Food Review August 2019

SOUTH AFRICAN

www.foodreview.co.za

Journal for food and beverage manufacturers AUGUST 2019 Vol. 46 • No. 08

Ingredients to create brilliance

Rethink meat with these plant-based protein ingredients

Harness the power of beverage processing technology

New packaging for ultimate convenience

Your wine will love it.

Best solutions and services for the purest taste.

Good wine gets better with age. We, too, build on our decade-long experience when it comes to developing innovative products for wine processing. With our novel products for all primary filter stages and our Vinosart PS membrane filter cartridges, we offer solutions for all filtration steps and the final filtration of wine and sparkling wine to guarantee the highest purity and maximum microbiological safety for the filling process. All this with a long filter service life and therefore significantly reduced costs. Why should you treat your wine with less care!

Maximum Purity | Minimum Operating Costs | Best Service Want to learn more? www.sartorius-stedim.com Take advantage of the new Sartorius subsidiary in South Africa Contact us: Sartorius South Africa ¡ info.South Africa@sartorius.com

CONTENTS

AUGUST 2019 | Vol. 46 • No. 08

24 BEVERAGE PROCESSING TECHNOLOGY

Easy beer clarification

Flexible tech for high-speed production

PAGE

10 “Savannah Fine Chemicals, in conjunction with Barry Callebaut, recently held its first two-day industry cocoa knowledge workshop in Johannesburg ”

08 NEWS

Latest trends in personal nutrition

Alpla commits to going green

New peristaltic lab for WMFTG

Lizelle Gerber appointed Nederburg cellar master

Intermediate bulk containers for flexible powder handling

Aseptic packaging is the perfect fit Hygiene from brew to bottle

Afrox gas gets connected

Can functional ingredients create innovation?

PAGE

34

Promote flexibility and automation in packing

The World’s Leading Supplier of Solutions for Material Handling Interroll offers hygienic, energyefficient solutions for the entire food and beverage manufacturing chain. From Conveyors to Sorters, from Rollers to Drum Motors, we have the right answer for your application. Get in touch with us to discuss your projects in the food industry.

12 NEW PRODUCT COMPETITION

A showcase of 2019’s entries

14 PROTEIN ALTERNATIVES

Pea protein is a nutritional powerhouse

Solutions for growing plant- based protein demand

A snapshot of new protein alternatives

19 CONVEYOR SYSTEMS

All your lubrication needs sorted

Interroll’s new MCP modular conveyor platform

Maximise conveyor efficiency with steel conveyors

23 LABORATORY &

TESTING SERVICES

Convey

34 FORM, FILL & SEAL

GEA’s Smartpacker for functional efficiency

Industrial cutting tools for VFFS

38 CONVENIENCE PACKAGING

Personalised packaging for ready-to-eat meals

Convenience for busy consumers

• • • •

Conveyor Rollers Modular Conveyor Platform Belt Curves Drum Motors

Sort • Horizontal Sorter • Vertical Sorter • High Performance Diverts

Pick • Carton Flow • Pick Tunnels

Store • Modular Pallet Conveyor Platform • Pallet Flow

A new facility for high-quality cannabis testing

August 2019 | Food Review

3

Visit interroll.co.za for more information

EDITOR’S COMMENT

EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmedia.co.za Layout & Design: Andipha Nkoloti +27 (0)11 877 6168 andipha.nkoloti@newmedia.co.za Contributors: Chané Brecher, Darryll Macdougall, Enrico Ciani, Guillaumme Rolland and Valerio Ferone

How food tech can help us thrive

M

eat consumption raises not only ethical, but medical, economic and environmental questions.

After following a group of test participants for decades, Harvard researchers found a connection between daily consumption of red meat and chronic diseases. The World Healthcare Association has also announced that beef, lamb and pork are carcinogenic when consumed as processed food. The organisation also linked red meat to heart disease as well as Type 2 diabetes.

Whatever your view, researchers predict that by 2020, 2.4 million people will die due to meat-related reasons. Oxford scientists estimate that by 2050, meat diets will cost the world economy at least US$1.6 trillion.

To restore ecological balance, it is suggested that western countries must cut beef consumption by 90 per cent.

If you take all these factors into account, it is evident there is enormous potential for growth in plant-based proteins. The challenge lies in finding a way for our sensory system to process the taste, smell, texture and nutrition of vegan food to get the same reward as real meat.

In our protein alternatives feature on page 14 we unpack pea protein and look at the collaboration between Royal DSM and French agro-industrial group Avril and their work in developing a protein, based on nongenetically modified canola. An overview of the most well-known protein alternatives rounds off this feature.

We also bring you the latest information on Chem-Science Laboratories’ new cannabis

testing facility located in KwaZulu-Natal (page 23). This development is a direct result of the need to meet the requirements of the exploding cannabis industry in South Africa.

DC Norris works with food and beverage producers across the African continent. The company focuses on supplying efficient and flexible processing solutions. On page 26 we highlight some of the latest trends in this market. We also look at why the beverage market for children is underserved.

Manufacturers can close this gap by using nutritional ingredients such as Wellmune - a yeast beta-glucan clinically proven to help support the immune system. With consumers increasingly time-strapped, the market for convenience food packaging is booming!

Some of the latest product trends in this sector are under scrutiny. More on page 38.

We finalised judging of our 2019 Food Review/Symrise New Product Competition entries in August at the Good Food Studio in Sandton, Johannesburg. A total of 29 entries were received – a good indication of what is trending this year. For a glimpse on who went head-to-head this year turn to page 12 now!

Happy reading,

ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmedia.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmedia.co.za Sales Executive: Daleen Filbey +27 (0) 83 409 3119 daleen.filbey@newmedia.co.za INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmedia.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmedia.co.za Production Controller: Mandy Ackerman Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park 2092 Tel: +27 (0)11 877 6111 Fax: +27 (0)11 877 6198 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published by New Media, a division of Media24 (Pty) Ltd MANAGEMENT TEAM MANAGING DIRECTOR: Aileen Lamb COMMERCIAL DIRECTOR: Maria Tiganis BRAND STRATEGY DIRECTOR: Andrew Nunneley CHIEF FINANCIAL OFFICER: Venette Malone HEAD OF HR: Camillah West

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.

Dr Heidi Grimmer CEO of Stratcom Branding, founding member of the glba (Global Local Branding Alliance)

Gail Angela Macleod

4

Food Review | August 2019

CEO: MEDIA24: Ishmet Davidson

Managing director of Symrise South Africa; chairman of SAAFFI.

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

Kerusha Pillay

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

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Hot Food Convenience for on-the-go consumers

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NEWS

Ambitious targets to reduce carbon footprint by 2022

A

Nutrition becomes personal

T

he idea of personalised nutrition is generating a significant buzz in the food industry. Innovators are seeking new ways to tackle the many and varied demands of the modern consumer.

Progress is clearly being made when it comes to specific dietary needs or interests.

In 2018, nine per cent of US consumers were following plantbased diets, six per cent keto, three per cent paleo and three

per cent vegan diets. There has been a corresponding rise in global NPD in these areas, with a 64 per cent increase in plant-based launches between 2017 and 2018 alone, while keto launches rose 76 per cent, paleo 33 per cent and vegan 27 per cent.

The industry is recognising that food and beverage can also impact on mental and emotional wellbeing, with guilt-free and feel-good products attracting more attention. •

lpla’s third sustainability report provides detailed insights into the company’s development strategy.

The report describes the progress of sustainable development from 2016 to 2018. This was used as a basis for formulating ambitious objectives for 2019 to 2022.

The company's sustainability record for the past three years is very positive: energy consumption in relation to production volumes was reduced by 6.6 per cent and consumption of freshwater to material usage by 40 per cent. The company even exceeded its target for using recycled materials. Demand has risen sharply in the reporting period.

'Alpla has more than 25 years of experience in recycling, both in the manufacture of recyclates and in their processing. That’s why we’re able to offer our customers functioning solutions on both side,’ emphasises Christoph Hoffmann, director corporate strategy, sustainability and circular economy. •

The home of industrial ideas

A

tlas Copco has solidified its position as a global pioneer in sustainable productivity solutions by delivering innovative cutting-edge technology, products and services to customers across sub-Saharan Africa for over seven decades.

The industrial engineering giant created yet another milestone in its history on 26 June 2019 with the hosting of an annual press conference.

Aptly themed to convey Atlas Copco's new corporate brand message - The Home of Industrial Ideas – the event showcased the company's vast capabilities. The three business areas take the value proposition of delivering world-class, reliable, Industry

4.0 compliant solutions to customers, from a one-man operation to a multi-faceted plant, so that they can take their productivity and profitability to the next level. •

The open day held at the Atlas Copco premises

8

Food Review | August 2019

NEWS

New peristaltic lab for WMFTG

L

ocated in Laser Park, West Rand, Watson-Marlow Fluid Technology Group’s new larger premises - totalling more than 2 300m2 will provide additional levels of technical support and service for the Bredel range of high-pressure hose pumps, MasoSine sinusoidal pumps and Watson-Marlow peristaltic pumps and tubing.

The new facility incorporates a full equipment training centre and test lab. This area has been designed to deliver operation 9.pdf and 1 maintenance 2018/03/26 training 11:34

to WMFTG's staff as well as distributors and customers.

Nico van Schalkwyk, general manager of Watson-Marlow Fluid Technology Group South Africa comments, ‘We're delighted that the investment in additional facilities allows us to offer a much deeper level of support to our many customers.

'I am particularly proud that we are offering the first peristaltic test lab in South Africa and which will keep us one step ahead of our competitors', he concludes. •

Libertas appoints new Nederburg cellar master

S

easoned, award-winning winemaker Lizelle Gerber is joining Nederburg Wines in Paarl as its new cellar master Lizelle Gerber from August 2019. Nederburg is part of the newly-formed Libertas Vineyards and Estates, Distell’s independent premium and fine wine company.

‘We are proud and excited to welcome Lizelle to the team,’ says Niël Groenewald, managing director of Nederburg. ‘She brings an impressive set of innate talent and creativity, as well as practical knowledge and experience to the position of cellar master.’•

C O M PA N Y F O C U S

Delivering a wealth of cocoa knowledge Savannah Fine Chemicals, in conjunction with Barry Callebaut, recently held its first two-day industry cocoa knowledge workshop in Johannesburg. The event proved to be a sweet learning experience for all who attended, writes Chané Brecher.

B

arry Callebaut is a highly regarded manufacturer of quality chocolate and cocoa products.

The company operates 60 production facilities in more than 30 countries.

The chocolate supplier has close to 180 years of history and heritage in processing quality cocoa powders from carefully selected premium cocoa beans. Its Bensdorp brand offers consistent quality, complemented by unmatched research and development expertise.

Savannah Fine Chemicals (Savannah) is the exclusive distributor of these fine cocoa derivatives. Curiosity and collaboration are two of Savannah’s core values. The company continues to focus on key areas that yield value while staying relevant.

Included in Savannah's cocoa portfolio are cocoa mass and cocoa butter from different origins. Cocoa powder is available in an array of different colours, flavours and fat content. This is not a one-size-fits-all ingredient. Careful attention to specific

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Food Review | August 2019

formulations must be considered before deciding what cocoa powder to use for a product.

Internal and external colour, fat content, pH levels and origin are important factors to consider. Whether your products are sensitive to fat; require even dispersibility; feature a crunch or a claim to differentiate itself from similar products, there are a host of solutions available.

COMPREHENSIVE WORKSHOP Savannah prides itself on having a can-do approach. The first Cocoa Knowledge Workshop was enthusiastically launched to share knowledge of this ancient ingredient.

