Food Review February 2018 by New Media B2B

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CONTENTS FEBRUARY 2018 | Vol. 45 • No. 2

Breaches

A riot

of flavours

in cyber security PAGE

PAGE

25 Beverage Review BeverageREV IE

10 NEWS

SOUTH AFR ICAN

February 2018 | Volume

www.foodre view.co.za

Afriplex’s new Joburg hub

Fuchs celebrates new lubricants division

CDP lauds Symrise

Palm oil producers speak up

14 INDUSTRY TALK Functional powders put an end

Februar

| Volu y 2018

me 43

| Number

16 COLOURS & FLAVOURS Sensient’s rich flavour profiles Is naturalness the new mega trend? Healthy food can taste great

T FILL TECHNOLO ING GY

How to expone ntially increase line effic iency Solutions for pH and acidic bevneutral erages

.za iew.co oodrev ww w.f

33 Packaging Review

re Explo y energn t efficieum vacuolog y techn nces y assura QualitM AP with

ty with capaci plant Unlocctk’s recycling Mpa

Doehler meets demand for bitter botanicals

23 PLANT SECURITY & SOFTWARE

Cybersecurity training is here to stay

The future of cloud-based analytics

Are your programmes modern enough?

Seam s conceples ts in HO

gREVIEW n i g a k c Pa

CAN H AFRI SOUT

to egg crisis

“Implementing heat treatment during beverage processing is a critical aspect.”

8 | Number 2

PAGE

40 “We unpack the operational activities of Mpact’s new recycling plant, alternatives to safer food packs in the form of coated and uncoated boards” February 2018 | Food Review

EDITOR’S COMMENT

EDITORIAL

Trends create a modern food culture

he start of 2018 has been marked with takeovers; branch and division launches and company anniversaries, but one of the most exciting developments is surely the resignation of former president Jacob Zuma. I trust that a new era in government is underway underpinned by accountable and decisive leadership. This might give the manufacturing industry the charge it needs to grow and innovate. It is critical industry doesn’t lag in implementing new trends, technologies and ingredients to reflect the country’s growing optimism. Paging through an edition of Forbes magazine recently, the following caught my eye – ‘Forecasting trends is a risky business. One of the most difficult aspects of financial and cultural analysis is recognising the importance of, and advising on, strategic implications of emerging patterns as trends. Smart growth strategy in food and beverage requires understanding of which leading-edge trends are scalable and which are likely to remain niche. Important questions marketers should consider include: What are leading-edge trends in your categories? Which leading-edge trends have the potential to scale? Which mainstream trends are weakening?’ What is apparent from a local consumer point of view is that artificial colours and flavours continue to decline in popularity. Consumers are increasingly open to novel, fresh, seasonal and bright botanicals as flavouring agents in a wide range of F&B products. This also ties in to the use of organics, single source extracts and sweetener solutions. We bring you information on a full kaleidoscope of new flavours including spicy, herbaceous flavours, bitter extracts for cocktails, gin and confectionery and rich intricate tea profiles – a perfect way to add flavour and depth to a multitude of products. Turn to page 16 for our comprehensive feature. Beverage processing technology is an evolving science. In this edition we look at Krones’ seamless twin flow concept for process engineering for highly sensitive beverages with a high fruit-cell content (page 28) to Serac’s combination PET linear blower with rotary weight filling machine (page 31). This technical feature is not to be missed! This month’s PACKAGING REVIEW investigates modern technology in modified atmosphere and vacuum packaging - a must read. I hope you enjoy this edition of Food Review. Please don’t hesitate to contact me with your latest news and views.

Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmediapub.co.za Assistant Editor: Aarifah Nosarka +27 (0)11 877 6209 aarifah.nosarka@newmediapub.co.za

Layout & Design: Kirsty Thomas +27 (0)11 877 6168 kirsty.thomas@newmediapub.co.za Contributors: Penny Ntuli and Stefan Pöschl ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmediapub.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmediapub.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 candida.giambo-kruger@newmediapub.co.za INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmediapub.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmediapub.co.za Production Controller: Rae Morrison Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park 2092 Tel: +27 (0)11 877 6111 Fax: +27 (0)11 713 9024 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published on behalf of Media24 by New Media Publishing (PTY) Ltd. MANAGING DIRECTOR Aileen Lamb CHIEF EXECUTIVE OFFICER

Happy reading,

Bridget McCarney EXECUTIVE DIRECTOR John Psillos NON EXECUTIVE DIRECTOR Irna van Zyl

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

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

HEAD OFFICE

Managing director of Symrise South Africa; chairman of SAAFFI.

Rudy McLean

Head of communications, Tetra Pak Sub-saharan Africa.

Penny Ntuli

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

Gail Angela Macleod

Food Review | February 2018

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

Food Review is published by New Media Publishing (Pty) Ltd 11 times a year and circulates to executives in the food and beverage industries. Views expressed in this journal, other than where specifically stated, are not necessarily those of the publisher. The editor welcomes for publishing consideration news items, press releases, articles and photographs relating to developments in the food and beverage industries. No responsibility is accepted should contributions be lost.

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

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New Media House, 19 Bree Street, Cape Town 8001 Tel: +27 (0)21 417 1111, Fax: +27 (0)21 417 1112 Email: newmedia@newmediapub.co.za

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Malaysia Internatio nal Halal Showcase

Food Review | February 2018

SIAL Canada

NEW ON THE SHELF Darling Brew’s

healthy mix drinks Spirited Flight is refreshing, light-inalcohol and a delicious healthy alternative to artificially flavoured beers and ciders. The range includes Golden Tail, a lemon Radler, inspired by the GoldenRinged Dragonfly. At 2.6 per cent alcohol this is a perfect low alcohol alternative to regular beer.

Bring back

the good times Chill Beverages International has launched Bashew’s Harry’s Cola Tribute Edition in honour of one of the founders of the Cape’s iconic soft drink brand. Dating back to 1899, Harry’s Cola celebrates over 115 years of Bashew’s refreshment. In keeping with the original family recipe, Bashew’s winning formula has been tried and tested to give families what they want - the authentic taste of eight fun filled flavours at a pocket friendly price.

Get

the soda

revolution started

A 330ml can of PURA Soda contains only 2.5 teaspoons, while other soda options could contain up to nine teaspoons in a single can. Available in a range of natural flavours – including Cucumber & Lime, Seville Orange, Cranberry, Lemon & Elderflower and Pomegranate.

A South African twist to classic ginger beer

Theonista’s all-natural, low sugar, and naturally caffeine-free composition makes it extremely versatile and suitable for all ages. The ginger beer is made with real ingredients like fresh pressed ginger, fresh lemon and a proprietary all-natural fermentation technique that incorporates organic rooibos.

Cheese

breaks new ground

Schweppes’ new range of

premium tonic water The company has announced a new range of premium tonic water, Schweppes 1783. The range features traditional Crisp Tonic Water, Light Tonic Water and Golden Ginger Ale alongside distinctive tonic water such as Salty Lemon, Quenching Cucumber and Aromatic Floral.

Food Review | February 2018

Fairview Cheese Company has introduced its brand-new cheddar range. It consists of four delectable flavours including Garlic and Rosemary, Dried Red Onion, Bobotie and Tomato and Chili. Packaged in single skinpack portions, these cheddars are a great new choice to use in everything from appetisers and breads to casseroles or simple lunchtime snacks.

Entries now open for the 2018 New Product Competition

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

NEWS

Afriplex spreads

its wings

New lubricants division for SA FUCHS LUBRITECH AND Fuchs Lubricants South Africa have created a Lubritech division, operational since 1 January 2018. Bernhard Biehl, CEO of the Fuchs Lubritech Group explains, ‘The Lubritene and Lubrasa businesses were integrated into Fuchs Lubricants South Africa in 2014. It was the right time to start a specialty lubricants division within the South African operation.’ The acquired businesses, mainly lubricants for the mining and food industries, brought initial sales growth and offer prospects for further expansion in South Africa and the entire southern African region. ‘By combining these advantages with the longtime specialty business of Ceplattyn Open Gear Lubricants and Cassida Food Grade Lubricants, we will hold a strong market position in the southern African region. At the same time, we have a strong team in place to increase our market share substantially and to set up new market sectors,’ Biehl concludes.

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Food Review | February 2018

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THE COMPANY HAS opened an office in Johannesburg, Gauteng. The new office will facilitate the company’s current marketing drive, creating awareness of the range of products and services on offer. Having a locally based office will ensure service excellence to customers in Gauteng and KwaZulu-Natal. Wayne Robinson has been appointed director of business development in the Gauteng office. He was the sales, operations and technical director as well as the responsible pharmacist for a pharmaceutical manufacturer for the last nine years. He is the director of scientific and regulatory affairs for the Health Products Association (HPA) amongst other accolades. Robinson’s appointment will play a significant role in expanding and servicing Afriplex’s customer base through the use of his invaluable skills, experience and knowledge in the pharmaceutical and food industry.

8/02/2018 9:20:57 AM

NEWS

SYMRISE’S PLEDGE to the environment THE RENOWNED NON-PROFIT organisation, Carbon Disclosure Project (CDP), has ranked the company amongst the top two per cent of outstanding A-list suppliers. It was particularly lauded for the categories: climate and water. Symrise is paving a path for other companies to an energy and resource-efficient future. ‘Their executives are always one step ahead in seizing opportunities for environmental protection,’ says Paul Simpson, chairman of CDP. Companies are divided into four different categories based on results: Symrise earned an A rating for climate and water protection for its activities in cooperation with primary suppliers. The company was also mentioned for responsible handling along the entire supply chain. A total of 100 companies achieved an A rating in the recently published CDP Global Supply Chain Report 2018. This ranking is based on analysis by the business consulting firm McKinsey & Company. It found that environmental risks are increasingly important for companies. 76 per cent of suppliers surveyed identified risks for businesses that are caused by climate change. 52 per cent reported that they have already integrated global warming as a factor into their business strategy. ‘Climate and environmental protection have the highest priority for us as a global company, especially in our sourcing processes and supplier relationships,’ concludes Hans Holger Gliewe, chief sustainability officer.

