Food Review February 2020

Journal for food and beverage manufacturers FEBRUARY 2020 Vol. 47 • No. 02

“Foodspec/Silesia: celebrating 40 years of partnership in South Africa” Celebrate the power of blue

How to brew alcohol-free beer

Modified packs for the freshest product

CONTENTS FEBRUARY 2020 | Vol. 47 • No. 02

PAGE

32

PAGE

14 “The story of the innovative partnership between Foodspec and Silesia has its roots on the 1970s when German citizen Hans Werner Olson moved to South Africa to work in the dairy industry”

New flexible filling solutions for sensitive products 24

PRIVATE LABEL MANUFACTURING

Retailers keep it in the house

The benefits of certification for food safety

28

BEVERAGE PROCESSING TECHNOLOGY

The fast route to alcohol-free beer

HPP technology locks in the flavour

Flexible filling for sensitive drinks

Waves of change in soft drinks

09

NEWS

Everyone wants to work for Mondelez

Parmalat SA’s new name

Brew beer with renewable energy

Barentz and Pakistan-based Matco foods enter a joint venture

13

INDUSTRY TALK

34

MAP & VACUUM PACKAGING

Building on future waste management strategies

Crispness and shelf life guaranteed

Modified packs for the best product

MAP fits the bill for modern consumers

COLOURS & FLAVOURS

Tray packaging gets fresh

Celebrate vivid blues and greens in food

Successful shelf life extension

Natural vanillin production increases

Meet Variovac’s latest thermoformer

Blue packs a punch

Vibrant colours that pop

22

PLANT & SECURITY TECHNOLOGY

Sensor range impacts hygienic production

Tips on reducing food waste

16

PAGE

37

Modified packs for the freshest product

PAGE

41

Successful shelf life extension February 2020 | Food Review

3

EDITOR’S COMMENT

EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmedia.co.za Layout & Design: Andipha Nkoloti +27 (0)11 877 6168 andipha.nkoloti@newmedia.co.za

Working the flavour factor

F

lavour is the single most important factor in consumers' food and drink choices, while interest in novelty and variety remains high. A report from Innova Market Insights reveals that three-quarters of global consumers ‘love to discover new flavours’. It is little wonder that innovators continue to experiment and innovate with taste profiles and to use flavour as a valuable marketing tool.

Such is flavour’s importance in food and drink development that many of Innova’s Top 10 Trends for 2020 have a clear bearing on its evolution. Detailed flavour descriptors and an emphasis on provenance reflect the #1 trend, ‘Storytelling: Winning with Words’ theme.

Growing diversity in the produce and botanicals used in flavourings is part of the #2 trend, ‘The Plant-Based Revolution’ and ‘Hello Hybrids’ is another major theme as more flavours familiar in one category cross over into others.

Generationally, Millennials are the most adventurous in their attitude to flavour, while Boomers are the most conventional. Gen Zs are also less interested in mixing it up when it comes to taste. ‘When asked if they like new, mixed or seasonal flavours, Gen Z agreement was generally at least 10 percentage points lower than that of Millennials,’ says Lu Ann Williams, director of innovation at Innova Market Insights. ‘There is still an element of boldness when it comes to genuine novelty, with 45 per cent of Gen Zs agreeing that ‘the crazier the flavour, the better’ - a much higher percentage than is found among the over 45s and over 55s.’

Looking ahead, flavour innovation will remain an essential part of food and drink NPD and key themes will include the diversification of authentic international flavours, further

Contributors: Tony Burgess, Maartje Hendrickx and Letitia Watson

exploitation of the wider plant world, permissible indulgence in the health and wellness arena and ongoing hybridisation.

Sustainability and the sourcing of flavours, including raw materials that go into them, will also become a more important issue and could well impact on future consumer choice as well as industry practice. For our take on the latest releases and innovations, turn to page 16 now.

The alcohol free-trend is massive in South Africa and set to continue growing. On page 26, GEA takes us through a journey with Finnish Laitilan brewery, whose Kukku beer was the first full-free malt beer to receive the international gluten-free production trademark in 2005.

We also look at natural and environmentally processes in beverage processing such as HPP (page 28).

We end this edition with an overview of the latest systems and technologies in MAP and vacuum packaging. Zibo, Multivac, Trempak and more are featured, starting on page 34.

Don’t forget your entry for the Food Review/ Symrise New Product Competition.

You can find all the details on our website at www.foodreview.co.za – just click on the banner and it will take you through to the entry form.

Happy reading,

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

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

Gail Angela Macleod

4

Food Review | February 2020

Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmedia.co.za Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 càndida.giambò-kruger@newmedia.co.za INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 info@eisenacher-medien.de Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 g.rotunno@ngcombroker.com Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 sydneylai@ringier.com.hk CIRCULATION Circulation Manager: Felicity Garbers felicity.garbers@newmedia.co.za PUBLISHING TEAM General Manager: Dev Naidoo Production Controller: Mandy Ackerman Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park 2092 Tel: +27 (0)11 877 6111 Fax: +27 (0)11 877 6198 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published by New Media, a division of Media24 (Pty) Ltd MANAGEMENT TEAM MANAGING DIRECTOR: Aileen Lamb

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Managing director of Symrise South Africa; chairman of SAAFFI.

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

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At Konica Minolta, we listen and deliver. We consider all existing needs – from instant customer feedback, to market requirements and after-sale-service. From this we have created the AccurioLabel 190. A high-class system that benefits from stable colour consistency and 1,200 x 1,200 dpi offset-style quality with all the advantages of a flexible digital press: ease of operation, production flexibility including an in-line finishing option that gives you the freedom to run off-line too, fast turnaround and variable data printing capabilities as well as world-class support and service. Because we care – before, while and after sales. For your benefit.

Konica Minolta South Africa Tel 011 661 9000 • E-mail labelprint@konicaminoltasa.com www.konicaminoltasa.com

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Make a

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splash The Food Review/Symrise New Product Competition celebrates its 26th event in 2020! Since inception, the competition’s primary goal has been to provide local and international brands, featured on South African shelves, the opportunity to showcase innovative new products.

Innovation is at the heart of the competition.

Entries now open For more information, contact Maryke Foulds on (011) 715 8012 or Maryke.Foulds@newmedia.co.za or visit www.foodreview.co.za Entries close 12 June 2020

Enjoy the spirit of South America in South Africa

Cachaça is endemic to Brazil but now available locally! This sugarcane spirit is produced from the juice of non-burnt sugar cane after fermentation and distillation. The product can also be aged in wood produced in Brazil for up to three years before being bottled.

Spanish chocolate brand ventures into the SA market

Steeped in history and the timehonoured Spanish tradition of chocolate making, Valor has made its debut in South Africa.

Present in over 60 countries around the world, Valor’s entry into the local market is an exciting one.

Sparkle with Appletiser’s latest hit

Appletiser Spritzer contains 50 per cent real fruit juice and 50 per cent sparkling water, giving it a clean, crisp and refreshingly light taste. Lower in kilojoules, the spritzer is available in two delicious flavours Apple & Strawberry and Apple & Exotic Lime and contains no added sugar, preservatives or artificial sweetener.

Share your heart this Valentines’ Day Cadbury’s brings its delicious Pop-Out Heart slab to chocolate fans. At the heart of this chocolate offering is the essential spirit of selfless giving in the unconditional interest of making someone’s day a little brighter.

Zero sugar but all the flavour

Greenall’s Bloom Jasmine & Rose and Greenall’s Wild Berry is distilled without the use of any sugar, which allows the botanical flavours to come through. The product provides natural taste and sweetness that complements the juniper character. In the Wild Berry variant, the sweetness comes from the natural berry flavours infused with the gin. The distillery works hard to marry botanicals and natural flavours to create a smooth taste.

8

Food Review | February 2020

Boost your breakfast with rooibos, matcha and more...

Boost the nutritional value of your smoothie, breakfast bowl or fresh pressed juice with Natural Herbs & Spices’ new range of smoothie boosters with a rooibos matcha base. The Natural Herbs & Spices Smoothie Booster range has no artificial colours or flavours and is suitable for vegans.

NEWS

MONDELĒZ SOUTH AFRICA CROWNED A TOP EMPLOYER IN AFRICA

T

he Top Employers Institute has awarded Mondelēz Southern Africa Top Employer status for 2020. This is the second successive year the company has won the certification.

Mondelēz Egypt also won the award and is the only snacking company in Egypt to be accredited. Organisations certified as top employers dedicate themselves to providing an exceptional working environment for employees through their progressive ‘people-first’ HR practices.

‘Our success as a business is dedicated to our purpose of empowering people to snack right. We continuously strive to create a culture that is conducive to attracting and keeping the best people by providing them with opportunities to learn and grow,’ says Swadheen Sharma, managing director, Mondelēz Southern, Central and Eastern Africa.

Research has shown that engaged employees given opportunities for career growth and development in an environment that enables collaboration, innovation, diversity and inclusion are happier, more empowered and productive. This in turn improves profitability and customer satisfaction.

These benefits are compounded when the purpose is instilled as the golden thread that holds the business and its people together.

‘Having a diverse team that is grounded in our purpose of snacking right and mindfully is of paramount importance at the end of the day. It is also why we can unleash their talent to its full potential, giving them the chances they need to succeed as well as keep buying into our brands and acting as their ambassadors to ensure they are relevant to changing consumer preferences,’ Sharma concludes. •

Acquisition of Systech International completed

M

arkem-Imaje has announced that Dover Corporation (Dover) has completed the acquisition of Sys-Tech Solutions, Inc., which will now become part of Dover’s Markem-Imaje business unit.

Markem-Imaje will combine its consulting and integration services division with Systech to create a focused and scaled-up integrated organisation under the Systech brand.

This will provide innovative brand protection and compliance solutions to global customers and lead

the digital transformation of the brand protection market. Systech, which is headquartered in New Jersey, US, offers an integrated Brand Protection Suite for compliance and brand protection applications, including serialisation, traceability, and non-additive anticounterfeiting and antidiversion solutions.

