Food Review August 2017

SOUTH AFRICAN

www.foodreview.co.za

Journal for food and beverage manufacturers AUGUST 2017 Vol. 44 • No. 8

Effective alternatives in

laboratory testing

Five ways to protect your data Paradigm shift for

INSIDE:

Beverage Review & Packaging Review

protein alternatives Food grade conveying cuts risk

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CONTENTS AUGUST 2017 | Vol. 44 • No. 8

Controlling Listeria monocytogenes presents some unique challenges to the food industry

PAGE

08

PAGE

16

Keep your company secure Cyber security has been top of the agenda for many businesses following the global Wanna Decryptor ransomeware attack that grabbed headlines in May 2017

07 NEWS

This fat replacer gets a thumbs up

ADM acquires Chamtor

Fruit producers target global trade

08

INDUSTRY TALK

Are you protected against cyber attacks?

10

PROTEIN ALTERNATIVES

Veggie protein powders hit the mark

Vegan substitutes for a growing market

Is flexitarianism the next big thing?

31

Beverage Review

Put the fizz back

PAGE

34

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16 LABORATORY & TESTING EQUIPMENT

Effective control of Listeria monocytogenes

Micromega strengthens local offering

Critical tests for food safe products

LabX software relooks the testing world

MLS laboratories expands its footprint

26

CONVEYOR SYSTEMS

Total batch transfer with Floveyor

Flexicon frees the flow

Stainless steel makes its mark

Understanding food grade conveyors

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ionary A revolut y in films discoverng multilayer upcycli

”Convenience is important to consumers, offering different packaging formats that meet this need could be a differentiator for many products” August 2017 | Food Review

3

EDITOR’S COMMENT

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

BE SAFE, SAVVY and SECURE

A

s food and beverage manufacturing plants become more connected to the Internet of Things, so does their exposure to cyber-attacks. Controlling risk is an all-encompassing facet for all players in the industry. Coupled to normal threats of contamination is a new one – this year there were over 45 000 Ransomeware attacks recorded in 100 countries.

Turn to page 8 now where ABB offers tips on how your company can offset risk.

The boom continues in vegan meat substitutes. A study by Mintel indicates that the greatest growth is among flexitarians. This group reflects the growing number of consumers who are cutting back on meat. This month’s feature on protein alternatives (page 10) unpacks some of the benefits of using innovative products such as pea protein, replacement products for egg whites, and new stabilising and texturising systems.

Laboratory and testing equipment is once again highlighted, especially in the face of growing concerns over contamination outbreaks such as avian flu. We look at systems and equipment for the control of Listeria monocytogenes and Salmonella. The growing product offering is investigated from food laboratory testing facilities in South Africa. More on this topic on page 16.

To offset risk during the process of conveying food products, producers are opting for food grade conveyors (page 26). While some producers are motivated by government guidelines, others are prompted by the desire to reduce exposure to product liability claims. Improving manufacturing efficiencies through faster sanitation routines also plays a part. We focus on conveyor and belt designs that assist in this quest!

In Beverage Review our focus falls on processing technology, particularly sensors and measuring technology. Measuring, testing, monitoring or automation is applied to everything from the recording of variables in process technology to the analysis of product characteristics in the food and beverage industry. Find out how sensors are used, with increasing success, to give products competitive features that set them apart without significantly increasing production costs (page 36).

Don’t forget to turn to page 42 where packaging editor Aarifah Nosarka sings the praises of convenience packaging and unfolds the latest in carton and board packs.

I hope you enjoy this edition of Food Review. Please don’t hesitate to contact me if you have any news to share with our readers.

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

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Happy reading,

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 | August 2017

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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.

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NEWS

Fat replacer gets the green light THE DESSERTS SECTOR is continuing its uninterrupted year-on-year growth. Clean label specialist Ulrick & Short’s latest addition to its product range aids dessert manufacturers in the fight against fat. Delyte 9 is particularly effective for dairy-based sweet goods such as custards and creams.

The product is shear-and heat stable,

making it suitable for all factory processes.

It is also clean label, non-GM and allergen free. With a tapioca base, it boasts the ability to reduce all fat types and milk solids by up to 50 per cent, allowing manufacturers to make front of pack fat reduction claims.

Delyte 9 promises to mitigate against increases and fluctuations of butter and

ADM aquires Chamtor Pierre Duprat, ADM president Europe, Middle East and Africa says, ‘France is well-known in Europe for its wheat production capabilities, and is a key destination market for starch-based products.

We are excited to add our global capabilities to an already strong business so that we can meet growing customer needs together.’ The French facility, which produces glucose, starch and proteins from wheat, is the most recent in a series of enhancements to ADM’s global sweetener and starch capabilities. In 2015, ADM purchased full ownership of corn wet mills in Bulgaria and Turkey, and a 50 per cent stake in a wet mill in Hungary.

Last year, the company acquired a sweetener and starch facility in Morocco, and announced expansion plans for the Turkey and Bulgaria plants.

‘With increasing demand for sweeteners and starches in Europe, the Middle East and North Africa, ADM is expanding in the region to ensure we meet those growing customer needs,’ Duprat concludes.

Chamtor produces glucose, starch and protein from wheat

cream pricing. Research and development manager, Danielle Schroeter explains, ‘Delyte 9 improves texture and simplifies declarations. It has been scientifically proven to enhance luxury mouthfeel with tribology testing. It is versatile and we have achieved good results in frostings, fillings and other sweet baked goods.’

African fruit producers and exporters create Afruibana THE ASSOCIATION OF fruit producers and exporters from Cameroon, the Ivory Coast and Ghana was officially launched in Brussels during a visit by Cameroon Trade Minister, Luc Magloire Mbarga Atangana. The minister was lauded for this initiative, which will allow fruit producers on the continent to combine their efforts with a view to having their voices heard in international trade.

Afruibana is an association established under Cameroonian law and gathers several representatives of producers and exporters from different sub-Saharan countries, notably Assobacam, the Cameroon banana industry association, and OBAMCI, an Ivory Coast organisation of producers and exporters of bananas, pineapples, “Afruibana has mangoes and other fruits. The thus become organisation is an open platform with the permanent a mission to defend the interests of African fruit farming. representative of In Brussels, Afruibana has thus a community of become the permanent representative fruit producers and of a community of fruit producers and exporters across Cameroon, the Ivory exporters across Coast and Ghana. The association Cameroon” will thus take steps to support competitiveness and export fruits to EU countries. It will also serve as an interface between producers in the sector and European institutions to secure financing and support for African fruit growers.

‘The European Union is the main outlet for African bananas, for historical and geographical reasons,’ says Joseph Owona Kono, chairman of Afruibana.

In the Ivory Coast and Cameroon, the agricultural sector makes up approximately 60 per cent of the economy. Farming is one of the main sources of jobs and income for most of the rural population. For this reason, Afruibana has an essential role in reinforcing our ties with European agencies, favouring trade between Africa and Europe, and promoting socioeconomic development and contributing in the fight against migration.

August 2017 | Food Review

7

I N D U S T RY TA L K

Keep your processes secure A

s food manufacturing plants become more connected through the Industrial Internet of Things (IIoT), the threat of cyber-attacks, and how much damage they can do, has increased.

Robert Glass, global food and beverage communications manager at ABB, offers advice on how to ensure your manufacturing process is kept secure.

IIoT is creating many exciting opportunities for the manufacturing industry. A drawback is that the increased use of connected devices and systems has resulted in a rise of cyber-attacks. For many, the phrase “cyber-attack” conjures up images of email hacking or stolen bank details. It can however have a significant impact on plant processes and production, if systems are not protected correctly. While it can be difficult to prevent a cyber-attack from happening, there are several precautions that manufacturers can take to minimise risk and protect themselves.

Cyber security has been top of the agenda for many businesses following the global Wanna Decryptor (WannaCry) ransomeware attack that grabbed headlines in May 2017. The latest in a line of high profile attacks, WannaCry saw over 45 000 attacks recorded in almost 100 countries, including the UK, US, India and China.

ABB offers top tips on how to avoid a cyber attack

“Firewalls are often the first line of defense against a cyber-attack, protecting the perimeter of a network ”

IDENTIFYING THE GAPS Research conducted by the UK government found that one in four large firms experience a breach in cyber-security at least once a month. On the downside only half take any action to address these vulnerabilities. Furthermore, only one third of the firms surveyed had any form of cybersecurity policy in place.

The first step in securing your plant’s system is to quickly identify the devices and software most vulnerable to risk. To do this, plant managers should appoint an individual or team, dependent on the size of the facility, that takes responsibility for cyber-security. Once appointed, they should conduct an in-depth security assessment, and establish a programme of regular monitoring. This will assist in identifying weaknesses and inform actions to be taken to improve security.

Many plants now operate a "bring your own device" (BYOD) policy, allowing employees to access systems, software and networks through their own devices.

8

Food Review | August 2017

The concept brings with it many benefits, including increased productivity and reduced IT costs. It is vital there is a security policy in place to stop breaches before they occur.

The biggest cause of breaches is the lack of a functional firewall and up-to-date firmware across a business. Firewalls are often the first line of defense against a cyber-attack, protecting the perimeter of a network. Users must ensure their devices have the latest software updates – these often include security patches to protect against potential new cyber threats. Cyberattacks are constantly evolving to get around security protocols. Connecting to unsecure Wi-Fi and Bluetooth networks also pose a danger. Security managers should ensure users always connect to secure networks that are password protected.

STANDARDS AND POLICIES The digital landscape is constantly evolving and the standards and policies that businesses put in place to protect themselves should constantly adapt.

There is no single solution to protect all businesses. It is important to seek the advice of organisations, such as ABB, to create a company-wide policy that can detect, deter and prevent the threat of a cyber-attack. In additon to a company’s IT network with traditional laptops, many food

and beverage manfuacturers also maintain a connected automation network. This network controls a manufacturing plant’s production; from simple control like mixing bagel dough, to potentially dangerous processes like decanting oils (where high kinetic speeds can pose safey hazards).

Recipes are managed on these systems, and companies have a large financial interest in protecting automation networks from cyber- attacks.

Software, like the ABB Ability™ System 800xA, provides bespoke cyber-security solutions across an entire system lifecycle.

It offers multiple layers of security controls that are continually updated.

Even with a robust security system in place, it is vital manufacturers keep an offsite back-up to ensure data is protected in the event of a cyber-attack. Keeping this back-up off-the-grid will ensure a much smoother recovery process of critical data.

While awareness of cyber-attacks has risen since May, businesses must now take action and ensure their systems are adequately protected. The WannaCry ransomeware attack has proven all businesses are vulnerable, no matter their size. No one can afford to take cybersecurity for granted. •

ABB – www.abb.com/africa

P R O T E I N A LT E R N AT I V E S

The PREFERRED PROTEIN Pea protein has drastically increased in popularity over the last few years, with an evergrowing desire for plant-based or plant-rich diets by health-conscious consumers. This comes as no surprise, considering the amazing makeup of this veggie protein powder: it is among the most hypoallergenic of all protein powders and contains no gluten or dairy.

A

GT Foods produces pea protein for inclusion in the manufacturing of a variety of foods, including cereals, breads, protein powders and bars. It is one of the few producers with the skills set to develop a product like pea protein into a functional alternative protein ingredient.

It is non-genetically modified (GMO free) and a hormone free alternative to soya in the baking and food manufacturing industries.

‘We are also introducing deflavoured pea protein to the trade, with the benefit

...AND THE WINNER IS...

AGT Foods and Ingredients Inc were recently awarded the IFT17 Food Expo Innovation Award for their clean-taste pulse ingredients at the Institute of Food Technologists (IFT) Awards Celebration in Las Vegas.

‘There is a consumer pull toward pulse ingredients that food manufacturers are trying to meet,’ said Igor Playner, vice-president of innovation and strategy, North America, Ingredion.

‘One in three consumers states they prefer a vegetable-sourced protein to an animal-sourced protein.’

10

Food Review | August 2017

of utilising it on a one to one ratio,’ says George Tomazos, AGT Foods Retail and Food Ingredients, South Africa. ‘The pea protein is versatile, functional and 100 per cent natural. It has successfully made its entry onto the retail shelf. It is easy on the stomach and doesn’t cause bloating, a common side effect of many other protein powders.’