Held on 14 and 15 May 2019 at the Barry Callebaut Chocolate Academy, the workshop proved to be a sweet learning experience to all who attended. Guests from various industries were taken on an informative tour of the history of the product. This spanned centuries from where cocoa was first discovered and eventually commercialised in the 1600s,

Barry Callebaut and other Savannah principals provide innovative, quality products to the local food and beverage industry

to the modern processing of cocoa beans today.

Sugar reduction was one of the main themes - incorporated and showcased through the afternoon hands-on sessions. Savannah’s cocoa ingredients weren’t the only focus. The presentation looked at the complete offering from Savannah, including products from other key principals such as milk powders, vanillin, fibre, proteins, gums and starches.

Imagine Croquoa flapjacks, chocolate meringues, gluten-free carrot cake, single-origin cocoa blended yoghurts, a vegan almond drink and decadent cocoa fudge. Savannah offers a value-driven ingredients package, coupled to quality suppliers and ingredients, service and technical support levels.

Incorporating cocoa into local products and exposing the South African

C O M PA N Y F O C U S

“Consumers are seeking companies that can prove traceability and the ethical use of ingredients. They are demanding sustainable products and are willing to pay for it…” industry to high-quality cocoa is a comprehensive task. Proceedings kicked off on day one with the investigation of challenges and solutions in the dairy, bakery and confectionery industries while cereals, nutrition and health headlined on day two. Both sessions started with an introductory session followed by a presentation on cocoa processing and sustainability.

Consumers are seeking companies that can prove traceability and the ethical use of ingredients. They are demanding sustainable products and willing to pay for it: these brands are currently outperforming conventional brands in several industry sectors.

Through the Forever Chocolate movement, Barry Callebaut plans to make sustainable chocolate the norm. Sustainable chocolate requires sustainable cocoa ingredients. The Cocoa Horizons Foundation developed and driven by the company, is committed to ensuring improvements in the livelihoods of cocoa farmers. Unlike other sustainability programmes like UTZ, Fairtrade and Rainforest Alliance, the Cocoa Horizons Foundation focuses solely on cocoa.

Theoretical sessions were held in the morning. These were concluded with the introduction of the Barry Callebaut cocoa range. Emphasis was placed on the defatted cocoa powder with less than one per cent fat. These ingredients are particularly used for aerated bakery applications sensitive to fat. Another key focus was dark chocolate powder.

This ingredient enables customers to make a chocolate claim on-label. The first-ever natural dark cocoa powder produced without alkalisation, is the pitch-black Ebony cocoa powder. This product is sourced from high-fat and single origin cocoa powders.

After a mouth-watering lunch, guests were treated to an afternoon hands-on sensory session. Delegates were divided into Ruby and the Gold teams and tasked with preparing various recipes to

Front: Julie Mondolfo, Carien Schoeman, Erik van der Flier, Noluthando Letsoalo, Minette Smith, Mary, Chané Brecher, Domingo Sanfiorenzo, Justin Kouakou Back: Victor Wilkins, Cildie van der Walt, Marli Taljaard, Clarissa Britz, Marlize Mostert, Nadine Wilkins, Tsholofelo Zulu, Carien Schoeman, Zwivhuya Makamu, Magdaleen Joubert, Chantal Botha, Chané Brecher, Belinda Bevis and Tanya Esson

Julie Mondolfo, Carien Schoeman, Erik van der Flier, Noluthando Letsoalo, Minette Smith, Mary, Chané Brecher, Domingo Sanfiorenzo, Justin Kouakou

experience how cocoa can come to life.

A very exciting chocolate tempering and moulding session was presented by the academy's own head chef.

Throughout the sensory session, Savannah colleagues shared important information regarding the use of certain products in each application.

Providing technical support to customers is a key component in ensuring Savannah’s reputation as a high quality, high-performance distributor and ultimately an idea partner in an ever-changing market. Although the workshop was aimed at promoting and re-introducing cocoa to large as well as

smaller companies, Savannah remains determined to create a love for cocoa, no matter the industry. •

Savannah Fine Chemicals – www.savannah.co.za

August 2019 | Food Review

11

NEW PRODUCT COMPETITION

It’s competition

time again!

The Food Review/Symrise New Product Competition offers a glimpse at some of the biggest trends to hit shelves this year. We received 29 submissions of various individual products and ranges and this year’s winner stands a chance of winning a fully paid trip to attend SIAL Paris in 2020!

Your sneak-peek to 2019's NPC entrants…

YOUR GO-TO SUMMER SPRITZER

TRENDSETTING LOCAL CHOCOLATES

Brutal Fruit’s new Ruby Apple Spritzer is bottled and brimming with pink happiness! Toast the good life with this premium spritzer - a delightful blend of zesty citrus with sweet apple and subtle hints of spice, grapefruit peel and honey.

Beyers Chocolates has embraced SA’ s newfound craft culture. The Beyers craft range of chocolates includes Craft Gin Truffles in three flavours: Classic Gin & Tonic flavoured chocolate ganache; Cranberry & Honeybush flavoured chocolate ganache and Ginger & Lemongrass flavoured chocolate ganache. The company also entered its Craft Beer & Pretzel Truffles range. Beyers Chocolates have cobranded with Beyers Brands by creating the panned range: Sweetie pie, Yottis Turkish Delight and Coach House Nougat are sure to hit the sweet spot!

PROTEIN YOGHURT PACKS A PUNCH

GOLD WEISS WITH A CITRUSY HOP

SPICE-UP YOUR FEASTS

DanPro’s yoghurt and drinking yoghurt range from Danone is packed with 10 to 20g of high-quality protein per serving and contains no artificial sweeteners.

These protein snacks are designed to fuel active lifestyles. The range includes spoonable yoghurt in plain, vanilla, strawberry, blueberry, peach and mango. Drinkable yoghurts are available in vanilla, strawberry and banana.

Darling Brew’s Pixie Dust is the perfect thirst-quencher for warm summer months. The beer features a yeasty, smooth mouthfeel and mild bitterness, hinting at fruity and spicy flavours while remaining slightly sweet. Bone Crusher Hoppy is a limited edition canned beer and will be available as a special edition for Christmas 2019.

The new Seven Colours Grill Seasoning is a spicy addition that’ll add extra flavour to any dish or snack. Available in a handy, resealable foil pack to retain total freshness.

PLANT-BASED FISH LAUNCHES

A NEW LINE OF ARTISANAL CIDERS

The Fry Family Food Co. are launching brand-new Fish-Style Fillets and Battered Prawn Style Pieces. These products are a sustainable and healthier way for consumers to enjoy a nutritious and convenient product that tastes like fish.

Coated in a golden crispy batter, they are a source of protein, contain fibre and are cholesterol-free and non-GMO. Fillets also contain added flaxseed oil - a source of Omega-3.

Loxtonia Farm has responded to South Africa’s demand for a genuine artisanal cider by introducing their first allnatural premium range.

Loxtonia Cider is free of any preservatives and artificial additives. The range includes: Crispy Apple Cider; Sparkling Apple Cider; Stone Fruit Flavoured Apple Cider and Pale Amber Apple Cider.

TONE UP YOUR TONIC

LONG LIFE TEA IS A TREAT

An innovative range of flavours to compliment alcoholic and nonalcoholic drinks. Flavours include Original Tonic (Sugar Free), Cucumber Tonic, Mandarin and Fiery Ginger.

Products have natural flavours to offer a better drinking experience.

It is a clear drink which emphasises the naturalness of the product. It is supplied through Woolworths.

12

Food Review | August 2019

Woolworths' range of iced teas are a great alternative to sugary carbonated soft drinks and other drinks on the market.

The range of teas include: Blueberry, Mixed Berry, Peach and Lemon are brewed and formulated with a focus on using less sugar in the recipe. It is a preservative-free drink.

ADD A DASH OF DELICIOUSNESS In line with food trends, diners are demanding new and exciting flavours in interesting dishes. Responding to this need, Delite Foods presents its Dash Of Flavour range, which adds intense, delicious flavour notes to any dish, without a hefty price tag.

FROSTY FUN GLUTENFREE CONE Good Value Foods has released a glutenfree ice-cream cone. The recipe is free from wheat, dairy, egg, artificial flavours, colouring and preservatives. The product is perfect for people sensitive to gluten and food additives.

NEW PRODUCT COMPETITION

A SWEET SUGAR SUBSTITUTE Nomu has launched an innovative range of sugar substitute products.

The three products entered includes Sweetly Substitute Sugar in a stick box, Sweetly Baking Sugar Substitute and Sweetly Chocolate Protein Shake Powder.

Perfect if you want to reduce your sugar consumption.

A CERTIFIED TWIST ON CITRUS Soga Organic is proud to grow, harvest, produce and pack the first and only Certified Organic citrus juice in South Africa. The latest addition to the Soga Organic family is its delicious Certified Organic Frozen Ruby Grapefruit Juice. It is a unique and healthy alternative to other sugar-loaded juices.

THE TIME FOR WAGYU BEEF IS NOW As the first and oldest Wagyu beef producer in Africa, Woodview Wagyu is passionate about the breed and has many years of experience when it comes to breeding superior genetics and excellent Wagyu blood lines. The range includes The Angus & Wagyu Beef cured range of biltong, droëwors and chlili sticks.

A CHOCOLATE ICECREAM BONANZA Woolworths’ Mini Chocolate and Caramel Ice Cream Bars allows portion control for indulgent eating at 30g per mini bar.

The product features Madagascan vanilla ice cream topped with sticky caramel and roasted almond pieces enrobed in milk chocolate coating.

KOMBUCHA FOR TUMMY HEALTH Woolworths Kombucha is produced exactly as this fermented drink has been for centuries. It is a batch brewed tea made using a symbiotic culture of bacteria and yeast (Scoby), which consumes sugar and creates a tangy, slightly fizzy, gut friendly flavoured drink, which has no added preservatives.

100 PER CENT PLANT-BASED SOUP Pesto Princess’ new soups are 100 per cent plant-based, contain no preservatives or thickeners and, most importantly, for every single soup sold, a hot meal is donated to a person in need.

The new range consists of Fresh Tomato, Pea & Pesto, Red Lentil, Creamy Carrot, Sweet Potato and Homestyle Butternut Soup.

CANNABIS BEER TAKES SA BY STORM Poison City is the country’s first cannabis beer. The lager contains no THC (the primary psychoactive ingredient in cannabis that delivers the high), but is brewed with hemp oil that creates its distinctive and refreshing flavour!

CAPE WINES FOR EASY AND AFFORDABLE DRINKING Woolworths’ range of Cape Wines is both affordable and extremely easy on the palate. All wines feature an affordable price point. Wines are non-vintage and non-varietal, rather focusing on being an accessible example in their respective categories. The following wines are available in the range: Cape Zesty White; Cape Sparkling White; Cape Juicy Red and Cape Sweet Rose.

MATURE CHEDDAR CHEESE NIBBLES

A RAW COCOA TREAT The range of Raw Cacao Treats is an organic treat is certified organic and Fairtrade. All items feature no sugar added and are sweetened with yacón syrup. The range includes Raw Cocoa & Buckwheat Slab; Raw Cocoa Gojiberry Bites; Raw Cocoa & Ginger Bites and Raw Cocoa & Hazlenut Truffles.

A SWEET AND SPICY COUSIN TO THE SAUCE FAMILY Pioneer Foods has launched the perfect partner to its iconic Sweet Chilli Sauce.