Hit all your inspection targets

Palm oil protests IN A MASSIVE show of opposition to the European Union’s efforts to impose a crop apartheid on Malaysian palm oil, smallholders took to the streets of downtown Kuala Lumpur to protest Europe’s proposed palm oil ban. The EU’s planned ban threatens 650 000 smallholders and over 3.2 million Malaysians who rely on the industry for their livelihoods. Rural communities across Malaysia would be devastated by the proposed restriction and thousands would be driven to poverty. The Malaysian government has previously warned that if any ban on palm oil would be implemented by the EU, government would take the necessary actions to protect rights and livelihoods. Datuk Amar Douglas Uggah Embas, chairman, Sarawak land consolidation and rehabilitation authority (SALCRA) explains, ‘Malaysia strongly condemns any actions by European politicians that will discriminate against our oil palm smallholders. Policies that are being proposed will harm Malaysia’s rural communities and reduce income for Malaysian families.’

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The EU’s proposed palm oil ban is meeting with stiff opposition

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February 2018 | Food Review

C O M PA N Y F O C U S

Do flavours right Staying the course for 20 years in an industry beset by competitive differentiation takes some doing. This is exactly why Creative Flavors is such a success. As consumers become more informed and have higher expectations, suppliers need to pay close attention to what customers want. By Maryke Foulds

reative Flavors is a family-owned The South African flavour industry is still business founded in 1998 at a time young. We have some way to go to be on par when international flavour with international flavour companies on a houses could only place technological level. minimum orders of 25kg. ‘We have a lot of skilful ‘We wanted to supply and intelligent people larger manufacturers, in the industry with but not lose sight of international experience smaller independents,’ to keep us current,’ Creative Flavors has an ever increasing database of raw explains general enthuses Melindi materials and chemicals used manager, Burrow, research in daily manufacturing of its Dalton Stander. and development flavours. The company receives Two decades on technician. ‘Creative new samples monthly to and the future is looking Flavors was one of keep up with trends and develop new ranges. rosy. ‘In coming the first companies to years we would manufacture flavours like to double our local from raw ingredients without and international blending flavours from market share. international companies. We probably We are also planning to have one of the most extensive range of open a few branches raw materials for flavour manufacturing in various countries. in Africa.’

DID YOU KNOW?

‘Cash flow!’ Stander exclaims immediately when asked what their initial concerns were on opening the facility. ‘We could only import smaller quantities of raw materials. These weren’t produced in South Africa and we didn’t have the client base or capital to import larger, more economical quantities. What made this very problematic is the African market is very unpredictable and companies struggle with accurate forecasting. We sometimes experienced pressure by having to import some raw materials for a sudden increase in order by air freight – which is notoriously expensive.’

PUTTING CUSTOMERS FIRST ‘There are usually two types of clients who approach us. The one group wants to start up a company with no specific idea of what they want or how to go about the process. We sit them down to get an understanding of the product they want to manufacture. Still going strong 20 years later

Food Review | February 2018

C O M PA N Y F O C U S

If they would like to enter the carbonated beverage market we will look at popular flavours, depending CREATIVE FLAVORS on their target market. If CELEBRATES 20 years the client has flavours in of service to the local mind, we select the most industry. It exported its appropriate flavours, with or first order 17 years ago. without colour, depending on preference,’ Burrow explains. ‘We offer a small sample of 30g to do testing before ordering larger quantities. We assist clients with a basic formulation and additional information regarding raw materials, where to buy it as well as options for bottling and canning.’ Existing clients tend to ask for specific flavours to expand their product or flavour range. As they know what will work, the research and development team selects the most appropriate flavour and provides them with samples. New and existing clients can also bring a sample to match. The matching process can be quick if they find the flavours match something in Creative Flavors’ current library. ‘When we develop a new flavour, we do a few sensory tests to determine the flavour notes and then start compiling. We provide the client with a sample to test first and wait for approval. If the client is not completely happy, we can change the formulation so they can test it again. Once approved, they can place orders from 1kg upward,’ Burrow notes.

FAST FACT

biggest export to the continent especially gin, malt, rum and whiskey flavours. Biscuit flavours are also doing well, especially butter vanilla, which offers a shortbread note. Our bestselling ranges to the local market are candy flavours including strawberry, bubblegum, raspberry, Wicky Wacks, cream soda and orange. Another big sector is neutral emulsions. I think cucumber flavours are going to be very big. The flavour and colours industry is really a process of understanding alchemy at work,’ Stander adds. Asked whether the African continent is a focus point, Dalton says most definitely. ‘Africa has been a priority for us since our first export order in 2000. We have built up contacts and appointed agents in various African countries. We regularly visit our current and prospective clients and work closely with the Department of Trade and Industry on accompanying them on trade missions.’ •

“We probably have one of the most extensive range of raw materials for flavour manufacturing in Africa”

Creative Flavors – www.creativeflavors.co.za

LATEST TRENDS Vanilla is making a big comeback in 2018. As there is a global shortage of real vanilla, the market for nature identical is now standing at 99 per cent. This is particularly true for soft drinks. The company is also seeing enormous interest in luxury items such as craft gin, while craft beer and especially radlers are becoming popular. ‘Alcoholic beverage flavours remains our

ACHIEVEMENTS TO DATE • Voted Best Exporter for SMME’s in 2011 by the JCCI • ISO 22000 certified and working towards FSSC 22000 certification • 100 per cent of flavours and emulsions are Kosher and Halaal suitable. Certification application upon request • Member of The South African Association of the Flavour and Fragrance Industry.

February 2018 | Food Review

I N D U S T RY TA L K

A solution to the egg crisis For 75 years, the company has been supplying high quality egg products globally

Sanovo Egg Group, part of Lactosan-Sanovo Ingredients Group, offers high quality egg powder solutions, in standard and customised formats. These meet the requirements of today’s food processors and consumers for natural and functional ingredients.

or more than 75 years, the company has been supplying high quality egg products from all corners of the world. ‘They have factories and sales offices in Europe, China and South America and a network of agents and distributors. This is your security for contingency in cases of unforeseen circumstances like Avian Flu,’ explains Sambashni Govender of local agent, Danlink Ingredients.

FUNCTIONAL AND VALUE-ADDED EGG PRODUCTS Sanovo supplies a full range of egg product solutions for the food and food service industries. The product portfolio includes free range, barn/cage-free egg products in standard and customised whole egg powders; standard and customised egg albumen powders and standard and customised egg yolk powders. •N atural ingredients Egg powder solutions are based on carefully selected raw-materials. The range includes barn and free range egg powders besides standard egg powders. •L abelling friendly products Allow label declaration for natural egg ingredients.

BENEFITS FOR MAYONNAISE PRODUCTS: • Increase physical stability and heat stability • Increased viscosity • Easy to establish stable emulsions • A stable and standardised high quality 18 month shelf-life • Consumer friendly labelling - pure and natural egg powder • Easy to dissolve in water • No bacteriological development.

Food Review | February 2018

FAST FACT • Functional foods The range of egg powder products is a functional alternative to using shell eggs in products. Application benefits include heat-stability, improved gelling and whipping abilities. Sanovo egg powders offer convenience, easy dosage and longer shelf life. Products can be customised according to specific requirements. • Stable quality Egg ranges deliver stable quality, with the right functionality and properties to fit specific processing and labelling requirements.

WELFARE AND FOOD SAFETY Many consumers have the welfare of the birds in mind when buying eggs. Consequently, free range and barn certifications are significant considerations for many egg purchasing decisions. Sanovo Egg Group shares customers’ concern for food safety. ‘The company sources eggs from approved farms. All egg powders are pasteurised with full traceability,’ Govender enthuses. ‘Free-range and barn egg ranges also comply with KAT regulations. KAT criteria goes beyond guidelines and regulations laid down by the EU and German animal welfare livestock farming directive and other aspects of animal welfare. The goal is cross-border compliance on criteria specified by KAT; control and monitoring of eggs using these rearing methods, and strict recording of goods movements from the egg farm to the consumer.

LACTOSAN-SANOVO INGREDIENTS GROUP (LSIG) was formed on 1 January 2010 with the purpose of creating and utilising synergies between Lactosan and Sanovo Egg Group. These companies are pioneers in their field of business with more than 70 years’ experience in developing cheese and egg powder solutions for food and flavour manufacturers around the world.

INNOVATIVE EGG PRODUCTS The company can assist in developing innovative products that will satisfy tomorrow’s requirements, in a way that only global players can. As a global egg products supplier, skilled research and development teams can assist food manufacturers in meeting tomorrow’s demand for innovative, tasty and convenient products. In cooperation with distribution partners, the research and development teams work closely with customers, providing anything from seminar-styled training to product development and application and reformulation advice. • Learn about the company’s quality control and download quality certificates at www.sanovo.com.

Danlink Ingredients – www.danlink.com

Global Egg Powder Solutions Excellent functionality - the natural choice www.sanovo.com SANOVO EGG GROUP is represented by: Danlink Ingredients (Pty) Ltd. Tel: 011 7047261 ( Johannesburg ) Tel: 021 9139818 ( Cape Town ) e-mail: info@danlink.com website: www.danlink.com

C O L O U R S & FL AVO U R S

A riot

of flavours

Sensient Flavors has launched its All Natural Flavour Collections. These trendy flavours will help food and beverage manufacturers respond to upcoming market trends and reflect current consumer preferences.

he latest findings of the company’s consumer and market research underpins Sensient’s new collections, which are split into five key botanical areas: florals; herbs; spices; tea and ginger. ‘Sophisticated consumers demand natural, healthier options and the chance to express their individuality. Botanicals are making the perfect comeback to reflect these trends,’ comments Barbara Lezzer, director of marketing Europe, sweet and beverage, Sensient Flavors.