The latter will help customers meet evolving product traceability regulations and growing consumer demand for product safety, security and authenticity. •

Lactalis South Africa is the new name for Parmalat SA

A

fresh era arrives for the South African PureJoy, Galbani, and Aylesbury. These familiar dairy industry this year as a new brands hold strong positions player enters the local market. across several dairy Lactalis South Africa is the new name for product categories, Parmalat SA and this name change came ranging from cheese, into effect on 1 February 2020. This is a yoghurt, milk, and name change only and will not custard, to flavoured impact the company’s existing range milk, cream, drinking of products, brands, projects or yoghurt, maas, fruit business operations. beverages, butter and Lactalis South Africa will remain the ice cream. Parmalat SA home of quality and trusted brands has been been part of such as Parmalat, Melrose, Président the international Lactalis Marek War zy woda and SteriStumpie, as well as Bonnita, family for the past nine

C C

years since the Lactalis Group bought Parmalat in 2011. The local name change to Lactalis South Africa is the final step towards fully integrating the South African business with its international parent company. Although the company name has changed to Lactalis South Africa, the existing company registration number, VAT number, banking details, site addresses, and telephone numbers remain the same. Marek Warzywoda, Lactalis South Africa general manager says, ‘The change of name in South Africa is an exciting step for the local dairy industry and shows that our global dairy group has confidence in the business opportunities in this region.' •

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February 2020 | Food Review

9

EV N EE WNST

How to brew beer using renewable energy

S

AB and AB InBev Africa’s breweries across South Africa are kicking off a multi-billionrand investment to purchase 100 per cent of the business’s electricity requirements at manufacturing sites across Africa by 2025.

Onsite solar power at its seven South African breweries will partially power each facility and represents seven per cent of the business’s electricity requirements. This is equivalent to taking about 2 000 vehicles off South African roads. The installation will allow for all electricity consumed to produce Budweiser at its Rosslyn Brewery north of Pretoria, to be sourced from renewable energy. This is part of SAB and AB InBev’s ‘Budweiser Renewable Energy 100’ goal.

AB InBev’s global renewable energy commitment is that 50 per cent of the company’s purchased electricity comes from renewable energy sources by 2020 and 100 per cent by 2025.

‘We’ve achieved our 50 per cent target in key markets across the globe ahead of schedule and we are well on track to achieve our 100 per cent ambition with good progress being made in Africa,’ says Taryn Rosekilly, VP sustainability, SAB and AB InBev Africa. SAB and AB InBev’s Renewable Energy campaign

was demonstrated with the use of the first electric truck to arrive on South African shores. The electric vehicle, known as the eCanter, is designed and manufactured by Mitsubishi Fuso Truck and Bus Corporation (MFTBC), part of the Daimler Group's global commercial vehicles business. Boasting zero emissions, the 7.5-tonne FUSO eCanter is the first of its kind in the world.

The vehicle has a battery capacity of 82.8kWh and a distance range of approximately 100 to 120km. It is currently operating in multiple countries, including Germany, Japan, Portugal, and has now been brought to South Africa for customer demonstrations.

SAB and AB InBev Africa are in the process of working on a Pan African Renewable Energy tender, which would seek to source an equivalent of 440 megawatts (MW) of solar capacity to meet its 2025 target in Africa. This represents an initial investment of approximately R5.6 billion (US$396 million) for installation at these facilities, which would be invested by the business’s development partners with a further R12.4 billion (US$866m) in energy cost that would be committed by AB InBev over a 20 year period.

The eCanter electric vehicle has a range of between 100 and 120km

The implementation will consist of three phases beginning with onsite solar installations with a capital investment of around R1.1 billion. Once maximum capacity onsite has been achieved, renewable energy solutions will expand to appropriately identified sites surrounding the breweries: · Phase 1 represents on-site solar installations. · Phase 2 are renewable energy solutions installed on land adjacent to SAB's breweries which would be hardwired to its breweries. · Phase 3 will involve offsite renewable energy solutions, which comprise remote installations requiring wheeling agreements to deliver the power to breweries.

In line with the above, SAB plans to migrate one of its South African facilities to 100 per cent renewable energy supply by the end of 2020, one of the first of its kind in the country. The multi-faceted solution will encompass a wind and solar energy mix, a wheeling arrangement and energy banking.•

Innovation at Afriplex

T

he company strives to provide its clients with innovative and unique product offerings for the food and beverage, CAMs and botanicals markets.

It is actively pursuing several new areas of research and technological development to order to retain its competitive edge.

Afriplex is proud to be the dedicated cannabis testing laboratory for the Cannabis Research Institute (CRI). Maintaining rigorous cannabis testing standards for locally produced and imported

10

Food Review | February 2020

product, Afriplex also conducts several novel research projects in collaboration with the CRI and other international research institutions.

One such project involves assisting the CRI with the integration of their new South African developed track and trace system with Afriplex's quality management system. This will ensure comprehensive traceability of cannabis material and products in all African countries where Afriplex offers custom-built facilities and technologies. •

NEWS

THE POWER OF PINK CAMPAIGN CELEBRATES 10 YEARS

T

he Power of Pink campaign was launched cost. Reach for Recovery could purchase the with the South African Mushroom Farmers’ prostheses at an average of R881 per unit Association (SAMFA) and Pick n Pay in where the average price of a single prosthesis October 2010. Reach for Recovery’s management on the open market is anything from board chairperson, Stephné Jacobs says, ‘We had R3 500 upwards) no idea the power we would unleash through International research continues to show the our incredible partners nor the extent of the link between breast cancer and mushroom success that lay ahead. Our achievements through consumption. The Power of Pink campaign this campaign have been nothing more than assists in increasing awareness of the miraculous. In October 2010, we raised R323 000. protective properties of mushrooms as indicated Now we consistently raise more than R500 000 by the research. a year.’

Mushrooms are rich in antioxidants which aids ‘We are extremely delighted to have achieved the immune system. They also contain selenium the R5 million mark in the 10th year of the Power in quantities much higher than any other plant of Pink campaign,’ says SAMFA chairperson Ross food. Selenium has been found to have an antiRichardson. This Pink campaign is one of very few cancer effect on prostate cancer particularly. breast cancer fundraising campaigns that support These elements work together to protect the body survivors who cannot afford reconstructions after against cancer by getting rid of free radicals and mastectomies. SAMFA and Pick n Pay value our defending the body against invading organisms. partnership with Reach for Recovery and are in Mushrooms are also a low energy-dense food awe of this 100 per cent volunteer-based NGO and that can help lower calorie intake which in the extent of the incredible work that they do.’ turn prevents obesity, a proven risk for breast Reach for Recovery South Africa consists of cancer. Mushrooms contain a fatty acid namely only 210 active voluntary members and these conjugated linoleic acid that can inhibit two extraordinary women, breast cancer warriors enzymes called Aromatase themselves, achieved the following during 2019: and 50 Alpha-reductase that are involved in • Supported 5 923 patients in hospitals and these cancers. • through continued visits • Handed out 3 013 care bags with support items and information leaflets to post-operative breast cancer patients in hospitals. (The production costs of the care bags and their content are also covered by the Power of Pink campaign) • Fitted 666 state patients who had a mastectomy and no medical aid with Ross Richardson SAMFA, Stephne Jacobs Reach for Recovery, Gareth O'Connell Pick n Pay and Beulah prostheses at no

Future shapers drives nutraceutical industry forward

V

itafoods Europe will be held from 12 to 14 May 2020 at Palexpo, Geneva. The show provides a key platform for the entire nutraceutical supply chain to find practical business solutions and discuss its greatest opportunities and challenges. To support health for more people, the three-day event will promote collaboration and encourage visitors and exhibitors to share opinions on topical issues such as increased consumer demand for transparency from ingredient to the shelf and the need to work together to achieve a more sustainable future.

As the meeting place for the nutraceutical industry, Vitafoods Europe will continue to lead the way in championing sustainability on the global nutraceutical stage, following its milestone achievement of being awarded the ISO 20121 Event Sustainability Management System certificate in 2019. The standard is designed to help organisations in the events industry have confidence in the sustainability credentials of their event-related activities, products and services. •

Jankelowitz Reach for Recoveryjpg

13294 - HOSTEX 2020 VIS 65x177 FOOD REVIEW PATHS.indd 1

2019/10/16 07:59

February 2020 | Food Review

11

NEWS

BARENTZ AND PAKISTAN-BASED MATCO FOODS ENTER A JOINT VENTURE

I

ngredients distributor Barentz has formed a joint venture with agribusiness Matco Foods, as it targets growth in Pakistan. Located in Pakistan, Matco Foods exports to over 60 countries around the globe from its four rice processing plants and one rice glucose plant. According to Dutch-based Barentz, the joint venture will better serve the rapidly growing Pakistani food processing market and will focus initially on human nutrition and pharmaceutical products.

The collaboration will utilise Matco Foods’ extended network within the local

Pakistan food industry combined with Barentz’ broad ingredients portfolio.

‘We already had a good partnership with Matco Foods and we both see complementary business opportunities in the local Pakistan market.

‘Pakistan has a fast-growing economy with a good variety of multinational and local food manufacturers. Our broad ingredients portfolio in combination with Matco Foods’ strong local network will certainly add value to the local life science markets, starting with human nutrition and pharmaceuticals,’ said Hidde van der Wal, CEI of Barentz. Khalid Ghori, CEO of Matco Foods adds, ‘We have invested in processing facilities to produce ingredients such as rice glucose syrup, rice proteins and maltodextrin.

Through these activities, we have an excellent insight into and an extended network with the food industry. We are proud to have set up this joint venture with Barentz and to further explore their strong global ingredient portfolio.’

Established in 1953, Barentz has operations in more than 60 countries with a strong presence in Europe and Asia. •

Syntegon Technology’s appoints chief executive

P

rocessing and packaging technology supplier Syntegon Technology has appointed Michael Grosse as chief executive officer.