Wellingtons’ new hot cousin, Sweet Jalapeño is made with the finest Jalapeño chillies and its secret Sweet Chilli recipe.

The product contains no added colourants, MSG or flavourings.

A PASSION FOR PREMIUM CSD’S With the growing health trend and the increase in sugar tax, Woolworths has released a better tasting range of beverages that are healthier and formulated with less sugar. These products have natural flavours that offer a better drinking experience.

The liquid is clear and featusre no added colourants. The range includes Blood Orange, Passion and Pine, Pear and Elderflower, Mixed Berry and Cucumber and Ginger.

ELEVATE YOGHURT TO THE NEXT LEVEL

Made from Breede River, six months matured cheddar cheese, Woolworths’ range of Cheddar Cheese Nibbles offer a sharp flavour with hints of caramel and fruity notes. A special process extracts most of the moisture, leaving light and crunchy nibbles.

The Strained Double Cream Ayrshire Yoghurt from Woolworths is made in a traditional method to remove the whey, giving it a thick and creamy texture with a slightly tangy taste. Products feature no added preservatives, is rBST hormone free and is alive with millions of bifidobacterium cultures.

A RUSK FOR EVERY OCCASION

A NOSTALGIC SWEET TREAT

Woolworths now has an impressive array of 30 types of rusk producs, and has fearlessly ventured where no ruskmaker has gone before. This year the range entered innovative products like the Honey and Oat, Doughnut, Digestive Bran and Almond Rusks.

Woolworths' range of Sweet Yeasted buns includes Cinnamon Buns, Caramel and Pecan Sticky Buns and Chelsea Buns.

A warm and delightful teatime treat for young and old!

August 2019 | Food Review

13

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

Hail the power of pea protein An explosion of plant-based food has seen predictions of huge growth in the next ten years. The targeted audience is consumers at large and not just traditional vegetarians or vegans.

DID YOU KNOW?

A

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

GT Foods began developing and producing pea protein - introducing it to the South African market as far back as 2013.

‘Pea protein is one of the best plant-based forms of protein that you can eat. It is versatile, functional and 100 per cent natural,’ explains George Tomazos, AGT Foods retail and food ingredients, South Africa.

The company produces pea protein for inclusion in a variety of food, such as cereals, bread, protein powders and bars. It is a GMO and hormone-free alternative to soya in the baking and food manufacturing industries.

‘These ingredients are not derived from any of the eight most common allergenic food used to create protein supplements.

These are milk, eggs, peanuts, tree nuts, soy, fish, shellfish and wheat. Pea protein is a safe option for people with various dietary restrictions,’ Tomazos points out.

‘Pea protein is a complete protein, which means it contains “AGT Foods produces pea protein for inclusion all nine of the essential in a variety of food… it is a GMO and hormoneamino acids - including branched-chain amino acids free alternative to soya in the baking and food (BCAAs) that consumers need to manufacturing industries” effectively build muscle. It also digests slowly. There is evidence that slower-digesting proteins are better for muscle growth over the long term. This is due to how your body’s muscle-building machinery processes amino acids into muscle tissue,’ he adds.

Pea protein can be included in daily diets by mixing it into smoothies, muffins, oatmeal and even pancakes and is gaining popularity with consumers as it is easy on the stomach, unlike many other protein powders. While the traditional market was the nutritional sector for sports, ingredient manufacturers are producing a variety of pea protein products to meet consumer demand for healthier food options. •

AGT Foods – www.agt.co.za

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Food Review | August 2019

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

A plant-based protein collaboration Royal DSM and French agro-industrial group Avril are working together to meet growing consumer demand for plant-based proteins.

T

he two companies will produce a unique protein, which is based on non-genetically modified canola.

The ingredient has excellent functional properties, high nutritional value and balanced taste profile. This makes it ideal for a range of applications including meat and dairy alternatives, beverages, baked products and bars.

‘It is expected that the earth must sustain 10 billion inhabitants by 2050.

Experts predict that global demand for animal and plant-based protein will grow.

Exponential growth is expected in plantbased proteins due to dietary shifts.

Through this collaboration, Avril and DSM will join forces to contribute to meet growing demand,' Avril CEO Jean-Philippe Puig explains.

"The ingredient has excellent functional properties, high nutritional value and balanced taste profile"

partnership. Both companies have an ambitious strategy of innovation in plant-based proteins and excel in human nutrition and health.

The partners' ambition is to develop a state-of-the-art industrial production

‘More people are opting for flexitarian, vegetarian and vegan diets for personal,

tasting, healthy, and sustainable food and

health and environmental reasons. With

beverages,' adds DSM chief innovation

our expertise, DSM can support all forms

officer Trish Malarkey.

of proteins produced to the highest

DSM's globally recognised expertise

sustainable standards. With Avril as a

in solutions for food and beverage is

partner, we are uniquely positioned to

complemented by Avril's 35-year legacy

serve this growing market and look forward

in agriculture and its ability to deliver

to helping our customers deliver great

high-quality agricultural supply for the

facility fully dedicated to canola proteins at Avril's Saipol facility in Dieppe, France.

Commercial availability from the first production could be as early as end 2021. •

DSM – www.dsm.com Avril – www.groupavril.com

• Proven more bioavailable than Whey Protein Isolate • Clinically backed by 6 human trials • Lower cost • Reduced calories • Less stomach discomfort ioProtein® is a high quality, bioavailability enhanced protein powered by patent-pending Ingredient Optimized® technology.

T: +27 (0)12 349 1543 | E: karien@chempure.co.za www.chempure.co.za

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Food Review | August 2019

DISCOVER THE WORLD

OF NATURAL COLORS with plant based coloring solutions

Sensient Technologies South Africa Ltd. Email: sfc-zaf@sensient.com Tel: +27 11 053 5200 Discover colorful insights at www.sensientfoodcolors.com

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

Keep it green with plant-based proteins The demand for high protein and lower carbohydrate foods are challenging developers to source alternative proteins suitable for the desired application.

S

oy, pea and chickpea are only some of the examples enjoying the limelight.

Nutritional profile, allergen status, flavour, functionality and cost-in-use are important considerations for a specific application when choosing a protein.

A protein's ability to disperse, solubilise or bind water are key factors assisting manufacturers in creating several final products providing the consumer with more options. Ultimately the challenge lies in creating plant-based alternatives that mimic the nutritional profile, taste and texture of conventional dairy-based proteins.

A SNAPSHOT OF THE WELLKNOWN PROTEIN ALTERNATIVES Soy protein: These concentrates offer a complete amino acid profile and economical cost-in-use benefits. Defatted soy proteins exclude anti-nutritionals such as soluble

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Food Review | August 2019

sugars and anti-nutritional factors, assisting with improved flavour profile and shelf-life duration. The ability of soy protein to deliver the desired characteristics in extruded applications makes it the preferred protein alternative.

Pea protein: A cost-effective alternative to allergen based proteins. It lends itself well to the combination with other proteins, for example, the combination of rice protein to achieve a complete amino acid profile.

Chickpea protein: The neutral taste and white colour will aid in formulating a favourable appearance and flavour profile especially when replacing dairy proteins.

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

Rice protein: Contributing to the environmentally conscious trend, rice protein is a sustainable and smart protein

alternative used in cereal and bakery applications. The ability to not influence the final product structure/expansion rate assists in formulating a consistent product with improved crispiness and bowl-life.

Fortifying with protein has several functional benefits and offers different claims such as dairy-free, soy-free, glutenfree, clean label, high in- and source of protein claims. These claims are also part of the current trends moving towards functional food products in bakery, cereals, confectionery, beverage, food processing and dairy industries. Depending on the criteria for the final product the correct protein may be chosen to offer consumers a product that will fulfil their needs. •

Savannah Fine Chemicals – www.savannah.co.za

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

All your lubrication needs from one expert Lubricants for the food & beverage industry are subject to a multitude of requirements.

Food Review spoke to Demelza Mulligan of Klüber Lubrication on what constitutes a good lubricant and some of the unique challenges faced by local processors.

Q: WHAT ARE THE BIGGEST CHALLENGES FACING THE F&B INDUSTRY IN SOUTH AFRICA AND ON THE CONTINENT?

variety of (food grade) lubricants to choose

• Klüber Summit FG series range

from; self-controlled or PLC-controlled

of products reduce oxidation in

lubrication systems. Our units are flexible,

pistons and valves for an extended

Avoiding contamination of food products

and can be used for applications subject to

during manufacturing while making

strong temperature fluctuations. They are

corrosion protection, good hot and cold

production processes as efficient as possible.

also suitable for precise lubricant metering

water resistance and provide ease of

The main challenge concerns food-grade quality, safety and compliance. Under- and

compact for use in demanding, applications

under strongly ambient temperatures and single or multiple lubrication points.

over-lubrication can also be problematic.

This could be due to a lack of skill, training or automation.

Q: WHY SHOULD CLIENTS CHOOSE YOUR PRODUCTS? WHAT MAKES THEM UNIQUE?

Q: HOW CAN YOUR COMPANY ASSIST IN OVERCOMING THESE CHALLENGES?

We offer a combination of personal

Klüber Lubrication complies with stringent

considerable potential to reduce energy,

registration of the ISO 21469 standard for hygiene requirements in the formulation, manufacture and use of H1 lubricants used in the food-processing industries. The entire manufacturing process of our H1 lubricants is certified.

All Klüber Lubrication manufacturing plants are certified to quality standards (DIN/ISO/TS 16949 or DIN EN ISO 9001); environmental standards (DIN EN ISO 14001 or eco-audit) and occupational safety standard (OHSAS 18001).

Our automatic lubricating systems ensure

consultation and a comprehensive lubricant range. The right lubricant carries savings on spare parts and labour costs while increasing productivity.

We never recommend a product without the appropriate technical and consultative site visit. We offer more than 100 different lubricants with halaal and kosher certification that are H1-registered, enabling Klüber Lubrication to support compliance across the complete production line.

Q: HOW CAN THESE PRODUCTS OPTIMISE PRODUCTION? • Special gear oils ensure long maintenance

reliable, clean and accurate lubrication

intervals, high efficiency and lasting

24 hours a day. Machine reliability is

component protection, even at the gear’s

safeguarded - there is always fresh lubricant

performance limits;

at the friction point, which assists in

• Prolonged service life of synthetic

reducing energy costs. Our solutions include

lubricants and the consequent longer oil

freely selectable lubrication intervals-

change intervals can reduce equipment

incrementally from one to 12 months; a

downtime and save resources;

compressor lifetime; • Sprayable greases have good wear and

application on open gears and slideways; • Lubricants for drinking water valves need to meet country-specific guidelines, are resistant to media, provide good sealing effects and offer good tactile properties at all temperatures; • Machines susceptible to water washdown can be given protection against corrosion and water accumulation on metal surfaces. Our products can displace a higher amount of water when compared to other products, even when compared to those without H1 approval; • High-temperature chain oils show 22 to 37 per cent lower evaporation losses when compared to the best competitor product; • Lastly, the use of our high-performance compressor oils allows our customers to reduce their energy costs and increase general reliability. Products are manufactured with less sulphur content; produce a smaller gas reaction; cleaner filters and coalescers and offer greater heat transfer efficiency with low oil carryover. •

Klüeber Lubrication – www.klueber.co.za

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

August 2019 | Food Review

19

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

Congestion-free on the deep freeze line Interroll has designed its MCP modular conveyor platform with decentrallycontrolled RollerDrive drive technology. Units can operate in environments as low as -30 degrees Celsius. The advantages of efficient material flow with zero pressure accumulation are now available for deep freeze logistics.