A KALEIDOSCOPE OF NEW FLAVOURS Floral Collection offers spicy, herbaceous and delicate, sweet flavours for a multitude of applications. These include cocktails and gin to confectionery and dairy. Jasmine, chrysanthemum, desert wildflowers, elderflower, geranium, rose and lavender feature in the strong line-up, alongside orange blossom, cherry blossom and hibiscus. Spice Collection adds a touch of natural sophistication and complexity. A modern twist places black pepper, pink peppercorn, star anise, clove bud and saffron firmly in the beverage arena, while

Food Review | February 2018

their inherent heat means that cinnamon, capsicum, cardamom and liquorice add warmth to bakery and dairy products. Completing this collection, juniper berry works well in meat-based savouries and even beer.

“The ability of tea to offer rich, intricate profiles makes it the perfect way to add flavour and depth to a multitude of products - from ice cream to chocolate and alcoholic beverages” Culinary herbs add naturalness and, from an aesthetic perspective, their delicacy catches the eye in cheeses and savoury snacks, soft drinks and cocktails. Sensient’s carefully curated Herb Collection comprises garden mint, coriander leaves, sage, rosemary, hops, oregano, basil, thyme, lemongrass and aloe vera.

Tea is no longer just a beverage. Exciting new offerings have consumers reaching for tea in different forms and flavours. It is associated with sophistication, flair, naturalness and health. The ability of tea to offer rich, intricate profiles makes it the perfect way to add flavour and depth to a multitude of products - from ice cream to chocolate and alcoholic beverages. Tea Collection brings together an extraordinary exploration of eight different tastes: green, matcha, white, cascara, Rooibos, chai, black and Earl Grey tea. Ginger is enjoying a resurgence amongst consumers of all ages. Sensient’s Ginger Collection comprises six distinctive flavour profiles: classic ginger beer, ginger ale, ginger root (gari), spicy ginger, Nigerian and Chinese ginger (galangal). Creativity can run riot with these versatile flavours in all sorts of applications. With over 70 years’ experience with ginger extracts and flavours, the Sensient team can tailor any of these to create the perfect sensorial experience for brands. •

Sensient Flavors – www.sensientflavors.com

NUTRIPHARMASOLUTIONS

C O L O U R S & FL AVO U R S

Combine nature and science

aturalness is a megatrend coupled to many subtrends, particularly natural sweeteners, fermented beverages, GMO-free products, organic food and single origin products. Prova predicts some of the biggest flavour and product trends for 2018.

silk and filmjölk. Kombucha, a fermented tea from Asia, is also showing sustained growth. There are many ways to flavour these naturally processed drinks. To ensure a clean label marketing positioning, it is better to use natural flavours or extracts in these products.

STEVIA AND MASKING FLAVOURS

ORGANIC EXTRACTS AND FLAVOURS

Natural sweeteners are a growing category. Globally, soft drinks containing stevia increased by 2.4 per cent on the period 2012- 2015, whereas aspartame and acesulfame K are losing ground with -2.8 per cent and -1.7 per cent respectively. This tendency is impacting on many product reformulations that require tailor-made flavours to standardise taste.

Certified foodstuffs are probably the most emblematic products following the natural trend. Those who buy these products are informed and highly sophisticated consumers. To ensure consistency, it is better to use flavourings that have an organic certification. Prova has expanded its organic offering. In accordance with regulations, 100 per cent of its organic natural vanilla flavours are made with organic vanilla beans. The supplier does not use any synthetic carrier for its organiccertified flavours and extracts. This is a key point as the carrier represents the largest part of a flavour in volume.

FERMENTED BEVERAGES The use of probiotics is on the rise. The growing fermented beverage category includes dairy beverages such as kefir, lassi,

K-CHEM 18

Food Review | February 2018

RECONCILING NATURALNESS WITH ALLERGEN-FREE It is sometimes difficult to marry naturalness with other trends such as allergen-free. When formulating with nuts for example, one of the benefits of synthetic flavours is that it is easy to manufacture, making them available in allergen-free versions. This is more complex with natural nut flavours. The company has developed a whole range of allergen-free nut flavours that can be labelled as natural.

SINGLE ORIGIN EXTRACTS Products are seen as a guarantee of naturalness, traceability and authenticity. The company can provide single origin extracts i.e. vanilla from Madagascar, Comoros, India, Indonesia, Tahiti or Papua New Guinea. Prova also offers various single-origin coffee extracts. It can source coffee beans from Brazil, Colombia, Ethiopia and India. •

Prova – www.prova.fr

Represented by K-Chem, Contacts: Phomolo Moeketsi and Kobus Oberholster | Tel: 012 653 5441

Find the smallest objects before they cause the biggest problems Our quality control systems leave no stone unturned. Or shard of plastic or glass. Or piece of metal or rubber. If thereâ&#x20AC;&#x2122;s a foreign body in your product, our machines will find it. Reducing product recalls and protecting your brand. Work in harmony with Ishida.

ishidaeurope.com

C O L O U R S & FL AVO U R S

Sweetener solutions at work Firmenich enables solutions that contribute to greater health, nutrition, hygiene and sanitation, while preserving nature’s most precious resources and empowering sustainable livelihoods across value chains.

rom a flavours perspective, Firmenich focuses on health and nutrition issues to help customers meet a variety of challenges. These include reducing calories, sugar and salt, coupled to consumer demand for protein content and other nutrients. Technical expertise, scientific innovation and creativity to taste solutions for sugar, salt, fat modulation, bitterness reduction, umami enhancement and cooling technologies are tools that assist customers to create fantastic taste experiences.

beverage manufacturers to reformulate new products with low and/or no sugar. Improving nutrition by reducing salt or sugar can change taste profiles in complex and undesirable ways. This results in bitterness, off notes, aftertastes and poor mouthfeel. This creates a taste gap and could drive down consumer preference. While consumers demand healthier food and beverage choices, they are not willing to give up on great taste just yet.

HOW SWEET IT IS

Moving beyond flavours, Firmenich OBESITY: A is launching a new GROWING family of TastePRINT™ In 2017 Firmenich removed CONCERN IN Sweetener Solutions, more than 150 000 metric SOUTH AFRICA which can achieve tonnes of sugar, the equivalent At least 13 per up to total removal of 600 billion calories from cent of children (100 per cent) of customers’ products without in South Africa are added sugar. The compromising quality overweight or obese; solution is sold as or taste. more than double the an optimised blend global average. Food and of flavours (modifiers, beverage manufacturers are maskers, tonality) plus a launching products with non-nutritive sweetener. When a reduced sugar and calories, which formulator wants to reduce, or completely have gone up by almost 55 per cent remove, sugar from a product, TastePRINT from 2014 to 2017. This is expected sweetener solutions can be used to replace to grow much faster due to the new some or all of the nutritive sweetener. initiatives from the local government to High-intensity sweeteners may combat growing obesity issues. add lingering aftertastes or off notes. TastePRINT’s solutions help SUGAR TAX A REALITY minimise these effects, restoring the The tax will be implemented on 1 authentic taste profile of a product, April. It will see the price of sugary protecting the brand and improving drinks increase by more than 10 consumer preference. • per cent as it levies 2.1 cents per gramme of sugar on all sweetened Firmenich – www.firmenich.com drinks. This new reality will require

DID YOU KNOW?

COLOURS AND FLAVOURS GLOBAL MARKET LEADER IN CHEMICAL DISTRIBUTION Brenntag South Africa (Pty) Ltd 11 Mansell Road Killarney Gardens Cape Town, 7441

Cape Town Johannesburg / KwaZulu-Natal info@brenntag.co.za www.brenntag.com

+27 (0) 21 566 1920 +27 (0) 11 396 3733

Food Review | February 2018

Welcome to Brenntag South Africa. We offer tailor made solutions to suit your colour and flavour requirements. Sourcing from our world class suppliers, we offer a wide range of both synthetic and natural derivatives. With an FSSC accredited application and blending laboratory situated in Johannesburg, our team is ready to offer up to date technical and regulatory support. FOOD AND BEVERAGE | PHARMACEUTICAL | NUTRACEUTICAL ACIDITY REGULATORS | ARTIFICIAL SWEETENERS | EMULSIFIERS | FLAVOURS | STABILISERS | PRESERVATIVES

Make Healthier Taste Great. Integrated sweetening solutions

Create great-tasting products that meet the demand for little or no sugar with our TastePRINTTM integrated sweetening + flavor solutions.

Reduces sugar from 30% up to 100% Addresses lingering aftertastes Cost effective with simplified development Labels as sweetener + flavor

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C O L O U R S & FL AVO U R S

Satisfy the most

ELUSIVE AND ADVENTUROUS PALATE

onsumers are constantly seeking new taste sensations. Bright colours, optimal texture, outstanding taste and offering a perfect multi-sensory product experience is all the rage. Doehler has broadened its range of botanical ingredients, offering a new and comprehensive range of high-quality bitter extracts. These ingredients are obtained from botanical sources such as vermouth, chiretta and quassia. Following demand for natural and bitter taste profiles, these extracts are ideal for a new generation of naturally bitter drinks. They can also be used to give a subtle but interesting bitterness to many innovative beverage concepts. Strong herb, spice and blossom infusions are ideal for clean label products. By forgoing technical concentration and additives, these infusions taste freshlybrewed. They add a pleasantly floral or spicy herbal note to several applications.

Authentic brown flavours play a vital role in the Doehler portfolio. With popular classics, such as chocolate, hazelnut or caramel, the supplier offers the finest flavours for innovative taste variants with pecan or Dulce de Leche. In terms of savoury preparations, Spicy Solutions are trending. Ready-to-use compounds are based on an assortment of more than 100 herbs and spices combined with different fruits and vegetables. Used as fillings or in dough, they make it possible to create a wide range of taste experiences. Product ideas such as Green Pesto Quiche or Mexican Tartlet takes consumers on a trip around the world accompanied by intense tastes and flavours. Doehler has developed a wide range of fruit gums with valuable ingredients, such as proteins or botanical extracts, which provide a healthy additional claim. Enriched with pure juice concentrate or

purée, these ingredients offer an extrafruity taste profile. A new range of hard boiled candies is impressive with the addition of acerola fruit powder and an increased amount of vitamin C. Innovative coating systems that create the perfect look include sugar polishes and glazes that provide natural colours with a shiny appearance. Chocolate polishes and confectioner’s glazes for long-lasting and brilliant shine on chocolates is a must. Gum polishes based on natural waxes and liquorice polishes for extruded liquorice products will prevent confectionery from sticking together. •

Doehler – www.doehler.com

Tel 011 608 4944 Fax 011 608 4948 Email sales@sensetek.biz

FLAVOUR DIRECTLY FROM THE SOURCE Sensetek.indd 1

Food Review | February 2018

2017/02/14 12:01 PM

P L A N T S E C U R I T Y & S O F T WA R E

Breaches in cyber security

Cisco South Africa has launched a cybersecurity experience centre and academy in Johannesburg. The centre aims to educate and fast track skills needed to deal with growing challenges in this sector.