The announcement comes after the company name change from Bosch Packaging Technology and follows the acquisition by CVC Capital Partners from Bosch in 2019.

Until recently, Michael Grosse was a member of the management board of Tetra Pak.

Syntegon said he has relevant leadership and management experience in the international mechanical engineering industry, particularly in the areas of process and packaging technology for the food industry.

Grosse, who will take up his post on 1 March 2020, will succeed Stefan Koenig, who spent 24 years working for the Bosch Group, ten of which at Bosch Packaging or Syntegon Technology. He has led the company as CEO since 2017. •

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Food Review | February 2020

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I N D U S T RY TA L K

Milk bottles: a recycling success story

As we enter 2020, we will continue to see new developments in waste management and recycling: 2019 left us with a high benchmark to build on.

L

ast year over 75 per cent of high-

value for waste reclaimers to collect.

density polyethylene (HDPE) milk

It has an easily removable sleeve label

perfectly for recyclability and they have

and beverage bottles were recycled,

and the cap is made from HDPE. Brand

a high recycled market value. Driving the

owners and retailers have a key role

right design for recyclability is a

injecting a significant amount of material into the market to be repurposed. The Polyolefin Responsibility Organisation (Polyco) provides insight into this recycling

to play when specifying the design of their products.

2. Fresh milk is distributed in the large

HDPE milk bottles are designed

key focus area to further grow the recycling economy.

Looking at ways to enhance the

trend and what the factors are that lead to

metros and there will either be

recycling economy is directly in line with

its success.

separation at source programmes

Polyco’s mission to end plastic waste in

in place or the waste reclaimers will

the environment. It aims to invest in new

used in the beverage packaging market

actively be separating materials of

infrastructure, innovate for designing for

and has a very high recycling rate. Over

value either on the kerbside or at

recycling and educating consumers about

20 000 tonnes of HDPE enters the market

landfill. As milk does not contaminate

the role they play to grow recycling in SA

per year of which over 17 000 tonnes gets

the bottle, it is a highly sought after

through a collaborative effort.

recycled – making it the plastic with one of

material as it does not have to be

HDPE plastic is a very common material

the highest recycling rates.

There are four main reasons why

heavily cleaned.

3. Major mechanical recyclers are all

this success has been achieved and

based in or close to the major metros

they include:

and will be looking for clean white

1. The milk bottle has been specifically

or clear HDPE. They will pay a good

designed for recycling. It is made from white or clear HDPE and is heavy enough (approximately 40g) to give it sufficient

price for the product – which again encourages its collection.

“HDPE milk bottles are designed perfectly for recyclability and they have a high recycled market value”

4. There is a strong end-use demand for white or clear HDPE recyclate, which is

‘Plastic plays a fundamental role in

used in quality critical products such

preserving the quality of food products,

as body care or detergent bottles. This

including dairy,’ notes Polyco CEO, Mandy

drives mechanical recycling demand,

Naudé. ‘Consumers must understand that

which in turn stimulates the collection

they have the responsibility to ensure that

of the material.

this material’s life-cycle is extended to extract the maximum amount of economic value and to keep it out of landfills. All we have to do is separate the packaging for collection and recycling.’

In 2019 75 per cent of high-density polyethylene milk and beverage bottles were recycled

Many brand owners and retailers are exploring the move from plastic to other materials due to consumer pressure and the belief that this other material is the more environmentally friendly packaging option.

Polyco’s research has shown that HDPE milk bottles have a significantly higher recycling rate compared to the materials currently being explored, which are not easily recycled.

‘Please share this success story far and wide and help us achieve a 100 per cent recycling rate for HDPE milk and beverage bottles by ensuring you and your neighbours recycle your bottles,’ Naudé concludes. •

Polyco - www.polyco.co.za

February 2020 | Food Review

13

C O M PA N Y F O C U S

years 40 of successful

cooperation in South Africa

The story of the innovative partnership between Foodspec and Silesia has its roots in the 1970s when German citizen Hans Werner Olsen moved to South Africa to work in the dairy industry.

O

lsen decided that the

to Silesia’s expertise in this

country offered a prime

product category.

opportunity to start a

A new generation is now

business, which he called Foodspec.

leading the business at

He went into partnership with local

Foodspec: Ralf Olsen is now

entrepreneur and international

managing director and Jenal

dairy equipment promoter

Harduth, daughter of Gino

Gino Ramasray.

Ramasray heads up the

Olsen was introduced to

flavour division.

German flavour house Silesia by a colleague in the stabiliser industry.

He visited Silesia’s headquarters and was very impressed with the company’s culture and technology. An agency agreement was struck between the two companies in 1980.

The dairy industry was the initial focus of the partnership. The first delivery, consisting of two flavour canisters, arrived from Germany by post and was delivered to a highly regarded dairy factory in South Africa.

After 40 years of hard work, enduring the political and economic challenges in South Africa, Foodspec and

‘Silesia brings top-quality Bronwyn Spenceley, key account manager, Jenal Harduth and Jeanette Govender, key account manager

grow our flavour business in South Africa.’

Creativity, customer briefings, internal objectives and current market trends form the basis of Silesia’s flavour development. Knowledge gained from analytical and sensory research concerning flavouring components detected in fruit, vegetables, herbs and spices, and prepared food is continually used in development work.

Silesia/Foodspec has evolved as a

Silesia have become major players in the flavour industry.

Jean-François Richard, Silesia’s regional sales director explains the partnership, ‘Foodspec has put an excellent

DID YOU KNOW?

system in place. Their approach to the business is based on top quality service, partnerships and adding value to customers. This matches Silesia’s sales strategy 100 per cent. It was the perfect synergy to develop and

14

Food Review | February 2020

invested a great deal in developing taste profiles that suit consumer preferences in South Africa and are very aware of local price constraints and offer costeffective solutions. As a company, they support customers at every stage of product development - from concept

“Sustainable sourcing of raw materials, energysaving and production process optimisation are a constant consideration”

market leader in the supply of savoury flavours. The range

The first delivery, consisting of two flavour canisters, arrived from Germany by post and was delivered to a highly regarded dairy factory in South Africa.

delivery and logistics

flavours to market. They have

of cheese flavours is often considered as benchmark products by food scientists and formulators. The company also places a special emphasis on beef and chicken flavours.

The suppliers are also very active in the beverage industry

(mainly in the juice segment).

Silesia’s range of apple, mango, pineapple and other tropical flavours are highly regarded. The business in the confectionery industry has developed enormously in the last decade, thanks

ideas to the recipe formulation and production process. They can finetune flavour profiles to match market demand,’ Harduth points out.

Foodspec and Silesia offer a perfect mix of Western approach and African flair. Silesia brings international flavour technology to the market with German efficiency and consistency while providing technical and sensory training to food producers. With their global foundation, they share trends and innovations from around the world, adapting them to suit the African market. Foodspec opens doors to a large customer base, from the formal

C O M PA N Y F O C U S

The Silesia team at the head office in Germany

to informal markets. A strong sale and

In conclusion, Harduth and Richard sum

after-sales service ethic and a perfect

up the partnership, ‘This 40th anniversary

understanding of local needs and

of cooperation is a great achievement

challenges underpin their offering.

for our companies. It is also the start of

This is coupled with warehousing and

a new era where Silesia and Foodspec

distribution facilities in Durban and

are committed to bringing better flavour

Johannesburg to secure supplies and

solutions to Southern Africa.’ •

buffer exchange rate volatility.

The two companies are also focusing on new challenges in the food industry.

Quality will always be the driver and the

Silesia – www.silesia-aroma.com Foodspec – www.foodspec.co.za

DID YOU KNOW? Foodspec is building an in-house application laboratory to strengthen local technical support and service.

high grade of the BRC certificate of Silesia is the best proof. Sustainable sourcing of raw materials, energy-saving and production process optimisation are a constant consideration. Social awareness is a top priority of Silesia’s management and it has gone through a SMETA- 4 pillar ethical audit for several years.

The “New Food” concept is now the Silesia flavourists and application technologist’s special playground!

Flavourists are developing flavour systems, product prototype formulations and concepts for new food products such as animal protein substitutes, protein-

YOUR BENEFITS CHOOSING SILESIA AND FOODSPEC • Flavours specially designed to local taste preferences • German quality • Latest global trends translated to your products • Technical and sensory training • Strong warehousing and distribution facilities • Best sales and after sales service • Long-term partnership.

enriched food, sugar and salt reduction, amongst others.

February 2020 | Food Review

15

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

Aqua makes a splash GNT’s market development manager, Maartje Hendrickx, explains how vivid blues and greens are helping consumers reconnect with nature.

Exberry Coloring Foods are the perfect way to tap into the industry’s new blue trend

FAST FACT:

Shades of Aqua provides a sense of the unexpected, creating eyecatching products that people want to share on social media.

I

n 2020, the company’s range entitled Shades of Aqua are set to dominate the food and beverage industry with

vivid blue and green colours. The palette can assist consumers to reconnect with nature, evoking thoughts of the sea and verdant landscapes.

Using blues and greens is not just a great way to create the right visual effect.

These colours can influence perceptions

Spearheading the switch to natural vanillin Solvay is instrumental in directing the switch to natural vanillin alternatives to satisfy demand for true-to-nature products.

T

he ingredient offers the advantages

facet, complemented by a touch

of non-GMO products, derived from a

of caramel

unique bio-conversion process from

• Delivers a powerful vanilla note with a

natural ferulic acid. It is compliant with the European natural flavouring Regulation

sweet, creamy, natural character • Worldwide labelling of ‘natural flavour’

(EC) No 1334/2008 and can be labelled as a

for consumer end-products stemming

natural flavouring or natural vanillin.

from a process of unique fermentation from natural raw material

NATURAL FLAVOUR LABELLING

• The solution is approved and used by

With vanilla prices at an all-time high,

major food companies and incorporated

Rhovanil Natural CW becomes the excellent

in leading brands in the fields of

alternative or complement to natural flavours:

beverage, pastry, ice cream and

it is the only natural vanillin that meets

dairy products.