The MCP modular conveyor platform

S

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

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

This not only facilitates planning, installation and maintenance, but also ensures short delivery times.

The conveyor platform is connected to higher-level IT systems through consistent standardisation of the interface technology. Modules are prewired and can be configured at the push of a button for the desired Fieldbus technologies, such as EtherCat, Profinet or EtherNet/IP. In conventional conveyor lines, central 400V geared motors drive long flat belts around the clock - regardless of the material being conveyed. With the RollerDrive there is no central drive

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Food Review | August 2019

station and compact drives are located in each individual conveyor.

This design allows each conveyor zone to be switched on or off individually and automatically. The advantage is there is only movement in the conveyor system when the material conveyed is present.

To optimise energy savings, only the unit needed for the optimum flow of the conveyed goods is driven. This results in potential energy savings of up to 50 per cent and a significant reduction in noise and wear.

problems in the deep freeze sector, engineers at the Interroll Research Centre carried out endurance and startup tests at very low temperatures.

The expansion behaviour of the metals and plastics used at different temperatures can lead to functional impairments.

It is also critical when unsuitable oil and grease become more viscous as temperatures fall.

MATERIAL FLOW WITHOUT DYNAMIC PRESSURE AT LOW TEMPERATURES

The introduction of its latest drum motor platform can provide customers with significant added value. All asynchronous and synchronous drum motors now fit in the same mounting due to identical axes.

An even greater range of speeds can be operated via an extended number of gear stages. This makes it easier for system integrators to meet individual throughput requirements for a conveyor solution. All options such as encoders, brakes or backstops are available for motor variants of the new platform and can be freely combined.

All drive solutions feature Class I certification from the European Hygienic Engineering & Design Group (EHEDG) and meet the material requirements of the USDA/FDA and EU Regulation EG 1935/2004 for use in the food industry.

Motors can easily be provided with a special rubber coating for special applications i.e. for use with form-fit driven thermoplastic belts.

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

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

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

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

HYGIENIC DRIVE TECHNOLOGY OF THE NEXT GENERATION

TESTED UNDER EXTREME OPERATING CONDITIONS To ensure the modified conveyor platform could be used without any

Interroll – www.interroll.co.za

The Interroll Drum Motor A Hygienic Belt Drive for a Broad Range of Applications Conventional gear motors are bulky, complex to install, and most importantly, non-hygienic. The Interroll Drum Motor, instead, can be hygienically cleaned and disinfected regularly using high-pressure water, steam and chemicals.

The Interroll Drum Motors are used in countless applications in the food industry for many reasons: Hygiene: it follows EHEDG guidelines and is perfectly suited for washdown-applications.

Energy-Efficiency: it has efficiency rates of up to 83%. This reduces the running costs of your drives by up to 50%.

High Torque, Wide Speed Ranges and Low Noise.

Compact, space-saving design: this allows to add more conveyor lines within the same facility.

Short installation time: it can be installed much faster than a gear motor.

It is extremely durable and robust and practically maintenance-free, helping you cut downtime significantly.

It is compatible with all MPB: our drum motor can drive all of your modular or thermoplastic belts.

za.sales@interroll.com interroll.co.za

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

Steel makes the case for hygienic conveying Ipco’s steel belts are used across the food industry in processes as diverse as baking, freezing, cooling, solidifying and conveying. The company is one of the larger manufacturers of steel belt conveyors and serves the African market from its regional base in Johannesburg.

F

or many of these applications, the thermal properties of steel are a key consideration. Steel belts can be used at temperatures from - 80°C to +750°C. The belt itself acts as a heat transfer medium, whether removing heat from a food product (e.g. chocolate cooling) or enhancing the baking process.

“The hard, flat, smooth surface of a steel belt ensures easy product release at the end of the conveyor” Durability is another factor: steel is more resistant to damage by corrosion, abrasion or impact than any other belt type. This makes it the ideal long-term solution for a whole range of potentially aggressive applications.

For many though, it is the cleanability of a solid steel belt conveyor, which is its most important quality. The hard, flat, smooth surface of a steel belt ensures easy product release at the end of the conveyor and enables faster, easier cleaning so the highest standards of hygiene can be maintained.

REDUCING ACRYLAMIDE LEVELS One challenge faced by all industrial bakeries is ensuring a clean processing medium. It doesn’t matter how clean the operation, a gradual build-up of carbon residues is virtually unavoidable and can be detrimental to the taste and appearance of a baked product.

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Food Review | August 2019

Stainless steel belts are ideal for use in bakeries

The negative effect of acrylamide on human health has also made it a health issue and manufacturers are looking to reduce levels of this potentially carcinogenic material. Belt cleaning is a top priority and oven builders now need to consider the cleanability of conveyors.

As well as minimising the risk of harmful acrylamide build-up, the inherent cleanability of a solid or perforated steel belt also means less water consumption, reduced use of chemicals and depending on the cleaning method, less energy expended on heat.

MAXIMISING CONVEYOR EFFICIENCY As a specialised manufacturer of steel belts, Ipco works closely with machine builders to ensure reliable performance and system efficiency. The success of a steel belt conveyor depends on correct installation. This will ensure smooth, reliable operation and long working life. The initial quality (straightness and flatness) of the belt is central to this. Bake oven belts also require the appropriate tracking and support accessories.

Ipco offers a range of active and passive belt alignment solutions. These include the

Compact Belt Tracker (CBT), which works with virtually any belt edge detector system. This device manages tracking by tilting the belt using a linear actuator and is available with a choice of control options. Easy to install with self-supporting construction, the CBT can be used on belt widths from 600mm to 3 000mm.

Belt support needs to be provided by means of cast iron skid bars and Ipco recommends that a minimum of 10 per cent of the skid bars should be graphite.

As the conveyor moves, a deposit of graphite is delivered onto the inside of the belt.

This reduces friction for optimum performance and increased belt life and protects against rust caused by condensation or general humidity. •

Ipco – www.ipco.com

L A B O R AT O RY & T E S T I N G S E R V I C E S

High-quality cannabis testing assured Chem-Science Laboratories has announced the establishment of its dedicated cannabis laboratory in KwaZulu-Natal.

M

anaging director Vic Soffiantini explains that this development is a direct result of the need to meet the requirements that the exploding cannabis industry has created for high-quality testing locally.

‘We have invested in specialised equipment and professionals to bring the Cannabis Testing online,’ he

“Quantitative assays will be used to ascertain the volume of THC, CBD, CBC, CBG and /or CBN in the respective identification samples”

Quantitative assays will be used to ascertain the volume of THC, CBD, CBC, CBG and /or CBN in the respective identification samples. Samples can include final powders, tinctures and oil extracts.

‘Chem-Science Laboratories can perform a full spectrum test on your product giving you the potency, pesticide, residual solvent and terpenes all on one test sample. We aim to be a recognised accredited laboratory that complies with the current Good Laboratory Practice and ISO/IEC 17025,’ he concludes. •

enthuses. ‘Good Laboratory Practice (GLP) is in place to ensure correct control throughout the laboratory via our ISO 9001 Quality Management System.’

CHEM-SCIENCE AND BIOSCIENCE LABORATORIES

The business was started in the Durban North home of Vic Soffiantini, an experienced and qualified analytical chemist. Soffiantini has extensive experience analysing fertilisers, chemicals and working in the sugar and dairy industries. He also worked in various consulting laboratories.

In 1991, the company moved to bigger premises at John Ross House in central Durban. During this time, many science students did their successful in-service training with the company. In 2004, the laboratories moved to larger premises in Umbilo Road, Durban.

Chem-Science Laboratories initially consisted of two laboratories – the one chemical and the other microbiological.

In March 2003, the microbiology laboratory broke away from ChemScience Laboratories and became a separate legal entity known as BioScience Technologies.

Due to rapid expansion, it became necessary to upgrade the legal identity of the small business. ChemScience Laboratories became a fully established company in 2012.

To date, both companies have trained well over 100 students and graduates.

Soffiantini and his team are committed to establishing a competent base of future technologists and scientists for South African industries and research laboratories.

Chem-Science Laboratories – www.chemsciencelaboratories.com

Cannabis Potency Testing New and Now Available!

Quantitative assays potency testing, to ascertain the volume and level of the cannabinoids THC-A; delta 9 THC; Total THC; CBD-A; CBD; Total CBD; CBN; CBC. As well as the toxic Terpenes!

Also, as required by some dispensers, doctors and clinicians:

Residual Solvents and toxic Heavy Metals Pesticide Residues Screening Microbiological examinations for Yeast, Mould, and the pathogens Coliforms & E.coli.

Contact us: info@chemsciencelaboratories.com or phone 031 206-1390.

August 2019 | Food Review

23

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

Quality Control of Food with FT-NIR Spectroscopy Whatever your application is ...

Beer clarification made easy To make beer, ground malted barley is first boiled to activate the malt enzymes that bring about starch hydrolysis and the production of maltose. This phase usually lasts about two hours with a variable temperature range according to the type of malt used.

F

grain, flour & milling products milk and dairy products meat & sausages oil and oil seeds feed & feed ingredients

Bruker offers solutions for the analysis of raw materials, ingredients and finished products in the laboratory, at-line or on-line. With the FT-NIR spectroscopy standard parameters like dry matter, fat or protein as well as more complex parameters like amino acids can be measured in seconds in different sample forms like powders, solids, pastes or liquids.

iltration follows and then the wort is boiled with the addition of different varieties of hops. This allows the wort sterilisation and the extraction of the hop alpha acids, which will define the aromatic character of the product.

Boiling is followed by whirlpool clarification to remove coagulated proteins and the wort is then cooled and transferred to the fermenter where seed yeasts will be introduced: Saccharomyces cerevisiae for high-gravity beers, Saccharomyces uvarum for low-gravity beers.

Fermentation usually lasts seven to 10 days at a temperature of 20°C for high-gravity beers and eight degrees Celsius for low-gravity beers. For a maltose reduction of approximately 80 per cent, the yeast dosage is about 70g/hl (~107 cell/ml ). For some types of beer, fermentation is followed by dry hopping and conditioning at four degrees Celsius. Other types do not need dry hopping and go directly to the conditioning phase - typically 14 days. The next stages are the coarse filtration of beer and addition of sugar, beer bottling and maturation in the bottle, generally for two weeks at 20°C. The production process of a raw high- or low-gravity craft beer lasts between 30 to 40 days.

A set of pre-calibrations for various industries is available for a quick and efficient start.

Bruker South Africa (Pty)Ltd. Ltd. Homestead Office Park, Block B 65 Homestead Avenue Bryanston - 2021 Tel: +27 11 463-6040 Fax: +27 11 463-6289

Innovation with Integrity

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Food Review | August 2019

Contact us for more details: www.bruker.com/optics info.za@bruker.com F T- I R

BIRRA DELL' EREMO The Italian microbrewery Birra dell’Eremo was established in 2012 and has a current production expectation of 3 000hl / year, with a 15hl brew room and a 30hl daily production. The fermentation room has six 30hl fermenters and an Alfatek bottling line. They produce different varieties of high-gravity

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

beers and a range of special beers brewed with autochthonous yeast strains isolated within the brewery. The beers produced are listed below: Beer name

Characteristics

Saggia

Blonde, 5% Vol

Fuoco

Golden Ale, 5% alcohol

Fiera

IPA, 6.5% Vol, dry hopping

Nobile

Dry hopping

Glaciale

Imperial Ale, 7% Vol, dry hopping

Magnifica

APA, 5% Vol, dry hopping

Terra

Oatmeal Stout 5.2%

Beer name

Yeast type

KO2

Kluyveromyces thermotolerans

TO2

Torulaspora delbrueckii

WE2

Wickerhamomyces anomalus

Due to the strong growth in craft beer consumption globally, the brewery has increased its volume of beer produced.

