Welcome to this edition of Food Review magazine. Our cover story features the booming South African beverages market. Neil Wiltshire, Senior Flavourist at Kerry South Africa, explores the trends driving this growth, including consumer preferences for convenience and innovative flavours. The market is projected to reach USD 25.74 billion by 2029, creating ample opportunities for new product formulations. Neil’s analysis provides a comprehensive overview of the market’s evolution and the exciting prospects it holds for the future. Turn to page 30 for more insights. We have a special section (see pages 12 – 17) dedicated to the women in the industry who continue to make a difference by pushing the boundaries. In celebration of Women’s Month, we feature an exclusive Q&A with Nomvuyo Mlombi, a dedicated and passionate Product Specialist in the food and beverage manufacturing sector. Mlombi shares her inspiring journey, from her early days studying food technology to her current role where she champions innovation, quality, and clean labelling. She discusses the unique challenges she has faced as a woman in the industry and how she has overcome them through perseverance and dedication. Her story is a testament to the power of resilience and the importance of continuous professional development. She also highlights a significant achievement in her career, where she empowered her R&D team to innovate and create products that meet the growing demand for transparency and natural ingredients. See page 12 . In another compelling article, we explore how Matrix Software is addressing Africa’s food processing challenges. Founded in 2006, Matrix Software specialises in innovative software solutions tailored to the food processing industry. Their hands-on approach ensures they understand and solve their clients’ challenges, offering scalable, customisable, and user-friendly systems. CEO Dewald Carelse shares insights into their philosophy of starting where the problem is and working from there, which has enabled them to develop fit-for-purpose solutions that elevate businesses. The article also discusses their partnership with Agventure, which aims to unlock Africa’s agrifood potential through technological innovation and entrepreneurship. Turn to page 20.
We hope you find this edition both informative and inspiring.
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
STRATEGY DIRECTOR: Andrew Nunneley
CHIEF FINANCIAL OFFICER: Venette Malone
CEO: MEDIA24: Ishmet Davidson
HEAD OFFICE
New Media, a division of Media24 (Pty) Ltd 8th floor, Media24 Centre, 40 Heerengracht Cape Town, 8001
Stay on top of produce with complete vegetable processing solutions
Bringing together leading brands in processing, inspection and packaging equipment for the vegetable industries. Our solutions set the standard for yield, efficiency, and safety across a wide range of industries. Whatever your product needs, we can meet it with precision and passion.
Produce Storage I Peeling, Grading, Washing I Electroporation
Cutting + Pureeing I Value-added Processing I Product Handling
Chicago, USA 23 – 25 October www.process-expo. us.messefrankfurt.com
September
Plant Based World
New York, USA 11-12 September www.plantbasedworldexpo.com
Dairy Expo
Nairobi, Kenya 10 – 12 September www.dairymanufacturingafrica.com
Label Expo Americas
Chicago, USA 10 – 12 September www.labelexpo-americas.com
Propak West Africa
Lagos, Nigeria 10 – 12 September www.propakwestafrica.com
November
FIVE NEW LONGLIFE NECTAR JUICE VARIANTS
Rhodes Quality has entered the growing long-life nectar juice market, off the back of the brand’s successful growth in the 100% fruit juice market.
With five new nectar flavours to hit shelves in July, the Rhodes Quality fruit nectar juice range has been launched in 200ml, 1 litre and 2 litre pack sizes to suit all occasions, in refreshing Apple, Guava, Tropical, Mediterranean and Red Grape flavours.
“As a brand we are very excited about offering this new product to price savvy consumers, without compromising on taste or quality,” says, Maria Soares, Head of Marketing at RFG.
ESKORT’S NEW FLAVOURFUL LINE
Bacon and sausages may be where Eskort started 107 years ago in the small town of Estcourt (where it still has a factory), but its product line-up has expanded vastly since then. The latest addition includes convenient air fryer-ready products.
To coincide with the arrival of these quick and easy dishes from South Africa’s leading pork manufacturer, Eskort’s latest campaign is encouraging consumers to turn the tables
EXBERRY® COLOUR SUPPLIER GNT EXPANDS INTO FERMENTATION
GNT is working to develop new plantbased, sustainable EXBERRY® color solutions for food and drink using unique fermentation technologies.
The company has been creating EXBERRY® colors from fruit, vegetables, and plants since its foundation in 1978. It is now expanding into fermentation for the first time to increase innovation and sustainability in its plant-based solutions.
Producing colors through fermentation allows for improved functionality and highly efficient and sustainable year-round production. Once the raw materials have been cultivated, they can be scaled up in larger bioreactors for industrial production. This
phase involves maintaining optimal conditions to ensure high biomass yield and pigment concentration.
To deliver on its aims, GNT has chosen to collaborate with Plume Biotechnology, a UK-based start-up focused on innovation in fermentation science and bioprocessing for natural colors.
Frederik Hoeck, GNT Group’s Managing Director, said: “As pioneers in plant-based colors, innovation has always been crucial to GNT and we’re fully committed to delivering cutting-edge solutions for our customers. As a family business, we understand the importance of acting responsibly and ensuring we are truly sustainable.
on the social media trend of posting pictures of complex meals that have taken hours to prepare.
“Life is hard enough without adding unrealistic expectations about what a delicious plate of food should look like, when in fact, the true success of a delicious meal should be measured by whether the plate ends up empty,” says Marcelle Pienaar, Marketing Director of Eskort.
To read more, visit:FoodReview.co.za
SCHENCK PROCESS FPM REBRANDS AS COPERION
Effective today, the former Schenck Process Food and Performance Materials (FPM) group of companies have officially changed their name to Coperion. The transition follows the September 2023 acquisition of the companies by Hillenbrand (NYSE: HI), the parent company of Coperion.
The integrated Coperion companies combine the strengths of multiple process industry leaders under a single brand, offering manufacturers a broader portfolio of solutions, technologies and services across the food, health and nutrition markets, such as baking, confectionery, pet food, pharmaceuticals and cosmetics, Visit: FoodReview.co.za for more.
Bureau Veritas Hosts Open Day
Bureau Veritas recently hosted an open day at its state-of-the-art facility in Ormonde, Johannesburg. This event aligns with the launch of their LEAP | 28 strategy, aiming to become the preferred partner for excellence and sustainability.
One of the global leaders in testing, inspection and Certification, Bureau Veritas has been brokering trust between companies, governments, and society at large for nearly 200 years. The company hosted an open day where various stakeholders were able to tour the state-ofthe-art facility in Ormonde, Johannesburg. This open day aligns with the recent launch of the organisation’s global LEAP | 28 strategy, an ambitious, customer-centric strategy to become customers’ preferred partner for excellence and sustainability, offering superior service quality and differentiated solutions. With a strong legacy built up over almost two centuries, Bureau Veritas operates across six global businesses: Marine & Offshore, Agri Food & Commodities, Consumer Products, Building & Infrastructure, Certification & Industry.
LOCAL LABORATORIES OFFERING GLOBAL SOLUTIONS
Bureau Veritas Southern Africa is home to its state-of-the-art AgriFood laboratories based in Ormonde, Johannesburg, and Brackenfell Cape Town, two best-inclass facilities offering a wide range of
services. The Ormonde facility was founded in 1974, and offers renowned product testing, inspection, certification, and audit services across various industries including Pharmaceutical and Veterinary; Microbiology, Agriculture/Soil/Pesticides and Water Analysis (Environmental). As part of a global footprint of laboratories, with subject matter experts in chemistry and microbiology, the laboratory is closely aligned to international testing practices and full accreditation in accordance with
"With a strong legacy built up over almost two centuries, Bureau Veritas operates across six global businesses: Marine & Offshore, Agri Food & Commodities, Consumer Products, Building & Infrastructure, Certification & Industry."
ISO 17025:2017 standards and is recognised by the World Health Organisation.
The laboratory continues to evolve and develop with recent activities including the streamlining and refining of processes to ensure smooth and efficient timeous turnaround times driven by robust and effective working methodologies. Quality assurance remains a priority and is rigorously monitored to ensure alignment to global standards.
Gavin Hefer, district chief executive for Bureau Veritas Southern Africa.
Top Employer with a proud legacy: With a powerful legacy built on trust, the company has recently obtained two enviable accolades, an affirmation of employee satisfaction. Voted as Top Employer in Southern Africa, followed by scooping the renowned award for Top Employer for Africa; Bureau Veritas focuses on creating long-lasting relationships with customers and stakeholders. “We are proud of our legacy and wholeheartedly geared towards Shaping a World of Trust,” commented Gavin Hefer, district chief executive for Bureau Veritas Southern Africa. “Our commitment to customers is key and we are constantly reinventing ourselves to ensure we can meet customer demands, with sustainability at the core of our strategy. We continue to grow and develop, constantly streamlining our processes and business efficiencies.”
STRINGENT GLOBAL STANDARDS DRIVE DIFFERENTIATED SERVICES AND INNOVATIONS
Bureau Veritas supports local protocols and strict international guidelines provide an advantage for the Bureau Veritas laboratories. The laboratories provide a broad, complimentary range of AgriFood testing services from Farm to Fork, to ensure peace of mind for customers. Supported by subject matter experts with a wide range of qualifications from across the globe, the resources provide vast experience and diverse skills. With an enviable reputation as a leading supplier of choice and a responsible player in the marketplace, Bureau Veritas offers the same services at its sister laboratory in Brackenfell, Cape Town. The latest laboratory testing services announced by Bureau Veritas M&L laboratories are performed in both Ormonde, Johannesburg, and Brackenfell Cape Town laboratories, always delivering the highest levels of service to its customers. Providing global competence from production to finished product, these services include product testing in the laboratories, inspection, certification, and audits.
THE LABORATORIES COVER FOUR PRIMARY AREAS OF EXPERTISE:
1. Pharmaceutical & Veterinary testing
This vast area of product testing includes
various categories: Post Importation testing, Stability storage and testing, Batch and raw material release testing, Dissolution profiles and Analytical method transfer.
