard flour’s phospholipid structure helps make the ingredient a very effective emulsifier. Mucilage found in the bran makes it a very efficient emulsion stabiliser. When used in combination, it can serve as a successful replacement to egg yolks in emulsified dressings and sauces.

Wisconsin Spice in the US has partnered with the US Association of Dressings and Sauces (ADS) to show the effectiveness of deheated ground mustard (DGM) as a replacement to egg yolk in full fat ranch dressing.

In this project, egg yolk was completely removed and DGM was added at a rate of

one to three per cent. Relative to control, dressing viscosity and emulsion stability was maintained throughout shelf life when DGM was used in place of egg yolk.

It is important to note that even though mustard bran will give immediate characteristics that match your control, the emulsion would risk breaking over time.

If mustard bran is used in an emulsified dressing/sauce, it is recommended mustard flour be used to some degree. This will stabilise the emulsion.

Apart from being an ancient known remedy for health concerns and spicing up food, mustard fits well with recent trends in the food industry.

• G luten-free: The market for gluten-free products has rocketed as celiac disease becomes better diagnosed and glutenfree diets for perceived health benefits increase in popularity. The challenge for food manufacturers lies in formulating products with flavour and sensory aspects consumers will enjoy.

• Free from: While gluten-free is well established, there is a growing free from trend. This includes food free from the biggest eight allergens namely milk, eggs, fish, shellfish, tree nuts, peanuts, wheat and soya. Euromonitor

predicts the market for free from foods will continue its rapid growth to 2020.

Mustard should not be overlooked as an important ingredient to add flavour and functional benefits to gluten-free and free from products.

• G M-free: The GM issue cannot be dismissed when talking mustard – although the issue is not as pronounced as with maize crops. Some activist groups in India are fighting hard to keep GM mustard out – but at the same time largescale field trials of GM mustard in India are already taking place. •

CARIKE VAN DER MERWE is a product specialist at Savannah Fine Chemicals.

Savannah Fine Chemicals – www.savannah.co.za

April 2018 | Food Review

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HERBS & SPICES

Full conveyor and detection integration Key Technology’s specialised Iso-Flo vibratory conveyor is designed for integration with metal detectors to inspect bulk foods on processing and packaging distribution lines. Compared to traditional plastic or fabric belt conveyor systems integrated with metal detectors, Key’s vibratory solutions reduce maintenance, minimising product spillage. This dramatically improves sanitation and maximises food safety.

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he technology has been upgraded with the latest sanitary design features. The vibratory conveyor combines three conveyor bed sections – a stainless steel infeed, a non-metallic section that passes through the metal detector’s aperture and a final stainless steel section with a reject device. Key Technology’s (Key) designs accommodate the customer’s preferred metal detector and aperture size.

The infeed section can incorporate a screen capability to scalp or remove fine, small particles or water. Popular reject device options include a pneumatic gate within the shaker bed, which opens and closes. A slide chute is situated at the discharge of the shaker bed that switches direction if metal contamination is detected.

Stainless steel conveyor beds feature a standard rotary polish within the product

“Compared to a typical 2B mill finish, Key’s rotary polished finish reduces bacterial attachment and biofilm formation”

Iso-Flo vibratory conveyor

contact zone. There are also improve product containment. several optional finishes to Vibratory shakers offer satisfy the needs of each a lot of sanitation customer. Compared to and operational a typical 2B mill finish, advantages, especially A biofilm comprises any group Key’s rotary polished compared to belt of microorganisms in which cells stick to each other and also finish reduces conveyors for to a surface. These adherent cells bacterial attachment this application,’ become embedded within a slimy and biofilm explains Mark Roedl, extracellular matrix that is formation. Standard oilarea sales manager composed of extracellular free drives, elastomer at Key Technology. polymeric substances. isolators, scalloped flat ‘Iso-Flo is recognised bars, patented stainless around the world as a steel ground arms and minimal premium vibratory conveyor laminations maximise equipment for its superior sanitation hygiene. This helps meet rising sanitary and reliability. Incorporating this fieldstandards and regulatory requirements. proven technology with a metal detector is Unlike plastic or fabric belt conveyors perfect for many applications.’ with hidden surfaces that can trap bacteria, Iso-Flo conveyors use independent, Key’s vibratory solutions present sanitary frame-mounted drives and spring arm bed surfaces that are easy to clean. Units assemblies that distribute energy equally feature no belting material, drive or to all parts of the conveyor bed in a discharge pulleys, bearings, drive belts or controlled natural-frequency operation. sprockets. The equipment’s robust vibratory As vibratory motion is contained. The unit systems minimise maintenance, maximise creates no noise or interference that could uptime and reduce total cost of ownership. trigger the metal detector to a false reject.

‘Our vibratory conveyor for use with Conveyors are backed by Key’s industrya metal detector is a great solution leading five-year warranty. This ensures for processors that want to equipment reliability and limits elevate hygiene and the food processor’s total cost of ownership. Key manufactures its vibratory systems in the US and Europe and supports customers through a global sales and service network. It is supplied locally through Eptech. ‘Our company can provide a single piece of equipment or complete turnkey design, construction and installation of food processing plants,’ John Binedell of Eptech explains. ‘Our team works with the client to develop an in-country spare parts inventory system along with a scheduled maintenance programme. Whether you are upgrading an existing process or developing a new food processing line, Eptech can assist with its years of experience in the field.’ •

DID YOU KNOW?

Eptech – www.eptech.co.za

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Food Review | April 2018

HERBS & SPICES

Imagine a world

free of spice adulteration

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Food Review | April 2018

Complexity of detection during spice adulteration makes the condiments industry very vulnerable to fraud. This was the conclusion drawn from a client study and published in the Food Control journal and highlighted on Securing Industry’s website.

Research examined fraud vulnerabilities of eight companies in the spice supply chain using the SSAFE food fraud vulnerability tool.

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he programme comprises 50 indicators categorised according to opportunities, motivations and control measures to provide a fraud profile.

Spices are very vulnerable due to ease of adulteration; complexity of fraud detection; high competition level in the sector and perceived value of spices.

Food fraud scandals and issues in the last few years have reinforced the need to understand the vulnerability of food in supply chains.

Herbs and spices represent an attractive category for potential offenders, as products have a very high value by weight.

Conversely, consumers have limited capacity to detect adulteration. Ground spices are most prone as milling and grinding changes the shape of the spice and the adulterant to powder. This makes it difficult to detect in the final product.

HERBS & SPICES

TOP

FAKE SPICES

1. Ingredients used to plump up the volume of saffron threads include yellow threads covered in food colouring, threads impregnated with syrups, glycerin or oil.

2. Turmeric has been found to be mixed with food starches or chalk powder.

3. B lack pepper can be substituted with papaya seeds.

4. Oregano may be cut with non-authentic herbs.

5. Dung has been listed as coriander powder.

6. Bran or sawdust can be listed as general spices.

FIGHT

FOOD FRAUD

IN A NUTSHELL

adulterate is common or complex. Control Ground peanut shells were discovered measures are divided into soft and hard. in powdered cumin in 2014. This resulted Hard control measures are observable and in a major recall due to the allergenic can be tested. It also affects the ‘hard’ properties of peanuts. Economic motivation aspects of an organisation such was behind the adulteration, not as planning, control, tasks and accidental contamination. responsibilities. Soft controls SSAFE’s food fraud vulnerability are non-tangible behaviour assessment tool, used in research relies influential factors in an organisation. on the premise that three key elements This influences motives, loyalty, are required for food fraud to take place. integrity, inspiration, norms and values These are: of employees.

• a suitable target Researchers noted it is a government’s • a motivated offender responsibility to set clear legal • absence of control measures. requirements and the food industry’s The overall principle of the tool is reflected responsibility to mitigate food fraud risk. in the formula: opportunities x motivations They also noted, however, that there x control measures = actual is high vulnerability and a low level of fraud vulnerability. control measures in many An example of indices. These indicate fraud opportunity-related specific measures are fraud factors of raw lacking or are set at materials and final a very basic level, products include Food fraud is defined as particularly in smaller the ‘deliberate substitution, indicators such as sized companies. • addition, tampering or the complexity misrepresentation of food, food of adulterating Information has been ingredients or food packaging, or spices and whether sourced in part from www. false or misleading statements made about a product, for the technology to securingindustry.com

DID YOU KNOW?

economic gain.’