European 1334/2008 and US Food and Drug Administration (FDA) 21CFR101.22 regulations

APPLICATIONS

regarding natural labelling, a key benefit for

Rhovanil Natural CW brings its sweet,

food international players.

creamy and cocoa characteristics to the

Solvay natural vanillin is approved by TTB,

following applications: dairy products, ice

the Alcohol and Tobacco Tax and Trade Bureau,

cream, chocolate, caramel and malt flavours

which is in charge of alcoholic beverages

to round off single flavour chemicals and

regulations, in addition to FDA approval.

cocoa extracts. All kinds of fruit flavours, including natural strawberry, raspberry,

FEATURES AND BENEFITS

banana and fruit blends, which are

• The range has a strong characteristic

transformed into sweet, creamy, candy-like

vanilla note with a soft and powdery

16

Food Review | February 2020

Solvay has doubled its production capacity of Rhovanil Natural Crystal White

profiles adored by children, confectionery

and sugars containing vanilla; biscuits, pastry, cakes and French pastry cream and beverages.

Rhovanil Natural CW range is compliant with the stringent regulations in force regarding “natural status” in food and cost-competitive with a sweet vanilla note consumers enjoy.

‘We are committed to supporting the switch to natural ingredients. By doubling the production capacity of Rhovanil Natural CW to 120 metric tonnes and aligning our production process with the National Organic Programme requirements in the US, we are responding to our customers’ global long-term natural growth needs. It also reflects Solvay’s environmental and socially conscious practices,’ says Peter Browning, president of Solvay’s Aroma Performance global business unit (GBU). •

Solvay – www.solvay.com

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

of flavour too, heightening the overall sensory appeal of food and drink.

Modern consumers want more than just vivid colours. They also want an ingredients list that is clean and simple.1 Many companies are moving, or have moved away from artificial colourants to clean-label alternatives.

GNT was founded on the straightforward principle of colouring food with food. The company offers more than 400 shades - created from fruit, vegetables and edible plants using only gentle physical methods such as chopping, heating and filtering.

To allow manufacturers to create products that tap into the Shades of Aqua trend while maintaining clean-label appeal, the company has enhanced its range of spirulina-based concentrates, including the launch of high-intensity blue powders. The ingredient is a nutrient-rich, highly sustainable form of microalgae that contains phycocyanin, a naturally occurring blue colouring component.

Spirulina is widely recognised because of its use in dietary supplements and because of phycocyanin. It’s a good replacement for artificial colourants, including brilliant-and patent blue and other additives such as copper chlorophyllin. To produce green shades, the spirulina concentrate is mixed with a yellow plant pigment, such as safflower or pumpkin.

Exberry is available in liquid and powdered form and is water-soluble and fat dispersible. It can be used across all food and beverage categories, including confectionery, dairy, bakery and savoury applications.

“By making the switch to Exberry Coloring Foods, manufacturers can combine Instagrammable colours with a simple ingredient list” Using colouring food requires technical knowledge, since the interactions between time, temperature and light that determine colour stability are complex.

It’s important to work with a partner that can help you find the right option for your product.

With the spirulina-based Colouring Foods range, heat exposure should be minimised as much as possible to ensure maximum colour retention.

Temperatures of more than 80°C cause denaturation of the protein to which the phycocyanin is bound and may result in some colour loss or a shift in the shade. An alternative solution is to slightly increase the Exberry dosage.

Whatever the shade or application, GNT has a wealth of expertise to offer manufacturers the best way to deliver the best possible results. Years of experience means it can offer a solution for almost every application. The company also assists in colour matching, stability testing, regulatory matters and upscaling.

By making the switch to Exberry Coloring Foods, manufacturers can combine Instagrammable colours with a simple ingredient list, getting the best of both worlds. Plant-based is also proving to be one of the biggest trends in the modern era. The range of vegan-friendly products are perfect for the 2020s and Shades of Aqua are particularly relevant.

Many consumers are on a mission to achieve holistic health and wellness, and the naturally occurring phytochemicals that give fruit and vegetables their colour have many positive health associations. Green represents a positive identifier for nutrition in vegetables, fruit, herbs and spices, while blue can offer subtle hints of healthy fruits such as blueberries.

The Shades of Aqua collection is just a part of the extensive range of Exberry concentrates. Regardless of the shade used, these products can ensure products stand out without compromising their clean-label credentials. • ¹Source: Innova Market Insights, Clean & Simple, July 2019

Exberry – www.exberry.com

February 2020 | Food Review

17

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

Bring blue to life!

Firmenich, the large privately-owned perfume and taste company has partnered with Pantone to bring its 2020 Color of the Year to life.

A

s one of Pantone’s first sensory partners, Firmenich flavourists put

their world-class creativity to work to shape an immersive, multi-sensory experience for Pantone 19-4052. The ingredient features a natural, fresh, blueberry taste.

‘Blueberry and fresh

wellness, blueberries are in a sense becoming rediscovered.

It is growing to be one of the most relevant flavours in different areas of food and beverages,’ he adds.

Flavourist Eric Tang's refreshing flavour is marked by its

green notes are a distinctive

elegant aroma

feature of Classic Blue

and initial fruity

and offer a familiar and reassuring flavour,’ explains Emmanuel Butstraen, president of flavours at Firmenich. ‘As consumers focus on health and

Pantone is a global provider of professional colour language Solvay – www.solvay.com standards and digital solutions.

It selected the Color of the Year for 20 years by analysing trends and influences across a wide range of lifestyle areas including the entertainment industry, art, fashion, design, and travel destinations.

taste of natural sweet blueberry. It also offers an experiential smell of fresh green and the maturing final finish of floral and classic blue notes. This distinctive

“Blueberry and fresh green notes are a distinctive feature of Classic Blue and offer a familiar and reassuring flavour”

FAST FACT:

taste was showcased during a Pantone launch event in a variety of products from jam to tea.

For the last eight years,

This year is Classic Blueberry. The decision was based and reflects industry-leading consumer insights and trend forecasting. In a recent survey across 16 countries conducted with nearly 5 000 consumers, Firmenich found that the number one emotion associated with blueberry was happiness, followed by a sense of comfort. •

Firmenich has been at the forefront of flavour innovation with its Flavour of the Year release.

Firmenich – www.firmenich.com

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

FLAVOUR DIRECTLY FROM THE SOURCE Sensetek.indd 1

18

Food Review | February 2020

2017/02/14 12:01 PM

+27 (0) 11 248 9400 https://www.continental-industry.com/en/Solutions/Fluid-Handling/Industrial-Hoses/Food-Beverage-Hoses

Industrial Fluid Systems

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

Discover a range of unique multi-sensory experiences At ProSweets, held from 2 to 5 February 2020 in Cologne, Germany Doehler showcased innovative concepts that provide an ideal combination of health and indulgence.

I

ngredients ranged from plant-based porridges, healthy snacks containing plantbased proteins and creamy chocolate

creations with crunchy fruit granules. These products were based on an extensive portfolio of natural ingredients including colours, flavours and ingredient systems.

AUTHENTIC TASTE FOR CONFECTIONERY AND BAKED GOODS The key to unlocking consumer satisfaction is to provide unique taste experiences coupled to new textures, brilliant colours and an outstanding mouthfeel. Plant-based muffins using walnut puree and confectionery produced and manufactured with plant-based ingredients

Doehler’srange of natural colours and flavours can be used in a wide range of products

were just some of the highlights.

The company also trialled its latest innovations, Fruitmallows. These fruity marshmallows contain no animal ingredients.

Using fruit powders made from 100 per cent raspberries, the product impresses with its unique taste and features an especially natural colour.

CHOCOLATE CREATIONS FOR EVERY TASTE

“… in the dark chocolate coated almond product, the crunchy almond core with fiery chilli extract creates a sophisticated combination of bite and spiciness”

High-quality natural ingredients for unique

The natural black ingredient is perfect for use in wine gums

chocolate creations were also in the spotlight and included crispy fruit pieces, creamy nut purees to traditional and innovative fruit preparations.

The most exciting innovation on display was a natural black produced from a mixture of

HEALTHY AND PLANT-BASED NUTRITION Demand for products that offer alternatives

The diversity of the product portfolio

different colouring concentrates – perfect for

extends from pralines with cinnamon and

use in a wine gum application. Further natural

sesame fillings to white chocolates with

colours also provide natural colouring to

orange pieces and botanical extracts - even

various confectionery products. From vibrant

plant-based chocolates that use oat syrup and

red from black carrot or beetroot to brilliant

coconut powder. In the dark chocolate coated

yellow from safflower – every product is turned

almond product, the crunchy almond core

into a visual highlight.

with fiery chilli extract creates a sophisticated

to traditional dairy products is growing.

Plant-based drinks like the Oat Drink, makes it an outstanding option on its own, with crunchy cereal or in a morning coffee.

Plant-based porridges are also popular with consumers.

Whether for breakfast or as a snack, the

combination of bite and spiciness.

BRILLIANT APPEARANCE AND COATING SYSTEMS

combination of fruit powders in exciting

VIBRANT COLOURS THAT POP

Coating systems are ideal vehicles that can render confectionery a special multi-sensory

passion fruit, coupled to premium fruit

If product formulators want consumers to be impressed by a product, its taste and

experience. Glazing and coating agents can be

appearance must be something special.

tailored to the exact confectionery product

Doehler’s broad spectrum of natural

(dragées, fruit gums and extruded liquorice

colours is tailored to various applications for

products) and its respective application. Easy

the food and beverage industry. The company

to use in development and production, they

showcased its colouring malt extract. This

are made from sustainable raw materials.

is a clean label malt concentrate with high

Doehler’s portfolio covers all ingredients

colour stability and an especially neutral

needed to refine a perfect coating finish,

taste, which can be used as an alternative to

including natural colours, fruit powders

caramel colouring.

and flavours.