2. Microbiology product testing
Product testing spans a wide range of assessments, including Food spoilage and Quality surveillance testing (high tech automated and conventional), Food safety inspection and testing, Pathogen testing, Shelf-life storage and testing, Pharmacopeial Microbiology testing (pharmaceutical), Preservative challenges and efficacy testing and Disinfectants and sanitizers efficacy testing.
3. Agri-Food & Commodities for Inspection and lab testing services
Bureau Veritas laboratories are highly specialized in the Inspection and laboratory testing of food products, boasting an exhaustive list of products that can be analysed and evaluated. A few examples of inspections services include Bulk inspections for Port to Port and Bulk, and container imports and exports inspections. Laboratory testing services include Pesticide trials supported by good laboratory practice, accredited tests to ensure the quality and accuracy of data whilst taking maximum residue limits of pesticide residue into cognizance; namely, the expected residue to remain on food products when a pesticide is used according to label directions that will not be of concern to human health; Agricultural, Maize and Ground nuts crop trials testing (Aflatoxins with Peroxide Value, Free Fatty Acids); as well as Contaminants, metals and food nutritional testing are also conducted. Full nutritional label claim testing is offered, whilst Organoleptic tests, involving the assessment of flavor, odor, appearance, and mouthfeel of a food product are also performed. The company offers an ISO 14001 Environmental certification which indicates compliance with the requisite acceptable standards.
4. Water analysis (environmental)
Water analysis for drinking and borehole water testing has become increasingly important and a mainstay, essential service. Bureau Veritas offers SANS241 potable
water testing, as well as Environmental contaminated water analysis and soil testing, mining, effluents, agricultural, domestic, river and dam water testing. Waste classification and safety data sheets are also provided at both laboratories.
Commenting on the laboratory, managing director Joanne Barton said: “We are particularly proud of our laboratories and the differentiated solutions they provide. It is extremely rewarding to play a small role in life changing moments, for example – the public obtaining their medications on time or food that is of the correct quality and safe to consume. We are a trusted businessto-society partner and that is crucial to our work. It is all about making a positive difference within a safe and integrity-driven environment.”
EMBRACING CONSTANT CHANGE
In conclusion, Hefer commented: “As business and laboratories evolve, we find ourselves in an exciting time of new technology and services, where constant change becomes business as usual. We embrace this way of working, ensuring we can meet customer demands in an everincreasing world of unpredictable change. That is the norm in the ever-expanding industry of testing, inspection, and certification. At Bureau Veritas we remain committed to safety which is rooted in trust as our non-negotiable.”
Bureau Veritas - www.bureauveritas.com
Joanne Barton, managing director for Bureau Veritas Southern Africa.
Plant-based boost for baked goods with faba bean
The increasing global interest in plant-based foods has extended to baked goods, creating a demand for suitable ingredients. BENEO’s faba bean protein concentrate shows promise as an egg substitute in muffin recipes, delivering comparable texture and taste.This innovation not only aligns with veganisation trends but also addresses cost reduction amid rising raw material prices.
Over one in two consumers across the globe are now interested in plant-based foods and beverages (59%). As more consumers incorporate plant-based products into their diets, there is rising demand, not only for plant-based meat alternatives but also for plant-based baked goods. Finding suitable ingredients is key for manufacturers. Trials conducted by the BENEO-Technology Center found that by using BENEO’s faba bean protein concentrate it is possible to replace the eggs in a muffin recipe, whilst still delivering in terms of texture and taste.
EGG REPLACEMENT: OPPORTUNITY AND CHALLENGE
On the one hand, egg replacement enables manufacturers to ‘veganise’ recipes and – if all the product’s ingredients are plantbased – to make such claims on pack. On the other hand, replacing egg with faba bean protein concentrate is also a viable approach in the context of cost reduction. Over the last year, key raw materials have seen significant price increases, with food price predictions continuing throughout 2023. Consequently, food manufacturers are searching for more affordable ingredients that are in line with consumers’ expectations towards more natural, tasty, and plant-based solutions. It is always a challenge replacing eggs in any bakery reformulation, as they contribute
to the adhesion, binding, aeration, browning and much more. With so much influence on the baked good’s final appearance and texture, finding a viable egg replacement is important. The BENEO-Technology Center team trialled faba bean protein concentrates as a possible egg replacer. The comparison of the reference muffins and their eggfree versions revealed that the muffins with faba bean protein concentrate were very close in volume and appearance to egg-containing originals. Furthermore, the plant-based muffins had a similar fine crumb structure, pleasant taste and crumb firmness comparable to that of the reference products even after two weeks of storage. As well as showing promising results for plant-based baked goods recipe development, the use of faba bean ingredients can also result in on-pack nutritional claims in the context of protein content, if the conditions of use are fulfilled.
MANIFOLD ADVANTAGES
The versatility of faba bean ingredients benefits both manufacturers and consumers. In fact, global product launches with faba bean ingredients almost doubled between 2017 and 2022.1 Having a mild taste, these ingredients show clear benefits when it comes to the flavour profile of end products. As a vegetal protein, BENEO’s faba bean protein concentrate can replace animal
protein (milk, egg) as well as soy protein in certain applications. It also has an excellent amino acid profile as well as a high solubility and very good emulsifying properties. In addition, faba bean starch-rich flour, being naturally high in protein, can help to boost the protein content in applications such as cereal bars, snacks, or baked goods.
Faba beans also offer benefits in terms of sustainability because they help to reduce greenhouse gas emissions at farm level. The faba beans can capture nitrogen from the air, to provide it for themselves and subsequent plants, which reduces the need for fertilizer input. BENEO strives to source its faba beans at Farm Sustainability Assessment (FSA) Gold level from German farmers with long-term contracts, to ensure production and supply stability.
While only one percent of sweet bakery goods had a vegan claim in 2016, by 2021, 13% were making this claim. This data demonstrates that with consumers increasingly wanting plant-based bakery, the industry is beginning to meet their needs. •
*References available on request.
of additives to help create the taste, texture, performance and appearance you need for your food & nutritional products. We represent leading global manufacturers & our specialists can provide you with unrivalled sales support bringing the highest quality products to market:
Bakery ingredients: flavour, texture and fortification - Beverage ingredients for innovation - Confectionary: healthier & tastier alternatives to enhance your brandCulinary solutions for sauces, dressings and prepared meals that will innovateDairy & Desserts: texture and functionality - Flavour & fragrance creation - Health & sports nutrition.
Q&A with Nomvuyo Mlombi, Product Specialist
In the dynamic world of food and beverage manufacturing, Nomvuyo Mlombi stands out as a dedicated and passionate product specialist. Her journey is marked by a commitment to innovation, quality, and clean labelling.
Q. Can you describe your journey to your current position in the food and beverage manufacturing industry? What motivated you to pursue this career path?
A. My journey to becoming a product specialist for one of the top food distributors has been both challenging and rewarding. From my early days studying food technology at university, I was always passionate about understanding the raw materials and food additives that play a crucial role in the food manufacturing industry. This passion drove me to pursue a career where I could influence and innovate new products, particularly those with clean labels, to improve the quality and healthiness of food products available in the African market. Working in my current position has allowed me to achieve several key goals in a relatively short period. I’ve had the opportunity to collaborate closely with R&D teams, ensuring that customer needs are met with innovative solutions. This has brought immense fulfillment, as I’ve seen firsthand the positive impact of our work on the quality of finished products. What truly motivated me to enter this field was the desire to enhance food quality and promote clean labelling. I believed that by working directly with distributors, I could play a significant role in shaping the market and supporting manufacturers in their quest for quality and innovation.
Q. As a woman in this industry, what unique challenges have you faced, and how have you overcome them?
A. Working with various food and beverage manufacturers has been a fantastic opportunity for personal and professional
“What truly motivated me to enter this field was the desire to enhance food quality and promote clean labelling.”
growth. However, it has also presented unique challenges, particularly as a woman in this industry. At times, I felt I had to work exceptionally hard to have my ideas heard and recognised, and there were moments when I felt overlooked, which impacted my self-esteem. To overcome these challenges, I focused on my core motivation: bringing clean labels and improving the quality of food in the market. I committed to continuous self-education and professional development, ensuring that my knowledge and skills were always growing. I learned to focus on the value I bring to the table rather than how others perceive me, understanding that not everyone will receive me in the same way. Through perseverance and dedication, I have witnessed the power of collaboration between sales, marketing, R&D, and procurement teams, achieving remarkable results. This experience has reinforced my belief in never giving up and staying true to my mission.
Q. Can you share a significant achievement or project in your career that you are particularly proud of?
A. One of the most significant achievements
in my career as a product specialist has been empowering the R&D team to freely express their challenges with existing products and in creating new ones. By working directly with suppliers, I helped find solutions to these challenges. This required extensive research and collaboration with various departments, including R&D, marketing, and procurement. Our goal was to create products that met the growing demand for transparency and natural ingredients while maintaining high standards of taste and quality. Working closely with sales, marketing, R&D, and suppliers, we are seeing remarkable results. Seeing the R&D team’s innovations succeed was incredibly fulfilling. This project reinforced the importance of clean labelling and showcased the power of teamwork and innovation.
Q. In your opinion, how does having women in both management and floor roles impact the workplace culture and productivity?
A. Having women in both management and floor roles brings diverse perspectives and approaches to problem-solving, which can enhance workplace culture and productivity. Women often bring unique skills in communication, collaboration, and empathy, fostering a more inclusive and supportive environment. This diversity can lead to more innovative solutions and a stronger, more cohesive team.
It’s the only one of its kind in the country to target decision makers in the manufacturing of food, beverages and their related industries. It offers incisive and authoritative reports on all aspects of the process, from raw material sourcing, to manufacturing and packing, right down to the distribution and marketing of finished goods. Food Review informs readers about the introduction of new ingredients, equipment, products and packing, and provides objective commentary on cuttingedge local and international market trends and issues. www.foodreview.co.za
Advancing women’s health: dsm-firmenich’s strategic innovations in wellness
As the world advances towards gender equality, women’s influence in society and business is growing. This trend is driving a demand for health-conscious products tailored to women’s needs.