D U FRA THE EUROPEAN COMMISSION has launched an expert network to share information on food fraud and food quality issues. The Knowledge Centre for Food Fraud and Quality brings together specialists to support EU policymakers and national authorities by providing access to, and sharing up-to-date scientific knowledge in this area. Measures to fight food fraud have risen in the aftermath of the fipronil egg scandal.

Concerns about food fraud and food quality undermine consumer confidence and could damage the entire food supply chain, from farmers to retailers. The centre will coordinate market surveillance activities, operate early warning and information systems and serve as a link point for information sources at the commission and member states.

It will complement the existing EU Food Fraud Network by providing an interface between science and policy making.

Surveillance will also be conducted on the composition and sensory properties of food offered under the same packaging and branding on several markets across the EU. This will address concerns where food manufacturers may break the law by selling inferior versions of brands to consumers.

‘The Commission takes the issue of food quality and unjustified differentiation very seriously and has already taken concrete steps to tackle the issue,’ notes commissioner for justice, consumers and gender equality, Vêrá Jourov.

April 2018 | Food Review

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LOGISTICS & COLD CHAIN

Autonomous robots move with the times

Food and beverage manufacturers are increasingly asked to provide a wider variety of offerings, without suffering a decrease in productivity. Bruno Adam explains how smart mobile robots are adapting to meet future food factory requirements.

Traditional pick and place robots in a vegetable processing facility

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anufacturers are under immense pressure to increase productivity and sales, while keeping costs down. A normal reaction to this dilemma is to increase production. Pressure from consumers demanding a wider variety of products, flavours, sugar and gluten-free varieties or different portion sizes means increased production is not the simple solution it once was.

Conflicting pressures have forced food and beverage (F&B) manufacturers to adapt production lines to try to satisfy customer demands, without sacrificing productivity. Some are looking to install smaller, dedicated lines, while others ramp up production by adding new lines. In both cases, the amount of testing required increases. There is also an increased need to transport smaller amounts of produce around the factory. Additional complexity introduces several issues with current production lines.

An increase in the number of test samples creates an issue with identification and traceability. This requires a robust tracking system. The need to transport product around the factory is generally accomplished by hand, with efficiencies gained from automation eaten away by additional staffing costs. One alternative method of transporting goods is automated guided vehicles (AGVs). These mobile

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Food Review | April 2018

FAST FACT robots can carry a tote from the management software is FLEXIBILITY one set position to another. integrated into the production TO RELEASE They generally use physical management system (Omron’s manpower guides to navigate, such as Sysmac software) all pick-ups from repetitive magnets embedded in the floor and drop offs are automatically jobs to more or painted lines. The downside logged. AIV’s can also check it is productive to AGVs is that when they are picking up the correct package by employment, required to do a different task, interrogating the machine using while providing physical navigation guides WiFi or optical networking. This comprehensive, fully automated must be moved, which can comprehensive system ensures traceability halt production. information required for testing will be a real A solution is found in new is accurate and reliable, cutting game changer generation mobile robots. down errors and reducing the risk in fast paced Autonomous intelligent of an expensive quality failure. food production vehicles (AIVs), such as Omron’s AIVs offer a number of and supply LD platform, use sensors to different configurations, environments. create a static map of their giving them the flexibility to surroundings, so they have no accomplish a number of tasks need for physical guides. The only initial in the F&B manufacturing plant. They can requirement is to take the robot to different have a fixed top, either flat or a lock box positions on the factory floor and let it scan to carry totes. A downside is they must be its surroundings. From the map, AIVs can loaded and unloaded by hand. Other fully work out an optimal route between any two automated configurations include conveyors points. Sensors are used to detect moving and cart transporters, including Omron’s LD objects in the AIV’s path. Vertical sensors Cart Transporter range. • are incorporated to ensure the AIV avoids any obstacles, such as spillages on the plant floor or the overhang from forklift forks.

BRUNO ADAM is Omron’s AIVs can work in fleets of up to 100 mobile mobile projects director Europe. robots and the workload is controlled by fleet management software. This also Omron Industrial Automation – assists AIV’s navigation by reporting on busy www.industrial.omron.co.za routes or blockages on the factory floor. If

LOGISTICS & COLD CHAIN

PnP’s competitive edge A mobile enabled, completely integrated delivery management solution delivers business growth and increased market share to PnP.

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eveloped and implemented by Resolve, an Imperial Logistics company, the system provides the retailer with real-time visibility across the delivery landscape. It enables effective management and decision making to ensure on-time and in-full deliveries to all customers.

‘PnP decided to upgrade its online shopping system from a manual pickfrom-store model to a centralised online delivery offering with regional warehouses for online orders,’ chief strategy officer Cobus Rossouw explains.

‘This new process requires an integrated delivery management solution that can utilise a range of different technologies to provide real-time visibility across the delivery landscape.’

PnP’s online shopping division needed to effectively manage, track and monitor the movement of deliveries between warehouses, hubs and customer delivery locations. It wanted a solution with the capability to send notifications to customers prior to delivery; to offer electronic proof of delivery (ePOD) functionality; allow capturing of delivery details; customer satisfaction surveys and visibility on reverse logistics of bins returned to the warehouse.

Technology that gives retailers the inside scoop

This was a collaborative process.

After establishing the One-Link Delivery Management Solution would be a close fit for the job, detailed functional and technical specifications were constructed to meet PnP’s requirements. The solution focuses on internal visibility and provides management visibility on drivers, vehicles and assets. A mobile application gives users access to numerous functions, including pre-trip vehicle inspections (with photographs of assets); electronic tripsheet information; routing and tracking information; incident reports; electronic proof of delivery (ePOD and status updates on delivery. It boasts a user-friendly interface and offers rugged tablets for use by delivery personnel, warehouse and hub managers.

The new technology introduced into the process such as RFID tags used for bulk loading, bin level tracking and mobile tablets minimise unnecessary manual processes that negatively impact process time and data accuracy. An increase in OTIF deliveries has been achieved, while redeliveries and returns are reduced. This results in time and cost savings. There is less shrinkage of items and equipment due to improved tracking and visibility. •

Imperial Logistics – www.imperial.co.za

Stand a chance to win a car at SAPICS

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o mark four decades of bringing supply chain professionals together to network and share knowledge in supply chain management, SAPICS says its 40th annual conference in June will be a milestone event. In addition to an exceptional line up of dynamic presenters, the leading supply chain association has announced that delegates will stand a chance to win a car.

‘In honour of the conference’s anniversary, and to celebrate 40 years of promoting supply chain excellence and professionalism, long-time supporter of SAPICS and conference Gold Sponsor Imperial Logistics is generously offering 2018 delegates the opportunity to enter a competition to win a Renault Kwid,’ says SAPICS president Mungo Park.

‘This year’s conference will be packed with inspiring ideas, networking opportunities and world class presentations,’ he states.

‘The 2017 event attracted 850 delegates and we are aiming to grow this number in 2018. This year’s exhibition will feature more than 30 exhibitors showcasing the industry’s latest products and technologies.

The eminent and sought-after local and international speakers that SAPICS has lined up for 2018 include business leaders, entrepreneurs, authors, technology and logistics specialists, to name a few. They will share success stories from Africa and around the world, as well as lessons learnt, best practice and cutting-edge technologies and trends,’ Park expands. •

April 2018 | Food Review

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LOGISTICS & COLD CHAIN

Keeping it cool in the supply chain Food Review spoke to Friedel Spies, business development director South Africa for ID Logistics on key challenges of handling and transporting fresh supply chain products.