20

Food Review | February 2020

flavours such as banana, mango and granules, creates an extraordinary taste sensation. Another perfect answer to the trend for purely plant-based nutrition is plant-based Cheesecake. Produced using coconut instead of milk and quark and its full-bodied taste and creamy mouthfeel make it just as good as classic cheesecake. •

Doehler – www.doehler.com

P L A N T & S E C U R I T Y T E C H N O L O GY

Hygienic food production with pressure sensors and level switches Food production is a matter of trust, and hygiene is the number one priority in the manufacturing process. Success is determined by the reliability and efficiency that make flawless production possible – whether during bottling, container filling or CIP cleaning.

T

his makes it important for plant operators to rely fully on

The universal, flexible hygienic adapter system of the new instrument series

the measurement technology

employed. Level and pressure sensors from Vega have made a name for themselves over many decades for reliability and longevity. Robust, versatile and easy to use: even under extreme conditions or strict regulations, these instruments provide important inputs for delivering greater plant safety and efficiency. customised from over 256 different

COMPLETE SUPPLIER FOR LEVEL AND PRESSURE

colours remains clearly visible, even

Vega completes its measurement

measuring process is running, if the

technology portfolio for food production

sensor is switched or if there is a

with two new compact instrument series,

possible malfunction in the process.

in daylight. The user can see if the

comprising pressure sensors and level switches. The products, Vegabar and

INTELLIGENCE WITH IO-LINK

Vegapoint, prove that automation can

There is a lot of sensor intelligence

be simple and highly efficient without

built into the new compact series: the

compromising dependability, hygiene

standard IO-Link protocol ensures both a

or accuracy.

universal and particularly simple system of communication.

“Vega completes its measurement technology portfolio for food production with two new compact instrument series, comprising pressure sensors and level switches”

This means the instruments have a standardised communication platform that enables seamless data transfer and simple system integration.

EVERYTHING’S EASIER WITH WIRELESS The new Vegabar and Vegapoint instrument series can be easily read out and configured with a smartphone or tablet. Device setup and operation

The new measuring instruments are

become considerably easier, especially

perfectly tailored to standard applications

in environments such as clean rooms,

that demand the highest quality. Their

where physical access involves a lot

standardised hygienic adapter system

of effort.

provides the flexibility needed to reduce

Vegabar pressure sensors and

and keep installation work and parts

Vegapoint level switches represent an

inventory at a minimum. The process

important milestone for the company.

fittings can be selected as needed and

Users have access to an entire range

adapted to local requirements.

of level and pressure measurement technology from a single source.

360° SWITCHING STATUS DISPLAY

Hygiene-optimised instrument

With all-round switch status display,

designs are extremely easy to install and

all sensor states can be visually

an application-based combination of

discerned from any direction. The colour

reliability, flexibility and reproducibility

of the illuminated ring, which can be

in the food production process. •

22

Food Review | February 2020

Vegabar compact pressure sensors with switch function and Vegapoint capacitive level switches are tailored to standard applications

ABOUT VEGA

Production processes are becoming complex. It’s vital that measurement technology used to control and monitor the processes are understandable and intuitive. Vega has set itself the goal of developing innovative measurement technology that is easy to install and operate and offers maximum safety and reliability.

The company employs over 1 480 people worldwide, 730 of whom work at its headquarters in Schiltach in the Black Forest, Germany. In just over 60 years, solutions to demanding measuring tasks are being conceived and brought to realisation: for the food industry, drinking water supply systems amongst other.

Vega is active in over 80 countries with its globe-spanning network of subsidiaries and distributors. The company and its products have all the necessary certificates and approvals for worldwide application. This applies to the technical safety as well as the quality of the products and services.

Vega - www.vega.com/food-industry

We bring colour into view!

Compact pressure sensors and switches with 360° custom-colour status display

256 colours Individually selectable: Measurement in progress Sensor switching Process malfunction

15 cm

Compact design

Hygienic adapter system

Adjustment via smartphone

R5 377.00 VEGABAR 39 Clamp 1"

www.vega.com/vegabar

P L A N T & S E C U R I T Y T E C H N O L O GY

Digitalisation reduces global food waste The scale of the global food waste problem is staggering. It is reported that up to 1.6 billion tonnes of food is lost or wasted every year. This equates to a total value of US$1.2 trillion wiped from the supply chain.

E

mbracing technology and digitalising the food supply chain can reduce food waste and loss. It

can also assist in ensuring there are enough resources to sustainably support the future global population.

INNOVATION TO REDUCE WASTE Most food waste occurs during production and consumption. The former is more common within developing countries, while the latter is more pronounced in developed countries with waste being caused by retailers and consumers.

The Boston Consultancy Group (BCG) indicates the amount of food waste created in the supply chain is set to rise by 1.9 per cent from 2015 to 2030. You may think this is a small rise but put into perspective with the current 1.6 billion tonnes wasted every year, this figure will increase by 30.4 million tonnes.

To combat this increase in waste, food

Allowing all stakeholders within the supply chain access to key data shared

USING INNOVATION TO IMPROVE CURRENT INFRASTRUCTURE

across integrated systems, processes can

The supply chain can also use digitalisation

supply chains need digital transformation.

be optimised further along the chain to

From production and processing to retailers,

maximise how the product is handled. A

systematic changes are required in food

bad batch of apples, for example, with a

supply chain management.

high percentage of internal browning would require a piece of specific equipment set

UTILISING IOT IN THE SUPPLY CHAIN

up and would need to be fine-tuned to

Better communication across the supply

from the apples. It is believed having this

chain will reduce the amount of food waste

connectivity could save the supply chain up

produced. Each aspect of the supply chain

to US$60 billion in waste.

must be in constant contact to ensure resources are managed efficiently.

The Internet of Things (IoT) can support

ensure the maximum value can be extracted

Through pre-warning of information regarding a batch of produce, farmers can optimise yields by reducing the risk of waste,

and improve supply chain efficiencies.

and stakeholders can also plan accordingly

Based on interconnected and interrelated

to prevent the cause of waste.

systems and processes, IoT allows each

The ability to share data through IoT

aspect of the food industry to have access

can help reduce waste from a consumer

to key data around the supply, production

standpoint. Retailers could use the real-time

and management of produce. Without the

data in stores to showcase when produce was

wider adoption of IoT, levels of food waste

harvested or picked and offer insights into

could increase by 50 to 90 per cent as a

the projected "sell-by date". This can educate

result of several combined factors, such as

consumers further on how long they can

the increase in food demand due to the ever-

eat the produce, helping reduce food waste

growing population.

through the implementation of technology.

24

Food Review | February 2020

to help improve the infrastructure it currently has in place.

Cold chain plays a huge role in the food industry creating waste, mainly due to poor infrastructure. In India, US$14 billion is lost every year through poor cold chain facilities.

Implementing innovative and efficient systems can go a long way in addressing the food waste issue – particularly in developing markets. Deploying advanced cold chain solutions within the emerging markets, which share the data across the supply chain through IoT, it could prevent large-scale food loss and waste.

The conditions can also change in cold storage, and temperature affects many sorting technologies, so the ability to link cold storage sensors to packing equipment can enhance performance.

This is nonexistent in many emerging markets, creating poor food storage and transportation conditions early in the value chain that leads to large-scale food loss. Deploying more advanced supply

P L A N T & S E C U R I T Y T E C H N O L O GY

chain solutions (including cold chain in

The final step is to layer artificial

Digitalisation won’t just help from

developing markets) could reduce the

intelligence to start to understand

a sustainability aspect, but also help

problem by US$150 billion annually.

previously unseen patterns and even more

businesses drive their profitability by

efficient ways of working.

improving processes and efficiencies.

Investing in efficient sorting and grading systems is a key approach in helping the

Although these KPIs tend not to be

It becomes the answer to the push-pull

supply chain reduce food waste created

designed to help limit the amount of waste

paradox for commercial benefit and

earlier in the supply chain.

produce, utilising sorting and grading

combating global food waste.

We want to know everything about a

technology can automatically support a

Tomra creates sensor-based sorting and

product – from the weight and size to the

waste sensitive environment by recovering

grading systems to help the supply chain

external properties and defects.

any produce and reusing it for another

win the battle against food waste. The

purpose, such as cattle feed or pet food.

technology aims to assist food businesses

composition to predict ripeness and

This means that rather than creating food

to maximise yield and ensure any product

longevity. There are only two points when

waste, an alternative, more suitable use

can be recovered and reused, increase

you can gather information on individual

is found. Lower quality fruits can be used

productivity with high capacity sorting

pieces of fruit: when it’s picked and when

for juices or pulped to become products

and provide consistent high-quality

it is sorted. These are critical data

such as guacamole or apple sauce, whilst

food assurance.

acquisition points.

starches can be used for medical purposes.

This could include internal chemical

Buyer’sguide

THE

KPIs must be based around

understanding the types of defect types

To connect sorting and grading systems,

These help reduce waste and put the lower

there is Tomra Insight. The technology

quality products to better use.

allows for sorting and grading systems,

and classes/grades per batch, to help

extract valuable information on the

sorting performance and the produce, and

the produce. This can help build up big

GOING DIGITAL TO FIGHT FOOD WASTE

data, meaning every batch gives you new

With the ever-rising stats around food waste,

Incorporating this further into a digitalised

insights and allows you to build a bigger

now is the time for the industry to adopt a

supply chain will help to close the link from

picture, creating the ability to make even

more digitalised approach across the supply

farm to fork in the future. •

more informed data-driven decisions.

chain. Implementing integrated and innovative

Where appropriate, data can be shared and

systems will allow all key stakeholders, from

augmented to ‘context’, such as weather

field to fork, to efficiently manage food and

data or geotagging.

reduce the risk of waste at loss.

create a complete map and total view of

make it transparent to food businesses.

2017/2018

Tomra – www.tomra.com

THE

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

2018/2019 2019/2020

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

2018/05/07 3:09 PM

February 2020 | Food Review

25

P R I VAT E L A B E L M A N U FAC T U R I N G

Major retailers keep it in the house

Do you think that private labels are a fad bolstered by a tough economic climate?