“Demand for cyber security experts has grown three times faster than any other IT role” Smith, managing director of Cisco southern Africa. ‘Security is a business priority. Many executives feel overwhelmed by the defender environment and cite certification and talent as two of the biggest constraints to adopting advanced products and solutions. ‘In this hyper-connected world, security attacks like WannaCry and Nyetya are a fact of life. It’s no longer a matter of if these attacks happen, but when,’ Smith concludes. •

lobally, there were more than most up to date trends in cyber threats from one million job openings in the around the world. It will provide necessary industry in 2016. Demand for cyber skills, knowledge and insights into some of security experts has grown three times the technology and expertise required to faster than any other IT role. A shortage fight the scourge of cyber crime. of cyber security professionals threatens ‘This is now the fourth most reported private and public sectors in the relentless economic crime in South Africa. Our evolution of cyber crime and shifting economy reportedly loses R1 billion each attack modes. year due to online criminal activities. Being Cisco – www.cisco.com The World Economic Forum, in its latest breached is the new normal,’ says Cathy paper entitled The Future of Jobs and Skills in Africa: Figure 1: Percentage of manufacturers that use Figure 2: Number of trained security personnel in manufacturing Preparing the Region for the solutions from six or more vendors organisations Fourth Industrial Revolution, Source: Cisco 2017 Security Capabilities Source: Cisco 2017 Security Capabilities Benchmark Study Benchmark Study states that many jobs in the region are becoming more intense in its use of digital technology. Average ICT intensity of jobs in South Africa increased by 26 per cent over the last decade, while 6.7 per cent of all employment in Ghana and 18.4 per cent in Kenya occurs in occupations with high ICT intensity. These trends provide both a challenge and an opportunity for South Africa and the continent. The centre is an immersive environment where public and private sector stakeholders will be exposed to some of the

February 2018 | Food Review

P L A N T S E C U R I T Y & S O F T WA R E

Analytics in a producer’s digital environment

New services modernise PLC operations

The Industrial Internet of Things (IIoT) has increased availability of information throughout the enterprise by orchestrating data from multiple sources and applying machinelearning applications.

Schneider Electric has launched a new service to help industrial manufacturers modernise its programmable logic control (PLC) systems easily, safely and cost-effectively.

Cloud-enabled analytics provide machine data organised in intuitive dashboards that pull from machines deployed across the globe

he power of new IIoT tools to improve machine performance is limited when those with access to information are not experts on the machine, leaving powerful machine information untapped. To better connect industrial producers with expertise outside their production environment, Rockwell Automation offers FactoryTalk Analytics for Machines cloud for OEMs. Cloud-enabled analytics provide machine data organised in intuitive dashboards that pull from machines deployed across the globe. ‘By bringing the expertise of OEMs into a producer’s ecosystem, smart machines perform better, and critical process anomalies can be quickly resolved,’ notes Christo Buys, business manager – control systems, sub-Saharan Africa, Rockwell Automation. ‘Cloudbased machine analytics give OEMs real-time and historical insights into how their equipment is operating from anywhere, so they can collaborate with customers to help reduce downtime.’ An IIoT-enabled packaging machine from Cama Group showcases the value of increased collaboration to both OEMs and end users. The machine offers independent cart technology for fast changeovers, while the FactoryTalk Analytics for Machines cloud relays critical KPI data to the cloud. Real-time performance insights are displayed to Cama Group service engineers in five, easy-tonavigate screens. A primary display shows a global map indicating every machine at all customer sites where the OEM has subscribed to the service. In addition to the display is summary information on machine status and recent OEE performance. A simple search function allows service engineers to filter by specific end users, locations or machine types for further analysis. At machine level, OEMs can view information about machine states, top events, production counts, cycle time attainment, custom process variables and counters for the last three months on pre-configured dashboards and drilldown screens. The system requires minimal setup from the OEM, and can be deployed and fully functional in a matter of minutes. •

Rockwell Automation – www.rockwellautomation.co.za

Food Review | February 2018

pgrading older or obsolete PLC systems increases safety, efficiency, reliability and profitability of a customer’s hybrid and process operations. This is the view of Nathalie Marcotte, senior vice president, industry services, Schneider Electric. ‘Our PLC modernisation service helps manufacturers to efficiently leverage Schneider Electric’s value-focused IIoT technology and expertise to gain better insight into its industrial operations. Upgrading to the Modicon M580 ePAC will empower their workforce to make better, accurate business decisions at the right time. This enables measurable improvements to operational profitability, safely and sustainably.’ Seamless migration combines a Unity M580 application converter with a migration expert configuration utility tool. This identifies operational gaps and provides recommendations to solve each customer’s unique systems challenges. The combination enables customers to easily convert Unity software applications on Quantum and Premium platforms to be compatible with the M580. It also provides the option of producing a pre-engineering proposal for the new M580 I/O. A quick wiring system for the TSX Premium processor allows upgrades to be completed in less than one hour.

INNOVATION CONTROLS OPERATIONAL PROFITABILITY ‘Today’s manufacturing pace, requires technology built for faster, more connected operations. Many customers rely on older, inefficient PLCs that are less reliable, have a higher total cost of ownership and leave operations vulnerable to new and emerging threats,’ Marcotte points out. ‘These services are the latest example of how we help our customers migrate to value-focused IIoT solutions via EcoStruxure Plant. Our open, interoperable, IoT-enabled system architecture and platform allows us to innovate at every level to improve the safety, reliability, efficiency and profitability of our customers’ operations in real time. It helps them convert their automation investments into the profit engine of their business.’ The Modicon M580 ePAC can help industrial manufacturers achieve better, earlier ROI and 100 per cent returns on their project investments in less than three months. Efficiencies gained with the Modicon M580 ePAC speed project execution and create better, more accurate and effective control over the plant’s operational profitability. •

OPERATIONAL BENEFITS • reduce time to market by up to 25 per cent • process energy consumption is reduced by up to 30 per cent • minimises the likelihood of cyber attacks • improves productivity of high-volume manufacturing applications by more than US$2 million annually • bottom-line performance of medium to large manufacturing facilities increased by at least US$1.3 million annually. Schneider Electric – www.schneider-electric.co.za

BeverageREVIEW SOUTH AFRICAN

February 2018 | Volume 8 | Number 2

www.foodreview.co.za

Seamless concepts in

HOT FILLING TECHNOLOGY

How to exponentially increase line efficiency Solutions for pH neutral and acidic beverages

NEWS

Sugar tax, not so sweet… THE TAX ON sugary beverages is expected to commence on 1 April 2018, but not everyone is happy with the development. The tax means that 2.1 cents per gramme of sugar will be levied on all sweetened beverages, with the first four grammes per 100ml exempt. It is estimated that the price of a beverage will increase by approximately 11 per cent. The tax is regarded as a duty at source and is payable in addition to any prescribed duties. New rules, in terms of the Customs and Excise Act, 1964 have been drafted to assist with its implementation. The South African Sugar Association (SASA) has stated that 3 129 jobs are immediately in jeopardy, with small-scale growers likely to go out of production first. SASA predicts that 20 000 direct jobs in coastal production regions could be shed in the next five to seven years. This is undesirable in a country where the unemployment rate is at 27.7 per cent - a 13 year high. Tax revenue, as described in the medium term budget policy statements, is projected to fall short of the 2017 budget estimate by R50.8 billion (the largest under-collection since 2009). Former president Jacob Zuma tasked the finance minister and presidential fiscal committee to find ways to add R15 billion to the nation’s revenue. It may be inaccurate to state that the primary reason for imposing sugar sax is to curb the spread of noncommunicable diseases, such as diabetes.

NEW TASTES in juice CONSUMERS STRIVE FOR healthy lifestyle and eating habits but are not ready to compromise on taste. Diana Food is pleased to announce the launch of a new generation of natural juice concentrates that offers a 100 per cent clean label. This unique solution is aimed at improving clients’ industrial performance thanks to competitive and sustainable innovation. It delivers a real taste signature, with no need

Optimised metering with Watson-Marlow

The contained pumphead design with integral leak detection reduces wastage and eliminates operator exposure to chemicals

THE NEW PUMP has been developed to offer highly accurate sodium hypochlorite metering in disinfection applications with flow rates up to 20ℓ per hour at a maximum of seven bar pressure. It is especially suitable for applications at well sites of smaller water treatment plants, where operators are often injecting into water lines at higher pressure. Qdos 20 features the same user-friendly interface and control options, ensuring that users have continuity with any existing Qdos applications. Offering low total cost of ownership, the new model is designed as a drop-in replacement for diaphragm pumps. Qdos pumps also include the ReNu pumphead for single, no-tools maintenance. Its intuitive interface provides simple control of the pump via manual, 4-20mA, contact or Profibus control. The brushless DC motor control maintains flow accuracy of +/- one per cent with a repeatability of +/-0.5 per cent and a turndown ratio of 3330:1. The pump is ideally suited to tight control for chlorine residual. Successful field

for other taste components. Only the best varieties of fresh vegetables are screened for their aromatic profiles. A team of agronomists ensure best sustainable farming practices and full traceability - from contaminant control to optimum harvesting time. To preserve intrinsic properties, cuttingedge technology, through gentle processes, ensures the original taste of vegetables are retained.