MAJOR INVESTMENT INTO AGT FOOD AND INGREDIENTS INC Fairfax Financial Holdings Limited will make an investment of C$190 million (just under R2 billion) into AGT in exchange for the issuance by AGT of 5.375 per cent interest bearing securities and common share purchase warrants. In South Africa, AGT Foods represents the retail, hospitality, spices, ingredients, popcorn, bakery and protein divisions as well as Pouyoukas Foods.

Fairfax Financial is a financial holding company based in Toronto, Ontario, which is engaged in property, casualty and life insurance and reinsurance, investment management and insurance claims management. Fairfax has agreed to subscribe, on a private placement basis and subject to certain conditions, for preferred securities in a maximum aggregate amount of C$190 million. The preferred securities will be unsecured obligations, will mature in 99 years and will be guaranteed by certain of AGT’s subsidiaries.

AGT has also agreed to issue a maximum of 5 714 286 warrants, each exercisable into one common share in the capital of AGT and exercisable at C$33.25 per share. Each warrant will be exercisable within seven years. AGT can also elect to require early exercise of the warrants if the five-day volume weighted average closing price of its common shares reaches C$53.20 at any time after the fifth anniversary of the closing.

Fairfax will have the right to nominate one independent director to the board of

directors of AGT and will become entitled to nominate an additional independent director upon the exercise of all of the warrants. The proceeds raised from the Fairfax transaction will be used by AGT for immediate repayment of debt, future growth initiatives and general corporate purposes.

‘Fairfax has an exceptional track record in global emerging markets and is an ideal partner for AGT as we look to grow our business and pursue our long-term goals,’ commented Murad Al-Katib, AGT’s president and chief executive officer. ‘We are very excited about this new relationship and look forward to working with the Fairfax team as we explore new strategic growth opportunities.’

The transaction significantly improves AGT’s balance sheet by providing attractively priced and near-permanent strategic capital. Management views this as a material de-levering event that equips the company with the necessary liquidity for its current and future growth needs.

Al-Katib adds, ‘AGT is well positioned to capitalise on the long-term growth trajectory from population and income growth in emerging markets. Fairfax is the right partner for us in the next stage of development of a strong and diversified AGT.’ •

AGT Protein – www.agt.com

DID YOU KNOW?

AGT Foods and Ingredion Inc received the IFT17 Food Expo Innovation Award for its range of clean-taste pulse ingredients.

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P R O T E I N A LT E R N AT I V E S

Meatless alternatives for the mass market A study by market research institute Mintel, shows the greatest growth is among flexitarians with reduced consumption of meat. Mintel talks of a paradigm change, as niche vegetarians turn into mass market flexitarians, and the market potential for meat alternative products.

New vegan nuggets: enjoyment meets convenience

T

hese products are only successful if their taste and consistency compare favourably to the meat product, and they offer health benefits and address the ongoing convenience trend.

Hydrosol has developed a new stabilising and texturing system that lets manufacturers of meat alternatives address the wishes of ever broader target groups. Vegan nuggets suitable for hot consumption is a current example.

What’s special about these nuggets is their meat-like texture, achieved with the aid of HydroTOP High Gel. ‘The system is based on a specific combination of hydrocolloids and fibres that act as emulsifying and stabilising components,’ explains Dr Carsten Carstens, head of

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Food Review | August 2017

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product development for meat and sausage products at Hydrosol. First an emulsion is made with HydroTOP High Gel 30, oil and water. This stabilises the hydratised texturate through thermoreversible gelling. This means that heating the formable mass turns it into a product pleasantly firm to the bite. Treating the texturate with the HydroTOP emulsion creates a formable, slightly sticky meat analogue comparable to a ground meat mass used for meatballs. This adhesive property allows vegetables with smooth surfaces like corn or peas to be worked into the mass without problems. The meat substitute mass can be individually seasoned and produced continuously on a conventional line.

HydroTOP High Gel 30 is suitable for all standard commercial wheat, soy and pea protein-based texturates.

‘In application, the synergies and interactions between HydroTOP and the protein texturate are used to full effect,’ reports Dr Carstens. ‘High Gel 30 turns the fibrous structure into a meat-like structure.’ The vegan nuggets can be pan or deep fried. In addition to their texture, these products offer another clear advantage - they are declaration-friendly as they are vegan, and free of soy and gluten. Neither flavour enhancers nor phosphates are used.

Besides vegan nuggets, manufacturers can use HydroTOP High Gel 30 with the texturates from the Hydrosol Stabiprot series to make many other products. Examples include vegan burgers and patties, as well as vegan schnitzel with breading. All products can be deep frozen.

With High Gel 30, all other formed ground meat, fish, poultry, diced ham and similar products can be made at low cost with excellent quality. The meat and fish products have a firm bite, are juicy and retain their shape. •

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2017/08/15 10:32 AM

Hydrosol – www.hydrosol.com

P R O T E I N A LT E R N AT I V E S

Flexitarianism on the rise A growing number of omnivores are cutting back on meat, creating a new class of ‘flexitarians’.

W

hole Foods Market listed flexitarianism as one of the top 10 food trends for 2017. This is in response to the growing number of consumers who reject strict diets and labels, favouring a more flexible approach.

Food producers would normally respond to this trend by creating meat alternatives containing soy, gluten and egg. A growing number of consumers are rejecting one or more of these ingredients because of concerns about allergies and intolerances.

To cater for the entire flexitarian market, a meat substitute must be free from these ingredients.

This creates a challenge for manufacturers. Egg white is the cornerstone of many meat substitutes.

The addition of egg white to patties and other meat-free products binds material together. The growing number of nonvegans rejecting foods that contain egg limits the potential market for products.

AN ALTERNATIVE TO EGG Dow has expanded its Methocel range with innovative methylcellulose grades.

The new stabiliser, Methocel Bind, has a lower melt-back temperature than other products in the standard methylcellulose range. This should improve the structure and texture of food at hot and cold temperatures, offering greater stability, bite and firmness. The higher water binding capacity of this new grade provides freeze-thaw stability, and contributes to a juicy mouthfeel.

The key question for food producers is whether these characteristics translate into products that match or exceed those created using egg. Dow performed internal studies with reformed soy patties

“i want to create plant- based products packed with protein” ADM feeds your food business with innovative plant - based ingredients.

As an industry leader, we offer the most extensive, innovative and on-trend ingredient solutions and systems to help you provide consumer-preferred experiences. We’re specialists in understanding the mechanics of taste, texture function and nutrition. In fact, ADM is your problem-solving team of culinary, flavor-creation, productdevelopment and sensory professionals who are at the ready to help you craft meat and meat alternative products, soups, sauces and sides.

Learn more at www.adm.com.

sfc-info@savannah.co.za

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August 2017 | Food Review

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P R O T E I N A LT E R N AT I V E S

made using Methocel stabilisers or highgel egg white powder through a series of tests.

Dow’s first test looked at the cold structure of patties. This property is crucial, as food producers need patties to hold their shape during transportation.

Patties containing either one per cent Methocel or three per cent egg white were formed with a burger press and placed on a beaker. The edges of the patties overhung the beaker. The egg white patties collapsed immediately. The Methocel patties were still intact after five minutes. Findings suggest Methocel’s properties result in better cold stability than egg white.

A second test looked at stability at higher temperatures. Patties formed with a range of concentrations of Methocel and egg white were pan fried and put through the beaker test.

Egg white powder patties were stable at concentrations above 3.5 per cent.

Methocel-based patties achieved the same degree of stability at concentrations of 0.6 per cent and above. That means producers can use lower concentrations of Methocel. Dow calculates this reduces stabiliser costs by up to 50 per cent.

Participants associated the Methocel patties with a juicier mouthfeel than those containing egg whites. This finding is in line with expectations based on how Methocel releases water during the thermal gelling process.

“Participants associated the Methocel patties with a juicier mouthfeel than those containing egg whites”

ASSESSING METHOCEL’S STRENGTHS The small, in-house tests run by Dow suggest the performance of Methocel matches that of egg white in key areas, with additional benefits in terms of cost in use and mouthfeel. Patties made with Methocel were more stable at low temperatures. Less Methocel was needed to deliver the same degree of stability at high temperatures, making cost savings possible. Methocel patties were as well liked by consumers and had a juicier mouthfeel.

These findings suggest Methocel offers some clear advantages over egg white. It is an efficient solution for binding and stabilisation of vegan and vegetarian products. •

Costs are only part of the equation.

The stabiliser must also produce a pattie consumers want to eat, enjoy and buy.

To gauge consumers’ acceptance of the patties, Dow gave products formulated with one of three grades of Methocel or egg white to 16 non-trained participants.

Patties were consumed at a warm eating temperature immediately after frying. The participants rated how much they liked the patties on a nine-point Hedonic scale.

The test found no significant difference in the overall liking of the patties with Methocel or egg white. Soy patties formulated with either ingredient were given positive or neutral scores by most of the participants.

Dow found a difference in perceptions of the mouthfeel of the patties.

Dow – www.dow.co.za

Bringing high-tech fine ingredients to Africa Introducing

Nikken Foods Japan: Umami – and Kokumi natural flavors

DCP Ingredients Netherlands: Innovative high-performance bovine collagen proteins

Umami Flavor building blocks can be used to:

• Improves the yield in convenience minced products and whole muscle meat

• Boost Flavors

• Improves the firmness and reduces ripening

• Increase taste sensation of other flavors

time in fermented sausages

• Can assist in the reduction of sodium

• Can replace fat, act as an emulsifier and Kokumi Flavor building blocks can be used to:

improve overall structure of cooked and

• Provide a mouth-watering punch at initial taste

smoked sausages

Regular Cellulose Fibre that is made from Wood with non-GMO status • Highly purified CMC (>99.5%) • Cold and Hot water solubility properties • Acts as a thickener, stabilizer and has water retention capabilities Thixotropic CMC has:

• Lends an overall balance and richness to food • Heightens the richness and sensation of other flavors • Without sacrificing the taste, Kokumi can reduce sodium, sugar, oil, fat and MSG

Akzo Nobel Akucell CMC’s: AF 3285 / AF 3265 / AF 3275 Thixotropic CMC

Used in:

• High-water absorption charateristics – 1.60

• Brine for tumble and injections

• Viscosity build up with higher sheer

• Emulsified and comminute meat products

• Low Viscosity during higher temperature processing • Ideal for processed Foods, Bakery, Pet Food, Instant noodles, Dairy products and Sauces & Dressings

www.chemelco.com l africa@chemelco.com l T +27 21 876 3644 Chemelco.indd 1

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Food Review | August 2017

2017/08/14 10:14 AM

L A B O R AT O RY & T E S T I N G E Q U I P M E N T

When less is not more Controlling Listeria monocytogenes presents some unique challenges to the food industry.

It is widespread in the environment, readily found in soil, water and decaying vegetation.

Humans, domestic animals and raw agricultural commodities are common vectors and, as a result, L. monocytogenes is often found in food packing and processing environments. The organism is environmentally persistent and can be found recurrently in equipment and the processing environment. By Linda Jackson

I

n addition to the obvious product testing, a robust Listeria environmental monitoring programme (LEMP) is recommended by key organisations such as the FDA, the Grocery Manufacturers’ Association in the US, and the Food Safety Authority of Ireland.

According to the FDA, a well-designed LEMP promotes knowledge and awareness of the environmental conditions that could result in product contamination and is a more effective than product testing alone. The FSAI maintain that if control of L. monocytogenes in the environment can be established, (e.g. food contact surface contamination) then the risks of product contamination will be reduced. An LEMP will help verify the ongoing effectiveness of the cleaning and sanitation programme and will also help determine if further control measures are necessary to eliminate or reduce contamination.

As with all food safety programmes, your LEMP should use a risk-based approach. In general, the greater the risk that an RTE food could become contaminated with L. monocytogenes

16

Food Review | August 2017

and support growth of the organism, the greater the frequency of environmental sampling and testing, and the more stringent the corrective actions.

Your LEMP should be a formal procedure that addresses the following questions:

Where to sample?

that even the smallest processors collect samples from at least five sites of FCS and five sites of non-FCS on each production line for RTE foods. These samples should be taken weekly for those RTE foods that support growth of L. monocytogenes. Composite samples should be avoided.