Q: ID LOGISTICS IS THE NUMBER TWO LEADER IN PERISHABLE DISTRIBUTION IN SA AND A LEADER IN CONTRACT LOGISTICS IN OVERSEAS MARKETS. WHAT IS THE IMPORTANCE OF THE PROPER MANAGEMENT OF PERISHABLES IN THE SUPPLY CHAIN? A: The perishables supply chain and convenience products market is set to grow in the coming years. The challenge of moving fresh products onto shelves is going to become even more challenging. Smart and lean cold chain logistics have to leverage state-of-theart technologies, equipment and monitoring systems, which are key to prolonging the life of fresh goods, which can spend 50 per cent of time in transit before reaching the shelf.

As a contract logistics specialist in fresh products, the most important thing is to keep investing in innovative systems and technologies. This strategy drives solutions to improve efficiencies and redundancy and optimise our network.

Friedel Spie Three critical factors underpin s the cold supply chain: quality; time and distance. IDL South Africa completed 75 cost saving initiatives to enhance its network during 2017 and implemented global quality standard certification at all five local sites.

Our investment in cooling and refrigation systems and centralised monitoring is critical, as risk associated with non-compliance is high. These systems require ongoing maintenance and upgrading to ensure the whole supply chain remains competitive and efficient.

Maintaining product quality and freshness prevents spoilage and shrinkage. It also gives peace-of-mind to retailers or producers who wants to avoid being involved in a health scare as a result of inferior supply chain management.

Cold chain logistics operations are more expensive to maintain because of the capital investment needed for temperature-controlled storage and transportation.

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Food Review | April 2018

LOGISTICS & COLD CHAIN

Fresh supply chain products are pricier to transport than ambient goods, so it’s critical to achieve first time execution.

Another important aspect of the cold supply chain is proper training of human capital in this sensitive area of logistics. This includes personnel in offices, warehouses, distribution centres and vehicles to retail stores.

This plays an even more critical role in sea, air and long distance transportation of fresh products.

Q: WHAT ARE THE KEY CHALLENGES OF TRANSPORTING FRESH PRODUCTS? A: The complexity of perishable products, which include varying short shelf life of the various product categories. This includes the handling of different product types on distribution vehicles without compromising quality. The main criteria from a retail perspective is on-time delivery and increased frequency of deliveries to stores e.g. three times per week to specific outlets.

IDL FR 177x130mm option2.indd 1

As most of our customers receive delivery within 24 hours of order, the adherence to all cut-offs is critical.

Logistics is not a perfect science and is impacted by all sorts of diversions.

Ongoing communication in the advent of operational disruption is key to the efficient management of fresh products to avoid delivery failure.

With fresh products, there is not enough time to return products to source. Products can quickly become non-saleable items due to short shelf life. This is even more important in out-of-town deliveries. The result of failure results in loss of revenue and reputation for all parties in the supply chain – supplier, distributor, retailer, logistics partner and the end user.

One of the challenges for medium and smaller customers is how to manage their route to market with perishable products. With our national network and temperature management capabilities and economies of scale, we assist regional customers grow their fresh distribution operation to become national suppliers, or alternatively, access new customer bases.

Q: WHAT ARE THE MEASURES THAT NEED TO BE TAKEN TO PREVENT FAILURE? A: We have to ensure our network is robust and reliable and our warehouses and vehicles have quality temperature control management systems in place. Equally important is the correct alignment with our customer in terms of order-to-delivery lead times, cut-off times, accurate documentation and robust real-time traceability systems.

What adds complexity is that not all customers carry inventory at their current locations. Products are often crossdocked to hubs or warehouses for onward distribution to end customers.

We need to manage temperature compliance inbound and outbound and conduct and document inspections at various stages. It’s critical to ensure we maintain an unbroken cold chain to achieve freshness and quality of goods. •

ID Logistics – www.id-logistics.com/za

4/6/18 10:37 PM

April 2018 | Food Review

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P U M P S & VA LV E S

New generation liquid ring vacuum pumps

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range of single stage, variport liquid ring vacuum pumps is ushering in a fresh era in design performance and reliability.

TRVX Pompetravaini’s technology offers tangible benefits for food and beverage manufacturers. The new hydraulic profile allows performance increases of more than 10 per cent over traditional liquid ring designs. Increases in efficiency and operational cost savings can now be achieved over the entire pump life.

ADVANTAGES WHEN COMPARED TO TRADITIONAL LIQUID RING VACUUM PUMPS: • Pump weight is 30 per cent less on average compared to traditional designs • Units are compact and dimension and volume is 40 per cent less than traditional designs • Features single and direct service liquid connections • Up to 50 per cent less service liquid usage reduction

• Central body impeller housing with integrated suction and discharge manifolds. This feature reduces pump components and increases robustness • Suction, discharge port plates and impeller in stainless steel allows greater reliability.

• Standard ISO 3069/DIN 24960 mechanical seals are easily obtainable. This reduces component stocking • Mechanical seals can be replaced without disassembly of the pump reducing downtime • Features external precision regulation of the impeller shaft, resulting in easy maintenance, performance optimisation, assembly time and cost • Length between bearing supports is 25 per cent less than traditional

®

pump designs. This results in a reduction of eventual vibration and shaft deflection • Connections are universally flanged to meet both DIN-EN and ANSI standards.

The TRVX is a true leader in its own class with capacities up to 2 000m³/h with a maximum vacuum of 33mbar abs. •

Air & Vacuum Technologies – www.vactech.co.za TRVX Pomperavaini’s liquid ring vacuum pump

NEW INOXPA HCP – EHEDG & 3A HYGIENIC CENTRIFUGAL PUMPS Prolac HCP Prolac CIP-R

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HYDRAULIC DESIGN

• Extensive use of advanced CFD tools • Higher efficiency • Lower NPSH requirements • Low noise levels

HYGIENIC DESIGN

• EHEDG and 3A • Hygienic mechanical seal • Double mechanical seal • Ra 0.8 µm std, Ra 0,5 µm optional

• Compact design • Bi-directional balanced • Fluid pressurized (barrier) or without pressure (buffer) • 2 identical mechanical seals

INOXPA SOUTH AFRICA

GAUTENG - SOUTH AFRICA Tel. +27 (0)11 794-5223 - sales@inoxpa.com www.inoxpa.com

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Food Review | April 2018

2018/04/16 7:43 AM

P U M P S & VA LV E S

Sanitary guarantees ensure quality

Inoxpa’s range of pumps have received 3-A certification

INOXPA specialises in manufacturing equipment for the food and pharmaceutical industries. The company has obtained 3-A certification for its Prolac HCP and SLR pumps. This certificate guarantees that food and pharmaceutical equipment complies with the highest global quality and hygiene standards.

3

-A Sanitary Standard Inc is a US organisation that evaluates machine and equipment design for use in the dairy, food and beverages industry. The certification is a renowned hygiene standard that ensures high safety and hygiene levels. INOXPA’s Prolac HCP centrifugal pump and SLR rotary lobe pump ranges includes the 3-A quality symbol, or in INOXPA’s case, the standard 02-11.

It is worth noting that the pumps achieved 3-A certification for their standard version, with few changes made. This means buyers obtain a significant price benefit as no additional costs are required. Units feature quick and simple pump handling. This enables simplified cleaning and inspection processes.

INOXPA underwent a thorough certification process at its facilities to obtain the 3-A certificate and testing compliance with established 3-A Sanitary Standards requirements. This independent inspection, called Third Party Verification, ensures independent authorisation and protects the integrity of the symbol. It also indicates high-quality levels behind the seal.

The award includes a unique authorisation number: Code 3563. It is a publicly available guarantee for online verification of the authorisation granted to INOXPA to use and display products with the 3-A quality symbol.

SLR - A SAFE HYGIENIC ROTARY LOBE PUMP The 3-A certificate adds to the SLR pump’s existing certifications. The SLR lobe rotor pump complies with FDA, EC 1935/2004. An ATEX version is also available.

This pump is one of the INOXPA rotary lobe pump range, along with the HLR rotary lobe pump (EHEDG certified), the SLRT rotary lobe pump (for use on trucks), and the TLS rotary lobe pump (compact close-coupled design).

The HCP and SLR pumps are ideal for facilities requiring a high level of hygiene and high performance due to their designs, materials and certificates. •

Inoxpa – www.inoxpa.com

PUMP RANGE FEATURES HYGIENIC DESIGN AND SUPERIOR EFFICIENCY Known for its hygienic design the Prolac HCP centrifugal pump range features EHEDG certification. This ensures comprehensive pump cleaning using CIP, without requiring disassembly. It complies with the FDA, EC 1935/2004. An ATEX version is also available.