Beverage Review | February 2018

trials and SCADA data indicate a considerable improvement in variation of chlorine residual compared to even the highest specification diaphragm metering pumps. This is achieved via the twin offset rotor design. The Qdos 20 peristaltic pump technology uses two tube channels; where the channels are operated out of phase. Although peristaltic pumps are generally lower in pulsation than other positive displacement pumps, Qdos 20 reduces this pulsation even further by alternate tube compressions ensuring pulsation is balanced out. This results in almost continual positive fluid displacement, and consistent metering of chemical into the application. Process uptime is maximised by facilitating quick, safe and easy pumphead removal and replacement, with no need for tools, no specialist training and no maintenance technicians needed on site. The contained pumphead design with integral leak detection reduces wastage and eliminates operator exposure to chemicals.

NEWS

Sweeten naturally with Starleaf PURECIRCLE, A LEADING producer and innovator of great-tasting stevia sweeteners has announced it will vastly increase the amount of StarLeaf stevia it plants in 2018. The company aims to plant nearly 16 000t in 2018, an increase of about 200 per cent over the prior year. PureCircle’s StarLeaf is a proprietary non-GMO stevia plant that yields roughly 20 times more of the newest and best-tasting stevia leaf sweeteners than conventional stevia varieties. These stevia sweeteners make it far easier for food and beverage companies to deliver great-tasting, sugar-reduced and sugar-free products across a wide range of food and beverage categories. With the planned increases in planting, the company estimates that 80 per cent of the stevia plants it uses this year will be StarLeaf – likely increasing to 90 per cent next year. PureCircle utilises a wide and expanding global agricultural network

for its stevia supply, sourcing it from an increasing number of countries around the world. Part of the dramatic increase in StarLeaf planting this year is the result of new farming partnerships in the US. Some farmers are starting to use land that once grew tobacco, to grow StarLeaf plants. The food and beverage industry has seen a steady increase in product launches featuring stevia as an ingredient, as evidenced by the 10 per cent increase in 2017 as compared to 2016 according to Mintel. Since 2008, it has been utilised in more than 16 000 products globally. PureCircle’s research, development and innovation has enabled it to offer a range of stevia-based sweetener ingredients with sugar-like taste and zero calories. These from-nature

sweeteners, often used in combinations with each other, work well in a wide variety of beverages and food. Processors have an increasing need for such an ingredient, because consumers, health experts and governments are increasingly concerned about obesity and diabetes, while health and wellness conscious. PureCircle has developed solutions for food and beverage producers both to enhance their use of stevia for best taste and to simplify their work with stevia. PureCircle is supplied locally through Savannah Fine Chemicals.

{PureSweetness}

Discover your next taste breakthrough with StarLeaf stevia TM

www.savannah.co.za Savannah.indd 1

2018/02/08 11:46 AM

February 2018 | Beverage Review

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

Hot-filling of fruit-chunk products Krones’ seamless concept covers process and filling technologies for producing and bottling beverages that contain fruit chunks and fruit fibres. The twin-flow concept is ideally used during process engineering for highly sensitive beverages with a high fruit-cell content. By Stefan Pöschl

hen filling juice consisting of sacs, fibres, fruit chunks or pulp it is important that juice is separated from the actual fruit content. This happens during process engineering for thermal treatment and in further downstream filling technology. In hot-fill applications, Krones uses a pre-dosing filler for fruit content before filling the carousel. The goal of the filling process is to run hot pre-dosing into containers with a 38mm mouth. This process can accommodate fruit-fibre or a fruit-chunk mixture with a fruit content of around 50 per cent in chunks measuring up to 10x10x10mm in size, plus 50 per cent juice, before the actual free-jet hot-filler. Until recently, piston fillers were used for this FlexiFruit rounds off the twin-flow concept

Beverage Review | February 2018

purpose. These products are often not hygienic enough as they must be partially dismantled for cleaning. Post-dripping, plus uncontrolled emptying of the filling tubes, will ultimately lead to droplets on the neck finish. This will impair accuracy of the dosing function. Krones wanted to develop a simple, hygienic system that’s easy to clean, doesn’t drip after dosing and operates at least as accurately as a piston filler.

PRE-DOSING WITH DIAPHRAGM VALVES During the research and development stage, the decision was taken to opt for a solution featuring diaphragm valves. The great advantage is that when these valves close they displace the product from the sealing gap, minimising damage. Laboratory tests have proven that even highly sensitive mandarin sacs (required to remain completely intact after filling) suffer little damage. A second diaphragm valve serves to circulate the product and keep it hot. The dosing function for the part with fruit chunks is timecontrolled. Filling parameters are autonomously determined during routine setup for new products. These parameters are automatically stored in memory for each variant. To ensure no product is lost through postdripping, remaining quantities are emptied into bottles using sterile air. Where a filler is rated at 36 000 containers an hour, the pre-dosing starwheel features

40 filling valves. This enables a pure treatment time of 2.8 seconds for the fruit content. The star wheel is a Monotec design, engineered for optimum hygiene and features a servodrive. FlexiFruit’s pre-dosing filler can be retrofitted into existing hot-fill lines, and is suitable for handling large particle sizes and products of very high viscosity. It provides high filling accuracy and is amenable to CIP/ SIP procedures. If pure juice without any fruit chunks is being bottled, the predosing filler is decoupled.

PRODUCT HOMOGENEITY ASSURED A vital aspect during fruit dosing is product homogeneity. Filling accuracy for fruit content in the end-product depends closely on homogeneity and fruit consistency. This can be influenced significantly and by fast-rising or falling particles or inadequate deaeration. To assure requisite homogeneity, a tank is provided nearby, with an agitator. From this tank, product flows through appropriately dimensioned pipes via a manifold to a valve support construction featuring an annular channel. Thanks to careful design of the cross-sectional areas, product is kept in continuous motion. This negates product separation, often observed in large tanks.

DOWNSTREAM JUICE FILLING WITH A WEIGHING-CELL FILLER One of the system’s major advantages is that the dosing filler doesn’t need an additional measuring instrument. The entire fill quantity is measured in the downstream weighing-cell filler, where juice without fruit cells is bottled. Juice quantity depends on the amount of fruit content involved, which is continually optimised during the production run.

USER-FRIENDLY MAINTENANCE In comparison to a piston filler, designers chose a very lightweight construction, since forces acting on the carousel are not nearly as high as with a piston-type model. Operator-friendly maintenance was also a priority. The complete unit, comprising dosing block and lifting unit, can be removed from the filler by simply unscrewing two bolts. This unit can be overhauled in a workshop, while the filler continues to operate with the replacement valve. By developing the FlexiFruit pre-dosing system, Krones has successfully closed the circuit required for holistically gentle production of beverages with a fruitchunk content. •

Krones – www.krones.com

50% L SS P CK G NG IS STILL 50% TOO MUCH.

The KHS solution for more sustainability: New avenues in packaging technology. We are continuously improving our packaging. By applying innovative technologies and switching over to mono-material packaging we have halved our packing materials over the last ďŹ ve years. And we are soon to take another big step forward in using new, thinner types of ďŹ lm. www.khs.com

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

Real gain efficiencies

The installation of a complete end-of-line solution for Coca-Cola Bottling in Indonesia, has increased line efficiency by 50 per cent.

ounded in 1992, Coca-Cola Amatil Indonesia produces carbonated soft drinks, still beverages (juices, teas, isotonic drinks and water) and energy drinks in various packaging formats and sizes. Carbonated soft drinks, tea and juice are bottled in PET and tea in plastic cups. These cups represent the ultimate onthe-go format. It is convenient for a busy lifestyle - usually drunk in the street - and ideally priced for those consumers on low to middle incomes. The original line, built with equipment from a variety of different suppliers, featured manual palletising at its end-ofline. This was causing congestion, safety and labour-management issues. ‘It’s quite hot and difficult work,’ explains Grant McClean, technical manager for Capital Projects. ‘There are challenges in making sure that the work can be done safely.’ The company started searching for an automatic palletising solution that could enable a continuous production line with more efficient use of labour. Working closely with the team at the customer’s site, Gebo Cermex engineers designed a new automatic palletising solution tailored to Cikedokan’s needs. These comprised layer-by-layer palletisers, pallet conveyors and a stretch wrapper

Beverage Review | February 2018

to cover loaded pallets. The goal was to accommodate the production line to deliver 3 600 cases per hour. A system of three small palletisers, one from each packing area, connected with an unmanned shuttle-car system was the most economical and operationally efficient end-of-line solution. The shuttle-car was part of the plan proposed by Gebo Cermex, which reduced the traffic of forklift trucks, increasing site safety. Three palletisers supplied by 1 to 5

The new automated pallet system can move up to 3 600 cases per hour

Gebo Cermex are U-shaped with empty pallet infeeds and full-pallet outfeeds on the same side of the machine. The shuttlecar system continuously takes the loaded pallets to a pallet conveyor. The pallets are then stretch-wrapped before being taken to waiting forklift trucks and taken away for dispatch to the company’s warehouses. On its return journey, the shuttle-car system supplies empty pallets to the palletisers. Together with optimised efficiency and higher OEE (overall equipment effectiveness), this solution allows for a much better management of the labour force. The team at the Cikedokan plant has a more organised and efficient production line, which can run continuously and uses space in a smarter way.

RESULTS EXCEED EXPECTATIONS McClean underlines, ‘Within a few weeks of the installation, we conducted a test. The machinery exceeded standards for acceptance that we had set at the start of the project by a large margin. During operation, we’ve seen absolutely no decline in the efficiency of the equipment from the day of that test.’ Since implementation of the solution, the plant has seen a 50 per cent increase in efficiency and higher OEE. ‘One of our aims is to pursue a strategy of lean manufacturing. Our Cikedokan plant is like a pilot plant: it’s where we test our ideas for lean manufacturing and perfect them - before implementing them in other plants. The end-of-line solution that we chose from Gebo Cermex had to fit in with our lean-manufacturing strategy. ‘The company provided us with a good solution, good layout design and good quality of equipment. Spare part support, after-sales technical advice for maintenance and problem solving on the equipment is very important,’ McClean concludes. •

Gebo Cermex – www.gebocermex.com

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

Aseptic bottle packaging

is a reality

Serac has combined a PET linear blower (SBL) with a rotary weight filling machine in a single unit. By the end of 2017, around 15 Combox units were installed in Europe, North- and South America and Asia.

he Combox is also available in an aseptic version. It provides new opportunities in the dairy and beverages industry by offering low and medium work-rate solutions for applications using pH neutral and acidic products. Volumes of up to 12 000 PET bottles per hour for one litre formats and up to 18 000 PET bottles per hour for smaller 250ml formats are possible. The aseptic filling market currently offers a very limited choice of medium work-rate integrated filling lines. With Aseptic Combox, Serac now offers a single-unit, blowing-filling solution for medium work-rate lines.