The choice of sampling sites should When to sample? consider food contact surfaces (FCS) and Your LEMP procedures should non-FCS. A suggested methodology would also specify the time(s) at which be to define zones in the processing areas environmental samples will be collected. and link these to hygiene requirements The FDA stress that the best time to for each area. Floor drains should be collect environmental samples is several included in LEMP - particularly those hours into production (e.g. three to drains which present a high risk due to four hours) or preferably just prior to proximity to FCS's. Repeated negative cleanup, because this allows time for results from a particular sampling site L. monocytogenes (if present) to work may suggest that the sample site its way out of harbourage sites and is not a good indicator contaminate the environment, of control. Ensure you the processing line (including periodically review FCS sites), and, potentially, the sampling RTE product. sites to ensure According to the FSAI, there effective control.

How to sample is currently no European or The FDA and test? international agreement on recommend In most cases, microbiological criteria for you will use an L. monocytogenes in foods (with a few exceptions) or outsourced laboratory the environment. for identification and enumeration of these LEMP samples, but swabs will usually be taken internally. Swabs should always be the sponge type and a large surface area should be used. Detail the method of swabbing and train staff to maintain consistency. Ensure the methods used for the detection of Listeria spp. and L. monocytogenes are scientifically valid and accredited. It is also a good idea to include negative control samples to monitor your service provider. There are rapid methods available, although experience shows that these still require 10 to 14 days for results, which is frustratingly slow in controlling corrective action. Composite samples should be avoided. In-house LEMP test kits are available in South Africa but these must be validated with

DID YOU KNOW?

L A B O R AT O RY & T E S T I N G E Q U I P M E N T

positive result for Listeria species from a non-FCS should initiate a review of cleaning procedures and records.

If L. monocytogenes or other Listeria species are detected on a food contact surface, corrective action should ensure production batches, which may have come into contact with a contaminated surface are put on hold, sampled and tested. A review of cleaning procedures and records must then take place. In both cases, robust cleaning procedures and records are essential to allow effective investigation when there is a positive result.

According to the FSAI, there is currently no European or international agreement on microbiological criteria for L. monocytogenes in foods (with a few exceptions) or the environment.

Some countries allow low levels of Listeria monocytogenes <100 CFU/g to be present in certain foods while others adopt a zero-tolerance policy similar to the US. According to FSAI, while zero-tolerance can appear to be the safest policy it can lead to a false sense of security.

With this policy, end products may be tested randomly or on a batch basis and this may imply that all food is free of L. monocytogenes. A LEMP working with GHP, GMP, HACCP may be more productive than an emphasis on end-product testing in the long term. So, more rather than less testing is the name of the game for Listeria. •

“As with all food safety programmes, your LEMP should use a riskbased approach”

control swabs tested by the accredited laboratory to rule out false positives. You will require additional biosecurity controls in your in-house lab, in this case to ensure control of the pathogen and safety of your staff members.

What to do with positive results?

According to the FDA, a positive test result for the presence of Listeria spp. on an FCS or non-FCS indicates the potential for contamination with L. monocytogenes and suggests that conditions are suitable for survival and/or growth of L. monocytogenes. A positive test result for the presence of Listeria spp. does not establish the presence of L. monocytogenes so monitoring for Listeria species only may result in failure to recognise the presence of L. monocytogenes.

The types of corrective actions are highly varied (e.g. conducting intensified cleaning and sanitising, conducting intensified sampling and testing, conducting a root cause analysis, and implementing “hold and test” procedures).

Which corrective actions you take depends upon your specific situation. Guidelines generally advise that a

PICK THE RIGHT SWAB WITH SO MANY swabs to choose from, how do you ensure you use the right one for the job at hand? As distributors and users of the TSC brand of swabs, the staff at BioScience Technologies are extremely competent in helping to choose the right swab for your specific requirement.

Technical Service Consultants (TSC), with its own manufacturing plant in the United Kingdom, is ISO 9001 and ISO 13485 certified and has been in business for more than 30 years. Bio-Science Technologies is proud to have been awarded the sole agent and distributor in South Africa for TSC`s highly acclaimed products.

The TSC range is not limited to swabs, but also includes the Protect cryogenic microorganism preservation system, sterile loops, spreader, sample containers and a wide variety of other laboratory consumables.

Bio-Science Technologies has its own fully equipped laboratory, which can offer back-up testing services to the products sold. If swabs are brought in after swabbing, they will be tested for bacteria, yeasts and moulds.

* References available on request.

Food Focus – www.foodfocus.co.za

Good Quality Service is a lasting Impression!

Bio-Science Technologies are proud to announce that we are now the sole South African Agent & Distributors for the latest high quality imported swabs from TSC, a United Kingdom manufacturer: Probact Transport Swab Range offers a complete sampling solution for the safe collection, transport & preservation of microorganisms to the laboratory. The range also includes AMIES and the Cary Blair swab which is suitable for higher temperature storage and transport conditions.

Most popular is the TS/5-48 and TS/5-42 Hygiene Swabs containing a neutralising buffer to remove traces of disinfectants which can interfere with the bacteria count of the swabbed surface.

All Probact Transport Swab Kits are Full CLSI M40-A compliant, CE Marked and comply with the European Medical Device Directive 93/42/EEC. Also available are:

Synthetic & natural dry swab types

another very useful & sought after new product is the Preservation System

BATCH SPECIFIC QUALITY CERTIFICATES ARE AVAILABLE FOR EVERY PURCHASE ORDER We are the only supplier of swabs that can back up our service with our own in-house laboratory testing services.

Bring your swabs to us for pathogens & mould testing after swabbing!

BioScience Technologies – www.biosciencetechnologies.com

August 2017 | Food Review Bio Science.indd 1

17

2017/08/10 8:34 AM

L A B O R AT O RY & T E S T I N G E Q U I P M E N T

A wider choice

in risk management T Aspirata, a MicroMega Company has strengthened its local product offering with the acquisition of additional food laboratories in Durban and Cape Town.

he company, listed on the JSE under support services sector, purchased Aspirata, formerly a subsidiary of Centurion-based Aurecon South Africa in May 2015. The acquisition was facilitated in order to complement and enhance its portfolio of risk management, training, consulting and auditing services.

According to managing director, Venisha Bachulal, Aspirata conducts nearly 1 700 real-time, web-based and computerised audits a month. It operates extensively in the food safety and microbiological laboratory testing sectors, providing certification against ISO 22000 Food Safety Management Accreditation and FSSC 22000 Food Safety System Certification. ‘Our state-of-the-art laboratory, analyses in excess of 2 500 samples a month, utilising Two additional CSIR facilities are on board to offer additional services to the region

18

Food Review | August 2017

a customised laboratory information management system for the submission of results,’ she explains.

In September 2016, Micromega Holdings acquired two additional CSIR food laboratory facilities to add to the range of capabilities on offer in the region. The company is in the final stages of a complete overhaul of these facilities. This will position them as leading service centres in Durban and Cape Town. The facilities will extend the scope of Aspirata through the addition of chemical and food micro-testing services. This will bring additional support to the local food industry in order to meet local and international requirements. It will also assist in addressing critical food safety and anti-food fraud issues.

Services in these two facilities are expected to be operational in the last quarter of 2017. •

Aspirata – www.aspirata.co.za

With our ISO 17025 accredited, custom-built, state-of-the-art chemical and microbiological laboratories, Aspirata has been a leading provider of a broad range of tes ng and examina on services across Southern Africa... and we are about to get even be er.

Why would you trust anyone else?

www.aspirata.co.za

L A B O R AT O RY & T E S T I N G E Q U I P M E N T

Salmonella's new era validation Testing food for the presence of pathogens is critical. The standard method for performing these tests is based on cultures and can take up to five days to obtain a result.

Many alternative methods exist, which provide results in a faster timeframe. To ensure these alternative methods are fit for purpose, they must be validated and their performance compared against a standard method.

S

olus Salmonella ELISA and Solus Listeria ELISA have recently been granted renewed AFNOR validation certificates, valid until 18 June 2021. Both tests were validated using the ISO 161402:2016 protocol. ISO 16140-2:2016 specifies the general principle and the technical protocol for the validation of alternative methods for microbiology in the food chain. Validation requires the alternative method (in this case the Solus Scientific methods) to be compared in performance against the reference method for a number of parameters. This certification gives assurance that the results obtained by the alternate method is at least as good, if not better than the “gold standard” reference method.

The previous protocol ISO 16140:2003 was used to validate over 100 alternative methods (including the initial validation and extension study of Solus pathogen testing systems) and is a commonly accepted European and International standard.

In the US an organisation known as AOAC International, publishes standards including those for microbiological analysis. The aim of the organisation is to validate and publish reliable analytical test methods including those used for food safety analysis. AOAC validation is commonly accepted as the required standard for food safety testing in the US. Solus scientific pathogen testing systems are also approved by the AOAC performance tested methods programme.

In June 2016 the ISO 16140 standard was revised, while the principles of both 2003 and 2016 versions remained the same, a number of new approaches and acceptability criteria were introduced.

A significant intention of the revision was to achieve better harmonisation of requirements between Europe and North America.

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Food Review | August 2017

SOME OF THE CHANGES INCLUDE: • T he testing of at least five food product categories, excluding environmental samples, in order to apply for validation in the “all human food products” scope • New result calculation and interpretation methods, including an accuracy profile • Stricter tolerances for artificial spiking of food matrices targeting 1-3 CFU per 25g • For Salmonella detection, the number of strains tested has increased to 100.

The result of these changes has made the validation process much more stringent and as a consequence the methods tested can be shown to perform to a very high standard. Currently a low percentage of existing methods have been validated to the new standard, Solus Salmonella ELISA and Solus Listeria ELISA are among this elite group. •

Anatech – www.anatech.co.za

PATHOGEN TESTING SOLUTIONS IN THE FAST-PACED pathogen screening environment it is critical to process samples efficiently. As sample volumes fluctuate, the lab must have the flexibility to cope with varying demands, maximising throughput, whilst minimising wasted resources.

Solus Scientific’s proven testing systems are used by many international food testing laboratories and food producers. Committed to food safety excellence, the range features Solus solutions that bring significant productivity benefits to the food safety testing environment.

Solus pathogen testing solutions are highly efficient assays for the detection of Salmonella, Listeria Spp. or E.coli 0157.

Optimised selective media, ready to use immunoassay reagent kits containing pre-coated 96 well plates and DS2 instrumentation with dedicated software protocols minimises time required to process multiple samples. One instrument can deliver up to 192 results in one run and up to 500 results per eight-hour shift. The DS2 instrument runs unattended once the assay has started: simply load samples and return in two hours to view the results.

The DS2 fits easily into an existing workflow with a small bench footprint, bar code sample ID entry and electronic transfer of results to LIMS. A single pathogen detection protocol is utilised regardless of the food matrix being tested.

Why choose an ordinary pathogen test when you could choose an extraordinary one!

SOLUS

www.solusscientific.com

To find about To f i nd o ut out m omore re ab o utour o uoutstanding r testing systems, get in ms touch o u tstand ifood ng fo o d te sti ng syste , with ourwi approved Anatech. g et i n to uc h th o u r supplier, ap p roved sup p l i e r A nate c h.

SCIENTIFIC

FOR ALL YOUR MICROBIOLOGY NEEDS Supplied • Serviced • Application Tel: +27 11 462 6776 Support • Training Email: sales@anatech.co.za

www.solusscientific.com

L A B O R AT O RY & T E S T I N G E Q U I P M E N T

Eliminating the rotten apple

with LabX software

The Food and Drug Administration (FDA) and other regulators are progressively observing Current Good Manufacturing Practice (CGMP) violations involving data integrity during inspections. These have led to numerous regulatory actions, including warning letters for violations and non-compliance.

Titration workflow illustration

D

ata integrity requirements can be fulfilled with Mettler Toledo’s LabX laboratory system, which can connect a variety of laboratory instruments and meets all requirements regarding 21 CFR 11, EU Annex 11 and ISO 17025.

“Laboratory workflows involving more than one instrument may result in transcription errors when values are manually transferred between instruments” According to the FDA, data should meet the criteria of being attributable, legible, contemporaneous, original and accurate (ALCOA). This focus has highlighted the importance of laboratory administrative work. Following the example of a titration workflow, the usefulness of LabX software for ensuring data integrity is discussed.