The range is very extensive. There are twelve models, meaning the closest best efficiency point or BEP model is easy to achieve. Notable aspects include: • Compact construction • Reduced NPSH • High performance (up to 74 per cent depending on the model) • Two mechanical seal diameters for the entire range • T he double seal consists of two single seals, which results in lower stock keeping of spare parts.

Drawing on their extensive pharmaceutical sector experience, INOXPA designed a Prolac HCP pump with options customers require most i.e. Ra<0.5, USP Class VI and materials certification. This resulted in the development of the Prolac HCP-WFI pump. Specifically conceived for pumping purified water and water for injections, it adapts to high market standards.

Flotronic Pumps Limited are the inventors & manufacturers of the famous ONE-NUT-PUMP range of pumps. Ideal for pumping a wide range of liquids.

Vactech.indd 1

info@vactech.co.za

0861 VACTEC (822 832)

www.vactech.co.za

April 2018 | Food Review

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2018/04/10 12:36 PM

P U M P S & VA LV E S

Taking single to a

NEW PERFORMANCE LEVEL

V

ac-Cent Services has introduced the Vectra Series of liquid ring pumps and compressors. Supplied locally through GD Nash, the units employ advanced design technologies and ingenuity to achieve optimum performance and unprecedented production efficiencies.

Reliability, efficiency and flexibility, coupled with the comprehensive Vac-Cent Services expertise, service and technical support, provides clients with unmatched value in liquid ring pumps and compressors.

Maintenance of the units is extremely simple.

Vectra XL ranges from the XL 35- XL 950.

Units are available in cast iron construction as well as 316 stainless steel construction. Stuffing box sealing arrangements on Vectra units are normally gland packed, but also available with single or double mechanical seals. It is specifically designed for the higher pressures and performance found in many process applications, including vapour recovery, flare gas recovery, corrosive gas recovery (e.g. VCM and chlorine) and hydrogen compression.

BENEFITS INCLUDE: • Single, conical port design • Fully supported rotor/shaft assembly • Single pressure boundary sealing point • Bolted head/body joint • API-681 compliance • 316 stainless steel construction • Longer bearing life • Horizontal, self-draining inlet/ discharge nozzles. •

Vac-Cent – www.vaccent.co.za Vectra is a single cone liquid ring vacuum pump which makes maintenance extremely simple

FEATURES OF THE VECTRA RANGE: • Reliable – low operating speeds, lobe purges and one moving part •L ow maintenance costs – external mechanical seals and bearings • Efficient – variable conical port design, Nash patented gas scavenging

• Compact design and single point connections – requires less floor space and no manifolds, reducing installation costs •M aterial flexibility – available in ductile iron or stainless steel.

VAC-CENT SERVICES (PTY) LTD

AUTOMATIC FLOW CONTROL VALVES

GARDNER DENVER NASH XL RANGE VACUUM PUMP PACKAGE

Head Office (T) +27 11 827 1536 Email: info@vaccent.co.za

Vaccent.indd 1

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Food Review | April 2018

www.vaccent.co.za

Durban Office (T) +27 31 572 4495 Email: nelson@vaccent.co.za

2018/04/18 8:10 AM

BeverageREVIEW April 2018 | Volume 8 | Number 04

SOUTH AFRICAN

www.foodreview.co.za

Listeria:

dairy industry fights back

Solutions for processing sensitive products

Probiotics - the must-have ingredient for 2018

NEWS

Perfect for highly flexible production SIDEL HAS INTRODUCED the versatile Aseptic Combi Predis, a new solution that can produce still beverages and carbonated soft drinks in PET bottles aseptically.

This results in a high degree of production flexibility and productivity while contributing to reduced costs and lowering the environmental impact.

This solution can produce a wide variety of products efficiently, with increased flexibility, reliability and product integrity. ‘By reducing total cost of ownership and enhancing end-product quality, the Aseptic Combi Predis helps ensure that the beverage business remains sustainable,’ explains Guillaume Rolland, sensitive products vice president at Sidel. ‘This version

benefits from all the practical advantages of the proven Sidel Aseptic Combi Predis platform. This platform has received Food and Drug Administration approval and is validated for low acid manufacturing and commercial distribution in the market.’

Suitable for high and low-acid sensitive beverages (teas, juices, UHT white milk, soya milk), in PET bottle formats from 200ml to two litres, the solution strengthens the aseptic production flexibility to handle both still and carbonated soft drinks (CSD), with or without pulps, and with more natural and preservative-free recipes. The modular design allows the needs of current beverage producers to be met and opens doors for the introduction

of any new products to easily and quickly adapt to market trends which are becoming less predictable.

The same filling valve handles aseptically all types of sensitive beverages with no need of changeovers. The filling configuration can be adapted to the main production performance factors required by the beverage producers with two different filling valve variants.

The Aseptic Combi Predis can be equipped with the new Capdis™ Multilanes, the dry cap sterilisation system that can handle multiple cap designs (flat and sport caps) and diameters (from 28 to 38mm) with no need for manual changeover, to enlarge capability and to manage a wide range of stock keeping units.

Nederburg in the lead of

most admired wine brands THE PAARL WINERY features in the esteemed World’s Most Admired Wine Brands top 50 list by Drinks International, a UK-based publication, for a third consecutive year. In 41st position, Nederburg is the highest placed of the three South African wineries featured on this year’s list.

The judging panel comprises a broad spectrum of global wine professionals, including commercial buyers,

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Beverage Review | April 2018

importers, wine professionals, masters of wine, journalists and wine educators.

To make it into the international lineup of the top 50 wine brands demands consistent or improving quality; a reflection of region or country of origin; a responsiveness to the needs and tastes of target audiences; excellent marketing and packaging and strong appeal to a wide demographic.

This achievement puts Nederburg in the company of several of the world’s famous names in wine, including Spain’s Torres, Chile’s Concha Y Toro, the USA’s Robert Mondavi, Argentina’s Trapiche, Australia’s Penfolds, Italy’s Antinori, and French icons Chateau Margaux, Chateau Lafite, Chateau D’Yquem and Chateau Latour.

‘Nederburg is built on a rich history and tradition of winemaking excellence spanning more than 200 years. It is driven by zeal, innovation and sense of ongoing discovery,’ says Robyn Bradshaw, global marketing spokesperson for the brand. ‘Being highlighted in this prestigious international list

of top global wine brands for a third time in a row is a great privilege and honour. Such high-level affirmation for Nederburg is a huge boost as we build the brand’s global presence and profile to retain its relevance, appeal and popularity amongst a wide spectrum of wine consumers.

‘We’ve taken Nederburg to the next level with a refreshing new global communications campaign and newlook packaging, intended to reach and better relate to new wine consumers worldwide, while strengthening ties with existing brand supporters. We are especially proud of our viticulture and winemaking teams, who work tirelessly to satisfy a worldwide demand for Nederburg’s delicious wines. They are all united in their passion, patience and precision to maintain Nederburg’s name as the byword in South African wine excellence. New wine growing areas are being explored, new vines are being planted, exciting new blends are being trialed, new wood regimes are being pursued and techniques adapted.’

DA I RY D R I N K S

Dairy leads the way with

listeria environmental monitoring The last few months have been dominated by discussions around Listeria monocytogenes.

For food safety news to have been on the front pages of every major South African newspaper is unprecedented.

Although the Department of Health has named the so-called source, this should not mean we can take our eye off the ball, writes Linda Jackson.

I

t is the right time to ensure robust preventive programmes are in place so that this scale of outbreak never takes place again. In addition to reviewing cleaning and sanitation schedules, reevaluating personal hygiene regimes and maintenance activities you should also be implementing a listeria environmental monitoring programme (LEMP).

SOUTH AFRICAN GUIDELINES

this easy-to-use guide underlines the importance of many building blocks of your food safety management system.

Specific touch points are stressed that, if overlooked, can lead to problems with Listeria monocytogenes in your facility.