THE IDEAL SOLUTION Bottles play an important role in the long conservation products market, particularly small and medium size formats (white, flavoured or supplemented milks, vegetable milks, baby milks, nutritional drinks, fruit juices). Packaging of beverages in small bottles, outside the cold chain, is perfectly adapted to the needs of nomad consumption (at school, in sport halls, the office) with resealable and easy-to-hold bottles. By investing in the Aseptic Combox, manufacturers give themselves the opportunity to get on board with this trend, taking advantage of new market opportunities. The range of products can rapidly expand thanks to the use of a

production tool offering high performance and flexibility: • Positive and direct transfer of containers by the neck between the blower and the filling machine limits the risk of container contamination and reduces investment costs • No open-air conveyor results in a more compact and reliable system (reduced dimensions). It also results in less risk of blockages • A single operator for the entire blowingfilling unit (both HMI control panels are on the same support, improving user friendliness) • H2O 2 decontamination of containers reduces the risk of re-contamination just before filling • An extremely flexible system with fast, easy and risk free change of container format. As the blower is located outside the sterile

zone, there is no risk of re-contamination when changing the forming mould. The change of tooling at the filling machine exit also takes place outside the sterile zone • Safe and easy maintenance with easier access points outside the isolator. The Aseptic Combox solution incorporates the SAS 5 filling machine, which meets the strictest requirements for sensitive products. Equipment is available on the market where the containers (bottles and caps) are sterilised as standard with hydrogen peroxide (H2O 2). Serac will soon be launching the Aseptic Combox where container decontamination is carried out by e-beam. This is thanks to its latest sterilisation module known as βluStream. •

Serac – www.serac-group.com

Combox is turning what we know of aseptic dairy and beverage processing on its head

SMART PACKAGING SOLUTIONS For your dairy product innovation

Discover us at

www.dairy-packaging-machines.com www.serac-group.com

February 2018 | Beverage Review

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

Beat the

beverage nemesis Implementing heat treatment during beverage processing is a critical aspect. It ensures nutritional quality is not lost during heating and packaging. It also assists in attaining correct shelf life. By Penny Ntuli

ir can degrade juice quality during filling. It can also lead to foaming during de-aeration, causing uneven pulp distribution in packages. Air aids microbial growth, which could lead to yeast and mould growth. This spoils products and promotes the spread of harmful pathogens. It is essential to remove all air from the processing and package filling wherever possible. To assist further, flash heating is implemented to destroy many of the pathogens found in beverages. An example is orange juice. The product must be heated to a higher temperature than other products to inactivate enzymes, compared with lower temperatures for pathogenic microorganisms. There are five main factors that influence the quality of juice: • Raw material and how it is processed • Temperature and time stored • Level of hygiene achieved during packaging • How well packaging protects the contents from air and sunlight • At what temperature the final product is stored either in warehouses or on shelves. The health halo is a major part of why consumers drink juice, particularly orange juice. It’s comforting to know that the flash heating process ultimately has little impact on the vitamin C content of the product. Even when it is heated for the longest period of 30 seconds at the highest temperature of 105C° it’s proven to only lose 2.3 per cent of its vitamin C content. It’s only after processing, during storage that orange juice loses the greatest amount. It is estimated that as much as 20 per cent can be lost if it is incorrectly stored or if packaging is used allowing oxygen or other

Beverage Review | February 2018

FLEXIBLE PRODUCTION MEETS CONSUMER EXPECTATION

contaminants to breach the pack. Packaging is pivotal to sustaining juice quality. Today, good health and environmental concerns are close cousins for consumers. Juice is processed from the beginning to the end of a season, during which fruits change flavour. Juice producers process fruit throughout the season then store the juice and mix different batches to get a consistent taste. There are two ways to store juice: by freezing and by aseptic process. Freezing maintains nutritional and taste qualities as does the aseptic process (juice is processed and stored in an airfree environment). Primary advantages of aseptic over freeze storage is that it uses less power to maintain. Product can be stored at a warmer temperature and the product doesn’t have to thaw when it’s mixed for packaging. Frozen product must be thawed quickly, since longer product exposures degrade its nutritional qualities. Quick thawing is an energy-intensive process as it is stored at freezing point. The aseptic process uses less energy – important in a country like ours with rising energy costs and water availability. Processing and storing juice and other liquid and solid food products is a complex undertaking. Each different category has its own quirks and requirements. Today there are safe, hygienic, and healthy solutions for health conscious and environmentally sensitive consumers, such as the aseptic long life process used for milk and juices. •

Tetra Pak – www.tetrapak.com

PENNY NTULI is the

communications director of Tetra Park in South Africa.

SIDEL HAS INTRODUCED the versatile Aseptic Combi Predis, a new solution that produces still beverages and carbonated soft drinks in PET bottles aseptically. This system results in a high degree of production flexibility and productivity, while contributing to reduced cost and lower environmental impact. The industry is seeing increased requirements for refrigerated and ambient drinks with natural, preservative free recipes. This solution produces a variety of products efficiently, with increased flexibility, reliability and product integrity. Guillaume Rolland, sensitive products vice president at Sidel explains. ‘This version benefits from all the practical advantages of the Sidel Aseptic Combi Predis platform. The system has received Food and Drug Administration approval and is validated for low acid manufacturing and commercial distribution in the US market.’ ENHANCED, FLEXIBLE ASEPTIC PRODUCTION The system is suitable for high and lowacid sensitive beverages (teas, juices, UHT white milk, soya milk, etc.), in PET bottle formats from 200ml to two litres. It also strengthens aseptic production flexibility to handle still and carbonated soft drinks, with or without pulp and with more natural and preservative-free recipes. The same filling valve handles all types of sensitive beverages aseptically. There is no need for changeovers. Filling configurations can be adapted to main production performance factors required by beverage producers with two different filling valve variants. Aseptic Combi Predis can be equipped with the new Capdis Multilanes, the dry cap sterilisation system. The system handles multiple cap designs (flat and sport caps) in diameters from 28 to 38mm with no need for manual changeover. This enlarges the capability to manage a wide range of stock keeping units. • Sidel – www.sidel.com

PackagingREVIEW SOUTH AFRICAN

February 2018 | Volume 43 | Number 2

www.foodreview.co.za

Explore energy efficient vacuum technology Quality assurances with MAP

Safer recycling for food safe cartons and boards

NEWS

Mapping a route to freshness

ICROBIOLOGICAL ORGANISMS AND biochemical reactions can cause food spoilage. With the fast pace of consumers’ lifestyles, great importance is placed on unadulterated taste and longer shelf life of food products. To satisfy these needs, industry has developed reliable techniques such as modified atmosphere packaging (MAP). This serves as a more natural way to protect perishable products against spoilage. In this edition, the focus is on modern technology to measure gas compositions in MAP. Undoubtedly, gases used in this method of packaging are crucial to the application’s success. On page 36 PACKAGING REVIEW goes behind the scenes at a new facility established primarily for the development of new products and machines for MAP packs. You can also stay abreast of the latest carton and board developments, featured on page 40. Until next month.

Assistant Editor Aarifah.Nosarka@newmediapub.co.za

Representatives of the Global Plastics Alliance

Growth in leaps and bounds A NUMBER OF representatives of the Global Plastics Alliance (GPA) gathered in Penang, Malaysia from 13 to 15 December 2017 as guests of the Malaysian Plastic Manufacturers Association. The congregation was met with a view on how to accelerate and advance The Declaration of the Global Plastics Associations for Solutions on Marine Litter, is also known as the ‘Joint Declaration’. Plastics|SA’s sustainability director, Douw Steyn says more than 19 countries from across four continents are currently participating in this joint initiative. These include Canada, India, Japan, Malaysia, Russia, South Africa, Thailand, Turkey, Vietnam, Colombia, the US and Europe. ‘Marine litter is a complex problem that requires creative thinking and a holistic approach. There is no single solution. It is therefore important to hear different perspectives on issues facing industry. It was hugely encouraging to see so many plastic manufacturers from across the globe come together. The objective? Finding ways to keep used plastic out of the environment and further improve the sustainability of these energy and resource efficient materials,’ Steyn adds. Africa’s voice in these matters is represented by Plastics|SA and Packaging SA, which recently became signatories. ‘We have launched various successful clean-up and recycle initiatives, such as our annual International Coastal Clean-Ups, Operation Clean Sweep, sponsoring litter booms and initiatives such as the Aqua Amazing schools education programme as part of our commitment to reducing plastics litter in the environment,’ he concludes.

Packaging Review | February 2018

Craft beer makes headway in France

A RECENT EUROMONITOR report indicates craft beer was the most dynamic category in France in 2016. This is set to continue as French consumers increasingly seek a wider selection of beers from around the world. As a result, enterprising retailers have taken up the challenge of meeting this demand. One example is Neodif, a French beverage retailer based near Nantes. The company specialises in foreign beer distribution. The owner developed a relationship with American brewer Noble Rey in Texas and ultimately signed an exclusive agreement with rights to produce, fill and sell the brand’s beers in France and potentially other locations in Europe. After a decision to package the beers in cans, Neodif partnered with Brasserie Duyck and Crown Bevcan Europe and the Middle East to develop stand out designs that would appeal to consumers on-shelf and provide true differentiation from the competition. The finished product, named ‘Sex in a Can’, features a fiery redheaded, mermaid-inspired figure blowing a kiss to potential consumers from a contrasting aquamarine coloured background. ‘The team at Crown’s Leicester studio were highly professional throughout the design process and really opened our eyes about what can be achieved using metal packaging. It was an enlightening experience that will enable us to explore new looks and finishes going forward as we bring craft beer to the people of France,’ explains Gildas Hays, MD at Neodif.