Laboratory workflows involving more than one instrument may result in transcription errors when values are manually transferred between instruments. LabX, in combination with a SmartSample kit, helps improve the workflow by automatically transferring sample data from a balance to a titrator as well as to LabX. Firstly, sample data is stored in the radio-frequency identification (RFID) tag,

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Food Review | August 2017

which is attached directly to the beaker to help prohibit potential permutations. When titration begins, all accumulated results, raw data and metadata are automatically transferred to the LabX database.

LabX connects various laboratory instruments from Mettler Toledo to one system. The entire sample information only needs to be recorded once and

is then transferred automatically and unambiguously. By removing the need for manual data recording and data entry, valuable time is saved on each sample and transfer errors are easily avoided. •

Mettler Toledo – www.mt.com Microsep – www.microsep.co.za

SIMPLE AND QUICK SALMONELLA SCREENING HYGIENA’S INSITE SALMONELLA is a quick and easy test for the detection of Salmonella species in food processing environments. Its all-in-one test format combines sample collection, pre-enrichment and selective steps in a single device. This improves measurement, reduces costs, maintains security and minimises the risk of cross contamination. It also retains the active culture for any subsequent verification and identification tests.

InSite Salmonella is a self-contained, ready-to-use swab test, which contains a specialised liquid medium - changing colour when Salmonella species are present in the sample. A colour change from purple to bright yellow indicates presence, with positive results in as early as 24 hours from sample collection. The all-in-one test device eliminates the need for sample

preparation materials, saving material and labour costs.

Other environmental Salmonella tests require several complicated steps after sampling including several media, and transfer of enriched sample to a different test device. InSite Salmonella’s convenient design eliminates the need for any special preparation, measurement, or enrichment outside the test device, simplifying the assay so any level of user can successfully run the test, virtually eliminating the possibility of operator error.

InSite Salmonella joins Hygiena’s line of rapid microorganism tests, including those for total viable count, Listeria species, Enterobacteriaceae, Coliform, and E. coli. Other products from Hygiena include the world’s best-selling ATP monitoring systems and convenient allergen prevention test kits.

A quick and easy test for salmonella

DATA INTEGRITY SIMPLIFIED LabX® multi-instrument control and data acquisition system www.mt.com/labx

Johannesburg: Tel: (011) 553-2300 • Cape Town: Tel: (021) 914-0393 Durban: Tel: (031) 701-4705/6 • Port Elizabeth: Tel: (041) 365-5168 e-mail: info@microsep.co.za www.microsep.co.za

L A B O R AT O RY & T E S T I N G E Q U I P M E N T

AT THE FOREFRONT of testing innovation M LS Laboratories, in operation for 10 years, has expanded its footprint. The company now offers micro, chemical, allergen, residue screening, and nutritional analysis for the food and beverage industry.

In this space, personal hygiene, sanitising and temperature monitoring are the most critical to ensure a food safe culture.

Verification testing is done as per the client’s food safety plan. This ensures compliance for food safety and security.

Director Thea Laufs explains that preliminary results, critical for product release, are available within 24 hours after sample receipt. The final report is ready within five working days. ‘We place an enormous emphasis on offering customers personal service. Customer contact is generally with laboratory signatories or senior management.

‘Our electronic reports minimise admin delays, resulting in quicker results. Alerts on pathogens are sent within 24 hours of sample receipt. MLS completes a result

interpretation on the report for easy reference. An electronic non-conformance system is also available. Here clients can log in to action their non-conformance online.

Technical assistance and problem solving are available at no cost. We believe that each customer is unique. This is attested to by our flexible and customised solutions that are geared to offer the highest quality service at a reasonable cost.’

Laufs believes current laboratory trends in South Africa compare well with international

standards. This is of course taking some of the challenges on the continent into account.

‘We continually invest in technology to ensure that we remain at the forefront of innovation in the industry.

‘We also offer training in aseptic sampling techniques and services comply with the needs of the retail and food service suppliers’ environment. Safe food is a fundamental right. Food suppliers operating in the chain have an ethical, moral and legal obligation to provide safe food to all consumers. Increased consumer awareness, globalisation, and the demand for safe food has led the industry to implement effective food safety management systems,’ Laufs concludes. •

MLS Laboratories – www.ltlconsultants.co.za

HOW IT WORKS Quotation request

Quotation submission and acceptance

Sample collection

Sample receipt and commencement of testing

MLS – NATIONAL LABORATORY SERVICES AND SUPPLIES Lab No T0450

MLS is a SANAS Accredited Laboratory that has been operating a part of the LTL Group of Companies for the past 10 years Our methods enable us to submit prelim results within 48hrs and final reports within 5 working days.

Residue DNA Effluent water Chemical Nutritional analysis Shelf life

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Food Review | August 2017

Pesticides Aflotoxins Microbiological Organoleptic Allergens

Industries serviced include: Abattoirs and Meat Processing plants Beef/Pork/Lamb/Chicken/Game Ostrich and Crocodile Food and Beverage facilities Fruit and Vegetable Farms/Packhouses Health and fitness facilities Manufacturing facilities Contact us today for your tailor made testing package!

Info@mlslabs.co.za 010 010 0685 082 853 2247

Steel Belts for the Baking Industry

We are your reliable partner for steel belts when it comes to continuous production in the baking industry. We can provide you with complete solutions, no matter if you need steel belts or machine parts.

Your advantages: 

Continuous production



Higher output

 Operating temperatures up to 400°C 

Unique product quality over the whole length of the belt



Perfect tracking

Austrian quality

Berndorf Band GmbH T: +43 2672 800 0 b a n d @ b e r n d o r f. c o . a t www.berndorfband-group.com

C O N V E YO R S YS T E M S

MAXIMUM AVAILABILITY using minimum energy interlocked for operator safety. Optional air ports are available for dry cleaning or a speciality pack for CIP wet cleaning.

Optional automation features include the following: • Integrated electric of pneumatic baffle place that eliminates the risk of starting or stopping the system under the load and provides flexibility in controlling material feed;

Floveyer has just released the simpler, smaller industrial aero-mechanical conveyor that delivers throughputs up to 105 000kg per hour using low maintenance 1.5 to 7.5kW shaft-mounted gear motors.

I

deally suited to straight line installations up to 20m at angles from zero to 90°. The Floveyor Industrial Aero-Mechanical Conveyor moves dry powders and granules up to 12mm in size.

Fluidising aero-mechanical technology delivers total batch transfer and handles friable and blended products without degradation or separation.

Standard safety and cleanabilty features include quick release hinged access points and hatches that are electrically

A complete

“Fluidising aeroSOFTWARE SOLUTION mechanical for the Meat, Food & Beverage Industry technology delivers Abattoir Slaughter Control total batch•transfer • Full Meat Stock Control Systems and handles friable and blended• products Software For Food And Meat Industry without degradation • Full MRP & Traceability Solutions A complete or separation” • Specialists In Meat Systems (Abattoir / Debone / Production) SOFTWARE SOLUTION

for the Meat, Food & Beverage Industry The Floveyor Industrial Aero-Mechanical Conveyor

• Retail Point Of Sales Systems

• Abattoir Slaughter Control • Scales, Label Printing And Probes Solution's • Full Meat Stock Control Systems

Yield Control Systems A complete • Recipe A& complete

• Software For Food And Meat Industry

SOFTWARESOFTWARE SOLUTION •SOLUTION Mobile Systems (Smartphone / iPad / Android)) • Full MRP & Traceability Solutions for the Meat, Food & Beverage Industry

for the Meat, Food & Beverage Industry • Specialists In Meat Systems (Abattoir / Debone / Production) • Retail Point Of Sales Systems

• Abattoir Slaughter Control • Abattoir Slaughter Control

• Scales, Label Printing And Probes Solution's • Full Meat Stock Control•Systems Full Meat Stock Control Systems • Recipe & Yield Control Systems • Software For Food And•Meat Industry Software For Food And Meat Industry • Mobile Systems • Full MRP & Traceability Solutions • Full MRP & Traceability Solutions

(Smartphone / iPad / Android))

• Specialists In Meat Systems (Abattoir / Debone / Production) • Specialists In Meat Systems (Abattoir / Debone / Production) • Retail Point Of Sales Systems • Retail Point Of Sales Systems • Scales, Label Printing And ProbesLabel Solution's • Scales, Printing And Probes Solution's • Recipe & Yield Control Systems • Recipe & Yield Control Systems • Mobile Systems

(Smartphone / iPad / Android))

• Mobile Systems

(Smartphone / iPad / Android))

MATRIX MATRIX S O F T W A R E S O F T W A R E

MATRIX MATRIX S O F T W A R E

www.matrixsoftware.co.za

www.matrixsoftware.co.za [e] info@matrixsoftware.co.za

S O F T W A R[t]E+27 16 423 5537 • [f] +27 86 605 5406

MEAT

FOOD

S O F T W A R E

S O F T W A R E

[e] info@matrixsoftware.co.za P.O Box 24424, Vereeniging, 1941

Meat Matrix•Software (Pty) [t] +27 16 423 5537 [f] +27 86Ltd 605 5406

VAT No: 4470228604 • Registration No: 2005/000495/07 MATRIX MATRIX P.O Box 24424, Vereeniging, 1941 www.matrixsoftware.co.za Meat Matrix Software (Pty) Ltd MEAT FOOD www.matrixsoftware.co.za

MATRIX

S O F T W A R E

26

S O F T W A R E

VAT No: 4470228604 • Registration No: 2005/000495/07

S O F T W A R E

[e] info@matrixsoftware.co.za [e] info@matrixsoftware.co.za [t] +27 16 423 5537 • [f] +27 86 605 5406 [t] +27 16 423 5537 • [f] +27 86 605 5406 P.O Box 24424, Vereeniging, 1941 P.O Box 24424, Vereeniging, 1941

MEAT Matrix.indd 1 FOOD

MATRIX

MATRIX

Meat Matrix Software (Pty) Ltd

MEATVAT No: 4470228604 FOOD • Registration No: 2005/000495/07 Meat Matrix Software (Pty) Ltd MATRIXMATRIX VAT No: 4470228604 • Registration No: 2005/000495/07 MATRIX S O F T W A R E

Food Review | August 2017 S O F T W A R E

S O F T W A R E

2017/02/28 9:18 AM

C O N V E YO R S YS T E M S

THE ALL-NEW INDUSTRIAL FLOVEYOR •E co friendly conveying – The equipment is energy efficient, dust free and low noise.

It conserves water during cleaning cycles. Compared to baseline technologies, these benefits can assist with LEED certification.

•M inimises product degradation – Effortless and gentle transfer of raw materials.

One of the only conveying options that will not separate blended products or damage fragile and friable materials.

• I ntegrates with existing plant – There is no need for filter systems and expensive complementary equipment and structural supports.

•D ifficult to handle materials – Delivers hassle-free conveying of difficult materials such as titanium dioxide and carbon black due to its unique fluidising action.

Floveyor rope in tube cutoff section

• Automated sequencing of start-up and shutdown which can be interlocked, with inline sensors for reliable process control; • A range of early warning condition monitoring sensors for monitoring of system operating speed; • Bearing temperature and vibration.

The Industrial Aero-mechanical conveyor is compatible with Floveyor’s full range of rope assemblies, and includes eddy current and x-ray detectable variant for contamination-critical applications, designed in accordance with the EHEDG guidelines. An optional remote tensioning

•S uits any installation – Operates at any angle with diminishing maximum. throughputs. Delivers high throughputs comparable with much larger systems requiring a far greater footprint while also eliminating the need for heavy structural supports.

• Dust-free materials flow – The fully enclosed conveying line contains and prevents dust generation, promoting workplace comfort and safety as a clean solution while minimising requirements for zoned areas.

•S afe for hazardous materials – Safely handles materials with dust explosion risks and suitable for installation in zoned areas. Designed in accordance with Atex Directive 2014-34-EU with optional hazardous area components and or certification.

system for the rope assembly allows for inspection and maintenance from ground level within minutes.