These controls, if properly implemented, will ensure control of all pathogens.

That is the point of your food safety management system.

There has been much talk in the press about lack of regulation in relation to listeria. Although levels of regulation may be the subject of debate, the principles of control have been covered in national 1. E NSURING RAW AND PASTEURISED standards on hygiene. They are even PRODUCTS ARE included in the compulsory EFFECTIVELY SEPARATED specification for frozen Listeria monocytogenes has seafood products. been associated with Taking a stand raw milk. The CCP against Listeria of pasteurisation, if There are several listeria global monocytogenes, the properly validated guideline sources, published by Dairy Standard and controlled regulatory services, to assist the Agency published a should eliminate industry: https://www.fsis.usda. bespoke guideline gov; http://www.foodsafety. the hazard. Post govt.nz; https://www.fda. to assist the South pasteurisation gov; http://ucfoodsafety.

African dairy sector. recontamination is ucdavis.edu Although this guidance the concern and should is focused on practices be the focus in ensuring in the dairy industry, its adequate and effective application is universal. separation of activities, Drawing inspiration from US dairy personnel, and equipment. The same industry guidance and with the input principles would apply to any process of esteemed South African academics, where raw and heat-treated products are

DID YOU KNOW?

handled. Post treatment recontamination must be avoided at all costs.

2. C ONTROLLING THE ENVIRONMENTAL CONDITIONS AND PRACTICES (GMPs) Although personnel hygiene is such a basic requirement, controlling people is anything but basic in application.

Providing the right protective clothing, handwash basins and boot washing facilities is the easiest part. Ensuring effective adherence to protocols is the challenge. Given the current food safety crisis we are facing, it is likely all your employees will have some knowledge of listeria. It is a good time to cement this knowledge with more training on how it is spread in your facility; and the importance of handwashing and control of footwear. It is also time to bolster supervision activities. Paying for an extra supervisor to ensure the correct behaviours will be a small price to pay in relation to the damage of a product recall.

3. E FFECTIVE EQUIPMENT DESIGN AND MAINTENANCE Controlling the environment in a dairy can be very challenging. Steam, water and condensation can wreak havoc with floors April 2018 | Beverage Review

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DA I RY D R I N K S

FAST FACT

has played a huge role in this listeriosis outbreak. If you haven’t YOU CAN DOWNLOAD The been sampling your Dairy Standards Agency environment before, Guideline for Listeria Control at: http://www. you should be doing dairystandard.co.za/ so now. Using a riskimages/stories/guidelines/ based approach, a Guideline_Control-of-Listeriarobust sampling plan monocytogenes-260218.pdf should be set up to identify Listeria spp. in the environment.

Listeria spp. are a broad indicator group, and when detected they provide you with a signal that conditions are also favourable for the growth and survival of L. monocytogenes growth. The goal of a LEMP is to aggressively look for, find, and eradicate all Listeria spp. from the processing environment, ensuring the absence of L. monocytogenes. The number of samples, sampling sites, and recommended actions to take for positive results are defined. • and ceilings, creating ideal growth niches for Listeria spp. A zero-tolerance approach is essential to ensure harbouring does not take place. Given the persistent nature of Listeria monocytogenes and its ability to form biofilms, design and construction of equipment is critical to ensure proper cleaning takes place. Maintenance staff will need to be trained on the pathogen; how to recognise possible growth sites and the right way to eliminate these from a design and maintenance perspective .

4. C LEANING AND SANITISING PROGRAMMES The DSA Listeria guide indicates that a well designed, effective cleaning and sanitising programme is an essential element of the full pathogen control equation. Enhanced cleaning procedures are proven to compensate for weaknesses in facility or equipment

design until improvements can be implemented. Both routine and nonroutine cleaning regimens are essential to remove bacteria and prevent bacteria from potentially becoming persistent.

Your master cleaning schedule is in place, but is it working? Don’t assume anything. All elements of your cleaning programme should be interrogated, including the following: • w hat chemicals are used • at what concentrations • contact time applied • temperature of CIP cycles • cleaning methods • e ffectiveness of post cleaning inspections.

Food Focus – www.foodfocus.co.za

5. E NVIRONMENTAL PATHOGEN MONITORING Once all the above is in place, environmental monitoring starts to make sense. Environmental sampling

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䠀愀氀愀愀氀 愀渀搀 䬀漀猀栀攀爀 愀瀀瀀爀漀瘀攀搀

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Beverage Review | April 2018

DA I RY D R I N K S

Ideal solutions

for sensitive products

The Innosept Asbofill ABF machine supplied through KHS supplies a tried and tested linear filling system for hygienic filling in the medium capacity range.

Three new developments make this proven plant engineering more powerful than before.

KHS’s new development offers operators greater microbiological safety and flexibility

INNOVATIVE STEPS 1. New transfer module enables it to be blocked with a standard KHS stretch blow moulder.

2. Modular system permits various modules to be retrofitted or replaced at a later stage.

F

eaturing enormous flexibility, the Innosept Asbofill ABF is up to the minute and features large product varieties and increasingly smaller batch sizes. This means the number of product changeovers is getting bigger. The great diversity of beverages and different container sizes call for systems that can quickly and easily adapt to demands of beverage producers.

A new transfer module forges a basic link between the rotatory stretch blow moulder and the linear filler. The continuous rotational motion of the stretch blow moulder had to be converted into the linear, step-by-step cyclic movement of the filler. With this specific challenge mastered, the innovative block system now rounds off the KHS portfolio for sensitive products.

ENORMOUS FLEXIBILITY The module can be varied according to the bottler’s requirements and product range. The base machine with its respective sterilisation, drying, filling and capping modules can be easily and cost-effectively retrofitted with further units. Feasible options include a second filling module to boost capacity when running larger container volumes or an extra capping module for foil seals. A dosing module can also be installed as an addition or alternative to the classic filling system. The system’s great flexibility permits fast format changeovers within the space of just five to ten minutes or product

changeovers in only 30 minutes. The system is qualified to process a multitude of different products, regardless of consistency, bottle geometry, container volume and type of cap.

“Innovation at its best: blocking the energy efficient rotary blow moulder with the reliable and flexible linear aseptic filler enabling KHS’s customer to profit from both market leading technologies” TRENDS FOR CHUNKS Product ranges are seeing trends towards larger chunks – not just in food but also in beverages and milk products. Depending on the size of the fibres or chunks, various filling systems are needed. Juice producers usually fill their entire portfolio using a pulp nozzle. The equipment can process fibre and particle content of about 10 per cent, fibre lengths of 15mml and chunks with crushable particles measure 2 x 2 x 2mml. Dairies mostly use a standard nozzle. This permits product viscosity up to 1 000 millipascal seconds - equivalent to the consistency of a drinkable yoghurt.

The new chunk filler is the right option for all thicker products with a viscosity of up to 3 000 millipascal seconds i.e. set yoghurt, quark, syrup, honey and chunky

3. First chunk filler for the aseptic area from KHS can fill bigger particles.

This gives users maximum flexibility when designing their products.

products. Dosing units can manage particles with a length of up to ten millimetres: this includes chunks of peach, whole cherries and strawberries. The only limits for chunk size is bottle neck diameter.

Innosept Asbofill ABF provides two basic means of adding solid particles to a liquid.

Either a fully mixed product is filled. In this case, the chunk filler is used in place of the normal IFM- based filling systems. Chunks can be added upstream, as is the case with milk products. If a fruit mix must be shaken up from the base of the bottle before drinking the chunk filler must be integrated before the standard filling system.

MINIMUM ASEPTIC ZONE The system scores with the same hygienic safety naturally found throughout the KHS aseptic portfolio. Due to unique neck handling, which gives users maximum freedom of design regarding the bottle shape, the dimensions of the aseptic zone can be kept to an absolute minimum. Even in the variant with the highest capacity this only takes up 1.5m3 of space. The linear platform is arguably superior to larger rotary systems, especially for smaller batches in a capacity range of up to 12 000 bottles per hour. This superiority is further underlined if we look at the system’s flexibility: format changeovers are quick and simple as only a single drawer must be replaced, leaving the aseptic zone untouched. •

KHS – www.khs.com

April 2018 | Beverage Review

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DA I RY D R I N K S

Systems to boost dairy production Schneider Electric’s food and beverage solutions increase efficiency and sustainability. They allow users to seize new market and profit opportunities, thanks to zero waste and 100 per cent traceable production.