It must maximise production yield and reduce the beer maturation process from 14 to seven days, ensuring the same quality standard of turbidity and yeast concentration (104 cells/ml ). For this reason, the brewery has taken into consideration a cartridge filtration step downstream from the conditioning tank.

SOLUTIONS The beer from the conditioning tank after seven days has a high colloidal suspension

of proteins and yeasts. In the preliminary filtration tests on a complex beer such as Glaciale - with an important protein structure given by the different types of malt used, and considerable hop residues due to dry hopping Sartopure PP2 8 μm filter sensibly reduced turbidity.

A Sartopure PP2 5 μm gave a clear beer with a filtration yield of approx. 60 l / m2. Given the complexity of the product, Sartorius proposed the Jumbo system for the process tests.

Jumbo Star Sartopure PP2 5 μm has proven as an excellent filtration system for beer after the conditioning phase.

The duration was reduced to seven days thanks to the complete retention of suspended colloids, which results in a clear beer with an extremely low yeast count.

Yeast concentration after filtration can be measured considering the beers produced by Birra dell’Eremo have a concentration of 105 cells/ml after seven days of the conditioning phase, and contemplating a dilution of the filtered (clear) beer with the unfiltered beer it is possible to reach the target of ~104 cells/ml .

Based on the tests carried out, the intended target cell concentration is reckoned to be achievable by filtering 80 per cent of beer and mixing it with 20 per cent unfiltered beer.

CONTROLLING THE QUANTITY OF YEAST IN THE BOTTLE OFFERS THE FOLLOWING ADVANTAGES: • Beer with reduced turbidity • Reduced precipitation in the bottle • Improved organoleptic quality • Beer clarity • No addition of yeasts for refermentation. •

ABOUT THE AUTHORS ENRICO CIANI is the founder

and head brewer of Birra dell’Eremo and VALERIO FERONE is sales engineer F&B, application specialist filtration technology at Sartorius.

Sartorius – www.sartorius.com

Test results with filter Jumbo Star Sartopure PP2 5 μm and different types of beer: Beer

Batch

Conditioning time

Concentration after fermenter (20ml sample)

After Jumbo Star Sartopure PP2 5 μm (20ml sample)

Yeast concentration after filtration (20ml sample)

Saggia

1 300l

Seven days

105 cells/ml

0 cells/ml

104 cells/ml (80 per cent filtered with Jumbo, 20 per cent unfiltered)

Fuoco

3 000l

Seven days

2*105 cells/ml

0 cells/ml

104 cells/ml (70 per cent filtered with Jumbo, 30 per cent unfiltered)

Fiera

3 000l

Seven days

105 cells/ml

0 cells/ml

104 cells/ml (70 per cent with Jumbo, 30 per cent with a filter bag to retain suspended hop of dry hopping)

MLS NATIONAL LABORATORY SERVICES Our methods enable us for certain tests to submit prelim results within 48hours and final report within 5 days

Contact: Info@mlslabs.co.za 082 853 2247

Microbiological Chemical Nutritional Aflatoxins Allergens DNA

Effluent Water Organoleptic Pesticides Residues Shelf- Life

Any where in SA we can help you. With Labs in JHB and CPT. August 2019 | Food Review

25

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

Beverage solutions take processing to the next level DC Norris works with food and beverage producers across the African continent.

The company focuses on supplying efficient and flexible processing solutions.

Food Review sat down with Stuart Rigby, Jet Cook product and process manager to chat about some of the latest trends developing in the market.

WHAT IS MOST IMPORTANT TO YOUR CUSTOMERS? We have worked with many companies throughout Africa on a variety of products.

These range from baby food and pie fillings to beverages such as Maheu, Mabele, milkshakes and Chibuku. We can adapt each system to suit the customer's individual needs and flexibility.

We're often asked if we can reduce a customer's processing times while improving product quality. Our new, all-inone Jet Process System addresses process areas such as cooking, cleaning, entraining and sterilising. Traditionally, African producers use multiple processing vessels.

This can result in uneven heating and poor

finished products due to inconsistent gelatinisation of maize. Burn-on can also be an issue, coupled with poor agitation in the vessel resulting in hot spots.

This year we developed a solution for local beverage producer Take 5 to produce 18 000 kilos/ph of fully hydrated and cooked maize for Maheu and Mabele. This is the world's fastest producing Maheu system, capable of producing 6 000l in 20 minutes with a single vessel and operated by a single person.

The system has a footprint of 4x7m, which consists of four patented Multi In-Line Jet Cook units. The specially designed 1 000l Jet Entrain powder induction system can entrain 6 000kg of maize flour in just two minutes.

Training on the Jet Cook system at the CPUT test kitchen in Cape Town

HOW DO YOU ENSURE PRODUCT QUALITY? Ingredient flavours are improved due to the reduced thermal impact of rapid heating and mixing. The total system is controlled

Maintaining freshness with MAPAX® and FoodFresh™ The way foodstuff is packaged is critical when it comes to prolonging shelflife and food safety for consumers. To prevent loss of natural freshness and quality of packaged products, Modified Atmosphere Packaging (MAP) was developed by employing the properties of specific gases or gas mixtures to slow down those decay mechanisms that have the dominant effect on packaged food products. MAP offers food manufacturers a way to extend shelf-life without altering the physical or chemical properties of foodstuffs or adding any unusual ingredients.

Developed by Linde Gas and available from Afrox, MAPAX® solutions are application-specific packaging solutions to extend shelf-life, the natural way.

MAPAX® solutions are customised for the following industries: dairy; dry foods and bakery; fish and seafood; fruit and vegetables; meat; and prepare and catered foods.

Customer Service Centre: 0860 020202

Afrox MAP Advertorial 177x130.indd 1

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Food Review | August 2019

Shop online: www.afroxshop.co.za

Afrox has also created a MAP gas range called FoodFresh™ to meet the special quality requirements of the food industry, and to assist customers in complying with strict food standards legislation in packaging, storage and distribution.

The FoodFresh™ range of gases and gas mixtures cover all current MAP processes.

With over 80 outlets across the country and a comprehensive nationwide delivery service, Afrox has the supply option to best suit your needs. For more information about MAPAX® solutions and the FoodFresh™ range of gases and gas mixtures, contact the Afrox Customer Service Centre on 0860 020202 or visit www.afrox.com.

Africa’s leading gases and welding solutions partner

www.afrox.co.za

2019/05/09 12:04

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

by the DC Norris recipe manager software.

This alleviates deviations in the process and temperatures by operators and results in consistent and recorded finished products.

African producers want the flexibility to produce smooth or coarse Maheu and other beverages using ingredients such as cassava, sorghum and milk powders. The Jet Cook's product flexibility is critical, coupled with its ability to maintain and improve product quality consistently. We can vary the texture of the finished product by controlling the amount of shear we create inside the Jet Cook chamber. The same system has the flexibility to make different beverages including milkshakes, condensed milk and fruit juices.

WHAT IS DC NORRIS' REACTION TO DEMANDS FOR EFFICIENT, ENVIRONMENTALLY-FRIENDLY SYSTEMS? Certain locations are suffering severe drought issues and so we try to reduce water usage during cleaning. We've addressed this by designing a jet clean function, which heats, atomises and accelerates water through the patented jet unit. This high pressure, high flow cleaning system removes

grease and debris in the vessel and only uses a minimum amount of water.

In a recent installation, a customer used 13 one tonne vessels to produce its Maheu base. Each one used 1 300l of water to clean with the addition of a caustic solution. We've replaced this with a single six tonne vessel, which requires cleaning only once at the end of the day. It uses less than 4 000l per day.

The system can pay for itself in 16 months, based on the cost of water saved.

YOU HAVE SYSTEMS ALL OVER THE WORLD. HOW DO YOU MANAGE THE DEMAND FOR YOUR SERVICES, SYSTEMS AND TIME? I work from our headquarters in the UK. I can analyse customers' recipes in full confidentiality to identify ways of reducing processing times, improve product quality, particulate integrity or to reduce fat, starch, salt and other spices.

The information can be relayed to the customers Recipe Manager Software onsite. At our test facility in South Africa at the Cape Town Peninsula University, we can assist African Manufacturers with product development and training. We travel to

Take 5's Jet Processing System

Africa regularly and can assist our customers personally. Our agent Courlanders, also has their own jet process trained engineers and technicians to assist customers locally. •

Courlanders – www.courlanders.co.za

New continuous processing solution for the high speed production of beverages & liquid foods Jet Cook

Jet Entrain

Jet Sterilise

Jet Clean

Jet In-Line

Jet Heat

TM

“After nearly 40 years of using steam pots, it was time to move onto the next generation of cooking. We were up and running within 4 days – it worked as promised, and more.”

world leaders in industrial food & beverage processing equipment www.dcnorris.com | jetcook.dcnorris.com

Courlanders Agencies (Pty) Ltd  +27 43 722 5513  c.tucker@courlanders.co.za

August 2019 | Food 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

Flexible beverage powder system for high quality products Fixed mixers and inline conveying systems during beverage processing can waste time.

Each manufacturing process must be completed before the material can move to the next processing stage. If process steps can be decoupled to work autonomously, then the waiting time reduces significantly.

A

further challenge is that product quality is constantly at risk.

Beverage powder mixes can be prone to separation. This can result in scrapping a batch or running the risk of poor customer satisfaction.

DECOUPLE PRODUCTION TO IMPROVE EFFICIENCIES A simple step towards flexibility is the use of Intermediate Bulk Containers (IBC).

These items can be used to decouple the fixed mixer from the packing lines.

It works by emptying the fixed mixer contents straight into the IBC, which transfers and feeds into the packing line as demand dictates.

The second step is to deploy IBC blending instead of a fixed mixer. Product is blended within the IBC so there are no contact parts to clean between blending different product batches. The IBC blender can immediately accept the next IBC, regardless of whether it is a different recipe. This offers the ability to mix any recipe at any time; fill orders on demand and reduce inventory risk.

Up to four batches per hour can be processed through one IBC blender. This

1

provides the ability to supply multiple packing lines, which may be used to fill different consumer SKU types.

GREAT PRODUCT QUALITY It is vital to handle each recipe batch with care. Recipes are typically a mix of different ingredients in varying proportions, with different particle sizes and varying densities.

A mix of granular and fine particles is generally present. These can move and separate during the transfer procedures.

The ‘fines’ can settle to the bottom leaving the bigger particles at the top or they can be blown upwards as air transfers from the receiving vessel in exchange for receiving the powder (elutriation).

The Matcon IBC system is designed to prevent this segregation risk. Product is blended within the container on an IBC blender.

This means there is one less transfer required. When feeding to the packing line, the innovative cone valve technology in the Matcon IBC creates mass-flow discharge, which protects the blend against segregation. The powder flows across the whole cross-sectional area of the container. All particles move

1: Decoupling production improves efficiencies 2: Matcon IBC with Cone Valve technology

2

KEY BENEFITS

• Increased production as downtime is reduced • Elimination of campaign manufacturing • Reduction in inventory • Short lead-times and make to order capabilities • Removal of cross contamination risks.

downward at the same rate. The product that entered the IBC first will be discharged on the first-in, first-out principle. Particles don’t move against each other, so each dose out of the container should be the correct combination.

This method ensures that you achieve a quality finished product in the final pack.