Floveyer provides a full range of complementary equipment including mobile conveyors, FIBC bulk bag uploaders, tubular

drag conveyors, screw feeders and lump breakers. Equipment is available locally through Capack. •

Capack – www.capack.co.za

SIMPLIFY YOUR MATERIALS HANDLING

AERO-MECHANICAL CONVEYING SOLUTIONS GET THE FLOVEYOR EDGE • DESIGNED FOR CONTAMINATION FREE MATERIALS TRANSFER • MINIMISE EXTERNAL ENVIRONMENTAL CONTAMINATION • EASILY CLEANED USING WET AND DRY METHODS • APPROVED FOR FOOD PRODUCTION

info@capack.co.za

www.capack.co.za August 2017 | Food Review

27

C O N V E YO R S YS T E M S

Stainless steel is

SOLID GOLD

Sandvik supplies an innovative range of solid and perforated steel belts for the food industry. Its product portfolio includes belts for bake ovens, fish freezers, fruit and vegetable drying lines, meat cutting tables and confectionery cooling. Straightforward conveying operations round off the company’s offering.

W

hile initial input costs may be higher than other technologies, the units feature proven productivity gains. Hygiene and food safety is another area in which steel belts offer significant benefits compared with other materials.

ANSWER THE CALL FOR ALL FOOD PROCESSING APPLICATIONS Steel belts can be produced in carbon or stainless steel to suit different applications and can be manufactured to virtually any length or width. They can be supplied in solid form, or perforated to provide a longer lasting, lighter alternative to wire mesh belts. They also offer a unique range of thermal properties. Steel belts can operate in temperatures from -80°C to +750°C, making them equally well suited to both freezing and baking as they are to straightforward conveying.

BAKE OVEN BELTS FOR COOKIES – AND MORE

HYGIENIC CONVEYING FOR MEAT CUTTING OPERATIONS

Products as varied as bread, pizza bases, granola bars, biscuits, cakes, macaroons and brownies can all be baked on a steel belt. The solid surface provides a crisp base that cannot be achieved on any other conveying medium. Its hard and smooth quality delivers a clean product release.

Several bakeries have recently switched from wire mesh to Sandvik bake oven belts to meet the demand for American-style cookies. With their high butter content, these products can only be baked on a solid belt. The excellent heat transfer and thermal conductivity of the belt delivers a crisp base and rich, buttery cookie.

Stability, durability and resistance to stretching means steel bale oven belts deliver a much longer working life than other materials, in some cases up to 20 years.

Food scares have put meat processing operations firmly under the spotlight. The complete lack of crevices, textures or fibres in a solid steel belt conveyor means there is nowhere for bacteria to hide and breed.

A steel belt conveyor can be cleaned using heat, pressure, brushes, detergents or chemicals. Quick and efficient cleaning results in reduced consumption of water and cleaning chemicals or detergents, leading to lower costs and less environmental impact.

This inherent ease of cleaning has a significant impact on safety standards in a meat processing facility. Research by Finnish food laboratory VTT Expert Services Ltd has shown that bacterial build-up on steel conveyor belts is lower than that on plastic belts.

RELIABILITY BACKED BY GLOBAL SERVICE While Sandvik’s core business is the supply of belts to manufacturers of process systems such as ovens, coolers and drying lines, the company has extensive experience in working with industry partners in the development of conveyor systems. This expertise is readily available in the form of advice and support in the design of component parts.

If required, Sandvik can also supply conveying components including drums, compact belt tracking devices, belt and drum cleaners, safety scrapers and belt edge detectors, cast iron skid bars, graphite skid bars and both active and passive belt tracking controls.

All Sandvik steel belts benefit from the support of the company’s global sales and service network, with installation by trained personnel and technical support available 24/7. •

Steel belts are used extensively in the meat industry

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Food Review | August 2017

Sandvik – www.sandvik.com/steelbelts

C O N V E YO R S YS T E M S

A step up in hygiene for food grade conveyors

Food processors are continually looking at improving equipment hygiene. Some are motivated by new government guidelines, or the desire to reduce exposure to product liability claims. Others want to improve manufacturing efficiencies through faster sanitation routines or by maximising food safety.

C

onveyors are continually scrutinised for their ability to contribute or undermine sanitation initiatives. Conveyor design features can improve hygiene and sanitation, and many sanitary features can be applied to multiple conveyor types. Stainless steel is the preferred material for food-grade conveyors rather than coated mild steel. It resists bacterial growth, and withstands caustic washdowns. 316 stainless steel provides better corrosion resistance than 304. This is important for acidic foods or processes.

The surface finish of stainless steel impacts hygiene as smoother surfaces resist bacterial attachment and the accumulation of bacterial cells.

Compared to the industry standard of 2B mill finish, a rotary polish offers a more consistently

PDU elevating conveyor

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August 2017 | Food Review

29

2017/02/10 9:57 AM

C O N V E YO R S YS T E M S

The most hygienic type of belt conveyor features positive drive urethane belts

smooth finish to improve sanitation, which maximises food safety.

At a minimum, stainless steel and rotary polish should be considered within a conveyor’s product contact zones.

Extending the use of stainless steel to areas not in direct contact with food, such as the conveyor’s support structure, improves hygiene since bacteria can migrate from one area to another. Ground and polished stainless steel within the “drip, drain or draw zones” where pathogens can drip, drain or be drawn into the product area, further enhances food safety.

All product contact zones should feature 100 per cent continuous welds, rather than skip welds that can harbour bacteria.

The most hygienic conveyors feature no enclosed hollow bodies that could harbour bacteria and leak. Hollow bodies such as tubes, traditionally used in conveyor frames, are increasingly replaced by open section supports made of plate or formed sheet metal. Conveyors designed with free trading surfaces, where the conveyor bed is at a slope can drain, minimising build-up of moisture during production. This also eases washdown.

Another source of contamination is oil from drives, especially when equipment is mounted over other equipment. Currently, conveyor drives

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Food Review | August 2017

can be designed for use with food grade oil, but the move to oil free drives is underway.

Electromagnetic vibratory conveyors are always oil-free. Natural frequency conveyors, which have mechanical drives are being developed with oil free electric vibrating motors to eliminate the gear box, drive belts and motor oil from the process. Natural frequency conveyors can be built to grade, de-water, de-oil, align, feed and accomplish many processes while conveying. The opportunity to improve equipment hygiene with this shift to oil-free drives is substantial.

Food processors require different degrees of sanitation, with meat and dairy processors often relying on the most stringent high pressure washdown that uses caustic cleaning agents to limit the risk of bacterial growth. Clean-inplace (CIP) systems are common on many food grade conveyors, but are also being scrutinised as a potential source of bacterial contamination. CIP systems introduce additional pipes and additional pipe threads where bacteria can grow. For this reason, it is now understood that effective manual sanitation routes are often better than CIP systems. These should be limited to areas that cannot be accessed by the sanitation crew, such as conveyors that are mounted in the air.

BELT AND BUCKLE CONVEYORS In addition to the design and construction features, a variety of other considerations apply to belt and bucket conveyors.

In general, fabric belt conveyors with exposed belt edges present the least sanitary environment as belts can fray and contaminate products. Fabric belts with encapsulated edges are preferred, and may be a more sanitary solution, than modular plastic belt conveyors. The technology features crevices that can trap bacteria and are time-consuming to clean.

Iso-Flo conveying system

The most hygienic and sanitary type of belt conveyor features positive drive urethane (PDU) belts. This seamless homogenous thermoplastic belt eliminates the frayed edges of a fabric belt, and the many crevices of a modular plastic belt.

Unlike traditional flat belt conveyors, PDU systems drive their belts on sprockets like a modular plastic belt conveyor and are not under tension. This allows for easy lifting of the conveyor belt for relatively fast and thorough cleaning.

For applications that require elevating the product, modular plastic belts and PDU conveyors can be designed with flights. Compared to traditional bucket conveyors, which run on two chains that inherently challenge sanitation, processors can achieve the same rise in elevation with a PDU conveyor and improve sanitation. Modular plastic belt conveyors and PDU conveyors are unable to change direction, moving in a C-shaped path. Processors that require this motion will either need a bucket elevator or alter the line configuration to accommodate that limitation.

VIBRATORY AND HORIZONTAL MOTION CONVEYORS Vibratory conveyors are widely recognised as being inherently more sanitary than belt conveyors as they minimise product contact with moving parts and present a flatbed surface that is easy to clean. Horizontal motion conveyors further improve sanitation as the product slides along the bed. This produces a shelf-scrubbing action that eliminates the build-up of seasonings that can break off.

The most sanitary vibratory and horizontal motion conveyors feature many of the design and construction attributes mentioned. Not every conveyor type can accommodate every feature. For example, open-section supports and oil-free drives can be used on vibratory conveyors, but are not possible on horizontal motion conveyors due to engineering constraints.

Most conveyor suppliers offer a variety of equipment designed to satisfy various levels of standards, from basic to enhanced. Recognising that different suppliers include different features in their various models, that not all basic features are the same and not all enhanced features are the same, allows the food processor to understand what makes a conveyor sanitary. They can then better compare options and make the ideal selection given their applications and objectives. •

Key Technology – www.key.net

BeverageREVIEW SOUTH AFRICAN

www.foodreview.co.za

Global trend It is projected that global sales of beverage processing equipment will reach the US$ 20.02 billion mark by 2020

Sensors put an end to product contamination Enhance craft beer’s appeal with

Air Products’ Freshline range

August 2017 | Volume 7 | Number 8

NEWS

SAB’s technology investment

ANHEUSER-BUSCH-OWNED South African Breweries (SAB) will invest R2.8 billion in expansions at its Alrode and Rosslyn breweries. Both breweries will benefit from new packaging lines that work with returnable glass, producing up to 45 000 bottles, in 660ml and 750ml formats, every hour. The packaging lines take up 4 500m2 of floor space and will increase SAB’s capacity by 400 million litres a year. The Alrode packaging line will be online by August, with the Rosslyn line set to follow in October. The investment will make both lines more efficient, create jobs and contribute to a sustainable future through increased bottle recycling. SAB has also ordered four million new plastic crates and 48 million locally produced returnable glass bottles as part of the investment.

R1.5 billion will go to SAB’s brewery in Rosslyn, Pretoria. It includes a state-ofthe-art brewhouse that will be operational in the first half of 2018. The brewhouse can produce 14 different brews – each with capacity of 75 000 litres a day. The remaining R1.3 billion will be used to construct a greenfield malting plant at the Alrode brewery. The installation will expand SAB’s malting capacity from 110 000 to 150 000 tonnes of malt per year, meaning almost all the company’s malt will be manufactured in South Africa. That last investment will create 28 jobs on its own, and all the investments are expected to create 70 new positions in total.

SAB said that it was committed to a sustainable South Africa, and was creating opportunities for both individuals and businesses to help achieve it. Ricardo Tadeu, SAB and Anheuser-Busch zone president for Africa, says, ‘We strive to create a growing world where everyone has the opportunity to improve their livelihood.’

SAB's Rosslyn factory

From workhorse to glamour grape South Africa stands the strongest chance of making an impact in the US by linking its wine marketing message with a single varietal in the way New Zealand has done with Sauvignon Blanc and Argentina, with Malbec. This is the view of Lauren Buzzeo, the recently appointed managing editor of respected publication Wine Enthusiast, based in the US but read worldwide.

‘To associate Chenin Blanc with South Africa in the minds of US consumers is a way to begin the conversation. It’s easier for them to first get their heads around South Africa as a producer of this amazingly refreshing wine that’s so foodfriendly, than to tell them the country’s strongest suit is its ability to make wine in a huge variety of different styles. The US is currently the world’s biggest wine market by value, and has been since 2013.

‘As awareness and demand grows, there will be a mainstream place for bright, lively, approachable South African Chenins, characterised by ripe stone fruit and citrus flavours. Producers of South African Chenins should also be wary of underpricing their wines.

To over-deliver on quality in relation to price is to run the risk of implying the wines are not worthy and that they don’t deserve to be taken seriously. We need to see mid- to top-level bottlings priced higher, at US$25 and above, to demonstrate a pride and confidence in their world-class stature.’

Coca-Cola Beverages Africa acquires Equator Bottlers South Africa-headquartered Coca-Cola Beverages Africa Proprietary Limited (CCBA) and Africa’s largest Coca-Cola bottler has announced the conclusion of negotiations to acquire Equator Bottlers, the third largest Coca-Cola bottler in Kenya. The acquisition has been approved by the country’s Competition Authority.