T

his is achieved through implementation of EcoStruxure Hybrid DCS (formerly known as PlantStruxure PES). The systems assist customers to manage dairy processes in an easy, smart and energyefficient way. The new platform improves production monitoring and control systems, while making provision for future expansion.

Current dairy markets are dynamic and competitive, and reflect demand for safe and nutritious products. Innovation and flexibility are critical when growth hinges on the ability to meet consumer requirements, while striving for zero waste.

Woodlands Dairy is one of the largest dairy food and beverage manufacturers in South Africa. The plant recently invested in a second-hand powder plant from Denmark. With an outdated control system, the unit was not suitable for modifications required to adapt the process to the company’s specifications.

Top of the agenda was the installation of a single platform that could integrate all disparate plants on site. It had to preserve expensive assets and legacy systems, while making provision for future expansion.

The ArchestrA System Platform was selected. The system consists of an Application Server, InTouch HMI, Historian and Historian Clients’ trending and reporting tool.

The technology offers the following: • Universal data connectivity to cope with Woodlands Dairy’s variety of PLCs • Object orientated technology that is maintainable and promotes standardisation • Ease of reports and retrieving historical data • Full redundancy • Scalability • E xcellent support available in South Africa.

Total implementation took about six months.

Half was spent on a new powder plant commissioned first. While the powder plant was a Greenfields project, the processing plant upgrade and expansion was done live during weekly shutdowns. Standards developed for the powder plant were rolled out for these projects.

Other process areas were also upgraded.

These included a new clean in place (CIP)

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Beverage Review | April 2018

SCHNEIDER ELECTRIC COMBINES THE STRENGTH OF THE FOLLOWING COMPANIES: • Wonderware is a leader in manufacturing software for the food and beverage industry • Pack drive is a specialist in packaging automation • Modicon is the inventor of PLC - a global delivery capacity and a strong partner ecosystem.

station; cream pasteuriser/butter plant; upgrade to the milk pasteuriser; pasteurised milk silo and milk lines; and pasteurised cream silo and milk reception area with its own CIP station.

SOLUTIONS FOR DAIRY The dairy industry is facing an increasingly competitive environment. Companies are starting to improve sustainability programmes. Quick results, with acceptable return on investment, requires strong methodology.

ENERGY PERFORMANCE Schneider Electric’s solution delivers and sustains top and bottom line improvement. It addresses sustainability, energy purchasing strategies and utilities usage in a production context. It improves environmental sustainability of operations and reduces

energy bills per production unit by up to 30 per cent.

MANUFACTURING EFFICIENCY Product safety and quality during production processes are critical. Regulated milk prices require minimised production costs, including reduction of waste. Operations must be agile enough to respond to changing consumer demands. Comprehensive automation solutions, encompass steps from device to ERP integration, from process and machine to power management, from small site to multisite management. It strives for zero waste while increasing flexibility on the plant floor.

SMART POWER MANAGEMENT Dairy is a rapidly changing environment.

Plants are continually modified to add processing lines or increase capacity. In this context, with limited local resources, maintaining power availability and safety is a central challenge. Improved safety, availability and power flexibility during the whole plant lifecycle, keeps power safe, available and green.

OPTIMISED SUPPLY CHAIN Complexity of supply chain networks and tremendous volatility of raw material prices are forcing producers to look for ways to improve operational and strategic decisions for better performance and profitability.

Cloud-based software solutions collect and manage information about the entire supply chain, to help the decision-making process and performance improvement. It provides full visibility to the value chain, to increase end-to-end throughput and reduce logistic costs. •

Schneider Electric – www.schneider-electric.co.za

DA I RY D R I N K S

Probiotics

tops nutraceutical agenda Digestive health is the number one priority for consumers. Experts attribute these findings to growing awareness on the importance of healthy gut microbiota and the potential of probiotics.

O

rganisers of Vitafoods Europe asked 220 nutraceutical industry professionals to choose the three most important health benefit areas for their companies. Nearly a quarter (23 per cent) named digestive health, with the same number identifying general wellbeing and healthy ageing. Another 22 per cent named cardiovascular health, while 21 per cent said immunity was a key area.

This is the third time the Vitafoods Europe poll has been conducted, but it’s the first time digestive health has been a top concern for the industry.

DRIVE THE PROBIOTIC BOOM Importance placed on digestive health reflects the current boom in the global probiotic industry - expected to reach a value of €53 billion by 2023. In the US, the number of products promoting probiotic content grew from below 100 in 2002 to nearly 1 800 in 2016.

‘Rapid growth of the global probiotics market is due to increased interest in functional food and rising incidence of digestive and gastrointestinal disorders,’ explains Rosanna Pecere, executive director of the International Probiotics Association Europe. ‘Consumers are becoming aware that a balanced microbiota is essential for the normal functioning of the body. They’re looking for ways to ensure the correct balance is maintained.’

‘Growth in the functional food and beverage market is driven by consumer interest in healthy living,’ says Dr. Yiannis Kourkoutas of the department of molecular biology and genetics at Democritus University of Thrace, who will be discussing the potential of probiotics at Vitafoods Europe 2018. ‘This is particularly true among younger demographics, but population ageing has also been conducive to sector expansion.’

The importance of the microbiome, and the potential of probiotics, are

MICROBIOME VENTURE ANNOUNCES STRATEGIC PARTNERSHIP THREE MONTHS AFTER its formation, the DuPont Nutrition & Health Microbiome Venture announced its second strategic research and development partnership. The newly forged relationship with the Center of Food and Fermentation Technologies (TFTAK) in Tallinn, Estonia, will focus on developing cultivation and bioprocess capabilities for next-generation probiotics.

The term next generation, as defined in this partnership, refers to commensal microbes naturally resident in the gastrointestinal tract and demonstrated to be associated with health and wellness. Such microbes typically have fastidious growth requirements, which must be mastered in order to be able to produce them at scale.

The Microbiome Venture is a focused entrepreneurial team with a strong connection to the larger DuPont organisation, tapping into capabilities including research and development, manufacturing, regulatory, legal and marketing. The investment will complement DuPont’s existing product portfolio, especially in the areas of probiotics and prebiotics, including human milk oligosaccharides.

supported by increasing scientific evidence.

Dr. Kourkoutas explains, ‘Thanks to largescale research efforts, we know the composition of gut microbiota is associated with a growing number of diseases. There is a large body of evidence supporting the concept that the maintenance of healthy gut microbiota provides protection against a range of problems – not just local gastro-intestinal disorders, but neurological, respiratory, cardiovascular and even mental illnesses.’

He adds, ‘The role of probiotics is unique in the development of healthy digestive function. Daily intake of dietary products fortified with probiotic cultures may stimulate the growth of preferred microorganisms, crowd out harmful bacteria, and reinforce the body’s natural defence mechanisms. Probiotics can be exploited to manipulate the gut microbiota with beneficial effects for health, including reduced symptoms of lactose intolerance and lower risk of certain cancers.’

EXPLORE PROBIOTIC OPPORTUNITIES This year’s Vitafoods Europe will be held from 15 to 17 May 2018 in Geneva, Switzerland and focus on digestive health.

In the Education Programme the Probiotics R&D Forum, sponsored by DuPont Health & Nutrition, will explore challenges such as ways to incorporate beneficial bacteria into a food matrix.

Vitafoods Europe Probiotics Resource Centre, in association with the International Probiotics Association (IPA), will include new product showcases, a guide including a probiotics discovery trail, a presentation theatre, digital iPad presentations and infographics showcasing the latest market statistics.

For a detailed report on the future of the digestive health market, visit Vitafoods Insights, the new online resource offering the best content from Vitafoods events: http://www.vitafoodsinsights.com/digitalissues/2017/12/vfi-digestive-health.aspx •

April 2018 | Beverage Review

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DA I RY D R I N K S

Calcium enriched dairy S

and alternative drinks

witzerland-based company, Omya has established itself as a leading global supplier of natural calcium carbonate.