As the world continues to make strides towards gender equality and women empowerment, the voice of women is becoming a lot more prominent, both in society and in business. Women are influential, not only with their voices but also with their wallets and this makes them a strong consumer group that should be taken with great consideration. A big trend being driven by women and presenting an opportunity to food and beverage manufacturers is that of health and wellness. There is a growing market demand for health-conscious products tailored to women’s needs. The rise of health and wellness is driven by many reasons, consumers are choosing to put a higher value on their health, wanting to live better for longer and women have unique nutritional needs that change throughout different stages of life.
Of course, health and wellness means different things to different people, this is the same even amongst female consumers. Brands need to consider these needs and create bespoke products for women. Healthy eating that looks at functional food products that boost immunity or support specific lifestyles are just some of the examples, nutrition and permissible indulgent products that support brain health, mood and better sleep are some of the opportunities this trend is opening for brands. The choices women are making are not only for themselves but their entire families. True to form as nurturers, women are looking to food and beverages manufacturers for products that speak to their family needs of holistic health
“Always at the forefront of innovation, dsmfirmenich under their Taste, Texture and Health Business Unit is well positioned to help brands leverage the growth.”
and wellness. Innovating in this area can meet consumer demand and drive business growth. Predicting these needs and innovating towards them can be tricky, this is why dsmfirmenich conducts over 2000 surveys to AI-generated insights, to discover how they can anticipate and fulfil evolving needs of consumers to support their customers.
HEALTH AND WELLNESS INNOVATION
Always at the forefront of innovation dsmfirmenich under their Taste, Texture and Health Business Unit is well positioned to help brands leverage the growth. With a
broad portfolio of ingredients, flavours, and technologies including one of the largest natural flavours library in the industry, nextgeneration sugar reduction technologies and sweet taste optimisation, they are leading the industry in calorie removal from consumer diets, while keeping optimum taste; not forgetting the cultures, enzymes, vitamins, hydrocolloids, nutritional premixes and so much more. Understanding the woman consumer who is always looking to enhance the nutrition they provide not just for themselves but their entire family, dsm-firmenich has a strong focus on fibers, vitamins & minerals and extracts to improve nutrition and add ingredients that help consumers boost immunity, sustain their wellbeing and improve microbiomes. They combine their broad portfolio with boundless creativity to create something truly special.
The business is supported by over 2000 scientists and R&D facilities on four continents, working to deliver a mouthwatering array of products and ingredients, from flavours and tonalities to nutritional lipids and micronutrients. They excel in customisation, localisation, and regionalisation, leveraging their extensive local presence. This capability, bolstered by comprehensive consumer insights and nutritional expertise, perfectly aligns with their commitment to tailoring solutions to match customers’ distinctive taste, texture, and health preferences within their specific local contexts.
At dsm-firmenich, we bring it all together –because we believe today’s consumers shouldn’t have to choose between what tastes good, what feels good, and what’s good for them. We unlock possibilities so that your brand can deliver food and beverages that sustain us all – but healthier. More delicious. And better for people and the planet. Contact us today to discover how.
www.dsm-firmenich.com
Celebrating the role of women engineers
International Women in Engineering Day (INWED), an annual event that celebrates the incredible contributions of women engineers worldwide, marks its 11th anniversary in 2024 under the theme of #EnhancedByEngineering.
This year, INWED celebrates women engineers who have enhanced lives and livelihoods through their work. These remarkable individuals contribute to building a brighter future for all of us.
An ECSA technician candidate and an associate member of SAIEE, Shongeleni matriculated at EPP Mhinga Secondary School in 2012, focusing on physical science and mathematics. She obtained both her National Diploma in Electrical Engineering and BTech in Electrical Engineering from the Tshwane University of Technology.
During her six-year career to date, Shongeleni has gained experience in sectors as diverse as mining, consulting, and milling solutions. She started out as a learner technician at Palabora Copper Mine in 2018 and worked as a design engineer at EHL
Engineering Group in 2019 before joining Bühler Johannesburg in November 2022.
As a hardware engineer, Shongeleni designs Motor Control Centres (MCCs) using industry-standard software such as COMOS and Ruplan. She collaborates with the automation and installation teams to ensure the successful execution of projects, from conception to completion.
Her scope of work includes organising automation kick-off meetings, reviewing process diagrams and equipment lists, generating power summaries for plants, developing automation concept diagrams, and efficiently managing material ordering through SAP.
“The opportunity to solve complex problems and witness tangible results that impact various industries is what drives my passion for engineering,” comments Shongeleni. Being able to contribute her skills and expertise to projects that have real-world implications is incredibly fulfilling and motivates her to
continually strive for excellence.
“Bühler Johannesburg is committed to creating an inclusive and diverse workplace where every employee feels valued and respected,” notes Shongeleni. It has various initiatives in place, including mentorship programmes, networking opportunities, and educational outreach efforts, to support and encourage the participation of women in engineering roles.
She says women can greatly contribute to this year’s INWED theme of #Enhancedbyengineering by bringing diverse perspectives, innovative ideas, and unique problem-solving skills to the table. By actively engaging in engineering projects and initiatives, women can showcase the transformative impact of their contributions on enhancing technological advancements and driving societal progress.
“My message to girls aspiring to pursue a career in engineering is to be confident in their abilities and embrace the opportunities
“Bühler Johannesburg is committed to creating an inclusive and diverse workplace where every employee feels valued and respected.”
that come their way. And not to be discouraged by the male-dominated nature of the field; instead, see it as a chance to make a difference and inspire change. Stay curious, keep learning, and believe in your potential to succeed in engineering,” concludes Shongeleni.
Savannah studied draughting at the African Academy in 2018. Bühler Johannesburg offered her a learnership in the engineering department to be part of the women in STEM engineering program.
She officially started working for the company in 2019, with this marking her fifth anniversary at Bühler Johannesburg. During this time, she has studied mechanical engineering part time, obtained her N6, and is currently furthering her mechanical engineering studies. In addition, she is studying towards her CAPM certification. “I started out as a learner and slowly made my way up to a Project Engineer,” comments Savannah.
She works closely with the project manager to support project planning, ordering, and related project management tasks. “I assist the design team with 3D designs and various drawings. My role is a hybrid role between project management and a plant designer,” explains Savannah.
Savannah grew up watching her dad fix and build various things. “I eventually got to an age where I could help him. I found it interesting how things worked and was always determined to find solutions to problems. A high school project saw her design a Ferris wheel. “I thought it was the coolest thing ever,” she says.
Savannah’s passion saw her recognised as the top learner for engineering, graphics, and design in her district in matric year, which is when she realised that her talent matched her interests. “Later I became exposed to the positive impact engineering has on the world. I have always been passionate about helping
people and a career in engineering aligned with what I wanted.”
Bühler Johannesburg has many initiatives to promote inclusivity and diversity including supporting women in STEM fields, plus a mentorship programme where it works closely with the surrounding communities to offer full bursaries to hardworking students who wish to better themselves.
“I think women engineers are still underrepresented in the workplace. By highlighting women in engineering, young girls can see that anything is possible with hard work and determination,” Savannah says about the importance of INWED.
“Engineering spaces are still dominated by men, but women are slowly making their
way in and leaving an impact while doing so. It is important to celebrate these women and give them the recognition they deserve, and #EnhancedbyEngineering is doing exactly that.”
Savannah concludes: “To all the young girls, the only thing stopping you from doing what you want to do is yourself. You have the creativity, intelligence, and determination to excel in anything you choose to do. There will always be someone who disagrees with your path and career choice, but the only opinion that matters in what you choose to do is yours.”
Introducing a new food conveyor platform
With its new Special Hygienic Conveyor (SHC), Swiss material handling equipment supplier Interroll has introduced a conveyor platform that has been specially designed according to the guidelines of Hygienic Product Design.
SPECIAL HYGIENIC CONVEYOR
The modular SHC platform, based on a stainless-steel design, enables for the first time the transport of standard E2 crates with zero pressure accumulation in the food sector. Its features include a reduced hole pattern, no undercuts and sloped or rounded guides to allow unobstructed drainage of cleaning liquids. The SHC also has both roller and belt conveyors used to transport fish or meat products. All available components of the conveyor, including electrical products like RollerDrive and corresponding controls such as the IP 55 MultiControl, are certified to at least IP 55 standards and protected from splashing water, ensuring easy cleaning with no residual liquids left behind that could negatively impact functionality or hygiene.
In terms of roller conveyors and belt conveyors, the new plug-and-play platform provides a multitude of freely combinable modules that are easily installed and operated. They include straight conveyor lines, compact curves with an inner diameter of just 600 millimeters, ball diverts and line modules with an integrated incline. These modules can also be easily combined with others that do not belong to the SHC series. Patented
"The modular SHC platform, based on a stainless-steel design, enables for the first time the transport of standard E2 crates with zero pressure accumulation in the food sector."
solutions for water tightness ensure for the first time that no water remains in the system and adversely affects hygiene after cleaning procedures. Thanks to a special transfer module with an extremely small deflection radius, the SHC can also be connected to existing conveyor systems without the need for technical adjustments.
INTERROLL LAYOUTER SYSTEM
In the future the Interroll Layouter, system integrators will also be able to design, plan and virtually commission complete SHC system concepts on the computer, making presentations and decision-making processes Interroll – www.interroll.com
more meaningful and significantly easier for end users. The Interroll Layouter also improves preparations to ensure the smooth installation and startup of the solution. Depending on customer requirements, conveyors based on this platform can be driven by either drum motors or RollerDrive made of stainless steel. Combined with Interroll’s IP 55 MultiControl controls, the system can be used to achieve highly efficient flows of goods with zero pressure accumulation – the standard in modern package centers and other distribution units. These zero pressure accumulation systems work with separately driven conveyor zones, which are only driven when goods need to be conveyed. The advantages: Alone in the start-stop operation, the intelligent drive concept results in energy savings of up to 50% compared to centralised drive solutions that run continuously. And it simultaneously ensures an improved working environment with lower noise emission and reduced wear in the conveying of standard E2 crates, which also serves to limit hygiene problems in the food industry. •
Solving Africa’s Food Processing Challenges
Matrix Software, founded in 2006, specialises in innovative software solutions for Africa’s food processing industry. Their hands-on approach ensures they understand and solve clients’ challenges, offering scalable, customisable, and user-friendly systems
Matrix Software’s philosophy is simple: start where the problem is and work from there. They’re a software solutions company specialising in the food processing industry that was started in 2006 from the ground up, because they wanted to be close enough to the problem to gain the specific knowledge and experience needed to solve it. Today, this approach continues to serve them well as they truly understand their clients’ challenges. They meet clients where they’re at and journey with them to develop innovative and fit-forpurpose solutions that elevate their business and truly make a difference.