Equator Bottlers Limited is now owned by CCBA (via wholly-owned subsidiary CocaCola Sabco East Africa Limited (CCSEAL).

Equator Bottlers, previously a subsidiary of Kretose Investments Limited is one of several authorised Coca-Cola Bottlers, which supply products in the western regions of Kenya. It was established in 1966 and is based in Kisumu. The company brings to CCBA a plant and three manufacturing production lines. These supply thousands of outlets in Kisumu and surrounding areas in Western Kenya,

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Beverage Review | August 2017

including Kisumu, Kakamega, Kericho, Bomet, Siaya, Busia and Vihiga.

CCBA bottles and distributes trademarked beverages owned by The CocaCola Company. It is Africa’s largest CocaCola bottler and the world’s 10th largest.

With over 14 000 employees in Africa, and 30 bottling plants in 10 countries, CCBA services over 450 000 customers with a host of international and local brands.

Commenting on the transaction, South Africa based CCBA’s managing director for the international division, Jacques Vermeulen says, ‘The acquisition makes perfect sense for us and for consumers in Kenya. We see a compelling long-term growth opportunity for non-alcoholic ready-to-drink (NARTD) beverages in the country. We believe that this is a more efficient model that supports the growth potential.

‘This acquisition will allow us to share best practice and improve our service for both the formal and informal markets and at the same time, encourage greater innovation. It will also allow us to achieve enhanced efficiencies which will mean an improved and more seamless service for customers.’

‘The creation of CCBA last year was designed to provide a stronger, more successful Coca-Cola system in Africa.

It creates greater shared value for the business and communities served across the value-chain, including local suppliers and retailers.’

‘CCBA’s aim remains to drive long-term sustainable growth, leverage our scale and build capabilities to accelerate sustainable growth. We believe this acquisition aligns very well with that ambition,’ Vermeulen notes.

FOOD & BEVERAGE PROCESS SOLUTIONS

TURNKEY SOLUTIONS FOR YOUR BREW HOUSE Metal Tank Industries (Pty) Ltd is a South African based company with over 20 yearsâ&#x20AC;&#x2122; experience in the supply of stainless steel vessels for all process industries.

The company specializes in turnkey project solutions, with strong expertise and experience in the beverage and food sector particularly the traditional drinks market for Sorghum beer and Maheu, as well as small commercial clear beer breweries.

Our scope of supply includes design, process engineering, process and production validation, plant building, pipelines, rigging, site installation, assembly and commissioning.

Typically, plant would include stainless steel vessels, pipework, valves and instruments, pumps, cooling towers, boilers, filters, steelwork and electrical panels.

Our large premises, only 20 minutes from O.R. Tambo Airport in Johannesburg, allows us to prefabricate and pre-assemble complete plants for the local and export markets.

We are well placed and equipped to deal with supply throughout Africa. Our logistic service includes, crating, containerization, loading, unloading as well as rigging and craneage.

Metal Tank Industries (Pty) Ltd. 146 Geldenhuys Road Putfontein, Benoni, South Africa

Process Solutions Built Around You

+27 (0)11 021 0501 +27 (0)83 462 6228 +27 (0)83 269 3636 sales@metaltank.com www.metaltank.com

I N D U S T RY TA L K

Put the fizz back into craft beer Craft beer brewing has evolved from a hobby to a precise and complex process. Air Products is a supplier of gases, such as oxygen, carbon dioxide and nitrogen to several microbreweries in Gauteng. The company plays an important role in supporting microbreweries to create craft beers suited to the local market.

U

sing the correct gases, at the correct time, in the correct quantities is vital to ensure the best product outcome. Freshline oxygen is added to the wort prior to the fermentation process. This improves yeast performance, which ultimately affects the flavour of the beer.

Freshline carbon dioxide is used for carbonation of the final product, while Freshline nitrogen is used to create the head or collar of a beer.

This adds attractiveness to the final product.

Air Products’ Freshline product manager Neli Dlamini explains the use of Freshline oxygen, ‘Brewing craft beer is an intricate process. It is important to ensure a secure supply of oxygen to the brewery. Malt and hops, water, yeast and oxygen is required

Eben Uys (middle) from Mad Giant

for the fermentation process.

Without oxygen, the entire process and ultimately the quality of the beer is affected.

We understand the process and aim to ensure that we supply product to the microbreweries, enabling them to produce quality, tasty craft beer.’

Air Products has formed a strong relationship with microbreweries in Gauteng and is proud to be associated with their growth in market share in the last two years.

To breweries such as Drayman’s Brewery, Mad Giant and Ubuntu Kraal Brewery, it is extremely important to ensure gases are available during specific parts of the brewing process. Delays or interruptions due to a lack of oxygen and other ingredients will have an impact on the final product.

"Craft beer is expected to take at least 10 per cent total market share of South Africa by 2022"

Air Products South Africa (Pty) Limited manufactures, supplies and distributes a diverse portfolio of atmospheric gases, specialty gases, performance materials, equipment and services to the Southern African region.

Air Products touches the lives of consumers in positive ways every day, and serves customers across a wide range of industries from food and beverage, mining and petrochemicals, primary metal and steel manufacturers, chemical applications, welding and cutting applications to laboratory applications.

Founded in 1969, Air Products South Africa has built a reputation for its innovative culture, operational excellence and commitment to safety, quality and the environment.

In addition the company aims to continue its growth and market leadership position in the Southern African region.

Service that delivers the

Difference

www.airproducts.co.za 34

Beverage Review | August 2017

I N D U S T RY TA L K

Neli Dlamini and Ndumiso Madlala Air Products’ infrastructure enables the company to supply microbreweries via cylinder, Maxitank, Minitank or CryoEase. such as Kallmeyer, Madlala and Uys, The latter is an effective and convenient the growth of craft beer is inevitable. alternative to cylinders, suited to customers There is no question – Air Products with smaller operational spaces. will be supplying the product needed Moritz Kallmeyer from Drayman’s Brewery by the brewers to continue to brew comments, ‘As a craft beer brewer, I strive quality products.’ • to constantly improve the brewing process.

South African Food Review, 132 x 200 mm, CC-en46-AZ368 08/17 A part of what I would like to achieveLimette, is Air Products – www.airproducts.co.za to brew beer with a lower oxygen count, more stability, greater clarity, improved balance and better head retention.

As a microbrewer, modern technology is costly to acquire. We don’t hesitate drinktec 2017 to consult the Air Products Munich, 11 – 15 September team to advise us on Hall B6 improving our beer quality by altering our gas usage and composition. We consider Air Products to be a part of our brewing team.’

Chief beer officer at Ubuntu Kraal Brewery, which produces Soweto Gold, Ndumiso Madlala, says Air Products has been a part of its operations from the beginning when the brewery was commissioned. He states, ‘It is important for us to ensure our product is available to our customers at all times. With the assistance of Air Products, we can ensure our beer is available to our Soweto Gold lovers through the focus on prompt delivery and efficient customer service.’

‘As a chemical engineer and a beer lover myself, quality is of the essence, whether it be the appearance or taste of the beer. Through Air Products’ commitment to ensure a supply of product, we can pride ourselves on the quality and availability of our beers as the market demands, especially in light of the fact that we also sell our beer at the brewery,’ says Eben Uys from Mad Giant.

Craft beer is expected to take at least 10 per cent total market share of South Africa by 2022.

Dlamini concludes, ‘We are fortunate to form part of the growth of the craft beer market. With the knowledge, skills and insight of brewers

Partner for Performance

We do more.

CC-en46-AZ368_0817.indd 1

07.08.17 11:15

August 2017 | Beverage Review

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B E V E R AG E P R O C E S S I N G T E C H N O L O GY

New approaches to an old objective Measuring, testing, monitoring or automation is applied to everything from the recording of variables in process technology to the analysis of product characteristics in the food and beverage industry. Sensors are used with increasing success to give products competitive features that set them apart without significantly increasing production costs.

T

he AMA Association for Sensors and Measurement Systems estimates the number of manufacturers of industrial sensors and measuring systems in Europe to be around 1 000 companies. There are about 3 000 European companies that work in the field of sensors, including manufacturers, retailers, engineering offices and specialised service providers. Against this backdrop, measuring technology is a future-oriented sector with a high demand for innovation.

Companies must combine their strengths in terms of quality, production and innovation to succeed in the highly competitive world market. In 2007, GHM Messtechnik developed the vision of combining different areas of expertise and profiling itself as a champion for the development of customer-oriented solutions that are appropriate for the market.

The GHM Group, consisting of Greisinger, Honsberg, Martens, Imtron and the Italian environmental measuring technology manufacturer Delta OHM, concentrate on bundling the synergies of these five companies. The Martens location has been focused on producing hygienic sensors for conductivity and temperature for several years. This has been expanded over time into a complete product portfolio of modern and extremely compact sensors for breweries and beverage producers. Two application examples from these areas are described below.

‘We see many opportunities for our range of hygienic instrumentation in the South African food and beverage market,’ comments Jan Grobler, managing director of GHM Messtechnik in South Africa. ‘From our hygienic flowmeters, level and temperature measurement devices through to our precise and accurate bench-top measurement, we know that the accuracy, reliability and quality of our technology is what gives GHM Messtechnik the edge in this sector,’ Grobler enthuses.

Grobler adds, ‘We recently introduced the GHM Messtechnik Turbidimeter, MAT 433/437, which is used for phase detection in the food and beverage industry. The absorption measurement principle, per EN ISO 27027, is designed to measure very high turbidity. The

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Beverage Review | August 2017

turbidity is output as a percentage of the maximum measurement value. This value can be converted with an integrated conversion table into material-specific concentrations or into the formazine based unit FAU. This is a very high-tech measurement device, which ensures less wastage, particularly in the dairy and brewing sectors.’

YEAST MONITORING Multi-function tanks are often used in modern breweries with the objective of avoiding frequent product change. They are also used for the fermentation process. The yeast used in this process settles in layers in the lower portion of the tank. To work efficiently and with high quality, dead yeast cells are separated from active yeast cells. While the dead cells are no longer used in the brewing process, the active yeast cells can still be used as pitching yeast. To ensure this, only the lowest layer of dead yeast is removed from the tank in an initial step. Then the next layers are separated from still fermentable yeast and beer in

another step. For this purpose, a turbidity sensor is installed directly at the tank outlet or in the yeast return line. This sensor measures the turbidity of the yeast/beer mixture flowing through it, independently of colour.

After the end of the storage or maturation time, most of the yeast remaining in the tank has now settled as lees. Since this portion of the yeast is decisive for the quality of beer, it should be separated from the beer as precisely as possible when emptying the tank. This task of phase separation is also monitored by the available turbidity sensor. It is therefore important that the turbidity value is measured as precisely and reproducibly as possible.

Only in this way can the possibility of product contamination and beer product losses be eliminated, assuring a consistent quality of beer. The turbidity value, which is a direct output as a 4 to 20mA current signal or alternatively via a pre-adjusted limit value contact, can be used with an external control unit for control of downstream valves. This includes delivery to a membrane filter unit or

B E V E R AG E P R O C E S S I N G T E C H N O L O GY

in the storage tank. The MAT433/437 turbidity meter is particularly suited for the above measurement applications.

SMALL BATCH PRODUCTION AND INDIVIDUAL BEER TYPES For production of small batches and individual types in 50l vats, the GHM Messtechnik Group offers new measuring and regulation components for the equipment of small breweries. This makes it possible for dedicated regional beer brewers and private home brewers to achieve a verifiable process with strict adherence to the recipes created.

The desired beer is the result of the individual recipe based on experience and creativity.

For this purpose, modern measuring and regulation technology is used in combination with state-of-the-art communication technology for simple and transparent use. A compact GHM-ONE multi-function regulator mounted directly in the system processes all measurements of the sensors certified for food production. These sensors include the durable and precise GHM-GTL series temperature sensors, GHM-MFI flow meters, GHM-MLP fill level sensors, and the GHMMLC limit level switch. These can recognise two different media by their capacitive properties, such as beer and foam. The GHMONE communicates the appropriate control

commands to the heating and cooling units, pumps, three-way valves and stirrers in the system. The colour display of the regulating device shows the operator the status of the recipe process and the quality of all regulating circuits and provides graphic and text-based instructions for the progression of the process. The operator confirms this locally on the touch display of the GHM-ONE. A special feature is the individual recipe specification, developed for the practitioner, with a clearly arranged table with the individual steps and their selected parameters. This shows the brewer their individual recipe “step-by-step”, as specified for the process. This can take place via a screen of any size in the form of a Windowsbased laptop, industrial panel PC or tablet.