NEWS

Pyrotec’s management team

Restructure strengthens markets PYROTECHNICAL MARKETING (PYROTEC), which includes Tower, PackMedia and PackMark brands, has been operating as one company for the past 50 years. In the last two years, the PackVerifi, Pyrotec Finance and PackLink brands have been added to the company’s service offering. ‘These new brands relate to PackMark and PackMedia, which both service industrial sectors. While Tower incorporates office and hardware products, kids and signage

ranges and MyTowerLabels. It serves completely different industries – retail and commercial customers,’ says Rowan Beattie, Pyrotec’s MD. Beattie says Tower will be separated from the Pyrotec brands to enable each company to focus on its strengths and continue to grow within its markets. The brand will move to new facilities with its ownership and leadership in the hands of MD, Stephen Beattie and his current team.

Tower is dedicated to supplying self-adhesive labels. For the Pyrotec brands – PackMedia, PackMark, PackVerifi, Pyrotec Finance and PackLink – it’s business as usual. With their relevant teams, both GMs Timothy Beattie and Brandon Pearce continue to head up PackMedia and PackMark respectively.

Extensive solutions on display ISHIDA EUROPE WILL be highlighting key offerings at this year’s Foodex, from 16 to 18 April in Birmingham, UK. The company aims to showcase a number of offerings to indicate its ability to devise complete food packing line offerings covering weighing, sealing and quality control. There will be a special focus on its mid-range high performance RVE series. Additional models on show will include a specialist Fresh Food Weigher (FFW) that accurately weighs fresh and sticky products, an IX X-ray inspection system and DACS-GN checkweigher. Ishida’s new CCW-RV-E-214W multihead weigher is ideally used for weighing free-flowing and semi-sticky products for mass amounts of dry, fresh and frozen food applications. Its six-head CCW-R2-106B FFW is designed for smaller production batches. With this technology, a conveyor belt typically delivers products to the top of the weigher. An operator then distributes products via six belt feeders to the weigh hoppers to ensure an even distribution. This helps increase the speed and efficiency of the weighing process. Ishida Europe invites to all show attendees to visit its stand at the food processing, packaging and ingredients event.

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February 2018 | Packaging Review

M A P & VAC U U M PAC K AG I N G

NIP FOOD BACTERIA in the bud

Modified Atmosphere Packaging (MAP) is well established in the food industry and continues to gain in importance. PACKAGING REVIEW provides insight into what’s happening in the MAP and vacuum packaging sectors.

he standards required by MAP are comparatively high and have to be controlled and monitored to ensure safety. Food manufacturers, therefore, rely on modern MAP gas technology and various levels of quality assurance for maximum process safety. Sourced from HTK in Germany, AtmoCheck One and its ‘sister’ technology, the AtmoCheck Two are available locally from Artic Driers International. These solutions are great for measuring the gas composition in sealed packaging to ensure product freshness. AtmoCheck One is a practical

Packaging Review | February 2018

hand-held, battery operated oxygen/nitrogen analyser for random sample checking and measurement of residual oxygen and nitrogen levels in gas-treated food packaging. It is a fast, accurate mobile checking device that can be used at a packaging machine, in a warehouse or a laboratory. It is easy to operate, has short measuring times and low gas volume sample requirements. The integrated data logger supports traceability and provides complete

BENEFITS OF MAP PACKAGING: • fewer preservatives • appealing package design • influence on product quality • chemical and biochemical spoilage • reductions in microbial spoilage.

documentation (HACCP/IFS/ISO). This technology’s software has uncomplicated communications. It also has functionality to convert handwritten measurements to electronic records. Electronic measurement records are also exportable to excel documents.

A NEW FACILITY FOR ULMA The AtmoCheck One

The Guipuzcoan cooperative, which belongs to the ULMA group, has moved

M A P & VAC U U M PAC K AG I N G

“We have cemented our relationships and contracts with our top barrier packaging film suppliers such as Bemis Europe and Allfo/ Allvac Germany” client offerings. These will include barrier packaging solutions for food products, which protect valuable contents, extended shelf-life and the avoidance of unnecessary bacteria growth of all strains. ‘Supported by our BRC approved facility and years of service in this industry, our clients will benefit from our expertise and our international network.’ It is a myth that carbon Last year the company secured the sole South African monoxide in meat distribution rights for BOSS Vacuum, a manufacturer of The Goribar facility packaging extends the chamber vacuum packaging equipment for all forms of normal shelf life of barrier pouches. The company also supplies equipment red meat. the manufacturing activity of its traysealing from small table top systems to fully automatic, in-line machines to a recently opened plant in the Goribar vacuum- and shrink lines. neighbourhood in Oñati (Gipuzkoa). The facility Schiess says after the upcoming Anuga Foodtec event set to comprises a 5 000m2 spread over two floors. It can be expanded in take place in March in Cologne, Germany, the company will be able to future to incorporate an adjoining 4 000m2. welcome world renowned manufacturers of high quality thermoforming and The new plant offers a production capacity of approximately flow-pack systems. This will be added to its portfolio of brands. 400 machines per year with the option of future expansion. ‘This will complement our endeavour to be an expert supplier of all major ‘Expansion can take place because of an annex building forms of barrier packaging solutions, offering clients a final product, which situated close to the plant that has already been acquired. When was designed, sourced, processed and packed with integrity on a system expansion takes place this will double the current capacity,’ serviced by experience,’ Schiess concludes. • explains Eddie Rademan, MD at ULMA Packaging in South Africa. He says the group has a plant in Garibai, just a few metres from Artic Driers International – www.articdriers.co.za Geiger & Klotzbücher – www.g-k.co.za the new facility. Ulma Packaging – www.ulmapackaging.com ‘ULMA’s strategy for traysealing machinery for the last few years has been focused on product development, speed improvement, reliability and efficiency. The new product range has been received very well in the market, which meant strong growth in terms of sales and the need for higher production capacity.’ Lean production principles have been implemented on these production lines. This was based on a management model focused on the creation of a production flow that offers maximum value to customers using the minimum resources necessary. AtmoCheck® ONE is a All of this has been achieved by applying the most innovative practical battery-operated technologies in terms of sustainability, energy consumption that oxygen analyser for random results in an energy efficient plant. sample checking and The construction and transfer of this plant was completed in a measurement of residual record time of less than a year. oxygen levels in gas-treated According to Rademan, the new facility has provided a solution food packaging (MAP). to the growth in traysealing sales. ‘It also provides space for the AtmoCheck® ONE excels growth of the flowpacking and thermoforming lines at the Garibai with easy operation, plant and represents a competitive improvement for ULMA short measuring times Packaging’s entire business.’

DID YOU KNOW?

ATMOCHECK® ONE

and low gas volume sample requirement.

GEIGER & KLOTZBÜCHER CEMENTS ITS PORTFOLIO In recent months the company has re-aligned its product portfolio on equipment and materials more intensely towards packaging solutions. Christian Schiess, sales manager at the company says casings and the related equipment will remain a stronghold of the company. ‘We realised there are only very few suppliers in highbarrier packaging technologies that offer a one-stop solution, top level equipment and materials sourced from the world’s leading suppliers of flexible barrier packaging.’ Geiger & Klotzbücher has dedicated itself to focusing more exclusively on the product ranges listed above. ‘We have cemented our relationships and contracts with our top barrier packaging film suppliers such as Bemis Europe and Allfo/Allvac Germany. We are confident that with their know-how and development technologies we will be able to extend our

Arctic Driers.indd 1

The AtmoCheck® ONE software permits fast, uncomplicated communication and is safe and easy to use.

Call now for details & availability

+27 (0)11 420 0274 • www.arcticdriers.co.za Since 1991

February 2018 | Packaging Review

2018/02/14 8:24 AM

M A P & VAC U U M PAC K AG I N G

Why choose energy-efficient vacuum technology? An advanced meat processing company in Switzerland implemented Busch Vacuum Pumps’ centralised, automatic vacuum packaging system. PACKAGING REVIEW explores the benefits the system provides to the company.

uttero Bazenheid, an Ernst Stutter company, processes beef, veal and pork and supplies it to other companies for wholesale and retail sale. The facility commenced operations in 2012. It was built following the ‘Minergie’ standard. This means it complies with strict regulations for sustainable construction. It has a photovoltaic system installed on the roof to enable environmentally friendly energy generation, with solar power being fed into the local public network. Energy for the entire Ernst Sutter and Suttero Bazenheid premises is generated from hydropower. Around 75 per cent of the energy from refrigeration is also used to generate hot water. Suttero Bazenheid relies on a centralised vacuum system from Busch to create vacuum packaging. This is significantly more energy efficient in operation than decentralised vacuum supplies on individual packaging machines. Ernst Sutter has created a production plant that corresponds to the latest standards, both from a technical and ecological perspective. Products being packaged at the Sutter Bazenheid facility

The raw ingredients, mostly comprising pork and beef cuts, are predominantly procured from the nearby Bazenheid abattoir or Gossau. The pork and beef cuts are placed into cold rooms and separated by animal type.

THE SYSTEM IMPLEMENTED

The vacuum packaging technology for the facility is generated by a centralised vacuum system as this represents the most energy efficient type of vacuum generation. Fewer vacuum pumps are needed for a centralised vacuum supply than would be necessary for decentralised vacuum generation. Busch’s centralised vacuum system supplies the tray sealer packaging machines with three independent ring lines. A rough vacuum of 50 millibars is constantly kept available in one of these. A vacuum accumulator guarantees that the required level is permanently and readily available. In a second ring line, there is a medium vacuum of four. If packages are evacuated, this initially only takes place up to the rough vacuum level. Once this is complete, a valve switches to ‘medium vacuum’ and final evacuation to four millibars of ultimate pressure is performed. This control ensures the packaging chamber and packs can be evacuated quickly and reliably before being closed, enabling very short cycles. Because central vacuum It provides the forming supplies have modular stations in the packaging designs, individual lines with what is referred modules can be to as a forming vacuum of 100 disengaged for maintenance. millibars. This is used to pull the heated plastic film into shape. The centralised vacuum system is controlled on a demand-driven basis in such a way that the required pressures are automatically kept available in all three ring lines. The only vacuum pumps in operation are the ones that are actually needed. Busch planned and implemented the centralised vacuum system in such a way that it was tailored according to the technical conditions at Suttero Bazenheid. The

DID YOU KNOW?