Matrix Software is passionately focused on and firmly rooted in Africa – a continent which they believe is rich in untapped potential and many opportunities.
“We believe that sustainable success and scalability are built upon a foundation of long-term thinking, and as such we have dedicated ourselves to cultivating strong partnerships and fostering growth as a team and as a business. Agventure’s investment in Matrix Software during 2021 is an example of a partnership that we believe will accelerate our expansions into Africa to unlock the continent’s agrifood potential through technological innovation and entrepreneurship,” says Dewald Carelse, Matrix Software’s CEO.
AFFORDABLE,SCALABLE AND CUSTOMISABLE
Matrix Software provides affordable, scalable, customisable and user-friendly solutions for the challenges faced by Africa’s meat and food processing industry.
The launch of a new poultry extension is on the horizon, which will offer users real-time insights and control for every poultry processing stage - from Live Bird Receiving (LBR) through to the retail floor. This extension improves stock management and traceability, ensures better quality control, and streamlines poultry planning and processing overall.
Says Carelse, “Relationships build our foundation and people drive our progress. Our clients are at the heart of all we do and through our hands-on approach, we have developed a wide range of solutions to meet their evolving needs. With our team’s technical support and consulting expertise, we engineer success by dismantling obstacles and nurture the successful operations of our own business and that of our clients.”
“Our clients’ interests steer our every move, and our success starts with them.”
“Our work speaks for itself - we are the architects of exceptional user experiences, crafting software that solves the challenges of stock control, yield management, traceability, plant productivity and tracking cost margins,” states Carelse.
The complexities inherent in the food processing industry demand robust solutions that go beyond standard off-theshelf software. Matrix Software’s solution, powered by Microsoft’s SQL Server and running on standard Microsoft Windows
machines, offers our clients a cost-effective and scalable option tailored to their needs.
EXPERTISE IN MEAT PROCESSING
Their proven track record shows that they have the knowledge and know-how to meet the requirements of the meat processing industry – one of the toughest perishable sectors – and their system can be easily adapted to other perishable processing industries. Many clients in the seafood, dairy and fresh produce industries have tangibly benefited from their solutions to increase profitability.
A tailor-made system consisting of a wide variety of configurations ensure that clients have accurate job costing, complete stock control, fit for purpose quality control, and complete process traceability, equip food manufacturers with the tools necessary to navigate the industry’s nuances effectively. Furthermore, the Matrix Software system integrates the latest technology, including Android-based mobile scanners, integrated RFID solutions, automated weighers and easy-to-use label designers.
The software is developed in South Africa specifically for the South African and African markets, so it’s designed to be cost-effective and easy to support. The systems are leased on a month-to-month basis, which makes it simpler for businesses to get started without a large capital investment.
Pápai Hús Enhances Quality with X-ray
Hungarian meat brand Pápai Hús has improved food quality and security with the Ishida X-ray inspection system, ensuring their diverse product range meets high standards.
An Ishida X-ray inspection system is providing renowned Hungarian meat brand Pápai Hús with improved food quality and -security across its diverse product range.
Established in 1913, the name Pápai Hús is synonymous with smoked ham to consumers in Hungary. Nonetheless, the company provides many more types of meat, including butchering, chopping, pre-chilled and frozen meat, smoked and heat-treated meat products, ham, bacon and sausages, cold
meats, grilled and vegan products.
GLOBAL REACH AND INNOVATION
Pápai Hús has long exported across the world and continues to innovate, with the latest addition being a vegan range, launched in 2020. These factors – export and innovation –combined in 2017, when a new deal to supply into Japan required that Pápai Hús invest in an X-ray inspection system at its factory in Pápa, West Hungary.
“It wasn’t even, ‘choose an X-ray machine,”
explains Benedek Szabolcs, technical director at Pápai Hús. “They specifically directed us to order an Ishida X-ray machine!”
Supplied and installed by Ishida’s agent in Hungary, MasterQuality, the IX-GN-2443 soon recommended itself to Pápai Hús for reasons beyond its initial selection.
“The nature of delicacies such as disznósajt (a traditional ‘head cheese’ that is made by combining various pork meats) means there can sometimes be small traces of bone or cartilage in the meat, which is unwanted by consumers,” confirms Benedek Szabolcs. “We realised that Ishida’s X-ray can easily be programmed to identify any packs containing these traces, allowing us to reject them before they leave the factory and therefore improving food quality.”
HOW X-RAY TECHNOLOGY WORKS
X-ray technology works on the principle of producing X-ray wavelengths from a generator tube which traverse through the product to be inspected onto a line sensor. The line sensor system converts the incident X-rays into a greyscale image that is further processed and ultimately displayed on the screen. The darker the area of the image, the higher the density and in this way foreign
bodies which are denser than the product can be detected.
The excellent sensitivity of the Ishida X-ray means it is able to detect impurities down to 0.3mm in size, while the place of contamination can also be accurately pinpointed. In particular, the machine’s unique self-learning Genetic Algorithm (GA) technology delivers maximum detection sensitivity and reliability. The technology focuses the machine to identify difficult to detect contaminants with a high degree of accuracy, even at high throughput rates, using image data analysis over a number of trial runs. This enables operators to optimise
the X-ray system for greater sensitivity to specific and in particular to low-density foreign bodies.
Today, the Ishida IX-GN-2443 is used to check every pack of disznósajt, black pudding and cubed bacon at the Pápa factory. Intuitive pre-set options allow for easy changeovers between product and pack types which is necessary, given that the likelihood of bone or cartilage present varies according to the product.
DAILY OPERATIONS AND VERSATILITY
Designed for high-performance X-ray inspection, the IX-GN-2443 features versatile
“Supplied and installed by Ishida’s agent in Hungary, MasterQuality,
the IX-GN-2443 soon
recommended itself to Pápai Hús for reasons beyond its initial selection. ”
detection settings that cater exactly to Pápai Hús’ inspection requirements. With seven levels of image analysis and user-friendly operation, the Ishida X-ray machine makes the most complex inspection process simple. Due to the limited space in the factory, the IX-GN-2443 is set up as a standalone machine; products are fed manually, with accepted packs being conveyed into pallets and rejects dropping into a locked reject bin.
Used daily, the machine is now a critical part of Pápai Hús’ operation. “We are very satisfied with how the Ishida IX-GN-2443 X-ray machine performs, and our partnership with MasterQuality helps us to get the best out of it,” says Benedek Szabolcs.
As well as the initial installation and training, MasterQuality service engineers deliver an annual check-up. “In addition to completing essential preventative maintenance, our visits are also the perfect opportunity to discuss the performance of the Ishida Xray system with Pápai Hús, so we can assess any refinements that may benefit the factory’s operation,” says Balázs Korsós, Sales Representative at MasterQuality.
“The service, support and advice from MasterQuality is exceptional,” adds Benedek Szabolcs. “But what is most helpful to Pápai Hús is the reliability, ease of use and outstanding performance of the Ishida IXGN-2443 X-ray inspection system.
Buckle Packaging, a Johannesburg-based specialist in bag closing, recently assisted an agricultural wholesaler in the Northern Cape.
Buckle Packaging has been successfully finding solutions for businesses since 1979. Recently Buckle Packaging was asked to help streamline an agricultural wholesaler’s operations in their Northern Cape Plant. This well-established company, which has been operating for the last 30 years, needed to expand their production capabilities to accommodate growing demands in the export market.
The decision was to put in two new 25kg poly woven bags of pecan nuts securely and efficiently for packaging. The company’s requirements were to find the right equipment that would uphold their prestigious health and
“Recently the company was asked to help streamline an agricultural wholesaler’s operations in their Northern Cape Plant.”
safety standards.
“We recommended the Fischbein MP100 stitching machine as this is the only bag closing machine that would maintain the clients brand image while providing them with the best
securely and neatly stitched bag every single time”, explains Mathew Mason, marketing manager for Buckle Packaging.
At the same time, the company installed two 3.3-meter conveyors that allowed the stitching machines to be used more efficiently, saving time and money and protecting operators from deadline stresses. “The equipment was delivered, off loaded and set up in just 40 minutes”, continues Mason.
Buckle Packaging –www.bucklepacking.co.za
Images: Supplied by Buckle Packaging
Meat Spoilage Solutions
Brenntag supports producers in ensuring safe, wholesome products and developing greattasting food through technical expertise.
With South Africans having dealt with increased bouts of load shedding recently, the spoilage of meat products has been thrusted back into the spotlight. Assisting producers with the supply of wholesome and safe to consume products is a key fundamental for us at Brenntag. We also assist our customers in developing great tasting food products through our technical expertise and supplier support.
INHIBITING SPOILAGE OF MEAT PRODUCTS
To address the issue of food safety in meat products, we have partnered with Corbion, a supplier of a range of food ingredients and solutions for use in foodstuffs to reduce the susceptibility to microbiological spoilage
of such products. When it comes to food safety, few products can perform as well as our Opti.Form Powder. Opti.Form delivers top-shelf Listeria control and extends shelf life, all while improving yield, purge and texture in meat and poultry products. The product is a very effective antimicrobial powder blend suitable for use in dry blend and liquid applications. It’s low dosage rate makes it a very cost-effective solution for use in a wide range of applications and is often incorporated in batch pack solutions or can be used directly in emulsions and/or brine solutions. We have seen the impact of Listeria in the ready-to-eat meat segment and recommend this offering for the control of Listeria specifically. As noted, this blend of antimicrobials with sodium lactate, sodium
acetate and sodium diacetate combined with the specific production method, makes this a highly effective food safety offering.
DEALING WITH SODIUM REDUCTION CHALLENGES
The use of salt as an antimicrobial agent in lowering the water activity and enhancing flavour is well documented, but this humble ingredient also plays a role in food texture. Salt, however, has several functionalities in meat products from allowing proteins to bind more fat and water to controlling colour development in fresh meat products.