The independently operating GHM-ONE multifunction regulator communicates with these PCs via its integrated Ethernet interface or wirelessly with the tablet via a standard WLAN gateway. With these devices positioned conveniently alongside the production system, the specially developed GHM-CAT tool runs with the new ‘beer production programme editor’ function, which simplifies operation of a brewing system. The brewer creates the necessary steps per their mash method of choice (e.g. comprising more than 60 different variable steps).

Specifications are entered for the exact parameters of the temperature profiles, holding times and step enabling conditions, the duration and number of pumping processes between the mash tank and lauter tun, the corresponding heating and cooling processes and the freely variable repetition processes for mash processing.

With this clear representation of the recipe in the logical sequence of the process and the corresponding set-points and actual values, the brewer recognises the successful progression of the brewing process at first glance. In addition to monitoring of close tolerance ranges for quality control and documented verification, the brewer is also provided with graphic trend representations and selectable process data reports to record batch production data.

This brewing solution offers all creative beer brewers and their system manufacturers a professional and transparent, individual process that is also suitable for small batches. •

GHM Messtechnik Group – www.ghm-messtechnik.de

Tel: +27 11 708 0408 Fax: +27 11 708 0415 kerri@brewtech.co.za henry@brewtech.co.za

P.O. Box 6928 Weltevreden Park 1715 South Africa

We are excited to announce…

We now do Change Parts ● ● ● ●

Star Wheels Ploughs Scrolls Bottle and Can Inverters

Call us now to set up an appointment 38

Beverage Review | August 2017

PackagingREVIEW SOUTH AFRICAN

August 2017 | Volume 42 | Number 8

www.foodreview.co.za

Huge

growth for convenience packaging

Unboxing carton and board demands

A revolutionary discovery in upcycling multilayer films

NEWS

The art of

convenience

The multihead weigher at Leo Dunne

C

AN YOU IMAGINE a world without packaging? Impossible, isn’t it? A single visit to the supermarket would be challenging, not to mention inconvenient.

We are spoilt for choice with the array of packaging options with their convenience features evolving year on year, making goods easier to use and store. Just when you think it cannot get any easier, it does, particularly with the rising demand for convenient food in emerging economies. Fuelled by busy lifestyles and an ageing population, consumers want the food that not only saves them time, but also involves less effort to prepare. Technology and innovative packaging options have widened the food choices and packaging options available in the market. To read more about progressions of convenience features in packaging, turn to page 42.

Until next month.

Assistant Editor Aarifah.Nosarka@newmediapub.co.za

Weigher increases productivity A 10-HEAD WATERPROOF, mid-range model, multihead weigher from Ishida has played a central role in assisting Leo Dunne, an Irish vegetable grower, to expand its supply of processed carrots. While oversized or irregular carrots are not suitable for the prepared carrot market, they are still high quality products. The company has realised these carrots can be successfully marketed through further processing, which is why it required an effective processing and packing line.

The Ishida technology with three litre hoppers not only delivers reliability, but

also achieves around 55ppm on 500g bags of carrots with an overall accuracy rate of 98 per cent. The machine’s ease of operation, including fast start-up using the simple-to-use remote control unit, gives it the flexibility to cope with the varying production demands of Leo Dunne.

‘All our staff are fond of the machine’s ease of operation. It is also far more intuitive than other weighers. If there are any minor issues during production, the machine will identify them and inform the operator how to fix them. This is vital to maintaining production,’ says Emmet Dunne, manager at Leo Dunne.

New international sales manager for Hugo Beck MANUFACTURER OF HORIZONTAL flowpack, film packaging and post-print processing machines, Hugo Beck has appointed Mario Möginger as international sales manager. The position will see Möginger provide cross-sector sales support with a specific focus on Mario Möginger applications in the automation and flowpack sectors.

‘During my career I have come to know Hugo Beck as a company with a high level of visibility in the marketplace and excellent technological expertise.

When the opportunity arose to join the

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Packaging Review | August 2017

business, I immediately saw the potential to build on this platform and use my experience to promote Hugo Beck as a global leader in the supply of horizontal film packaging solutions,’ he comments.

Timo Kollmann, sales director and authorised signatory at Hugo Beck says Möginger is perfectly suited to the new position in terms of the specific challenges that mark projects in the field of corporate automation processes.

Möginger has experience in mechanical engineering and previously held a variety of senior national and international sales positions.

NEWS

Praise

First-rate

worth singing FOR TWO CONSECUTIVE years, KHS has been voted one of the most popular machine and systems manufacturers in Germany. This is according to a Best Employers special survey published in the German magazine, Focus.

The survey names the most attractive employers among medium and large companies. In the machine construction and engineering sector, KHS is named ‘the best company’ in the North RhineWestphalia area.

KHS also gained third place among the industry’s big corporations. The company was among the top five in the overall ranking of all German machine and systems manufacturers over the last year.

Together with its cooperative partners, Statista and Kununu, Focus pinpointed German companies where employees were especially satisfied with their jobs in 2016.

Among other factors, the rating is based on assessments with personnel inside and outside the company.

financial results

Roelf Staab

Rolf Staab, head of the central human resources division at KHS, considers the renewed accolade proof of the company’s constantly high level of employee satisfaction.

‘We're continuing to work towards creating the best possible working conditions. The basic tools we apply in this respect include our multidisciplinary trainee programmes and an extensive range of courses of basic and further training,’ he concludes.

Multilayer films present a revolutionary discovery PARTNERS OF THE innovative Virtuous Circle project recently announced the results of ground-breaking research into new recycling options for multilayer food packaging.

These findings shed new light on the potential of this type of packaging to be upcycled for use in products of value in a circular economy.

Multimaterial multilayer films are an innovative type of packaging used to preserve food. They offer protection from contamination and oxygen, which leads to faster degradation of food.

While highly effective, multi-layer packaging has been criticised as challenging to recycle, which includes separating the different layers and sorting

them by type. In addition, the general perception is that even if these materials can be technically recycled, the resulting raw material is of such poor quality that it effectively amounts to down-cycling.

Research undertaken has demonstrated other potential uses for higher volumes of multilayer comingled film waste. These additional uses can add economical value in larger market segments Until now, it has been necessary to add recycled high-density polyethylene (HDPE) to recycled multilayer waste to achieve stiffness and strength in end products.

Owing to the research carried out by DuPont and RWPA Solutions, a new way to recycle multilayers and contribute to high quality products without the use of HDPE have been successfully tested.

The project, coordinated by DuPont in close collaboration with FutureLife, EqualTrade4 and Amcor, among others, uses a circular economy approach through the combination of smart food designed to meet the needs of children in isolated communities. It also incorporates smart packaging to keep food fresh for as long as possible.

SACMI RECENTLY PRODUCED one of its best financial results since inception. Revenues from sales and services amounted to €1.4 billion, about 40 million more than in 2015, and a net worth of €642 million.

These figures were illustrated at a shareholders’ meeting on 19 May at the company’s new auditorium.

The results are said to have been exceptional for three years in a row.

Paolo Mongardi, president of Sacmi Imola says the increasing specific weight of the Italian market reflects a significant rise in investment within the industry.

‘Sales are rising and the consolidated net result stands at about 34.5 million euros,' Mongardi comments.

The results were driven by the excellent performance of the ceramics, and closures and containers divisions. Particularly noteworthy were Sacmi's Industry 4.0 projects.

This was part of a broad policy encompassing all the cooperative's divisions and businesses. Alongside ceramics, the success of the Continua +line and new Eko kilns has been combined with large slab storage and handling systems developed by Toyota Handling Italia. These were recent developments by the company in the beverage industry which have focused on total integration of production lines. The concept has extended from cap and preform to filling, labelling and secondary packaging.

August 2017 | Packaging Review

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I N D U S T RY U P DAT E

Used cartons now recyclable in South Africa Juice and milk cartons have long been one of the contributors to waste in South Africa’s landfill sites. In what is a major development for the local paper and packaging recycling market, Mpact Recycling is pleased to announce that liquid cartons are now recyclable.

T

his is owing to an investment of R46 million in a Liquid Packaging recycling plant at Mpact’s Springs Paper Mill facility. The investment forms part of Mpact Group’s various recycling initiatives to increase available materials for all its mills.

John Hunt, MD at Mpact Recycling says it was previously not possible to recycle juice and milk cartons, polycoated cups and wet strength bags, as these are not made of typical paperboard.

‘Although approximately 75 per cent of liquid packaging content is paper, to make it liquid-proof the product is lined with low density polyethylene, which acts as a watertight barrier. A lining of aluminium foil serves as a barrier to light, flavour and oxygen and enables the contents to last for months without preservatives or refrigeration. A coating with kaolin clay is also included to improve the printing surface,’ he says.

The mix of plastic and metal (polyalu) meant cartons could not previously be recycled as the polyalu could not be separated from the paper of the carton.

‘This needs to be removed before the paper can be recycled. This was facilitated by two developments. Firstly, local liquid carton manufacturers have over the years redesigned their processes to significantly reduce the amount of plastic used in the packaging. Secondly, Mpact’s new Liquid Packaging recycling plant has

DID YOU KNOW?

Liquid cartons,

previously nonrecyclable, can now be recycled.

the capacity to recycle 25 000t of used liquid cartons per annum. It will also allow us to produce approximately 18 000t of recovered fibre, which will be fed directly into our paper division for use in new paper products,’ Hunt explains.

ACQUISITIONS, INVESTMENTS AND AWARENESS To complement the company’s initiatives to expand its collection of recyclable materials, Mpact acquired Remade Holdings a year ago. In May 2016 the group invested

R350 million into Mpact Polymers to develop a plant that would process up to 29 000t of PET bottles annually.

The company also invested R765 million to upgrade its Felixton mill, which will produce an extra 60 000t of paper from recycled fibre each year. Mpact Recycling’s goal, through its extensive collection network of paper, containerboard, PET and now liquid packaging, is to supply its mills with sufficient volume to match its capacity.

This is why the company embarked on a campaign to raise consumer awareness around the recyclability of juice and milk cartons and that they should be placed in Ronnie bags for kerbside collection.

Consumers must ensure the cartons are empty and flattened. In the event there is no kerbside collection, recyclable items can be dropped off at the nearest Ronnie bank at schools or community centres.

Alternatively, cartons can be delivered to any of Mpact’s buy-back centres, which are located countrywide, or to one of its seven Mpact Recycling operations for payment.

‘Liquid carton packaging provides a category of waste that can be recycled and will add considerably to land preservation in South Africa as consumers can redirect cartons away from limited landfill space,’ Hunt concludes. •

Mpact – www.mpactrecycling.co.za

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Packaging Review | August 2017

C O N V E N I E N C E PAC K AG I N G

PRACTICAL PACKS

shape the future Consumers want ways to economise, which will lead them to buying in bulk and making multipack purchases. At the same time, the demand for small on-the-go portions and conveniently packed products is proliferating. PACKAGING REVIEW reveals why.

O

liver Sperber, chief innovation officer at Mondi Consumer Packaging (Mondi) says food brands need to differentiate their on shelf packaging to divert consumers’ attention to more convenient products. ‘They should also diversify their pack style portfolios to accommodate changing eating habits.’

Mondi’s offering focuses on convenience, look and feel and sustainability. Its products include: • SteamFast – a range of functional packaging including pouches, bags and lidding films for microwave steaming. It has been designed for consumers who lead busy lives. The award-winning valve technology enables pressure to build up within the bag or pouch, effectively cooking the product under pressure, which is maintained throughout the cooking time duration. No preparation is required before or during cooking. This means there is no requirement to add water, stir the product or pierce the bag. The packaging is also easily disposable;

“New substrates, design effects and novel ways of packaging drive the need for innovative ink solutions” • CornerPack – a bag with semi-circular scoring lines in the corner for easy opening. Consumers are able to easily dispense the product inside, in a controlled way; • The paper FlexziBox – a new paper, flatbottom bag, first introduced at Interpack 2017. The solution literally stands out on shelf because of its flat, stable base with rounded edges. It is easy to open and reseal and is described as an ideal packaging choice for dry products. ‘The high quality of the printed graphics (including both flexo and roto gravure) combined with the natural feel of the product make the FlexziBox an exciting

PaperPack pack with window

The FlexziBox

A SteamFast pouch

alternative for brands looking for that certain something,’ Sperber comments; • The PaperPack bag with window – this offers a natural touch and feel to the pack. This option was designed to engage consumers’ senses. The window helps the product stand out on shelf by making its contents visible.