Each ‘dose/portion’ has just the right proportion of ingredients, giving you and your customer peace of mind they are getting what it says on the label.

DON’T WASTE PRODUCT DOWN THE DRAIN In addition to not scrapping batches, you need to ensure expensive, valueadding ingredients aren’t lost during the manufacturing processes. Have you ever considered what you might be leaving behind in the fixed mixer? It might look as though most of the material has been emptied but often residue is left behind in the blender.

Another potential loss area is if the batch is compromised in any way.

Without good housekeeping practices and thorough cleaning, there could be a risk of cross-contamination from previous recipes. If this happens then there can be no option but to scrap the entire batch.

Blending inside the IBC and then using a process that ensures the full discharge, reduces residue build-up and crosscontamination to a bare minimum. •

Matcon - www.matconibc.com

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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

Healthy living drives dairy and plant-based beverage growth The global market for aseptic packaging is developing rapidly. The industry is witnessing an increase in healthy and nutritional product categories and aseptic packaging is the perfect fit to fuel this growth. By Guillaume Rolland

T

he most visible development is in the liquid dairy product segment. The milk market is booming due to the introduction of many new products, such as flavoured and UHT milk and dairy drinks mixed with fruits, cereal, nuts and spices.

These categories include special dietary products that contain high protein, low fat and low added sugar.

Dairy players must differentiate their brands and produce liquid products flexibly and cost-effectively. In this instance, PET packaging offers great marketing and business opportunities.

HYPER-FLEXIBLE PACKAGING SOLUTIONS Behind this positive development are many drivers. We have seen increasing recipe diversification in the LDP, as well as the juices, nectars, soft drinks, isotonics and teas (JNSDIT) categories. Pushed by a clear search for personalised nutrition, this results in a wider number of SKUs. Diversification means producers require hyper-flexible aseptic solutions to factor in future market needs. They must also deliver a variety of products with a long shelf life.

Bottle formats and shapes, cap and label applications vary strongly. This contributes to the need for higher flexibility and no compromises on line efficiency.

Brand differentiation on retailer shelves is becoming a must-have for sensitive beverage producers. Therefore, producers are shifting their production to PET, which offers stronger marketing opportunities.

This is due to the bottle design freedom enabled by the raw material itself and enhanced by injection stretch blow moulding technology. Round or square, asymmetric or with specific handling, the high versatility of the PET bottle opens possibilities to define any premium or affordable package.

Food safety standards remain a critical goal for food and beverage manufacturers.

This holds particularly true for sensitive products. Looking at the growth of aseptic PET packaging in this segment, success can be accredited to its excellent barrier properties and neck and cap tightness. This ensures optimal shelf life with no light, oxygen or microorganism spoiling the quality of the drink.

In conjunction with the material’s 100 per cent recyclability, this winning combination of food safety and long shelf life is proving key in emerging markets, where distribution patterns and logistics might be challenging.

From transparent to opaque solutions, PET packaging alternatives can ensure top product protection and quality, while delivering the expected shelf life without the need for aluminium foil.

Sidel is addressing aseptic packaging as one of its key business areas. Aseptic equipment sales have been continuously growing in the past four years: this clearly reflects market trends, but also represents the results of many initiatives implemented to enhance Sidel's research and development, project management and service capabilities in this field.

Sidel can deliver complete line solutions and integrate the processing equipment and capabilities of Tetra Pak Processing Systems.

A clear proof point of Sidel’s leadership in aseptic applications is the Food and Drug Administration (FDA) approval for its Aseptic Combi Predis blow fill seal filler.

This made the solution the world’s first aseptic PET filling equipment with dry preform sterilisation validated for low acid manufacturing and commercial distribution in the US market. The Sidel Aseptic Combi Predis is increasingly being chosen as a safe, simple and flexible production equipment by companies based outside the US who are planning to export their goods to the Americas.

Hyper-flexible aseptic solutions cater to the growing needs of the beverage industry

In 2017, Sidel introduced the Versatile Aseptic Combi Predis, suitable for still and carbonated soft drinks (CSD) in PET bottle formats from 200ml to three litres. To answer the consumers' ever-changing needs, this solution can efficiently produce a wide variety of products with no compromises on increased flexibility, reliability and product integrity.

It processes high and low-acid sensitive beverages (like teas, juices, UHT white milk, soya milk, etc.), with or without pulps, with natural and preservative-free recipes. This perfectly matches the requirements placed by new, healthier product alternatives, which are hitting the market. •

ABOUT THE AUTHOR GUILLAUME ROLLAND

is the vice president for sensitive products at Sidel.

Sidel – www.sidel.com

August 2019 | Food 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

Maintain hygiene from brew to bottle Hygiene during beverage manufacturing is vital to protect consumers while ensuring high-quality products. Even the slightest contamination can render a batch unsafe for consumption. By Darryl Macdougall Unhygienic beverage processing can result in productivity and financial losses

A

challenge faced by beverage producers is that modern consumer tastes demand new flavours. This demand runs contrary to the operation of traditional dedicated process lines where there is one pipe-run for one product.

To facilitate extra product lines, manufacturers must either build or recommission an existing line. The facility will suffer downtime during the turning around of an operational line.

Most modern production facilities have moved from a dedicated production line for each product or flavour to innovative multi-product lines. These lines can process several different flavours every day.

Lean, flexible manufacturing is the engine running the most successful operations. Processes must be consistent and reliable to accommodate perishable ingredients, storage, short-lead times for

retail clients and maintaining a safe and hygienic production line.

There are challenges with a multiproduct or flavour line approach. It includes deciding how best to manage the transition of one product or flavour to another when using the same line for batch production.

For liquids, the nature of substances can vary greatly in terms of viscosity, sensitivity to shear forces and abrasiveness. Linked to this, directives from the European Hygienic Engineering Design Groups (EHEDG) are intended to prevent contamination. These include a directive stating that every part of the production line should be accessible for cleaning.

"The most important criteria is to select the right pumping solution that will perform optimally, while handling the products with care and still meeting today's hygiene standards" Beverage manufacturers can consistently produce quality products and reduce waste throughout the production process. It is important to have an environment that meets and exceeds hygienic standards. This requires machines that are 100 per cent reliable and equipment that is safe while allowing for optimum production performance. The most important criteria is to select the right pumping solution that will perform optimally, while handling the products with care and still meeting today's hygiene standards.

Liquids can vary greatly in terms of viscosity, sensitivity to shear forces and abrasiveness

Throughout the beverage production process, there are many areas where hygienic pumps can be applied. These include clean water processing, pressing (local), evaporation (local), transport of liquids, distillery, mixing, cold zones such as pasteurisation, filtration, filling, hot zone in breweries, pulp transfer, flavour addition, clean in place (CIP), sterilisation in place (SIP) and wastewater runoffs.

The right pump for the application should be selected based on the following considerations: • Consider the material make-up of the pumping system to the product being pumped, i.e. electro polished stainless steel or centrifugal pumps that offer clean-in-place (CIP) technology; • Pump design or technology should be suitable for the product being transported; • A suitable pump design for the duty cycle required; • The pump itself and the system design must allow for efficient operation. The pump is selected to operate at the best efficiency point on the performance curve and is suitable for the multiproduct line; • Speed of the pump on duty point.

Pipework must be designed around correct velocities; • Power supply is adequately sized and correct switchgear is utilised; • Correct valves are in the system and in the correct positions.

Navigating the technical obstacles of selecting the right pumping solutions for specific applications can be complex.

Beverage makers must look to a trusted and reputable brand that can offer a wide range of pumping solutions that are longlasting, cost-effective and efficient. •

ABOUT THE AUTHOR DARRYL MACDOUGALL is managing director of Verder Pumps South Africa.

Verder – www.verder.co.za

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Food Review | August 2019

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

The connected future of gas supply Afrox gas cylinders, onsite bulk tanks and gas analysers will soon be connected to the Internet. This will allow automatic reordering for just-in-time delivery. Data collected can be used to analyse gas quality and usage trends while predicting needs and identifying leaks.

T

he technology is being tested through a secure Internet portal between customers and Afrox's gas ordering system. Hosted by a contracted telemetry provider, the portal offers real-time updates on gas pressure and other parameters.

Traditionally, critical applications are handled by keeping a back-up gas supply connected on site. As soon as the pressure in the active cylinder drops too low, the backup cylinder is immediately available. Sending an alert to Afrox's always-online ordering portal means the risks of running out of a critical gas is almost eliminated.

Gas analysers can now be programmed to capture samples and record analysis simultaneously. It brings with it significant benefits in terms of costs, efficiency, reaction times, safety and end quality.

For special gases, connectivity and digitalisation will allow specific formulas to

be ordered, mixed and checked online before delivery. Where purity of the gas is critical, the production or laboratory process system can be monitored by an analyser. Analysis data can be obtained and used as a reference for validation of the process in real-time.

By analysing time versus pressure data from cylinders or bulk gas supply systems, graphs can be created and detailed usage reports generated. This will give managers an excellent tool to see when and how the gas is being used and how much it is costing. This will make planning and accounting easier.

Once benchmarks have been established, this information can also trigger alarms as soon as leaks in the system emerge, reducing waste and saving money. •

Afrox – www.afrox.co.za

Verder offers a wide range of pumps for hygienic applications in the food and beverage industries. These ranges of pumps consists of the Packo Centrifugals, Verderair Double Diaphragm, Verderflex Peristaltics and the recently added JEC rotary lobe and twin screw pumps. With this complete range we can answer all your hygienic pump questions!

VERDER HYGIENIC

Offering a wide range of hygienic solutions

Your benefits Best cleanability 3A, EHEDG, EC1935/2004 & EC10/2011 certification SIP/CIP cleanable Easy maintenance, standard wear parts Various connections available Lowest total cost of ownership

VERDER S.A. Tel.: +27 (0)11 704 7500 www.verder.co.za info@verder.co.za

Advert_Hygienic_177x130mm_SA.indd 1

05-08-19 11:56

August 2019 | Food 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

Can functional ingredients create innovation?

Children are underserved by the beverage market, and manufacturers can close this gap by using nutritional ingredients. This is according to the producers of Wellmune, a yeast beta glucan clinically proven to help support the immune system.

T

he global beverage market is booming. Its value is expected to surpass US$1 trillion by 2022, according to statistics released

by Euromonitor.

Many products in the category are heavily consumed by children.

Few beverage products are explicitly created for children and relatively little new product development targets them.

Between December 2012 and November 2017, just five per cent of new water launches, six per cent of juice drinks and six per cent of other beverages were aimed at kids. By contrast, 17 per cent of new breakfast cereal launches over the

“The addition of functional ingredients may help restore the parent-appeal of beverages that have suffered a loss of reputation” same period were child-focused. [1] A new white paper from Wellmune demonstrates that healthy, functional ingredients offering nutritional benefits may be the key to kick-starting innovation in this category. Eight in ten parents say their choice of product is influenced by how it will affect their child’s health and well-being [2] and most prefer their kids to get health-enhancing ingredients from food and drink rather than pills. [3] The addition of functional ingredients may help restore the parent-appeal of beverages that have suffered a loss of reputation. Juices, for example, were once seen as a healthy choice for children, but are now often demonised for their high sugar content. The use of functional ingredients creates opportunities to offset such concerns, as well as offering nutritional benefits that allow product differentiation.