Brenntag – www.brenntag.com
Deliver unparalleled inspection with extremely high detection sensitivity for metals - whether ferrous, non-ferrous, or stainless steel - for all manner of food products, anywhere along the line.
CCL Label Expands Sustainable Shrink Sleeve Range
Go with the Float: CCL announces extended range of floatable polyolefin shrink sleeves that support PET recycling
CCL Label, one of the leading producers of labels and packaging solutions, has announced the extension of its award-winning low density, floatable polyolefin (PO) shrink sleeve that is a sustainable alternative for existing materials that are detrimental to recycling.
“We are proud to share our extended range of floatable shrink sleeves that work in established PET, HDPE and PP waste streams,” says Reinhard Streit, VP and Managing Director Food&Beverage at CCL Label. “We can now offer our local and multinational brand customers several options – from a high shrink version to a thinner version to a white version that is ideal for light-sensitive products like dairy, vitamins and supplements.”
To enable more mechanical recycling of post-consumer packaging, eco-design or design for recycling will be essential. As of today, there are still a lot of sleeve labels in the market that cause problems in PET recycling and are flagged by organisations like
"CCL Label, one of the leading producers of labels and packaging and packaging solutions, has announced the extension of its awardwinning low density, floatable polyolefin (PO) shrink sleeve that is a sustainable alternative for existing materials that are detrimental to recycling."
the Association of Plastic Recyclers that have created a comprehensive Design Guideline.
“EcoFloat sleeves made from low density material are an ideal alternative. They automatically separate from the PET flakes in
the sink/float process step at recyclers and float to the top of the washing tank – while the heavier PET flakes sink to the bottom. This is an ideal density separation that leads to very clean PET flakes that can be recycled back into new bottles – closing the loop,” explains Marika Knorr, Head of Sustainability and Communication at CCL Label.
High Shrink Version – for more versatile bottles shapes: “In recent years, brand owners have gravitated towards more complex bottle shapes. This calls for a sleeve that has a high shrink rate so it can contour to the bottle seamlessly. We have just released a new version where the shrink is well above 70 percent – which makes even difficult bottle shapes work with shrink sleeves,” states Shivern Reddy, Sales Director at CCL Label South Africa.
45 Micron Thin Version – for material efficiency: While the standard Ecofloat sleeve is 50 micron, a thinner 45 micron version is now also available. This downgauged sleeve material is ideal for many
bottle and container shapes and comes with the benefits of efficient material usage and a lower carbon footprint.
ECOFLOAT WHITE
“EcoFloat WHITE is a technology that enables greater recyclability for dairy packaging and other products that are light sensitive -
BENEFITS
Design for Recycling: EcoFloat shrink sleeves support the recycling of the rigid packaging in the PET, HDPE and PP recycling steams
Future-proof: Shrink sleeve material endorsed by the Association of Plastics Recyclers (APR), Extrupet in South Africa and EPBP in Europe
Alternative for widely-used PET-G, PVC or OPS sleeves that are still used and should be phased out to improve recycling and enable food grade recycling
we expect it to be a game changer. The dairy industry often uses opaque white bottles to protect products like milk, yoghurt and probiotic drinks.
However, these white bottles are rarely recycled back into food grade applications because they contain colorants- so the bottles leave the packaging loop or are downcycled,” explains Reddy. “Shifting from an opaque bottle to a clear PET bottle with an Ecofloat WHITE shrink sleeve provides product protection and increases the amount of clear PET that can be reclaimed for bottleto-bottle recycling. It is our goal to support this with a functional product decoration.”
ABOUT CCL INDUSTRIES INC.
A global specialty packaging pioneer, CCL Industries is the largest label company in the world with headquarters in Toronto, Canada and Framingham, Massachusetts. Established 1951, CCL has over CDN$6.4 Billion (2022) in sales, over 26,000 employees worldwide, over
213 production facilities in 43 countries, and is listed on the Canadian Stock Exchange. CCL is the world’s largest converter of pressure sensitive and specialty extruded film materials for a wide range of decorative, instructional, functional and security applications for government institutions and large global customers in the consumer packaging, healthcare & chemicals, consumer electronic device and automotive markets. Products include: extruded & laminated plastic tubes, aluminum aerosols & specialty bottles, folded instructional leaflets, precision decorated & die cut components, electronic displays , polymer bank note substrate and other complementary products and services.
CCL Label – www.ccllabel.com
South African Beverage Market Booms
The South African beverages market is experiencing significant growth, projected to reach USD 25.74 billion by 2029. This surge is driven by consumer preferences for convenience and innovative flavours, creating ample opportunities for new product formulations. Neil Wiltshire, senior flavourist at Kerry South Africa, explores these trends and their impact on the industry.
The South African beverages market has grown significantly in recent years.
Increasing consumer preference for beverages that focus on convenience and new flavours is accelerating growth and creating more opportunities in the beverage space. The beverage market has mostly been defined by traditional mainstream flavours like cola, orange, and lemon. More recent years have seen a growing social drinking scene and renewed interest in ready-to drink products, both of which are driving a strong opportunity for new flavour formulations.
“According to a 2023 GlobalData report, South Africa makes up 95% of the flavoured alcoholic beverages market in Africa.”
In fact, a 2024 Research and Markets report on the South African beverages market projected a 5.19% CAGR from 2024 to 2029,
growing from USD 20 billion in 2024 to USD 25.74 billion by 2029.
Social drinking in South Africa has been gaining popularity in recent years, as evidenced by the increased demand for alcoholic beverages, including beer. According to a 2023 GlobalData report, South Africa makes up 95% of the flavoured alcoholic beverages market in Africa. Premium alcoholic beverages have also come to the fore with local players introducing fruit hops into their craft beer to offer more flavours to consumers. This has been
Images: Supplied by Kerry
successful in positioning their craft beer as premium. Alcohol-free and low-alcohol options are having a moment too, largely due to younger consumers trying to stay healthier. Already, key industry players in South Africa have jumped on the flavoured beverage bandwagon. In September 2022, Coca-Cola introduced its new juice brand, Cappy, a 100% fruit juice product available in flavours such as Tropical, Orange Mango, Apple, Orange, and Grape. Similarly in July 2022, Red Bull in South Africa also launched a new Summer Edition Apricot energy drink flavoured with a blend of apricot and strawberry with a hint of peach. With innovation in the industry catering to this expanding interest in new flavours and alcoholic and non-alcoholic beverages, manufacturers have an opportunity to keep their product offerings attractive by delivering fresh, new tastes.
“Premium alcoholic beverages have also come to the fore with local players introducing fruit hops into their craft beer to offer more flavours to consumers.”
NEW BEVERAGE INNOVATION ERA
Traditionally, emulsion methods of adding flavours like citrus oils, mint oils, and spice oils to beverages result in a cloudy mixture that’s commonly seen in alcoholic beverages, fizzy drinks, sports and energy drinks, bottled orange juice, even flavoured water. On the molecular level, this mixture is also unstable. With the right flavour solution, such as Kerry’s new ClearBurst technology, flavour oils and water can mix better, resulting in flavoured drinks and alcoholic beverages in crystal clear formats with superior taste. Classified as General Business Gin, for example, is made from fermented juniper berries. With ClearBurst, manufacturers can use juniper oil to easily achieve either a gin-flavoured alcohol-free clear format beverage or enhance the flavour of gin. As ClearBurst works well with citrus oils too, it can be easily applied to other clear format beverage or enhance the flavour of gin. As ClearBurst works well with citrus oils too, it can be easily applied to other clear format alcoholic beverages, such as adding citrus flavours to vodka.
SUPERIOR FLAVOUR, AUTHENTIC TASTE
Globalisation and South Africa’s diverse cultural identity make the country unique in a way that while locals are open to international flavours, they still seek out familiar tastes and flavours. Achieving authentic flavours localised for individual markets is an area of strong potential for the beverages industry, yet it comes with challenges. For example, while citrus flavours are popular, the market is flooded with products that struggle to capture authentic
taste. Grapefruit, lime, lemonade, bitter orange, blood orange, and clementine are some of the fastest growing citrus flavours in South Africa in recent years, as seen in new product launches. However, often, citrusflavoured beverages that have certain taste claims end up tasting like something else. This is because citrus flavours are typically extracted using an essential oil wash method, in this case, a citrus oil wash. This method only retains the water-soluble portions of the flavour, extracting less than 10% of its flavour. This results in the loss of authentic flavour character, leading to a diminished taste profile. To gain a competitive advantage, authenticity in taste is crucial. In South Africa, manufacturers have been challenged to deliver the authentic taste of the well-loved naartjie (South African tangerine), which has its own nuances distinct from other varieties of mandarin oranges. This is where a solution like ClearBurst can come into play. By integrating science and local raw ingredients, ClearBurst technology can capture the naartjie’s unique flavour profile to help manufacturers create a clear format beverage product with an authentic South African taste, with notes that are brighter and richer. Being locally produced also allows manufacturers to optimise costs and create a more efficient production and supply chain.
THE FUTURE OF REFRESHMENT
As South Africa’s beverage landscape evolves, the consumer’s thirst for discovery and premium beverage experiences will continue to drive market demand. To stay ahead of the curve, manufacturers need to focus on cost efficient innovative offerings to excite taste buds while distilling the country’s rich cultural heritage through unique local flavours.
Kerry GroupTaste & Nutrition Ingredients and Science Tel : +27 31 344 0071
Email: ccsouthafricalocal@kerry.com
Kerry Group - www.kerry.com
The study reveals that users can save up to R-million annually in lubricant costs, significantly reducing their environmental impact. High-performance plastic bearings from igus eliminate the need for constant lubrication. Additionally, many working hours can be saved annually on relubrication tasks.
In the case study it was found that switching to polymer bearings across its 160 global sites, Heineken Brasil could save 20 tonnes of lubricant and R100- millions in personnel costs annually. This change would also reduce CO2 emissions by 28,814 kg, equivalent to saving over 12,000 litres
Beer brewers avoid grease contamination
A study by RWTH Aachen University and igus recently quantified the financial and environmental benefits of using lubrication-free polymer bearings over traditional metal bearings.
of petrol.