Here are six reasons why you should think again, writes Letitia Watson.

I

n terms of national brands, most

in, fast. The Shoprite Group reported

grocery and food retailers compete

in its interim results in February 2019

on a level field. Research by Daymon,

that its private label growth is double

the global private brand strategist group,

the pace of all the brands it sells, and

shows that on average, 98 per cent of a

participation of turnover is at 16 per cent.

retailer’s national brand assortment is

At PnP, participation is at 21 per cent with

the same as its competition.

plans to accelerate it, according to the company’s 2019 annual report.

SETTING RETAILERS APART

This growth is also echoed in the

This leaves nearly all product

results of Libstar, a large supplier of

differentiation up to private labels. That’s

private label goods to Woolworths, PnP

a prime driver of these products’ growth

and Shoprite. Private labels contribute

amid fierce competition for shoppers’

44 per cent to group revenue for the

spending money.

financial year ended December, compared to 41 per cent the previous year.

GROWING, FAST In South Africa, private labels have a

KINGS OF CONVENIENCE

21.1 per cent (20 per cent in 2017) share of the

The top five private label sellers in South

retail sector, according to Nielsen’s State of

Africa are long-life milk, fresh chicken,

the Private Label in South Africa 2018 report.

prepared foods, butter, and sugar.

The evidence for growth is however global.

Private labels’ market share is the

The convenience food category is one of the fastest movers in the private label

highest (over 50 per cent) and growing

sector. In South Africa, prepared food

most in the UK. While uptake is slower in

leapt from 12th position to be among

brand-conscious North America, private

the top five private label best sellers.

label sales are increasing across all

Libstar indicates on-the-go eating and

income and age groups.

convenience are currently among the

In the EU, private label market share

fastest-growing trends. The group is

is around 40 per cent, with private labels

expanding its prepared meal capacity to

outperforming national brands in the UK,

tap into it.

Germany, Italy and Spain, as shown by a

Convenience is one of the three

report by Information Resources Inc. (IRI)

strongest selling ranges at PnP. Shoprite,

on private labels in western economies.

who makes no secret of private labels being one of its major growth drivers,

ON EVERY RADAR

says its convenience products have

Woolworths has long been the main player

outgrown the retail market in this

in the sector, but other retailers are moving

category by 4.7 times in 2018.

26

Food Review | February 2020

“The rise of private labels in the local market is confirmed by strong sales and investment in private label categories by major retailers” UNLOCKING VALUE Consumers no longer believe that wellknown, national brands are best. Private label sales are driven by a quest for value, but there is improved perception of quality.

Retailers are focusing on growing their private labels' share of sales by developing premium and niche products as well as better labelling, says Nielsen. Shoprite says 51 per cent of its private label product innovation targets upmarket choice. IRI, the premium tier development helps to sway savvy shoppers from brands to private labels across countries.

HERE TO STAY The value and rising quality perception are not limited to poor economic performance. IRI’s research shows that in Europe and the US private labels are growing even when economic prospects are improving. At the same time, a private label decline in a tougher economic environment seems unlikely, as is evident in the steady rise of private labels in South Africa. •

Libstar – www.libstar.co.za

P R I VAT E L A B E L M A N U FAC T U R I N G

Committed to industry best practise

Food safety auditing and certification from NOSA

No retailer or brand owner worth its salt will consider business with a supplier that cannot prove its certification to a global standard. Certification enables your business to implement change, improve management systems and build your future success.

B

RC Global Standards for Food Safety (BRC) is one such an example. BRC was first introduced in 1998 and is

regarded as one of the benchmarks for best practice in the food industry. It has evolved into the framework on which many companies base their supplier assessment programmes.

This has extended from just manufacturers

“Certification enables your business to implement change, improve management systems and build your future success”

In certifying your organisation within

with a global application functionality.

Confidence: Through a robust

this standard, you automatically meet the

performance, the standard’s monitoring

fundamental requirements associated

assessment tools and transparent

with senior management participation;

process of logging complaints help to

adoption of HACCP; a documented quality

maintain the rigorous requirements for

management system and control of your

auditors’ competence, qualifications and

environmental standards, processes

experience. Much like the happy ‘ending’

and personnel.

of every fairy tale this is in fact just the

FIVE BENEFITS OF CERTIFICATION

You can ensure this through advanced software options, which help you track and monitor supply chain compliance to the relevant standards and requirements that dictate your organisation’s risk management system.

• Enlist global support

of private branded products to ingredient manufacturers and co-packing operations.

• Manage your supply chain compliance

beginning. Your certification is the first milestone in your continued pursuit for

How best to apply a global standard than with an ongoing conversation between you and your global partners? By enlisting the help of a global certification leader, you will enable your organisation to grow and change through food safety programmes.

Through the assistance of experts in the fields of quality; environment; aerospace; automotive; medical devices; health and safety, many other industries are impacted.

business excellence.

• Implement appropriate food By observation of and alignment to the

certification process.

5 WAYS TO ENFORCE INDUSTRY BEST PRACTICE

Credibility: An experienced technical services

• Enlist the services of exceptional auditors

are making a clear statement of your

team, with worldwide reach, offers peace of

The right auditors will understand that

mind through continual customer support.

applying a standard is not a paint-by-

Collaboration and continuous

numbers exercise. Small, medium and

improvement: Multiple technical experts

large organisations will require a system

and committees regularly review the

assessment that will ensure the application

standard to ensure continuous improvement

is appropriate for the business in question.

For a full discussion around potential

with food safety trends.

• Schedule a training calendar

Testing, Inspection and Certification (TIC). •

Consistency: A global training

A breadth of learning options that meet

infrastructure allows for localised,

market needs and delivered via a range of

language-based training and auditing

training modes will add defined value and

teams, with standardised audit reports

solid outcomes to you and your business

Clarity: It contains well-defined requirements built within a clear

and to ensure the standard remains current

safety programmes following food safety programmes you commitment to food safety best practice: • ISO (e.g. 22000, 9001, 14001) • HACCP • GFSI Standards (BRC/SQF/IFS) • GlobalGap. certification services, please contact NOSA

NOSA – www.nosa.co.za

February 2020 | Food Review

27

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

Membrane dealcoholisation for alcohol-free beer There are several different methods for producing de-alcoholised or non-alcoholic beer. Laitilan Wirvoitusjuomatehdas Oy (Laitilan) brewery in Finland wanted to avoid wort-like flavours and achieve the best results when it came to taste and quality.

A

n independent brewery in operation since 1995, Laitilan has grown to become Finland’s fourth-largest

brewery. Its Kukko beer is the world’s first fullmalt beer to receive the international glutenfree product trademark in 2005.

The brewery produces speciality beers, ciders, sparkling wine, soft drinks, waters and

“The cold process with membrane filtration has less impact on beer flavour and more aroma is maintained when compared to dealcoholisation methods”

long drinks – which totalled more than 20 million litres in 2019.

DEALCOHOLISATION WITH REVERSE OSMOSIS During a separator installation at the brewery in 2017, plant manager Tommi Suutari asked GEA about possible solutions for beer dealcoholisation. GEA had just developed and launched a new process using membrane filtration. Built on GEA's membrane filtration technology, AromaPlus works via reverse osmosis (RO). This allows alcohol and water to move through while retaining essential ingredients that contribute to aroma, colour and turbidity.

aroma is maintained when compared to de-alcoholisation methods, which rely on thermal processes. After a visit to one of the first producers of de-alcoholised beer using the AromaPlus, the Schönbuch brewery in Stuttgart, Laitilan was convinced. GEA product manager Ralf Scheiber explains, ‘We put a lot of effort in developing the new AromaPlus process. We’re seeing that demand for nonalcoholic beer is increasing. Our solution has been well-received and is very much appreciated by breweries and consumers.’

UNIT DESIGN AND LAYOUT The dealcoholisation unit is mounted on a frame and comes ready for installation. It

1

includes the filtration modules fitted with the special AromaPlus reverse osmosis

The system achieves the required alcohol-

membranes. The system features pumps for

free percentage of 0.5 per cent – down to

media transport or for providing the required

0.05 per cent. Several brewing frontrunners

system pressure, internal piping and a CIP

have chosen AromaPlus as it delivers in terms of cost and excellent tasting results.

dosing unit are installed next to the unit. It

COLD PROCESSING RETAINS FLAVOURS

automated operation.

also features control technology for semiIn addition to the process, the controller also manages cleaning-in-place (CIP) of the

The cold process with membrane filtration

system to ensure proper operation and

has less impact on beer flavour and

reliable cleaning of membranes. The modern

2

GEA AromaPlus units have a standardised layout. Depending on size, they are designed for batch processing from approximately 50 hectoliters to more than 600 hectoliters per day. GEA also offers larger de-alcoholisation units for continuous processing of more than 50 hectoliters per hour.

The brewery's de-alcoholisation plant was installed at the end of 2019 with the new products launching early 2020. ‘We're looking forward to starting up with the new products, and we believe that the new equipment will be working hard from the beginning of the year,’ concludes brewmaster Ville Vilen. •

1 & 2: GEA's AromaPlus membrane dealcoholisation unit was installed at the Laitilan Oy's brewery plant at the end of 2019

GEA – www.gea.com

28

Food Review | February 2020

We’ve bought Africa a little something special...

and it’s almost ready to ship!

Contact: 011 865 8360 | Email: info@phoenixpet.co.za | Website: www.phoenixpet.co.za

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

Technology that answers the beverage industry’s needs The food industry is looking for natural and environmentally friendly processes. The aim is to assist processors in keeping the flavour and nutrient characteristics of fresh food while providing food safety and extending shelf life. In this scenario, high-pressure processing (HPP) appears to be a sure fit.

H

PP is a non-thermal preservation

- Brand protection: Ensures food

‘HPP technology has become popular

technology that applies high

safety, reaching five log reduction of

in the beverage industry, particularly in

hydrostatic pressure during

pathogenic microorganisms.

the premium juice segment as it enables

seconds or minutes to packaged products (inpack). Its advantages are well known: - Premium quality: Sensorial, nutritional and functional properties are preserved up to

-

DID YOU KNOW? In-pack or in-bulk high-pressure processing technology is among some of the most technologically and innovative answer to the beverage industry’s needs.

three months in refrigerated conditions.