John Quilter, Wellmune’s vice president and general manager explains, ‘While strategies such as sugar reduction

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Food Review | August 2019

ABOUT WELLMUNE

are important, the real opportunity to differentiate kids' beverage products lies in the use of healthy, clinically-proven functional ingredients. They can further support the health halo of functional beverages for children, increasing appeal to parents and allowing products to stand out from the crowd. They could well be the key to giving the children's beverage space the innovation boost it needs.’

Immune health is a functional benefit area where there is a high potential for innovation and growth. Keeping kids healthy is a priority for parents, and young immune systems are vulnerable.

Despite high levels of interest, only two per cent of children’s food and drink products launched globally between 2012 and 2017 carried an immune system claim, indicating a major opportunity for manufacturers. [4] Kerry’s natural immune health ingredient, Wellmune, is a proprietary baker’s yeast beta 1.3/1.6 glucan. In clinical studies, children who took it reported two-thirds fewer upper respiratory tract infections. Nearly nine in ten (87 per cent) of consumers said they would be interested in buying a

Wellmune is a natural food, beverage and supplement ingredient clinically proven to help strengthen the immune system, making it easier for people of all ages to be well and stay well. Part of Kerry's ProActive Health portfolio, Wellmune is a proprietary baker's yeast beta 1.3/1.6 glucan and is patented, Kosher, Halal, non-allergenic, non-GMO, gluten-free and organic compliant. As a global brand, available in more than 60 countries, Wellmune has regulatory approval in major markets, including GRAS status in the US and novel food approval in Europe and China. A recipient of numerous industry awards, Wellmune is part of Kerry’s nutrition and wellness portfolio.

refrigerated juice product if it contained Wellmune and 81 per cent said they would prefer boxed juices for kids that contained Wellmune. [5] • 1) Mintel, Children’s Nutrition Insight, December 2017 2) GlobalData, Global Consumer Survey, Q3 2018 3) GlobalData, Top Trends in Baby and Child Care, April 2018 4) Mintel, Children’s Nutrition Insight, December 2017 5) Consumer Insights, Concept/Benefit Screen, 2014

Wellmune – www.wellmune.com

FUJI FORM-FILL-SEAL PACKAGING MACHINES

Renowned worldwide for their high speed, reliability and ease of operation

CX Wrapper FW3710 BS-B Standard and custom built Auto feeders are provided for most applications.

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F O R M , FI L L & S E A L

Promote flexibility and automation in packing GEA's redesigned high-speed vertical packaging machine, SmartPacker TwinTube, is a future-proof modular system. It features increased functional efficiency, higher operational uptime and ease of use.

T

he unit is suitable for packaging smallsized food products, such as sweets, nuts, dried fruit and other on-the-go products in pillow bags of different sizes.

The TwinTube forms part of a complete packaging process with upstream and downstream equipment operating in a dry manufacturing facility. It operates with two parallel forming tubes, achieving combined speeds of up to 500 bags per minute. It is also possible to run a different film reel for each tube, meaning calorie packs of different widths or designs can be simultaneously filled. A new feature to the machine is the Jumbo Roll. This allows film reels of up to 100kg to be used for long production runs, which boosts operational efficiency.

‘The unit has a modular construction, which allows customers to easily add new options and upgrade their machine.

We've increased operator friendliness by introducing toolless adjustment features.

This helps achieve shorter change-over times and proven/error-free setup of the machine.

This includes printers, labellers and the vertical sealing unit,' explains Martijn van de Mortel, product manager vertical packaging at GEA. ‘With these new updates, we can meet our customer demand in terms of automated process control, less operator dependence, more uptime and operational efficiency,' he adds.

• Automatic web tracking - If the film deviates from its path, due to variances in the film roll, the feature will correct

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Food Review | August 2019

the direction of the film automatically, without the need for manual adjustment.

This safeguards the quality of the resulting bags while saving on downtime.

• Reinforced sealing for more flexibility Features a new jaw-closing mechanism, optimised heating unit and a vertical rotational seal unit. This promotes robust packing performance and excellent tightness of the pack seals. The jaw closing mechanism offers more than triple sealing force as the previous one and can apply 6000N. This allows using thicker films or films with more diverse characteristics in terms of sealing requirements.

• Easy labelling, operation and maintenance - Fully integrated GEA TiroLabel unit, which makes the machine even more compact on

the factory floor. The dedicated labelling unit delivers a speed of up to 180 labels per minute at a width of 150mm and achieves millimetre precision during labelling.

• Comfortable to operate and maintain - Innovative open design with doublehinged doors for easy access and seethrough panels providing maximum visibility of the sealing area. Full access and easy maintenance are made possible via the machine's hinged front-plate – to which the sealing arms and vertical seal are attached – and which can be fully opened. This ensures all items requiring maintenance can be easily reached. •

GEA – www.gea.com The SmartPacker TwinTube offers full access and easy maintenance with a front-plate that can be fully opened

beverages

dairy farming

dairy processing

utilities

transport

food

core technologies

Milking & Cooling

Seperators

Decanters

Homogenisers

Valves

Spray Drying

Aseptic Filling

Brewery & Dairy

Compressors

Packages & Skids

Ice Machines

Freezers

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

www.gea.com

engineering for a better world

F O R M , FI L L & S E A L

Custom blades can save you money Earlier this month, Food Review caught up with Mikko Brunner of Renlaw, a Cape Town-based engineering firm specialising in industrial cutting tools.

W

e wanted to gain a little more insight into the options and benefits of blade customisation for vertical form, fill and seal (VFFS) machines.

Brunner explained that standardised tooling, supplied by VFFS machine manufacturers and agents is usually suitable for cutting a wide range of products. These standardised blades are not specifically engineered to any one product.

While this one-size-fits-all approach has its advantages, customers should be aware that customising blades to suit their specific application can drastically improve a machine's performance and longevity of each blade.

‘Think of the blades that we all use in our kitchens,' Brunner says. ‘Trying to dice carrots with a butter knife or slice a loaf of bread with a cleaver just seems counterproductive. In the kitchen, you choose your tool according to what you want to cut. There are so many South African manufacturers who keep on using the same blades - irrespective of the material being cut. Many people in this industry are totally unaware that the blades they use are not always the ideal or most effective choice.'

Brunner explains that there are several aspects a business should consider when customising blades for VFFS machines.

These include: • Material to be cut • Cut finish required • Cost of downtime during blade changes

• Speed of operation • Whether product or packaging material adheres to the blade (MSG can build up on a blade, rendering it ineffective) • Should the blade be resharpened?

These factors will affect which steel should be used; whether the blade should be coated and its design geometry.

Knife steels are chosen for their desired properties (wear-resistance, toughness, corrosion-resistance and costeffectiveness) and hardened in a carefully controlled process. This allows the various alloying elements of the steel to combine in the manner that produces the desired qualities. ‘In a production environment, paying a bit more for blades that will last longer is a no-brainer,' Brunner points out.

STEELS MOST COMMONLY USED IN VFFS BLADES Carbon steel – Not recommended for use in VFFS machines. Carbon steel blades offer poor quality cutting edges combined to a very low sharp-life. Companies using carbon steel blades suffer in the long run with damage to machines, breakages and losses during downtimes.

420 HC – This is a cost-effective, martensitic stainless steel with a fair wear-resistance and moderate toughness. The international standard for VFFS blades is 420 steel.

D2 (K110) – A high alloy tool steel, which offers toughness, good wear-resistance and a fair level of corrosion resistance under normal conditions. Blades made from D2 cost an average of 25 per cent more than the 420 blades and will outperform them by a fair percentage.

HSS (High-speed steel) – This product offers the best wear-resistance and good toughness. The steel is used in demanding applications such as the cutting of paper products. High-speed steel has limited corrosion-resistance. Because of its relatively high price, blades made from this steel are often viable only in production processes where tools do not suffer impact damage such as blade or tooth bending or breakage.

COATINGS

A range of blades for vertical, form, fill and seal machines

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Food Review | August 2019

There are a range of coatings that can be added to blades to improve their performance. These coatings are extremely thin layers (only 0.003mm thick) of special

metals or ceramics. They can significantly lower the coefficient of friction of a blade's surface and increase hardness by up to three times that of hardened steel.

These coatings increase the blades' sharp-life and helps to prevent product adhesion, reducing down-time during cleaning operations. The coating process can be pricey and is only worth adding to blades in applications where impact damage is not an issue.

GEOMETRIES Tooth geometries affect the cutting performance of the blades and the cut quality of the product. Standard tooth angles generally perform well across a range of materials, but teeth can be optimised for specialised applications to offer improved performance.

Brunner explains that there are there is a range of possible tooth shapes for VFFS machine knives, including the standard V tooth, scalloped tooth, zig-zag tooth, double V and many others. Each offers distinct cutting patterns. Tooth pitches also affect the cut quality of the product. Finer pitches result in finer cuts with smaller waves on the product edge. Larger pitches give a rougher edge, but require less cutting force.

Blades are often supplied pitched or tapered on their widths. Blades cut with a shear action and not along their full length at once. This allows the blades to cut with reduced force while offering the finer cut of a reduced tooth pitch.

‘There are so many different options available when we look at tweaking the designs of machine blades,' Brunner enthuses. ‘We are very fortunate that we are locally based and can work closely with customers to figure out individual solutions.

The positive feedback we get when our design modifications are implemented is amazing. Our ability to modify blades sets us apart from our competitors and is something that keeps our clients loyal to our brand.'

Renlaw's engineers work with suppliers, OEM's and end-user customers to find value-adding cutting solutions by minimising blade changes, improving blade performance and offering professional blade resharpening. •

Renlaw - www.renlaw.co.za

Renlaw CUTTING-EDGE TECHNOLOGY

Africa’s leading supplier of industrial cutting tools

CAPE TOWN BRANCH:

JOHANNESBURG BRANCH:

+27 (0)21 701 7917

+27 (0)79 155 7358

sales@renlaw.com

sales2@renlaw.com

www.renlaw.com

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

Personalised packaging for ready-to-eat meals The food sector is seeing enormous growth in convenience products. Consumption of ready meals, pre-cut fruit and vegetables, prepared salads and snacks are on the rise. Food Review spoke to Trevor Reardon of Goldpack to discuss some of the latest trends in this sector.

I

n this space, higher requirements are being set for packaging. It must look attractive, provide product information, preparation methods and offer the option of being used as a serving dish.

In the convenience market, pre-printed trays and bowls are often used to meet these demands. As an alternative for expensive printing on trays and films i.e. production, warehousing and logistics, it is now a viable and popular choice to use trays with a sleeve.

This offers better printing possibilities, higher resolutions and additional flexibility. The inside of the sleeve can be printed and when stacked on supermarket shelves, a large part of this printed area will remain visible.

LARGE VARIETY OF TRAYS AND SLEEVES The Jasa sleever personalises a tray by applying a pre-folded, pre-glued sleeve around it. Rectangular, round, oval and square trays, bowls and cups with a lid or topseal or flowpack are placed in cardboard sleeves that are closed on either or two or three sides.

"As the impact of changeover times on production is minimised, the user can process more trays compared to the regular production process" The machine is designed for food producers looking for an extremely versatile machine that can be changed from one tray sleeve combination to another within minutes. The compact design and various modular input and output systems ensure easy integration into existing production lines.

SHORT PAYBACK TIME As the impact of changeover times on production is minimised, the user can process more trays compared to regular production processes.

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Food Review | August 2019

Jasa packaging solutions for trays and cups in all sizes

Most sleevers require at least a half hour changeover time, but Jasa has reduced this time to less than five minutes. By using the Jasa sleever, the flexibility of manual sleeving remains, yet the output of automatic sleeving is much higher, which results in very short payback time.