According to Ian Hewat of igus South Africa the study is pertinent to local industries as the same principles apply. He said the study emphasises the substantial reduction in CO2 emissions when using polymer bearings. Heineken Brasil alone could cut CO2 equivalents by 180 kg annually at 600 bearing points.
“This highlights the increasing pressure on manufacturers to disclose the carbon footprint of their products. The study offers a scientifically validated assessment of the environmental benefits of igus’s selflubricating bearings, making a strong case
for their adoption across various industries,” says Ian.
Conducted by WBA Werkzeugbau, the study involved expert interviews with companies from sectors including automation technology, construction machinery, agriculture, food, packaging, and bottling. The research was carried out in collaboration with the Laboratory for Machine Tools (WZL) and the Fraunhofer Institute for Production Technology (IPT) on the RWTH Aachen Campus.
food-safe plastics
... for the food and packaging industry ...
Food-safe and FDA-certified igus® polymers for the food and packaging industry are lubrication-free, temperature proof and non-corroding. They have lowest humidity absorption, are resistant to chemicals, acids, to alkaline and alcoholic cleaning agents. Maintenance-free, with best wear-resistance for your applications. igus.co.za/food-industry
"Siyaka offers Shrink Sleeving and metalised ROSO with the ideal shrink effect that eliminates curling, lifting or bowing and has consistent sealing properties."
Leading brands are shifting from printed cans to ROSO (Roll On Shrink On)
High-Speed Bagging Unveiled
With its brand new SVX series Syntegon launched four machines for the most common vertical form, fill and seal applications in different food industries. “The new VFFS machine series combines high pack style flexibility with intuitive functionalities.
“Thanks to a wealth of easy upgrade options and access to Syntegon’s digital services, the SVX series helps customers keep up with market trends while running stable processes at all times.” State-of-the-art monitoring via the cloudbased solution Synexio allows to optimise production, while Syntegon’s value-packed service agreements ensure maximum uptime and performance, including maintenance, parts management, and tailored training packages.
CROSS-SEAL DRIVE FOR ULTIMATE CONTROL
At its booth, Syntegon presented two
SVX variants, which will be launched this year along two other SVX models: during live demonstrations, visitors experienced the new technology firsthand. The SVX Agile forms the basis for all single tube applications. The machine covers all basic tubular bag styles and can be upgraded with modules for corner sealed bags, 3-sided seal bags, doy-style, and doy zip bags. In contrast, the SVX Duplex features two film lanes on the same 1,220 mm wide frame, leading to higher output rates for basic bag styles such as pillow, gusseted and block bottom bags.
The core innovation of all SVX variants
is a cross-seal drive consisting of four independently controlled servo motors. The optimised solution, which currently has pending patents, gives manufacturers full control over vertical and horizontal movement, ensuring reliable seals. Thanks to a combination of four motors and low inertia, the drive contributes to achieving the highest outputs. “Customers are always looking for solutions that can produce reliably tight cross seals for added product safety. The SVX makes sure this is the case without compromising on speed.”
Syntegon – www. Syntegon.com
SVX Series
Image:
MILLING AROUND PEOPLE LIKE PMD WILL INCREASE YOUR PRODUCTIVITY SPICE UP PRODUCTION WITH PMD
PMD has been a reliable supplier to spice manufacturers in Africa for the last 50 years.
We offer an array of equipment to improve efficiency and maximise productivity. Sachets, pillow packs, block bottom bags and doy packs – we have a solution.
With representation in Gauteng, Cape Town and Durban, we are able to offer complete turnkey solutions for powder handling, whether you are manufacturing or co-packing.
Contact us to assist you in finding a customised solution, tailor made for your manufacturing facility.
compostable PLA bags
Enviromall, a leading provider of sustainable packaging solutions, proudly announces the launch of its revolutionary compostable PLA bags.
These innovative bags, made from plant-based materials, offer a sustainable alternative to traditional single-use plastics, revolutionising the battle against plastic pollution in the hospitality, retail, and packaging industries.
Studies have shown that a significant portion of plastic packaging goes unrecycled in South Africa due to challenges in processing certain types of plastics, leaving the environment vulnerable to pollution and harm. The compostable PLA bags represent a gamechanging solution to this pressing issue.
Unlike some conventional plastics that are made with a chemical-based film, their PLA bags are made from Polylactic
Acid (PLA) derived from renewable plantbased materials. This makes them suitable for industrial composting, leaving no harmful residues behind and minimising environmental impact.
VERSATILE SOLUTIONS
The company is one of the few manufacturers in South Africa producing compostable PLA bags, underscoring the company’s commitment to driving positive environmental change in the region and beyond. Natalie Larkins, managing director of Enviromall said, “The introduction of our compostable PLA bags marks a significant milestone in our journey towards a greener future. By harnessing the latest
technology and leveraging renewable resources, we are proud to offer businesses a sustainable alternative that reduces their environmental footprint without compromising on quality or functionality.”
The compostable PLA bags are designed to meet the diverse needs of businesses across different industries. Whether used for packaging food products, retail items, beauty products, or more, these locallyproduced bags offer businesses a versatile and eco-friendly solution that aligns with their sustainability goals.
Enviromall - www.enviromall.co.za
Fit-for-purpose packaging machinery that meets the needs of the product.
From horizontal and vertical form-fill-seal-machines and boxing systems to customized transfer and flow systems that provide efficiency and traceability. Fuji is the industry leader in automated packaging machinery technologies.
Setting the standard in conveyor technology
With over 20,000 units sold, FastBack stands as the go-to conveyor for handling a diverse range of challenging products, from fresh chicken to snacks, fresh produce, cookies, candies, and beyond.
Its patented slow-forward and fastback horizontal motion technology has revolutionised the industry, setting the standard for excellence.
Originally introduced with the FastBack Horizontal Motion Conveyor, the FastBack lineup now encompasses a comprehensive suite of feeding, proportioning, and lining solutions for product handling. Each solution in the range inherits FastBack’s signature benefits, ensuring gentle product transport through its unique slow-forward and fast-back horizontal motion cycle.
As the unrivaled leader in its field, FastBack continually innovates, incorporating design features tailored to meet customer needs and preferences. These conveying solutions prioritise product integrity, avoiding damage or segregation, and preserving coatings. FastBack reliably handles even the most challenging products, all while remaining energy-efficient, quiet, and adaptable.
PROPORTIONAL GATE 3.0 WITH CROSS FEEDER SECTION
This groundbreaking proportional distribution
system by FastBack uses unique cylindrical outlets that rotate to divert a proportional portion of product, so the main product supply continues to flow as it allocates amounts to individual weigher/bagmaker stations. Downstream stations are no longer “starved” and do not need to wait for product.
The patented design introduces various advantages that make it the premier gate in the industry.
Heat and Control –www.heatandcontrol.co.za
To access video, check out the Food Review Digimag.
Clean-Up and Recycle SA 2024 Campaign Launched
Plastics SA and the KwaZulu-Natal Marine Network launched the Clean-Up And Recycle SA 2024 campaign at a recent seminar. The event also honoured local environmental champions with the Caroline Reid EcoWarrior Award for their commitment to protecting South Africa’s waterways.
Plastics SA and the KwaZulu-Natal Marine Network utilised the NETWORK for NETWORKS seminar hosted recently by the SA Association for Marine Biological Research at uShaka Sea World to launch the highly anticipated Clean-Up And Recycle SA 2024 campaign. The event also honoured several local environmental champions with Plastics SA’s prestigious Caroline Reid Eco-Warrior Award which is awarded annually to individuals or groups who display an unwavering commitment to protecting the country’s rivers and waterways.
COMMUNITY SPIRIT IN ACTION
In an impressive demonstration of community spirit, Saturday saw volunteers rallying for a beach clean-up at Umbogintwini Beach in celebration of World Oceans Day on 8 June. Partnering with Plastics SA, Clean Surf Project, Sapphire Coast Tourism, and the Inkwazi Isu River Catchment Project and 300 children from local schools collected 300 bags of litter— amounting to nearly one ton of waste that will not reach the ocean.
During Environment Week, the ‘Save a Fishie’ initiative also made significant strides. The campaign, spearheaded by Zoë Prinsloo and her team, journeyed from the West Coast to Pretoria and Johannesburg in an effort to raise awareness about the
"In
an impressive demonstration of community spirit, Saturday saw volunteers rallying for a beach cleanup at Umbogintwini
Beach in celebration of World Oceans Day on 8 June, collecting nearly one ton of waste that will not reach the ocean."
2024 DATES
This year’s Clean-Up And Recycle SA week will take place from 16 – 21 September 2024 and includes several key dates aimed at mobilising communities nationwide:
• Clean-Up and Recycle Week SA: 16 –21 September
• National River Clean-up Day: 18 September
• National Recycling Day: 20 September
• National Clean-Up Day: 21 September
• World Clean-Up Day: 21 September
• International Coastal Clean-up: 21 September
importance of preserving South Africa’s beautiful beaches. Their efforts will soon extend to Richards Bay before they head back to Cape Town. Plastics SA, Polyco, Petco, and eWasa the proud sponsors of this monumental venture and are deeply appreciative of the team’s dedication.
Highlighting the seminar, Chris Whyte, a renowned environmentalist and founder of numerous organisations such as USEIT, Sustainable Tech, Pyrolysis Group SDG Africa, ImagineIF, and Africa Circular Economy, received a special award from Plastics SA. Whyte, a dedicated member and chairman of the National Recycling Forum and the KZN Marine Waste Network, was recognised for his unwavering passion and vision in protecting the environment and promoting a circular economy.
Other distinguished award recipients of the Caroline Reid Award in KZN included the Clean Surf Project, Ezemvelo KZN Wildlife, Wild Oceans and the Inkwazi Isu River Catchment Project, North Durban Honorary Officers, KZN Beach Clean-up, Cleansing and Solid Waste Services (CSM) SAAMBR and Sustainable Seas Trust (SST). The recipients based in other provinces will receive their awards in weeks to come.