Market expansion: Extends

a product to retain its freshly squeezed

shelf life by up to 10 times.

attributes,’ explains Dr Carole Tonello,

This technology allows

applications and commercial director at

the positioning of

Hiperbaric. The company is the leader

innovative products in new markets.

It is applied in a wide variety of products

in designing and manufacturing HPP units with a current market share of 60 per cent.

‘Other beverages such a vegetable soup, probiotics, fermented beverages or

including wet salads and

non-dairy milk also benefit from these

dips, meat products,

advantages. Very few products cannot be

seafood, ready-to-eat meals

processed by HPP,’ she points out.

and beverages.

STRATEGIC AND TECHNICAL ADVANTAGES OF HIPERBARIC 'S HPP - Versatile design: Intensifiers (highpressure pumps) can be installed alongside the machine, in a service corridor or a platform on top of the vessel.

This last design reduces the footprint and facilitates its implementation in a food industrial environment.

- Wide range of industrial machines: From 55 to 525 litres, HPP machines meet the requirements of start-ups, small-medium enterprises and large corporations.

- Labour saving and greater flexibility: HPP units are integrated with their loading and unloading lines and systems. Hiperbaric can provide further turnkey automation solutions adapted to customer needs.

- Aftersales service and support: Offers highly specialised field technicians, diagnostic services and remote monitoring, after-sales portal, etc.

All are customer-oriented to satisfy its requirements.

- Green technology: An environmentally friendly process because HPP machines only need water (which is recycled) and electricity.

30

Food Review | February 2020

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

Carole Tonello

“HPP technology has become popular in the beverage industry, particularly in the premium juice segment as it enables a product to retain its freshly squeezed attributes”

These advantages can reduce time-outs, resulting in fast and reliable processes. Since 2018, the beverage industry has a specific unit designed to achieve the highest efficiency and profitability in high-pressure processing.

‘HPP in-bulk technology is a global innovation developed by Hiperbaric. This new technology allows the processing of a large volume of beverages in bulk (before bottling).

The unit features a simpler process with fewer steps, but higher productivity,' Dr Tonello notes.

Beverages are processed in a bag hosted inside the vessel. This occupies 90 per cent of the total volume, which is roughly double than the one achieved with conventional HPP technology. In-Bulk technology fits perfectly

HPP machines meet the requirements of start-ups, small-medium enterprises and large corporations

into any large beverages production line and allows the use of any kind of packaging after HPP, no matter the material, design or size.

Hiperbaric also offers advice and consultancy for the development of new drinks by HPP in its pilot plants in the US and Spain. In this way, producers will be able to know the process adapted to their brand. •

Hiperbaric - www.hiperbaric.com

Control of spoilage & pathogens

Mantain quality of fresh juices Non-thermal process

Clean label

High Pressure Processing FOR JUICES & BEVERAGES High Pressure Processing (HPP) is a non-thermal processing technique by which juices & beverages are subjected to a high level of pressure, extending the shelf life and maintaining all the properties of the fresh product, without adding any preservative. www.hiperbaric.com

February 2020 | Food Review

31

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

New flexible filling solutions for sensitive products Print and apply labelling offers great advantages for production operations. It’s considerably faster and more reliable than manual applications. The system reduces waste, labour and possible operator errors, while impacting on running costs and downtime.

D

emand for functional food with

A NEW KID ON THE BLOCK

we minimise the risk of soiling. This has

less sugar is growing. ‘Keeping to a

KHS recognised the potential of PET

a positive impact on hygiene and line

healthy diet plays a central role in

the lives of consumers,’ explains Thomas Redeker, sales director for Dairy Europe at the KHS Group. ‘Demand for products that are sustainably packaged and attractively presented has also increased in the past few years.’

containers for aseptic filling 25 years ago. Its latest development is the linear InnoPET BloFill ABF aseptic block. The unit combines the rotary InnoPET Blomax Series V stretch blow moulder with the linear Innosept Asbofill ABF 712 aseptic filler.

DAIRY INDUSTRY INNOVATIONS FILLED INTO PET CONTAINERS PET bottles are the ideal vehicles for this new trend. Dairy products producers are relying on containers made of polyethylene terephthalate. ‘Producers and consumers are convinced by their many different advantages,’ Redeker points out. This includes capacity for individual designs offered by this type of container.

‘PET bottles lend themselves to the exclusive design. The cap and label can

The block yields many benefits. It takes up less space than individual machines and the air conveyor is no

“Fast format changeovers within the space of up to ten minutes also help to boost system availability”

also be perfectly tailored to the brand.

Fast format changeovers within the space of up to ten minutes also help to boost system availability. They are performed under aseptic conditions, doing away with the need for any additional cleaning and sterilisation. Short changeover times also let producers of sensitive beverages fill several different stock-keeping units (SKUs) in a short time. The linear aseptic block is designed to fill milk, mixed milk beverages, juice, smoothies and iced tea into PET bottles holding between 250 millilitres and two litres. The equipment outputs up to 12 000, one litre bottles and a maximum of 15 000 0.5 litre bottles per hour.

Bottlers also profit from the modular design of the dry aseptic block, which allows the filler to be expanded at any time. Operators can retrofit the block

This has a positive effect on brand

with a chunk filler or additional filling

positioning at the point of sale.’ Plastic containers also score well when it comes to their environmental balance as they are fully recyclable. PET bottles provide reliable product protection and good pouring properties.

availability,’ Redeker notes.

longer required. This cuts down on energy consumption. Another advantage is that personnel costs are reduced as only one operator is needed in place of two.

‘By blocking the machinery and including a continuous clock module

and capping unit. ‘The modular design gives our customers greater flexibility.

They don’t have to think about the precise products they want to bottle when purchasing the block. KHS enables them to retrofit the required modules onsite as soon as they expand their product portfolio,’ Redeker highlights. This, in turn, permits beverage producers to react more flexibly to changing market demands.

HIGH ENERGY SAVINGS - GENTLE ON THE ENVIRONMENT With the integration of the stretch blow moulder, the aseptic block gains several further plus points. One of these is that the heating system in the new Blomax generation consumes up to 40 per cent less energy compared to most standard heating systems. This is due to the optimised near-infrared heating concept and new Double Gate technology.

It is made possible by the near-infrared heater centrally installed in the closed reflector tunnel. In the heater, the preforms pass the centrally arranged The heating system in the new Blomax generation consumes up to 40 per cent less energy compared to most standard heating systems

32

Food Review | February 2020

heating units to left and right. Preforms are spaced just around 18mm apart instead of the previous approximately

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

KHS ensures this by gentle non-contact filling performed in two stages. This prevents any excessive beverage foaming.

After filling the bottle is conveyed to the capping unit. The closure is sterilised in the same manner as the bottle in the filling section. This entails two-step disinfection with H2O2 and two drying stages with hot sterile air. 'In the capper unit, we've made sure that all parts in the aseptic zone have a flat surface.

This prevents air turbulence, making cleaning and disinfection easier,’ Redeker comments. The bottle is then dated for full documentation of all information.

The linear Innosept Asbofill ABF 712 filler for sensitive products is available in a standard aseptic and ESL version

37mm. This considerably reduces the

several stages. First, the machine

number of heater boxes used.

disinfects the neck and bottle interior.

The air management system for heater

The inside of the container is sprayed

box ventilation has also been optimised.

twice with a hydrogen peroxide aerosol

‘The fan can be set separately for the

(H2O2) at a speed of up to 80km an hour.

neck, reflector and lamps. This means

‘This ensures that every part of the bottle

that the machine only cools the areas

is sprayed and sterilised; we even achieve

which need cooling.

this with individual designs and critical shapes,’ Redeker states. Secondly, two

EFFECTIVE STERILISATION WITH THE KHS SYSTEM

aerosol reaction cycles are initiated.

When further developing its linear aseptic

drying process which uses sterile hot air.

The process ends with a four-stage

filler KHS focused on increased efficiency. products is available in a standard

GENTLE FILLING ENSURES PRODUCT PROTECTION

aseptic and ESL version. In the KHS

To ensure the quality of the products, the

process sterilisation takes place in

aseptic zone must be clean.

The filling machine for sensitive

‘Our customers can always see which product was filled on which valve.’

ONE-BLOCK SYSTEM With its new dry aseptic block, KHS has reacted to current dairy demand for flexible, resource-saving filling of sensitive products.

The new system boosts line availability and considerably reduces energy consumption. Operators also have greater flexibility thanks to the short changeover times: format changes are facilitated by the well-coordinated interfaces. The modular design also enables customers to expand their linear aseptic filler block to meet current market demand. •

KHS – www.khs.com

Waves of change in soft drinks choice

Over the past 10 to 20 years, ripples of change in the global soft drinks market have threatened to become tidal waves. New categories are constantly emerging and genuine novelty is flooding the shelves.

A

report from Innova Market Insights

distinguishing themselves on a

highlights that the global shift in

global platform.

soft drinks indicate that juices and

As well as the emergence of new categories,

carbonates may still be the two most active

overlap between existing varieties is

sub-categories worldwide. Growth is much

continuing. ‘Hello Hybrids’, one of Innova’s

faster in alternative areas.

Top 10 Trends for 2020, is perhaps nowhere as

Ready-to-drink (RTD) sports drinks saw

important as in the soft drinks arena. ‘Category

launch numbers increase at a CAGR of

definitions are blurring all the time,’ says Lu

26 per cent over 2014 to 2018. This compares

Ann Williams, director of Innovation at Innova

with 12 per cent CAGR for iced tea and

Market Insights. ‘In the US, Odwalla has recently

coffee and 10 per cent CAGR for ‘other’ soft

developed the Smoobucha, which is a blend of

drinks, including novelties such as herbal,

fruit smoothie with fermented kombucha.’

jelly and vinegar drinks.