Packaging Review | February 2018

system consists of several vacuum modules for rough, medium and forming vacuums. There is also a reserve unit. This enables maintenance work to be performed during on-going operations. Individual vacuum modules are released for maintenance in this process. To enable this, the reserve module is automatically switched on. This also has the advantage that no service personnel need to enter the hygiene-sensitive packaging and processing area for maintenance work.

MECHANISMS DRIVING PERFORMANCE The key components of this centralised vacuum system are the R 5 rotary vane vacuum pumps and Panda vacuum boosters. With this combination, the pumping speed and ultimate pressure of the system are significantly increased. Lower energy consumption is required compared to using larger vacuum pumps with comparable performance. The demand driven control is programmed in such a way that all vacuum pumps reach the same number of operating hours, despite the fact that generally not all vacuum pumps are operated at the same time. In contrast to the decentralised installation of vacuum pumps directly in the packaging machines, where they usually run through, this has the advantage that fewer operating hours are incurred overall for each vacuum pump. The result is the extension of service intervals, which are organised in such a way that a visual check of oil levels is performed once a month. This is followed by an oil change and filter replacement, which is conducted during the annual maintenance process. Busch Vacuum Pumps and Systems Africa in Johannesburg, with branches in Cape Town and Durban can supply most pumps and blowers. It is equipped to service and overhaul pumps in its workshop and to carry out service work and commissioning at a customer’s site. •

Busch Vacuum Pumps and Sysems – www.busch.co.za

Worldwide No. 1 in Vacuum Packaging Discover the wide range of options for using vacuum in food packaging production and processes. We offer dry-running and oil lubricated vacuum pumps, liquid ring vacuum pumps, blowers, full service and repairs.

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Busch Vacuum South Africa (Pty.) Ltd. 87 Mimetes Road | Denver, Johannesburg Phone: +27 11 856 0650 | info@busch.co.za l www.busch.co.za

C A R T O N & B OA R D

More food,

more packaging

PACKAGING REVIEW looks at how upcycling recycled products can result in less waste. Potential uses such as food safe packaging, demonstrated by the recently launched ecobarrier paperboard puts the goal of ‘better with less’ packaging within our grasp.

pact has put into action its commitment to reducing the volume of carton packaging ending up in landfill sites by investing in a firstof-its-kind recycling plant in the southern hemisphere. Godfrey Zwane, Mpact’s Springs pulp mill manager discusses the details of the recycling facility’s operations and expected outcomes. The R46 million plant officially opened last July at Mpact’s paper mill in Springs. ‘What makes the facility unique is the technology being used to separate fibres and cartons from plastics and foils, which have not been used before in the country. A high density pulping system has been imported. When making use of the technology, a little water is added to the system. This is done at a ratio of between 12 to 18 per cent concentration of liquid. Heat is then used to separate the fibre from packs, which uses low intensity pulping,

Eco-barrier paperboard by Metsä Board

Packaging Review | February 2018

which means less energy is used during the separation of fibres. Mpact has different divisions that collect all recyclable liquid packaging materials for the company’s plant. Materials are recovered and sent to a mill before they are compacted into rectangular 3D shapes, then processed into bales and tied. After these bales are transported to the facility, they are sorted into different streams and loaded onto a conveyor belt system. Thereafter materials are placed into a hydropulper where chemicals are added. The materials and chemicals are mixed together in an effort to separate them. There are different screening stages to remove impure particulates from packaging. The stages include the removal of particles less than 20mm in size and larger than 1.8 millimetres sized particles. The result is a clean fibre material that can be used to create packaging boards. The facility uses about 12 to 18 000t of other recyclable paper such as white office paper and cardboard boxes. Cartons are also recycled to produce paper. These cartons are mixed with the rest of the recyclable materials. Although about 20 to 25 per cent of recyclable packaging reaches landfill, Mpact has set out an objective to avoid this happening in future. The organisation has partnered with Tetra Pak and other waste management partners to investigate additional uses for the materials produced.

A FOUNDATION FOR SUCCESS Metsä Board offers a range of foodservice boards. This includes coated boards for superb printability and brand consistency. There are also uncoated boards for a more natural finish, which is becoming increasingly popular. These boards are ideal for safer packaging in direct contact with food. They provide good protection and presentation qualities. Full traceability of the paperboard is essential for the food packaging sector, as safe food is one of the greatest necessities of everyday life. Metsä Board uses pure fresh fibres with a strictly controlled production process, which provides full traceability of all raw materials. Based on an estimate by the UN, the world population is expected to reach 9.8 billion in 2050, with over 65 per cent of people living in cities. This means more food consumption and more packaging. High-density populations require smart solutions for delivering, reusing and recycling packaging. The company is

Metsä Board’s products are ideal for food safe packaging

currently working with packaging designers and students to help promote a theme of ‘better with less’. Making innovation the key to creating better consumer experience with less impact on the environment. The company recently launched an international competition called the ‘better with less design challenge’. This involves Metsä Board working with packaging designers and students to help promote the ‘better with less’ approach. It is aimed at making innovation the key to creating a better consumer experience with less impact on the environment. The competition aims to inspire packaging designers and students to find new packaging solutions for frequently used and fast-growing types of consumer packs. Metsä Board created an eco-barrier paperboard called MetsaBoard Pro FSB EB1. It is a bio-based product described as recyclable and biodegradable. It has been specifically designed for “food on the go” applications such as sandwich, filled baguette and chip packaging where only ‘light’ grease resistance is needed. The barrier properties for this type of packaging are usually created by means of varnishing it at the printer. In this instance, the product comprises a prebarrier coating which means its varnishing layers and varnish application time and costs are reduced. ‘Sustainability targets and actions should be initiated and driven by the company’s top management. Sustainability and cost savings can go hand in hand. Efficient water usage often results in savings in energy as well as in costs. •

Metsä Board– www.metsaboard.com Mpact– www.mpactrecycling.co.za

Coffee time

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Carla Melless

Sales executive +27 (0)83 260 6060

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

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ADVERTISERS’ INDEX FEBRUARY 2018 Artic Driers.........................................................37......www.articdriers.co.za Brenntag South Africa..................................... 20......www.brenntag.com Busch Vacuum SA............................................ 39......www.busch.co.za Creative Flavors International ....................OFC......www.creativeflavors.co.za Danlink Ingredients .........................................15......www.danlink.com Eptech Products.................................................41......www.eptech.co.za Fried International Imports..............................35......www.fii.co.za Firmenich............................................................21......www.firmenich.com Geiger & Klotzbucher....................................... 36......www.g-k.co.za Heat & Control..................................... 10, 11, IBC......www.heatandcontrol.com Ishida Europe.....................................................19......www.ishidaeurope.com

K-Chem................................................................18......www.prova.fr KHS Manufacturing SA .................................. 29......www.khs.com Nutri Pharma Solutions.....................................17......www.nutripharmasolutions.com Savannah Fine Chemicals.......................... 13,27......www.savannah.co.za Sensetek............................................................. 22......www.sensetek.co.za Serac-Group........................................................31......www.serac-group.com Symrise .......................................................... OBC......www.symrise.com Syspro ...................................................................7......www.syspro.com ULMA Packaging Systems SA..........................5......www.ulmapackaging.com Wild Flavors & Specialty Ingredients.......... IFC......www.wildflavors.com

February 2018 | Food Review

WEB REVIEW HOME

NEWS

ABOUT

C O N TA C T

METROHM SOUTH AFRICA Metrohm SA is a subsidiary of Metrohm AG, a leading Swiss company. We are a regional support centre for all sub-Saharan countries, including Mauritius and Madagascar. We are proud suppliers of Swiss-made analytical solutions that greatly enhance the output, efficiency and reliability of your labs and processes. Our products are widely used in the environmental, pharmaceutical, food, mining, electroplating, petrochemical and water treatment industries as well as tertiary institutions for teaching and research.

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

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

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

DINNERMATES

FLAVOUROME

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

Flavourome provides our clients

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

formulating services in our fully equipped labs, as well as blending

within the food, beverage and health industries with innovative products, solutions and ideas. We are partnered with Firmenich and thus supply the world’s best flavours. Our state of the art facilities allow us to manufacture, blend and supply various, food colours, sweetener blends, juice compounds, cloudifiers, emulsions, health ingredients and Tea extracts. We also provide services in our powder and liquid facilities, offering our clients a unique and competitive edge.

www.flavourome.co.za

FORMPAK

KHS

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

The KHS Group is one of the leading manufacturers of innovative filling and packaging systems for the beverage, food and non-food industries. The group has an international production and service network.

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

We are the leading provider of hygiene, food safety and PARTNER für HYGIENE und TECHNOLOGIE PARTNER for HYGIENE and TECHNOLOGY technology solutions for food and beverage companies of any size. We will help you with design of your food processing plant to comply with hygiene and technology equipment you need for your food processing plant. We will supply you with the knowledge, service and expertise you need. Tel: +27 (0)86 1777 993 Email: info@pht.co.za www.pht.co.za

www.khs.com

QUANTUM COLOURS SA Your No. 1 industry leader for the most comprehensive ranges of both synthetic and natural colours – used in food, pharmaceutical, cosmetic and industrial applications. Our technical team is available to shade and colour match to specific requirements and / or Pantone references and to give legislative support on colours. www.quantumcolours.co.za

Innovation In Action

Complete turnkey solutions for Prepared Food Systems

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

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

Put our innovation to action in your plant today!

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