INNOVATIVE TECHNOLOGY WITH JASA SMARTDISPLAY The sleever is fully servo-driven and developed to use as few moving gears as possible. In conjunction with reliable PLC control and a linked Jasa Smartdisplay, this ensures a high level of operating convenience.

Pre-programming and start of operation are kicked off with the touch of a button.

The result is a sleever that combines easy operation with low maintenance costs.

The machine is built according to CE safety regulations, with security screens and safety sensors on doors and all moving parts.

SLEEVER CASSETTE GUARANTEES SHORT CHANGEOVER TIMES After evaluating several concepts, it became clear that changing from one sleeve to another had to be just that: changing the sleeve and nothing else.

This aim has been achieved by making the sleever cassette the heart of the

machine. Every sleeve has its own, custom-made cassette. While changing the cassette, the width of the tray guiding system is automatically adjusted by an auto tracking system. Within five minutes, the entire machine is changed from one set of trays and sleeves to another.

A COMPLETE LINE Besides modular in-and outfeed units, Jasa Packaging Solutions supplies related equipment to build a fully automated sleever line. In-house designed machinery and machines from partners can be integrated into the packaging line.

Depending on the specific requirements, this could include weighing and dosing systems, filling stations, delta robots, tray cup denesters, lid placers, tact conveyor, thermoformers and topsealers. The Jasa range of equipment is supplied locally through Goldpack. •

Goldpack – www.goldpack.co.za

The JASA Sleever PERSONALISES AND SLEEVES APPLES USING CARDBOARD TRAYS

JASA SLEEVER FOR APPLES Process up to 50 trays per minute with a single belt model or 100 trays per minute with a two belt model

PERSONALISES TRAYS AND CUPS USING PRE-FOLDED AND GLUED SLEEVES

The JASA SLEEVER can decorate many types and sizes of trays and cups, square, rectangular, oval or round.

Sleeves up to 50 trays per minute with a single belt model or 100 trays per minute with a two belt model.

• 100% CARDBOARD • 100% SUITABLE FOR RECYCLING

CAPE TOWN Tel: 021-534 0215 DURBAN Tel: 031-569 4199 JOHANNESBURG Tel: 011-312 4976 sales@goldpack.co.za www.goldpack.co.za TAS3420

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

Hot food convenience for on-the-go consumers Convenience food has made meal times so much simpler for today's fast-paced lifestyle. Packaging convenience is taken a step further with Berry Astrapak's new microwaveable foldover containers – perfect for self-service meals.

T

he new Hot Food Foldover container is made of polypropylene (PP) and forms part of Berry Astrapak's convenience line. The container provides a safe packaging for reheating pre-cooked meals and it is the solution for busy, on-the-go consumers.

Supermarket convenience meals can be dished into the container, and stored until ready to be reheated in the home.

Its square and compact shape allow for easy stacking and effective storage. Its versatility comes in three sizes, 350ml, 500ml and 800ml. Since PP is resistant to absorbing moisture, this versatile container can package a wide range of food items as well as protect contents from perishing.

PP is known as a thermoplastic. This means the container can be safely warmed in the microwave since the material can withstand high temperatures. Considering that PP is a low-density plastic-type, the container is lightweight, which ensures cost-efficient packing and transporting. As an added advantage, PP products can be recycled and repurposed into a variety of new products, such as food containers, car parts and compost bins. •

Easy stacking and effective storage is assured with the container’s square and compact shape

THE

Buyer’sguide

“The container provides a safe packaging for reheating pre-cooked meals and it is the solution for busy, on-thego consumers”

2017/2018

Berry Astrapak - www.astrapak.com

THE

Buyer’sguide

2018/2019 2019/2020

The directory for manufacturers of food, beverages, pharmaceuticals, cosmetics, toiletries, packaging and the printing industry

Available online: www.thebuyersguide.co.za Buyers Guide 2018.indd 1

40

Food Review | August 2019

2018/05/07 3:09 PM

Coffee

Soduko

time

Solution

ADVERTISERS’ INDEX AUGUST 2019 Afrox......................................................26......www.afrox.co.za AGT Foods Africa...............................15......www.agtfoods.co.za Berry / Astrapak....................................5......www.astrapak.com Bio-Science Technologies.................22......www.biosciencetechnologies.com Bruker SA..............................................24......www.bruker.com/optics Chempure.............................................16......www.chempure.co.za ChemScience Laboratories...............23......www.chemsciencelaboratories.com Courlanders Agencies........................27......www.dcnorris.com Emirates SkyCargo........................ OBC......www.skycargo.com/emiratesfresh Eptech Products..................................42......www.eptech.co.za GEA Africa...........................................35......www.gea.com Goldpack....................................... 33, 39......www.goldpack.co.za

Interroll SA........................................3, 21 .....www.interroll.co.za ISW Shrink............................................34......www.iswshrink.co.za Klüber Lubrication..............................19......www.klueber.com Leco Africa.............................................8......www.lecoafrica.co.za MLS........................................................25......www.mlslabs.co.za Plastics SA..............................................7......www.cleanupandrecycle.co.za Polyoak Packaging................................9......www.polyoakpackaging.co.za Renlaw...................................................37......www.renlaw.com Sartorius South Africa..................... IFC......www.sartorius-stedim.com Savannah Fine Chemicals.......OFC, 18......www.savannah.co.za Sensient.................................................17......www.sensient.com Verder Pumps SA................................31......www.verder.co.za

August 2019 | Food Review

41

To advertise in

Anita Raath

Sales executive +27 (0)82 976 6541

Carla Melless

Sales executive +27 (0)83 260 6060

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

Daleen Filbey

Sales executive +27 (0)83 409 3119

BUTCHER MEAT PROCESSING EQUIPMENT BMPE is the leading supplier of superior quality New and Refurbished Food Processing equipment. Providing professional Service, equipment & spares. BMPE has extensive knowledge of current machines, technologies and consumables and provide a modern Service & Maintenance Department to support our customers throughout their process. Servicing a diverse range of customers, from large & small Butcheries, Abattoirs, Supermarket Groups and Franchise Outlets in the Food, Pet Food and other Manufacturing Industries.

BUTCHER MEAT PROCESSING EQUIPMENT Tel: +27 11 664 8212

Tel: +27 11 664 8212info@bmpe.co.za info@bmpe.co.za www.bmpe.co.za www.bmpe.co.za

BMPE is the leading supplier of superior quality New and Refurbished food processing equipment to the African market.

Our primary focus is to provide a professional service to the food industry with regards to Equipment, Spares and the latest Technological innovation.

With more than 30 years hands-on experience, we provide our customers with an excellent service in all areas of the food processing industry and have over the years achieved a good reputation for being efficient, cost-effective and professional.

We import machines for our local clients across the whole of Leading through Innovation Africa, ensuring that they benefit from machines of the highest quality at anofexcellent price.

PHT is the leading provider state-of-the-art technology for Our staff have extensive knowledge of current Machines, hygiene and food safety.

Our unique systemsand offer efficient, Technologies and Consumables we also provide a modern Service and Maintenance Department to support our customers effective and sustainable solutions for your hygienic challenges. throughout the process.

We develop both individual integrated hygienefrom solutions We service and a diverse range of customers, Large & for Small Butcheries to Abattoirs, Supermarket Franchise your company. We are always there for you and Groups, we support youOutlets and Corporates.

PARTNER FOR HYGIENE AND TECHNOLOGY

NEW & USED FOOD MACHINERY – IN STOCK • A&K Corn Cutters & Huskers • FAM Dice, Slice & Strip Cutters • FAM TS-1D Transverse Slicers • FAM PMD Poultry & Meat Dicers • FAM 7944 French Fry Cutters • FAM 7407 Bean Cross Cutters • Feuma Apple Peelers • Femia Bean Snippers • Herbort Bean Top & Tailers

• Eillert 2-stage vegetable washers • Key 4” Hydro Food Pumps • Key Vibratory Shakers • Kronen GS10 Slicers • Kronen KUJ Dicers • Kronen Gewa 3800 Washers • Mado Meat Mincers • Ramon Bowl Cutters • Many Other Machines Available

CALL US NOW FOR A QUOTATION

Food Processing Systems & Technology, Paarl Tel: 021 - 868 -1594 | Fax: 021 - 868 - 1599 Visit us on http://www.eptech.co.za or mailto:info@eptech.co.za

through our actions, professionally and reliably. Hygiene and food safety is our passion. We care about our customers, our suppliers and our people – we measure our success by the way we touch their lives. Because we care, we design innovative and holistic solutions.

Tel: +27 861 777 993 | info.za@pht.group | www.pht.group

WEB REVIEW HOME

NEWS

ABOUT

C O N TA C T

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

We are proud suppliers of Swiss-made analytical solutions that greatly enhance the output, efficiency and reliability of your labs and processes.

Our products are widely used in the environmental, pharmaceutical, food, mining, electroplating, petrochemical and water treatment industries as well as tertiary institutions for teaching and research.

Offering the following across all regions in SA: • Food Safety Implementation (BRC, FSSC 22000, GFSI, GLOBALG.A.P.) • Customised food safety training • Pre-certification audits • Coaching and mentoring of Food Safety Manager • Food Safety Systems Maintenance & Support • Tempo paperless FSMS software solutions

Tel: +27 (0)11 656 1918/ +27 (0)21 852 0213/ +27 (0)31 265 0067 www.metrohm.co.za

info@entecom.co.za www.entecom.co.za

INNEROUT

MATRIX SOFTWARE

A FoodBev SETA accredited training provider offering training in the: •B akery NQF 2 + 3 qualifications •M eat and Fresh Meat processing qualifications •P ackaging qualification •F ood and Beverage Handling qualification

Matrix Software, specialist leading ERP software providers for the Meat and Food industry, offers various solutions to assist the factory floor function in production plants.

In addition to the above qualifications we offer numerous skills programmes that addresses the needs of the Food industry.

Training is offered across all regions in SA and Africa. shirley@iots.co.za www.iots.co.za

FORMPAK For over 40 years Formpak has supplied specialised processing, packaging and printing machinery to the pharmaceutical, cosmetic, plastic, glass, chemical, food and dairy industries.

Our diverse range of software offerings features a unique module listing of more than 700 modules (program nodes).

Our software solutions are tailored for the Feedlot/Abattoir/ Debone / Production Retail industries. Matrix Software is deployed in 8 countries throughout Africa, Australia, New Zealand and Seychelles. www.matrixsoftware.co.za

FIRMENICH We create Fragrances and Flavours for the world’s most desirable brands. Our aim is to delight billions of consumers around the world everyday.

Innovative Craftsmanship in

Tel: +27 (0) 11 828 8870/1/2 Fax: +27 (0) 11 828 8880 email: haase@formpak.com or service@formpak.com www.formpak.com

Fragrances and Flavours since 1895.

DINNERMATES

QUANTUM COLOURS SA

• Supplier to the hospitality trade and food factories • Service excellence, • Quality, portion controlled products (chilled/frozen /dried) • Innovation & Flexibility • Meat & chicken products tailored for special applications in the food industry • Dried meat products – real meat real flavour!

Tel: +27 (0)11 032 8600 email: sales@dinnermates.co.ca Tel: +27 (0)15 516 1515/4 email: factory@dinnermates.co.za/www.dinnermates.co.za

Your No. 1 industry leader for the most comprehensive ranges of both synthetic and natural colours – used in food, pharmaceutical, cosmetic and industrial applications.

Our technical team is available to shade and colour match to specific requirements and / or Pantone references and to give legislative support on colours.

www.firmenich.com

www.quantumcolours.com