CIP Recirculation Tanks
Have you ever wondered about the crucial role your CIP recirculation tanks play in your operations? These tanks are not just passive containers; they are pivotal in ensuring the efficiency and effectiveness of your cleaning processes.
Recovering and reusing CIP cleaning solution lowers water consumption and thermal energy as well as time needed for CIP due to solution being at temperature. When optimising a CIP set, the pre-rinses should remove all gross soil before applying the chemistry. The initial return of the detergent solution, containing the maximum soil, should be drained, the remainder being recovered, extending the serviceability of the re-use solution.
The questions are: What happens when things don’t go as planned? Is the CIP solution as optimum as it could be? Or, in normal production, how long can the solution be used?
Important factors (other than standard strength measurements) are the solution’s age, particularly for alkaline CIP solution as they can absorb carbon dioxide. This causes any or both of two issues - lowering
"Nutrochem has developed CIP X, a powerful tool that empowers you to make informed decisions about your CIP solution."
hydroxide alkalinity with minimal change to conductivity, resulting in the solution at the conductivity set point having lower cleaning capability. The second is that the cleaning solution may become buffered and not allow the hydroxide alkalinity to function as it should, lowering the cleaning effect.
READY TO OPTIMIZE YOUR CIP PROCESS?
MANAGING CIP RECOVERY TANKS
Enhanced
Perfect your rinse and dump times for maximum effectiveness
Extra Control: Monitor caustic and acid concentrations with precision
Take control of your CIP process and achieve the highest standards with CIP X
RECEIVE A COMPREHENSIVE REPORT DETAILING THE STATE OF YOUR CIP SOLUTION IN THE RECIRCULATION SYSTEM SHOWING HOW CLOSE IT IS TO ACCEPTABLE STANDARDS
Innovative Dairy Production
Marcel Gomolka (left), project engineer in the filling technology of the Theo Muller Group, at the control of the user interface with Joachim Ott (right), Business Development,
Sachsenmilch, established in 1990, excels in producing high-quality dairy products. With 2,800 employees, the Leppersdorf plant processes nearly 1.8 billion kilograms of raw milk annually.
The Sachsenmilch brand stands for high-quality dairy products. Whether butter, milk powder or long-life milk, most of the food products have been produced in the company’s own plant since it was established in 1990. Some 2,800 employees in Leppersdorf and the surrounding area ensure that everything runs smoothly. The product range particularly includes a wide variety of yogurts and different desserts that require special attention during the filling process. The Leppersdorf plant in East Saxony is designed so that almost 100 percent of the raw milk is utilized – a relevant figure given an annual processing quantity approaching 1.8 billion kilograms. Sachsenmilch relies on state-ofthe-art production processes to cope with this operation. Automated systems process, package and test the milk products in a matter of seconds so that customers always get the full flavor at the best price. As shown by the following example of filling fruit compote, the Wipotec inspection systems, which are always adapted to the individual application, perform impressively. A model from the SC-W series, a further development combining innovative X-ray technology with tried and tested checkweighers, is used for this purpose. No wonder then that the companies of the Theo Müller Group and the Wipotec team have enjoyed a longstanding partnership.
CHALLENGES IN THE PRODUCTION OF FRUIT COMPOTE
Sachsenmilch’s delicious fruit compote dessert, made according to a traditional recipe with fine semolina or vanilla custard, heads
first for the chiller cabinet and ultimately the customer’s stomach. However, the fruit compote has a long way to go before it gets there, starting at the Naturfarm company in Leppersdorf. It is there that raw fruits such as cherries and blueberries are boiled with the aid of complex equipment. More than 90 percent of fruit preparations are produced in-house at Sachsenmilch. The Naturfarm products, which arrive still boiling hot, travel straight to the filling plant through a sophisticated system. Once there, every product is assigned a suitable container, from the Theo Müller Group’s famous yogurt pot with corner to a 1 kilogram pot for fruit compote. A conveyor belt then transports the finished compote pots to final quality control. For Gomolka and the Sachsenmilch team, only an X-ray system from Wipotec came into consideration for this task. As usual, the SC-W 4000 system from Wipotec is distinguished by a very high level of accuracy. Thanks to their modularity, the machines are optimally tailored to the specific application. It is therefore possible to detect many foreign bodies, even in heterogeneous products.
INSPECTION SOLUTIONS
The experience gained by Wipotec in the development of X-ray systems is noticeable in the SC-W product family. The integrated scales are calibrated during installation which eliminates the need for hourly random checks on site in Leppersdorf. As Gomolka notes, this is a huge advantage with enormous potential savings. Process safety plus hygienic design are extremely important
at Sachsenmilch.
In Gomolka’s opinion, the integrated checkweigher with an EMFR Weigh Cell is essential for Sachsenmilch’s production processes. This module allows each individual pot to be weighed while at the same time sending feedback to the filling machine, enabling it to readjust the nominal filling weight accordingly. This is the only way to ensure that not a drop of the precious compote is wasted. Sachsenmilch thus utilizes the expertise of Wipotec and combines the advantages of dynamic weighing systems with those of a modern filling plant. In addition, the Leppersdorf plant can no longer afford to be without inline X-ray inspection which makes a critical contribution to product safety. Various Wipotec systems are involved in production at the Theo Müller Group. Among other equipment, X-ray scanners of the SC-I series examine thermoformed pots for foreign bodies in the FFS system itself. This technology can guarantee excellent detection accuracy with minimum false rejections.
Wipotec
Elevating product safety with ProdX
Introducing ProdX™ - The comprehensive inspection management and connectivity software solution from METTLER TOLEDO.
Microsep is proud to partner with METTLER TOLEDO to deliver advanced industrial weighing solutions, product inspection technologies and instrumentation. These offerings are designed to enhance every facet of packaging and processing within the food and beverage industry, driving productivity while elevating quality and safety standards.
STAY AHEAD WITH THE DIGITAL EVOLUTION IN FOOD SAFETY
METTLER TOLEDO Product Inspection’s ProdX™ is a dynamic software solution designed to meet the evolving food safety requirements in today’s market. Scalable from single-site installations to multi-device management across globally diverse locations, ProdX™ empowers food manufacturers by supporting rigorous quality control procedures and driving automation, control, and traceability throughout their processes. This powerful tool is key in helping manufacturers transition towards a more digitalised and sustainable future.
Automation and digitalisation for enhanced control: ProdX™ offers a complete quality inspection data management system that provides full digital control of production inspection equipment for real-time monitoring and food safety compliance. Designed for food manufacturers, ProdX™ improves data handling, quality control and operational efficiency in the food industry.
MODERN FOOD INDUSTRY
ProdX™ succeeds to meet the exacting
demands of food manufacturers seeking comprehensive, efficient and data-driven solutions. As a cornerstone for quality control and data management in food production, ProdX™ seamlessly integrates with METTLER TOLEDO’s range of product inspection equipment – including x-ray inspection, metal detection, check weighing and vision inspection - ensuring the secure collection and management of critical inspection data.
“ProdX™ offers a complete quality inspection data management system that provides full digital control of production inspection equipment for real-time monitoring and food safety compliance.”
Whether monitoring reject statistics, tracking contamination events, or generating reports, ProdX™ provides users with high levels of accessibility and automation. In the highly demanding food manufacturing industry, where precision and efficiency are critical, ProdX™ enables manufacturers to access real-time data, make informed decisions, and improve production line performance to meet the highest quality standards.
Improving data management for food manufacturers: ProdX™ plays a pivotal role in food manufacturing by securely collecting and safeguarding inspection data from product inspection devices. It serves as a secure repository, archiving essential data in a tamperproof central server while offering the flexibility to generate ad-hoc or automated reports.
BENEFITS OF PRODX™
We offer no-obligation demonstrations to showcase how ProdX™ inspection data management software can help you achieve your business goals and compliance requirements. Contact us to arrange an online virtual demonstration or an on-site visit at your facility.
Investing in ProdX™ food safety management software can offset initial costs within just a few months to a year. The benefits include:
• Greater data visibility, security and improved control
• Increased efficiency and productivity
• Full lifecycle support
✔ Avoid product waste
✔ Maintain compliance
✔ Ensure product integrit y
✔ Avoid product waste
✔ Maintain compliance
✔ Ensure product integrit y
✔ Avoid product waste ✔ Maintain compliance
✔ Ensure product integrit y
Celebrating 50 Years of Innovation and Excellence
Flexicon Corporation, a privately held firm and world leader in bulk handling equipment and systems, is commemorating its 50th anniversary in 2024.
“Fifty years ago, my father had the foresight to solve a simple conveying problem. Today, our company provides solutions for food, chemical, and a range of other industries with everything from stand-alone equipment to automated plant-wide systems that solve the most difficult bulk handling problems,” says David R. Gill, CEO.
Founded by William S. Gill in 1974, the company began manufacturing “flexible screw conveyors,” a term coined by the company. Their simplicity, reliability and economy made them popular for basic conveying jobs and demanding applications previously satisfied by more complicated and costly conveyors.
Flexicon advanced the application of these conveyors faster and further than any other manufacturer, being the first to introduce 115mm, 150mm, and 200mm diameter screw/ tube combinations that elevated conveying capacity more than 10-fold in an 8-year period.
As the capabilities of its conveyors grew, so did the company’s expansion into pneumatic conveying systems and tubular cable conveyors, as well as upstream and downstream equipment including: bulk bag dischargers, bulk bag fillers, bulk bag conditioners, bag dump stations, drum/ box/container dumpers and weigh batching systems.
The company now offers “Quick-Ship” delivery on popular models of flexible screw
“We are extraordinarily proud of our history and our people whose inventiveness, skill and dedication have propelled our non-stop growth over the last 50 years.”
conveyors, bulk bag dischargers and bulk bag conditioners, boasts over 25,000 installations, and offers a lifetime performance guarantee on equipment and systems.
GROWTH AND GLOBAL EXPANSION
In addition to stand-alone units, the company began engineering and manufacturing automated material handling systems complete with sophisticated control packages produced in-house for multi-point bulk storage, processing, and packaging applications, many of which involve difficultto-handle materials, sanitary requirements, and explosive environments.
A separate Project Engineering Division manages large-scale bulk handling projects across the chemical, mineral, food, dairy and pharmaceutical industries worldwide.