Using latest technology, raw materials are processed to specific particle sizes and functionalities, meeting a wide variety of innovative applications and demands.

Dairy and dairy-alternative drinks typically contain carbohydrates, proteins, fats and selected vitamins and minerals. Most sought after is calcium. As the principal component of bones, calcium is the most abundant mineral making up the human body, yet our bodies are unable to produce it. This makes regular dietary intake essential. Calcium fortification is a mainstream trend. It allows consumers ease and assurance in achieving recommended daily intake levels, while meeting individual dietary requirements in terms of nutrition, allergies, intolerances and taste.

With one of the highest calcium contents documented among all calcium salts, Omya Calcipur is the solution of choice,

Official distributor in RSA

when it comes to calcium enrichment. With 40 per cent available elemental calcium, it only takes a one-quarter gramme of Calcipur to provide 100mg of elemental calcium. This equates to 10 per cent of an adult’s daily requirement. Up to five times less Calcipur is required to meet the same calcium content and any possible nutritional claim, than other available solutions on the market.

When formulating dairy or dairyalternative drinks (based on soy, rice, oat, coconut or almond) sedimentation occurs over time. The right particle size is critical to ensure stability and that sedimentation rates are as low as possible. Omya Calcipur 90 – KP shows a slower sedimentation rate than standard calcium carbonate grades and smaller tri calcium phosphate particles. It results in overall less sedimentation due to excellent compatibility within a wide range of commonly used stabilising systems e.g. cellulose gum, Xanthan gum, Carrageenan and colloidal microcrystalline cellulose.

The nett effect of enriching dairy and

dairy alternative formulations with high purity, tailored Calcipur calcium carbonate is achieving exceptional opacity and whiteness, while providing a pleasant mouthfeel.

Omya is represented in South Africa by CJP Chemicals. •

CJP Chemicals – www.cjp.co.za

Omya Consumer Goods omya.com

Make your drinks come true!

Omya Calcipur® at 0.5% concentration in milk alternatives provides similar calcium content as found in standard milk.

Contact in RSA: lisadk@cjpchemicals.co.za

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Beverage Review | April 2018

PackagingREVIEW SOUTH AFRICAN

April 2018 | Volume 43 | Number 4

www.foodreview.co.za

Turn your packaging into products consumers must have

Quality labels for better

presence on shelf

Government calls for enquiry into

listeriosis-linked packs

NEWS

A mass customisation phenomenon

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HE DRIVE TOWARD pack personalisation has changed the way consumers shop. It not only puts them in the driver’s seat but also opens up a realm of opportunities for brand owners, manufacturers and suppliers. Since CocaCola’s 2013 Share a Coke campaign,

which introduced the ingenuity of digital print into mainstream, more and more brands and companies have followed suit in customising products. Whether in the form of personalised packaging or labels tailored for end users, these products increase shelf presence and create an emotional and meaningful connection with customers. The only constant is change and albeit an overused cliché, it holds weight in the ever-evolving labelling industry.

Tap into the history of packaging MODERN DAY PACKAGING plays many roles, from containing and preserving products to informing customers about a product’s contents. It includes ingredients, dosage instructions and more.

Packaging is a valuable platform for brand communication, a marketing tool to display brand identities, explains a product’s benefits and inspires consumers to buy goods.

To understand how far packaging has come, Pyrotec PackMedia looks back at its history. The earliest examples of packaging were made from natural materials. This includes reed baskets, wooden boxes, barrels and woven bags. Records dating back to 1035 note the use of paper to wrap vegetables and spices at a market in Cairo, Egypt.

In the 18th century, tin plate was used for packaging snuff, tobacco and other items. The French invented the tin canning process.

Cans were patented in Britain during 1810. The world’s first commercial

canning plant opened in London during 1813. This factory initially produced canned goods for the royal navy.

Corrugated boxes were first produced in England in 1817.

Prefabricated paperboard was invented in 1890. The industrial revolution called on a demand for mass-produced goods and packaging became an everyday item.

Today, packaging is more advanced than it was during the industrial revolution owing to developments in digital technology.

Additional innovations have made packaging more interactive and informative. According to Pyrotec PackMedia, this is both good and bad news for manufacturers. It means the competition is fiercer than ever in the retail environment.

By using innovative on-pack communications, brands can ensure their products stand out on shelf, include more information and inspire consumers at the point of sale.

Global brand sets new standards in waste reduction THE COCA-COLA Company recently announced it will be reshaping its approach to packaging. The beverage giant set a global goal to help collect and recycle the equivalent of 100 per cent of its packaging by 2030.

This goal is the cornerstone of the company’s new packaging World Without Waste vision, which the Coca-Cola system intends to back with a multi-year investment. This includes on-going work to make packaging 100 per cent recyclable.

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Packaging Review | April 2018

‘The world has a packaging problem. Like all companies, we have a responsibility to help solve it,’ says James Quincey, president and CEO of The Coca-Cola Company.

He says through the World Without Waste vision, the company is investing in making the packaging problem a thing of the past.

The Coca-Cola system aims to produce bottles with an average of 50 per cent recycled content by 2030. The goal is to set a new global standard for beverage packaging.

To remain competitive and profitable in this industry, label printers and suppliers have to keep abreast of the latest trends and opportunities. Turn to page 44 for more on this topic, diversified offerings within the market and insight into the production of quality labels.

Enjoy the read!

Assistant Editor Aarifah.Nosarka@newmediapub.co.za

ANC demands enquiry into listeriosis-linked packaging

THE AFRICAN NATIONAL Congress (ANC) has called on the South African Bureau of Standards (SABS) to urgently initiate an investigation at various identified food production factories. The call is to establish the quality of the packaging material used on recalled products and whether it conforms to basic hygiene standards.

‘These food production factories should ensure the packaging is not of inferior quality.

They also shouldn’t chase lower production prices at the expense of innocent lives. Whilst the disease is serious but treatable and preventable, the ANC is highly disturbed by the high number of fatalities as a result of listeriosis. To us, one death is too many. It is for this reason that we make a call to the people of South Africa to remain vigilant and visit health centres as and when they experience the symptoms for immediate treatment. We also urge members of the public to follow the advice given by the department to avoid all processed meat products that are sold as “ready to eat”, in order to prevent the spread of the disease,’ the party reports.

The ANC says it welcomes the recall of products that are implicated such as polony, viennas, russians, frankfurters, sausages, and other cold meats, which are not cooked before use.

‘We urge the Department of Health and the Department of Labour to undertake regular visits at all factories dealing with the production of food products to ascertain their conformity of the relevant legislation around health and employment.’

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TOGETHER, WE GROW

L ABELLING

LABEL DECORATION EXPERT extends footprint

Are you looking for a company that provides high quality label decorations? Forward thinking business, CCL Label will soon bring its expertise to South Africa to feed the need for unique labels, help clients optimise packaging lines and reach sustainability goals.

A

s Africa’s food and beverage industries grow, producers are more committed to the concept of brand differentiation. To grab consumers’ attention in a highly competitive market, a product must stand out from the crowd.

CCL Label (CCL) has been serving the packaging and promotional industry for over 60 years. With its expertise, network and know-how, it supports FMCG companies on a global and local scale. The company provides premium decoration and packaging solutions to multinationals, SMEs and consumers. The company’s beverage division is committed to helping its customers create their desired brand image.

TANTALISE TASTE BUDS Developing unique brand images has become top priority in the industry. Beer, water, soft drinks, wine and spirits producers are all looking for possibilities to excite loyal consumers and win over new ones. Younger target groups are in search of feature innovations. Consumers are spoilt for choice as global brands seek to create unique experiences. Whether it’s personalisation or innovative effects and trimmings – the aim goes beyond catching the consumer’s eye to

connect, convey a positive feeling and build or strengthen the relationship between the brand and its consumers.

CCL actively supports customers with a passion for new technologies and innovations as well as its limitless press capabilities.

CCL Label’s SA team

LOOK FORWARD CCL will soon begin the construction of its facility in South Africa, which will enable it to produce locally. It will offer local customers high-quality products combined with more flexibility.