LOCKING IN FRESHNESS Noel Cochius, owner of Proficient Packaging, says with the need for consumer convenience and ever increasing demands for freshness, ease of use, re-usability and recycleability, the company offers a number of products with these possibilities.

‘We make many different types and forms of packaging, and tend to favour the value added modes. This is because they give consumers more features and benefits, which essentially is value for money,’ he adds.

Some of these packaging items are: • Ziplock or zippered bags for products that require re-usable, portion protection and ease of closing. These are typically used for frozen products, fresh fruit and vegetables as well as bakery and confectionary products; • Double Zipper Bags suitable for products requiring enhanced protection or leak proof seals. These bags are easy to close and particularly suitable for dry goods filling, among others; • Re-closable bags are appropriate for a number of products and easily re-closable; • Self-sealing glue strip bags made from LDPE or PP. These bags are typically closed with a lip and Self Seal Tape, which has a backing liner that is removed to expose glue to seal it after filling. No sealing equipment for the packer is required.

These are suitable for multi-packing or

August 2017 | Packaging Review

43

C O N V E N I E N C E PAC K AG I N G

used for single-serve portions. Glossy film bags high decorative prints are used for confectionary and more.

Cochius says the company regularly works on new ideas and innovative methods of producing packaging. ‘This is not only to improve on packaging, but also bring new ideas and solutions to market. We are driven by working with clients to solve challenging packaging requirements.’

The company recently produced new zipper bags, the Polyprop Zipper bag. This can be Blown Polyprop and BOPP Zipper bags. ‘The high clarity and crisp clean look of polypropylene are popular and offers high class printabilty options for top end looks.

This is for enhanced shelf appeal coupled with re-closabilty that works and is cost effective,’ he comments.

Proficient Packaging, located in Cape Town, manufactures and supplies a range of bags, pouches, films, sheets and a diverse range of packaging.

INKLING FOR INKING The need for safe inks in the use of convenience food packaging, especially fast food packaging has never been greater.

This is according to Jonathan Johnstone, MD at Siegwerk, who says the increasing needs is because of the amount of fast food consumed directly from packaging.

‘Fast foods are often reheated in the same packaging before eating and although no detailed scientific investigation has been carried out on the effects of reheating or microwaving printed packaging containing fast food, it is important that food safe inks are used.’

In recent years gravure and flexographic flexible packaging have seen growth, particularly in stand up pouches. This, at the expense of cartons for traditional consumer products like breakfast cereals.

‘While more expensive, the product protection properties offered by flexible packaging is significantly

better than traditional carton board packaging,’ Johnstone comments.

Packaging is more than just providing information. It is key for food protection, convenience and functionality. The look and feel of packaging creates brand awareness, playing a significant role in attracting consumers.

‘New packaging requirements of brand owners and converters also have an impact on inks and varnishes. New substrates, design effects and novel formats drive the need for innovative ink solutions. That’s why an early and open exchange with brand owners and converters is a win-win situation for all parties concerned. When the ink manufacturer concretely understands what the brand owner needs, we can either better support the customer with state-of-the-art ink solutions or drive our R&D efforts in a specific direction to make the packaging idea feasible and ensure high quality solutions on a global level,’ says Dr Thomas Boucoiran, global head of brand owner business at Siegwerk.

The company not only offers printing inks for packaging applications and labels. It also provides packaging expertise and creativity skills to brand owners and converters seeking outstanding packaging designs to improve the impact of their packaging at the point of sale. Siegwerk aims to shape the future of packaging with this service.

It can be considered as the company’s innovation factory to identify optimal packaging solutions. It offers brand owners brainstorming, feasibility and technical setup studies with the goal to pave the way for the final realisation of any jointly developed packaging idea.

In the packaging market, there is a steady increase in regulatory efforts worldwide that is driven by stringent regulations like for example the Swiss ordinance. Large global brand owners have introduced their own policies based on current regulatory requirements.

Product safety is the most important and challenging aspect in packaging.

The company has taken a further step in its global commitment to product safety.

This is evidenced by the recent launch of its Ink Safety Portal (www.ink-safetyportal.com), which is in line with its goal of supporting customers in the manufacture of safe printed products.

The portal is aimed at knowledge sharing.

It offers condensed knowledge on crucial product safety and regulatory topics with regard to printing ink ingredients, regulatory affairs, exposure assessments and safety evaluations. •

Mondi – www.mondigroup.com/ flexiblepackaging Proficient Packaging – www.profpack.co.za Siegwerk – www.siegwerk.com

Siegwerk had a laboratory built in 2014 to ensure local support for global technology The CornerPack Packaging

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Packaging Review | August 2017

Protecting food well with Siegwerk Printing inkS Siegwerk has developed special low-migration inks and varnishes for food packaging. Our printing inks for food packaging are largely based on renewable, vegetable resources. They are low in odor and free of mineral oils or genetically engineered organisms. They make an important

contribution to the production of sustainability-oriented packaging solutions. Siegwerk printing inks facilitate modern, light-weight packaging with intelligent functionality and optimized durability for food safety. “Save food” with efficient solutions from Siegwerk.

www.siegwerk.com Siegwerk Druckfarben AG & Co. KGaA Alfred-Keller-Str. 55 ∙ 53721 Siegburg ∙ Germany ∙ Phone: +49 (0) 2241 304-0 ∙ Fax: +49 (0) 2241 304-777 ∙ save-food@siegwerk.com

C A R T O N & B OA R D

Unfolding carton novelties Ever thought adhesives could have a ripple effect on packaging? They can, particularly when it comes to carton, board and production efficiency. By Aarifah Nosarka

A

well-designed pack, in addition to providing consumers with a positive brand experience, can enable food and beverage products to stay fresher longer.

Adhesives are present in all packaging and help protect what’s inside. According to Smithers Pira, current trends in the use of packaging substrates will continue with 31 per cent for boards, 23 per cent for rigid plastics, 16 per cent for flexible packaging, 13 per cent for metal, seven per cent for glass, five per cent for paper and one per cent for foil.

Regarding end use, 31 per cent will be used for food and beverage packaging while 39 per cent will be used for industrial and bulk packaging.

H.B. Fuller states that markets continue to change more rapidly and often to keep pace with technological advances and consumer demands.

‘We have experienced dramatic changes in the adhesives raw material supply chain. There have been significant developments in the machinery used across the manufacturing sector,’ says Tom Meek, business director, Africa, H.B. Fuller Kenya.

Demographic shifts have also affected packaging design and production. The overall population on the African continent is expected to double in the next 30 years.

‘Consumer and durable goods manufacturers can’t overlook this healthy growth and expansion, and are increasingly investing directly in key African nations to satisfy domestic demand with locally

Rugani carrot juice

DID YOU KNOW? Since 1981, Cama has been developing, manufacturing and installing secondary packaging machinery around the world.

Cama’s complete flexible line

46

Packaging Review | August 2017

produced goods. Now more than ever, manufacturers and product distributors serving the world’s fastest growing population, require an adhesives supplier that can partner with them to respond to growing demand for both consumer and durable goods. The supplier must be focused on improving food safety, adhere to all legal and environmental regulations, consistently meet growing inventory demands, collaborate to promote brand loyalty, and help reduce costs while remaining innovative and socially responsible,’ Meek explains.

In February 2015, H.B. Fuller acquired an industrial adhesives provider in Nairobi, Kenya, complementing the company’s existing production facility in Cairo, Egypt.

It also enables the provision of highly specialised adhesive formulations and technical support to a growing customer base. In food and beverage packaging markets, key global trends such as a reduction in packaging materials used, a stronger focus on safety and sustainability, and the constant push towards lower production costs have resulted in some significant innovations in adhesives and adhesive application technology.

‘Basic hot melts based on EVA technology have lost share to products based on metallocene polymers or more specialised EVAs that can be applied at lower temperatures. The latest hot melt developments involve the use of new polymers and lower content of scarcer resources, such as tackifiers. These lower

C A R T O N & B OA R D Dairypack cartons

density products promise wider end-use temperature resistance, good adhesion to a variety of substrates and good resistance to difficult substances such as migratory oils and fragrances. It further offers a reduction in cost because less adhesive is required and no charring or degradation of the adhesive occurs in the applicator system,’ Meek adds.

COMPACT PACKING MACHINES AND ROBOTS The Cama Group (Cama) offers a complete flexible line, also suitable for the bakery industry. The line is part of its Break-Through Generation range. The complete system handles flow-packed crispy bread in piles, into pre-glued cartons. It incorporates a Cama Triaflex Delta robot top-loading unit with a high-speed continuous motion cartoner. The combined system is designed to handle two different product types in several loading configurations. Flowpacks are delivered with up to 600pcs per minute to the Cama line and received by a vertical race track. The Cama Delta robot picks up the flow wraps and places them in the right orientation onto the conveyor of the cartoning machine.

The robot creates the necessary loading pattern, giving the opportunity to handle flat and on-edge configurations, with or without product rotation within the carton. The continuous motion cartoner side-loads the groups of flowpacks into pre-glued cartons.

Speeds differ according to the different products and configurations, from 80 to 200 cartons per minute.

The guaranteed return on investment can be future proofed through the modular construction of the line and the use of offthe-shelf and standardised components. A second loading unit can be added providing an easy upgrade for supplementary production capacity. Versatility, reliability and size change alteration are standard components for the Cama installation.

This line is described as a great example of Cama’s unique selling proposition, providing experience, technology and service with the combination of four-axis robots and highspeed cartoners under the same hardware and software platform.

CONVENIENT CARTONS FOR LIQUIDS Polyoak Packaging’s new division, Dairypack Cartons, specialises in the marketing and distribution of aseptic packaging systems in southern Africa. It was launched as an exclusive partnership with IPI, which is a complete system supplier providing fully integrated filling machines, multilayer packaging and closure solutions for the aseptic packaging of liquid products in multilayer structures. IPI forms part of Coesia, a group of companies operating globally and headquartered in Bologna, Italy.

The partnership was formed to offer the market new and exciting carton shapes, pushing the boundaries in standard carton brick packaging.

‘Polyoak has a long established presence in the liquid food packaging market and, along with our core focus on customer service and producing high volume, high quality plastic packaging, we are confident

this partnership will drive innovation in the local carton market,’ says Garron Boshoff, executive for Dairypack Cartons.

The division offers a range of aseptic pack sizes, from 100 to 1 000mℓ, in different shapes with 28 options from which to choose.

The complete system service includes fully integrated filling machines, multilayer packaging and matching closures, as well as the necessary downstream equipment for secondary packaging, to produce a finished product at the highest quality.

This is augmented by Polyoak’s on the ground technical support and its extensive distribution networks, which are already well established in the liquid food, juice and dairy markets. ‘Dairypack Cartons looks forward to partnering with customers to explore and commercialise packaging opportunities to grow their businesses,’ he adds.

A case in point is Greenway Farms, a South African carrot producer that delivers more than 200t daily of the Rugani brand of carrots. The business started in 1992 as a small farmer growing different types of vegetables for the South African National Fresh Produce Market. In 2000, owners Vito Rugani and Vincent Sequeira began specialising in carrot farming and soon switched their vision to large-scale production.

Today, about 40 per cent of carrots consumed in South Africa are the Rugani brand. To meet growing demand, Greenway Farms opted for the SuperSlim aseptic carton from Dairypack Cartons. The slender carton comprises a King Twist cap on the 750mℓ packaging – the largest opening available to the aseptic carton market – making it more convenient and easy to pour. The carton is said to be ‘impossible to miss on shelf’, owing to its tall, streamlined shape. •

Cama Group – www.camagroup.com H.B. Fuller – www.hbfuller.com Polyoak Packaging – www.polyoakpackaging.co.za

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Packaging Review | August 2017

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Food Review | August 2017

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