Flexicon – www.flexicon.com
Flexicon Corporation, Lodi, New Jersey, circa 1974.
Multipurpose filler for bottles and cans
For the first time, the Krones Group presents a multipurpose filler that handles glass bottles, PET containers, and cans – the Barifill Canto.
Kosme wanted to be able to offer smaller craft breweries and wineries the greatest possible flexibility in container choice without requiring them to invest in three different filling machines. The Barifill Canto fills beer, CSDs, sparkling water, and sparkling wines in a variety of can types and sizes, and also handles PET containers or glass bottles – the latter in both the classic wine bottle format and the long-neck bottle used for beer and CSDs.
TWO FILLERS IN ONE MACHINE
This flexibility is made possible by an innovative filling valve. Kosme has taken the best features of existing Modulfill series filling systems and combined them into a single valve. The valve is equipped with a level probe for filling bottles and a volumetric system with an inductive flow meter for cans. In order to reduce the required space as much as possible, the necessary container sealers are also integrated into the filler: a Krones Modulseam for cans and a Kosme crowner for glass bottles. As an option, plastic screw caps for PET and roll-on aluminum caps or corks can be handled as well. In the filler as well as in the sealers, all parts that come into contact with the product are made of stainless steel, enabling reliable cleaning and ensuring their longevity.
UP TO 16,000 CONTAINERS PER HOUR
The Barifill Canto is as flexible in terms of speed as it is in its applications: Depending on
the product and configuration, it fills from 1,200 bottles or 2,500 cans per hour on the smallest layout to 9,500 bottles or 16,000 cans per hour on the biggest setup. Since its launch last year,
demand for the Barifill Canto has been extremely high. At the moment, Kosme is working to expand the output range to up to 24,000 containers per hour.
Reliability, efficiency and optimised resource consumption: Krones’ innovative filling and packaging concepts are perfectly tailored to your particular needs – for glass bottles, PET containers or cans. South African FoodReview, 132 x 200 mm, Packaging, CC-en30-AZ121 08/24
Multifunctional plant-based ingredients for clean label concepts
Herbafood Ingredients is adopting an innovative strategy by creating consumer-friendly products through the utilisation of side streams
In today’s world, a growing number of consumers prefer plant-based ingredients and clean label food concepts. Herbafood Ingredients is taking an innovative approach by producing consumer-friendly products through side stream utilisation. Their entire product range can simply be declared as apple or citrus fiber and apple extract. As the pioneer in the field of functional fibers, Herbafood Ingredients GmbH was the first company in the industry to introduce the process of side stream utilisation. The company is setting the trend for the valorisation of fruit peels into multifunctional fibers and apple extracts. These products are obtained from apple and citrus fruits after de-juicing and after extracting the pectin. Whether you want to texturise, stabilise, emulsify, or colour your product, Herbafood’s multifunctional products are an excellent choice to meet your functional requirements. With decades of experience in the development and manufacturing of highperformance fibers, the company’s products
“The company is setting the trend for the valorisation of fruit peels into multifunctional fibers and apple extracts.”
are the benchmark in the industry, known for their outstanding functional properties and consistently high quality.
ABOUT HERBAFOOD
Herbafood Ingredients produces high-quality food ingredients of a plant-based origin. They offer a wide range of functional dietary fibers made from fruit fibers, such as citrus fibers or apple fibers. One of their preferred raw materials is apples, from which they obtain not only functional fibers, but also their naturally colouring, flavouring, and sweetening apple extract.
DID YOU KNOW?
Herbafood Ingredients supports you with the most reliable ingredients and technical expertise in recipe development, reformulation ideas, cost adjustment and process implementation.
SAVANNAH
Established in 1990, Savannah retains its start-up philosophy by staying true to purpose:
• Curious by nature – keeps us learning and improving and staying relevant.
• Can-do relates to our positivity and enthusiasm – making us responsive and effective.
• Collaboration – we’re focused on connections that yield value for all. Savannah offers a value-driven ingredients package that improves the lives of our customers through being constructive, synergistic, and well implemented.
Trusting us with your raw material requirements allows you more time elsewhere – and with time being so precious, how valuable is that? And the value extends further – into the areas of your business where the right ingredients can make the difference between ordinary and brilliant.
HERBAFOOD INGREDIENTS is a pioneer in the field of multifunctional ingredients for the food industry, and offers an extensive range of natural apple extracts and functional dietary fibers from citrus fruits or apples. The entire product range is plant-based and declaration-friendly.
Innovative X-ray System Enhances Packaging
Universal Flexible Packaging has adopted Ishida’s IX-EN-2463 X-ray inspection system and DACS-G checkweigher to improve packaging for Itsu’s noodle cups. This solution ensures quality control and efficiency, handling 80 packs per minute, while meeting stringent UK retailer standards and enhancing overall operational reliability.
An Ishida X-ray inspection system and checkweigher combination has played a key role in enabling one of the UK’s leading contract packing companies to implement a new packaging solution for a major customer.
Universal Flexible Packaging, based in Leicester, UK, is a long-term partner of leading Asian-inspired food brand Itsu. Itsu wanted to reduce the amount of packaging for its premium noodle cup range with a new cup and foil sealed lid. However, this meant quality checks using traditional metal detectors would not be possible, and for a filling and packing system where the majority of the equipment is built of stainless steel, X-ray provided the best solution for both brand and consumer protection.
CHALLENGE OF KEEPING
LIGHTWEIGHT CUPS UPRIGHT
While X-ray inspection technology delivered
“The Ishida X-ray and checkweigher combination is handling two designs of pot at around 80 packs per minute and is in operation for up to 24 hours a day, five days per week. ”
effective quality control, the challenge was to keep the lightweight cups upright. With most other X-ray solutions, cups would topple as they pass through the protective curtains to enter the inspection chamber.
Ishida’s solution was to use its entrylevel IX-EN-2463 X-ray inspection system with a lower 50kV voltage and remove the protective curtains. As the pots enter the
chamber an extended guarding provides full protection from the X-ray process without the need for the curtains.
“We have a longstanding working partnership with Ishida, so they were the obvious choice for this particular application,” said Steve Potter, Universal Flexible Packaging’s engineering manager.
“As well being able to come up with a suitable solution, the company’s IXEN X-ray inspection system was very competitively priced.”
CHECKWEIGHER FOR FINAL QUALITY ASSURANCE
The IX-EN is integrated with Ishida’s DACS-G checkweigher, which provides a final weight check to ensure that all ingredients in the pot are present. The system incorporates Ishida’s Retail Reject Confirmation (RRC) software that checks and confirms that any out-of-spec products
or packs have been successfully removed from the packing line, in line with individual UK retailer quality standards and codes of practice. Two reject bins identify packs rejected by either the X-ray or the checkweigher.
“The installation and integration with the rest of the line was seamless, and both machines have proved very reliable and easy to operate,” said Steve Potter.
ABOUT ISHIDA
Ishida is a world leader in the design, manufacture and installation of complete weighing, packing and inspection solutions for the food industry, helping manufacturers increase automation, reduce cost and downtime, increase operational efficiencies and maximise profits.
With an installed global base well in excess of 100,000 industrial machines, covering a huge number of applications and end markets, the company is the undisputed world market leader for multihead weighers and one of the leading global suppliers of snack food bagmakers, graders, tray sealers, X-ray
inspection systems, checkweighers, leak detectors and Industry 4.0 solutions.
This extensive product range, along with the company’s in-depth knowledge and experience of many industries, mean that Ishida is able to design and install complete turnkey solutions for markets such as snacks and other dry foods, meat, poultry, fish, dairy, ready meals and fresh produce.
The company’s vision is to play an enduring and indispensable role in the global food supply chain, ensuring food products are delivered and consumed safely, efficiently and sustainably around the world.
The Ishida X-ray and checkweigher combination is handling two designs of pot at around 80 packs per minute and is in operation for up to 24 hours a day, five days per week. Importantly for Universal Flexible Packaging, the system has helped to increase efficiencies on the line.
A further benefit of the Ishida IX-EN is its ability to identify other types of foreign
bodies, such as glass, ceramics and stones. While it is highly unlikely that such items would be found in the cups, this capability adds a further level of quality assurance to Universal Flexible Packaging’s operations in line with its BRC AA* accreditation.
The latest quality control system joins the existing seven multihead weighers and 15 checkweighers currently in operation across Universal Flexible Packaging’s two factories in Leicester.
“Ishida has been a reliable partner for us for many years,” concluded Steve Potter. “As well as the quality of the equipment, we know that in the event of a problem or the need for a spare part, we will always receive a fast response. It is reassuring to have a large global company that is still able to deliver a personal, localised service for its customers.”
7 Bananas, strawberries and yogurt mixed together to make a _________
9 Mickey Mouse shaped _______ with eggs
10 Eat this warm with milk, raisins, and brown sugar.
13 Scrambled, poached and fried _____
What did the baby corn say to its mom?
Boost Output, Reduce Labour and Prevent Contamination with automated
Automated, sealed BULK-OUT® Discharger-Conveyor Systems replace multiple workers dumping hand-held bags manually, while preventing contamination.
Dual SWING-DOWN® Bulk Bag Fillers fed by weigh hoppers fill up to 40 bags per hour with only one operator connecting empty bags and one forklift removing full bags.
equipment and systems from Flexicon
Enclosed Bulk Bag Weigh Batch Systems feed a central weigh hopper mechanically, and remove weighed batches pneumatically, requiring labour only to attach/detach bulk bags.
Bulk Bag Discharging Systems can loosen solidified material and meter it into liquid streams (shown), screeners, size reduction equipment and continuous blenders—automatically.
Flexicon Bulk Bag Filling Lines automatically dispense pallets, fill bulk bags, and disconnect/accumulate filled bags, minimising operator involvement.
Flexicon automated equipment and systems can move your bulk materials with fewer personnel at higher capacities and lower cost, while preventing product and plant contamination
SOUTH AFRICA sales@flexicon.co.za +27 (0)41 453 1871
TIP-TITE® Drum/Box Tippers seal, tip and mate a discharge cone to a gasketted hopper lid, open a slide gate and feed downstream processes— automatically and dust-free.