Always striving for best possible label performance and functionality, CCL develops technologies to help brand owners optimise their packaging lines and reach sustainability goals. Today global beverage companies are relying on technologies like WashOff or EcoStream.

INDUSTRY TRENDS Self-adhesive labels offer a wide range of advantages compared to the wet-glue paper variant. There are no limits to design – almost all kinds of label shapes and sizes can be produced, every thinkable appearance can be created. Whether no-label-look or paper look and feel, pressure sensitive labels combine advantages such as faster and cleaner application, resistance to humidity and direct sunlight.

CCL also offers recycling friendly technologies for different types of containers and purposes. WashOff is used to improve

“Creating unique brand experiences has become one of the top goals for leading brands worldwide”

the circulation process of returnable glass bottles. The patented CCL technology makes sure the decoration is removed from the container inside the bottle washer without leaving adhesive or ink behind.

EcoStream is conquering the PET bottle market. Owing to its sophisticated label construction, the different materials of labels and bottles can be easily separated during recycling. Inks and adhesive do not compromise the PET flakes by staying on the detached label parts. The PET can be reused right away. Even though the labels are built to be recycling friendly, they offer immense creative freedom.

EcoSource and EcoSolve are the latest additions to the list of innovative label constructions. EcoSource labels contain a minimal share of fossil materials. They are made of up to 94 per cent renewable resources. A range of bioplastics and adhesives are available for ideal processability. This guarantees secure performance and premium appearance.

EcoSolve labels are described as biodegradable and compostable. They are the ideal solution for ecological containers such as bottles made of PLA. The composition is suitable for conventional printing technologies. With its outstanding characteristics, EcoSolve is a decisive step towards the next level of green packaging.

With its global network of production sites and label experts, CCL supplies customers with functional premium decoration. The new production site in Johannesburg will enable direct access to reliable and eyecatching labels for brands in South Africa and neighbouring countries. •

CCL Label – www.ccllabel.com

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Packaging Review | April 2018

An illustration of the soon to be built CCL SA plant

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L ABELLING

Label it your way Good labels stand out from the crowd and encourage purchase decisions. They also convey important information. Are your labels flexing with the trends?

Aarifah Nosarka looks at quality labels that help promote brands, industry trends and label production to reduce wastage.

I

n a competitive market more companies use the ‘humble label’ as an extension of their marketing. This is according to Luke Papadopoulos, MD of Paarl Labels, the labelling division of Novus Holdings.

‘Whilst labelling is a highly technical process, we actually believe the art to a good label is driven by service. Paarl labels attempts to understand upfront what the customer wants to achieve with the label. For beverages, labels and adhesives need to withstand icy temperatures.

We build the product around the brief.

This type of service allows us to offer innovative solutions that go beyond merely producing labels.’

Personalised labelling, also referred to as mass personalisation, is a global trend where brands offer consumers the opportunity to customise a label with a message or an image.

‘To remain relevant in an era of mass personalisation, labelling companies must offer clients value beyond standard labelling and printing requirements,’ he comments.

This is a trend driven by the advent of targeted online content. It puts consumers in the driver’s seat. Consumers want something unique whilst social media and digital media have changed the type of experiences people seek.

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Packaging Review | April 2018

Digital technology is a key piece of the innovation puzzle. It allows traditional printers to offer added value and solutions in the labelling space.

SKU diversity is another retail trend allowing labelling companies with good service and a digital offering to stand out from the crowd.

‘Retailers are experimenting with limited and unique flavours, which often don’t last very

“We have a duty to represent brands by producing exceptional labels”

long owing to rotating stock or merely because they are testing the market.

If the product doesn’t work, the SKU is culled. This requires shorter print runs, a reduction in print sizes and different labelling sizes. The flexibility required in this instance implies these formats are well suited to digital formats.’

According to Papadopoulos, while a technical process is used to produce labels, the human element is essential, so the supplier needs to understand the customer’s requirements.

‘We have a duty to represent brands by producing exceptional labels. Coming up with a product or solution that works is enjoyable. It’s this feeling, combined with the technical skill, which keeps me coming back for more,’ he explains.

DIVERSIFIED LABEL OFFERINGS Product Identification Labels (PI Labels) are pivotal in promoting a brand or product and to set it apart from other brands on the shelf. Campbell Gradwell, A labelled flowpack

L ABELLING “We give products the best shelf presence possible while keeping packaging waste at a minimum”

spokesman for Redfern This is a great way to Long Run Labels, says the cut costs and save on company works with brand packaging, while using the owners to provide products same surface area as a with the shelf presence single label.’ they deserve.

Redfern Long Run ‘One of our many Labels’ employee’s work offerings are shrink sleeves. with state of the art These labels provide technologies, which assist the benefit of 360° print coverage on a in optimising packaging. product. They maximise the advertising ‘We give products the best shelf area on packaging and allow for adequate presence possible while information on a product. keeping packaging waste at We have seen an increase a minimum.’ in this type of packaging.

Redfern Long Run Labels is There has also been a BRC certified. It has branches surge in BOPP wraparound in Johannesburg, Cape Town labels, another offering from and Durban.

Redfern Long Run Labels.’

Gradwell says peel and THAT’S A WRAP read labels have increased in Manufacturer of horizontal popularity. ‘These labels are flowpack, film packaging a great way neatly to package and post-print processing additional information on a machines, Hugo Beck ll e b Ca m p ell product. Peel and read labels has developed its latest Gradw allow about three to four layers flowpack machine. This of information on two labels, was designed to meet the directly on top of one another. demanding display requirements of the These can be separated like a mini booklet. chocolate and confectionery sector.

THE BENEFITS OF IN-HOUSE PRODUCTION WASTE REDUCTION AND control of the supply chain are two of the great advantages of in-house label production.

‘Outsourcing label printing necessitates rolls and rolls of label stock which take up shelf space. If an unexpected change of label design is required for any reason, all that label stock is instantly reduced to waste,’ says Shawn Bezuidenhout, owner of NSI 4 Africa.

It is estimated that more than 180 000 tonnes of labels go to waste annually in the UK. ‘There are no statistics available for South Africa but it’s likely a lot more because fewer manufacturers run label printing systems in-house,’ he adds.

There is no label waste issue when printing on-demand. Running labelling systems in-house means manufacturers can print exactly as much as they need for a production run and have complete control over design changes and time scales.

April 2018 | Packaging Review

47

LEBELLING

Heinrich Dankers operating a labelling machine at Paarl Labels

The flowpack X-D can be personalised to each customer’s specific needs. It delivers perfect results and produces special eyecatching display packs for confectionery products. The machine uniquely creates a header for the application of a label, which 10.pdf 1 2018/04/06 14:22 aims to deliver maximum impact on shelf.

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Packaging Review | April 2018

The box motion transversal sealing unit on the flowpack X-D enables a continuous seal for high output whilst simultaneously manufacturing the header. It uses two transverse sealing profiles to give the finished product its unmistakable appearance.

Packs can be collated using accumulation synchronisation or kept contact-free via cascade belts. At the same time, a colour printed card with product information and a best-before date can be applied to one side of the pack.

The machine’s additional features include a film-changing machine, control system for aligning the printed film, a choice of belt types for the intake area and parts specially designed to allow contact with the product.

It can operate at speeds of up to 200 cycles per minute.

Like all Hugo Beck flowpack machines with continuous motion, the X-D features a servo axis controller MotionControl and the latest generation of Siemens Sinamics.

These ensure high quality packaging and maximum machine uptime, even in a threeshift operation. Arctec Graphics is the South African agent for Hugo Beck. •

Arctec Graphics – www.arctec.co.za Novus Holdings – www.novus.holdings.com NSI 4 Africa – www.nsi4africa.com Redfern Long Run Labels – www.redfern.co.za

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April 2018 | Food Review

49

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ABOUT

C O N TA C T

METROHM SOUTH AFRICA Metrohm SA is a subsidiary of Metrohm AG, a leading Swiss company. We are a regional support centre for all sub-Saharan countries, including Mauritius and Madagascar.

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