Flavour trends also demonstrate the

At the same time, as suppliers seek new platforms for success, segmentation is also

changing face of the market. The fastest

changing the face of the soft drinks shelves.

growing flavours in recent years include

For example, Water+ is an established

matcha tea (+49 per cent CAGR 2013 to

concept, but is continuing to evolve beyond

2018), apple cider vinegar (+21 per cent

vitaminisation and added energy, with fibre,

CAGR) and kombucha (+21 per cent CAGR).

probiotics, collagen and mood ingredients all

These thriving concepts from Asia are now

finding their way into modern waters. •

February 2020 | Food Review

33

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

Original freshness and shelf life guaranteed Modified atmosphere packaging (MAP) food products is popular, offering several benefits to food producers, packers and consumers. Food Review spoke to Zibo’s Neil Engelbrecht on what makes this type of packaging ideal for the food and beverage industry.

F

ood is a biologically sensitive

DID YOU KNOW?

substance. Its freshness and shelf-life are affected by

a product’s inherent properties.

These include the presence of microorganisms, cell respiration, pH and food composition.

External factors, such as temperature, hygienic conditions,

Zibo offers a one-stop-shop for all your machine, tray and lidding film needs. The company can troubleshoot and resolve any problems or questions you might have.

gas atmosphere and processing methods can also impact the quality of a product. MAP is a natural shelf-lifeenhancing packaging method that maintains the quality of food by retaining its original taste, texture and appearance.

MEAT & MAP Zibo tray sealing machines can move through a vacuum and subsequent gas cycle where the right food gas is inserted into the meat trays to ensure that the right environment is present in the pack. The effect is that the pack inhibits microbial growth activity by effectively slowing down the spoilage or ageing process. The gas composition would be different for raw red meat and raw chicken. Carbon dioxide content in the pre-mixed gas is important as most microorganisms are strongly affected by the presence of CO² to prevent spoilage.

In the event of vacuum skin packaging, the vacuum cycle of the tray sealing machine is not followed by the gas flush cycle. A top sealing film (skin) seals over the meat cut onto the bottom of the tray surface. In this sterile environment, the meat products’

produce, temperature, maturity at harvest, mechanical injury and contamination.

In the case of fresh-cut fruit and vegetables packed in a rigid PET tray, the modified atmosphere can be achieved.

This is not necessarily by flushing the pack with a gas. While successful, it can be more expensive, but by sealing the tray with a permeable (breathable) top lidding film. This allows the fresh, living product to respire to effectively reduce the ripening or ageing process and in doing so, extending the product’s shelf-life.

Micro-perforated lidding films (mostly laser perforated) are supplied by Zibo to seal and preserve a wide range of fresh fruit and veg products.

Local packaging supplier Zibo supplies three major components for MAP packaging:

• Tray sealing machines with vacuum and gas features for gas flush and vacuum skin packs • PET monolayer or PET/PE laminated trays, PP trays and cardboard tray for skin packaging • Range of top seal lidding films for practically every application and a selection of appropriate high barrier or micro-perforated (breathable) lidding film are available for specific food applications.

Benefits of MAP for packed fresh produce products • Flavour and aroma is preserved • Texture is maintained by reducing dehydration

• Appearance is maintained • More hygienic as safe aerobic conditions are maintained.

shelf-life is greatly extended.

FRESH FRUIT & VEGETABLES Fresh produce is living material and continue to respire after harvesting and processing.

To extend a product’s shelf-life, the rate of aerobic respiration must be decreased.

The slower the product's respiration → the longer a products’ shelf-life. Many factors influence respiration and shelf-life including the type of

34

Food Review | February 2020

Vacuum skin packaging prevents the premature deterioration of packaged food products

Zibo Containers are manufactures of rigid plastic containers for a wide variety of applications predominantly for the food packaging industry. Zibo has positioned itself as a single source (one stop shop) supplier of recyclable PET food trays, lidding films and tray sealing machines all available from the Zibo sales offices around the country.

We are certified to BRCGS and Sedex standards.

Step it up a notch with the GRANDE from Zibo. This semi-automatic tray seal system is capable of producing MAP (vacuum gas), vacuum skin packing (VSP) and sealing of pre-formed trays and cups.

The manual turntable operation considerably cuts cycle times and optimises output. It allows the operator to load and unload trays at one station while the machine is performing a seal cycle at the other. When ready, the operator will rotate the table and the cycle begins again.

CAPE TOWN

JOHANNESBURG

DURBAN

PORT ELIZABETH

+27 (0) 21 905 3050 10 Rubicon Street Saxenburg Park 1 Blackheath Cape Town, Soth Africa

+27 (0) 11 613 6797 9 Purlin Street North 21 Industrial Estate Olifantsfontein Johannesburg, South Africa

+27 (0) 31 705 7532 107 Escom Road New Germany Durban, South Africa

+27 (0) 41 450 6228 +27 (0) 79 949 1959 17 A Darling Street North End Port Elizabeth, South Africa

Zibo Containers (Pty) Ltd

www.zibo.co.za

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

A SINGLE SOURCE VALUE ADD APPROACH

RECYCLABILITY OF MAP PACKAGING

Zibo supply customised tray sealing

For MAP packing of products PET (monolayer)

machines for most applications including

material is the polymer of choice as it is fully

pack, MAP and/or skin.

recyclable. The inherent barrier properties of

All machines are covered by a

the rigid PET tray make it ideal for MAP packing

manufacturer’s warranty.

of fresh products as discussed.

Trained technicians are situated in major

barrier, high clarity lidding film for MAP meat

and repair tray sealing machines. The

and convenience foods packaging is now over 95

company offers:

per cent polyester (PET). It is recyclable and the

• A wide range of spares for tray

ideal material to seal to monolayer PET trays.

sealing machines

FAST FACT:

Products that benefit from MAP technology include fresh meat, fish, chicken and convenience food items such as sandwiches, wraps, fresh pasta, salads and fresh-cut fruit and vegetables.

The recently perfected thin gauge, high

centres to install, train personnel, service

• Standard or customised rigid trays to pack a variety of products

Historically, plastic meat trays in South Africa have been made in a lamination construction of PET/PE (not recyclable). This has been the

• A wide range of lidding films for

case to accommodate a PE co-extruded high

every application

shrink lidding film. This film is of PE multi-layer

• Technical assistance for running

construction and cannot be recycled with the

product trials

PET tray in the same recycle stream. This film is

• Work in conjunction with the major gas

now outdated and superfluous.

supply companies in Southern Africa such as Air Products

A PET monolayer rigid tray (inherently adequate barrier properties and recyclable),

• Offers a gas analysis of the

sealed with the polyester (PET), high barrier

ECONOMIC BENEFITS OF MAP

pack’s atmosphere

lidding film is both recyclable and is fast

• Excellent retail shelf appearance →

• Tray sealing demo room where

becoming the preferred choice for the MAP

increases sales • Longer shelf-life • Increased supply chain reach • Less wastage → saves money.

customers can perform various machine

meat tray format. •

trials and see the MAP and skin machines in action • Expert advice and assistance.

Zibo – www.zibo.co.za

Find the perfect packaging solution for fresh products The presentation of your product is just as important as its quality. With so many options, it is difficult to decide on the best solution.

O

ne solution, where a top film acts as a

packaging available to smaller production

second skin laid tight over the product

areas. It also offers customers with limited

and all its contours, is skin packaging.

space the opportunity to package high-

This process improves food safety and extends product shelf life while maintaining product

quality products in attractive packaging.

The highly regarded Optimus

quality. Skin packaging is particularly popular

thermoforming is an ideal unit for those

for meat and fish products.

customers with a limited production area.

Skin packs are now possible on the

The technology offers innovative

Variovac Rotarius, supplied locally through

technology on a compact thermoformed and

USS Pactech. This semi-automatic tray sealer

is the perfect machine to get started with

with minimal space requirements makes skin

automatic packaging.

Rapidairsystem is standard on all Variovac systems and can achieve precision The Optimus thermoformer

packaging for both semi-rigid and flexible film applications at a higher output than traditional systems, while the Primus is ideally used in larger production areas.

This formidable packaging machine is fully automatic and available with versatile equipment options. •

USS Pactech – www.usspactech.co.za

36

Food Review | February 2020

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

Take a fresh look at tray packaging Fresh protein is a sector where advances in pack formats and packaging technology can have a marked effect on the quality and look of a product, writes Tony Burgess. demands. While always an issue when introducing new formats and technologies, the recent anti-plastic backlash in the consumer media has led to many companies and retailers seeking alternative materials, or lightweight existing trays.

Proseal has been working closely with film suppliers to devise suitable solutions that can meet the sealing needs of trays made from plastic and cardboard. This will ensure that processors have the flexibility to quickly change formats Manufacturers can easily switch between different size packs during production for different portion sizes

T

he introduction of shrink-wrapped trays first enabled retailers to offer pre-packed fresh products in a

conveniently-sized format that could meet emerging trends for convenience shopping.

The advent of top-sealing food trays with a heat-sealable film revolutionised this. The technology-enabled sealed packs to be better displayed, while the hermetic seal could improve food safety and open the chance for the application of shelf-life extension techniques.

by simply replacing a film reel with no need to adopt new tooling at the same time.

Amidst all this potential change in pack materials, one thing remains constant: in competitive markets handling perishable foods, the ability to maximise throughput is vital. Any tray sealer solution must keep up with other equipment on the line.

Cycle speed is naturally key, but another following motion and intelligent buffering capabilities. This enables trays to feed continuously into a tray sealer without having to pre-sort and adjust pack spacing - saving valuable time.

The proliferation of pack formats means that tray sealers must easily handle all these manufacturers can switch between different size packs during production to prepare different portion sizes. It is also important that tray sealers feature an element of

These techniques or modified atmosphere widely adopted. The system improved product protection and significantly

• operate effectively at variable speeds • compatible with a wide range of materials • feature an element of future-proofing • stay relevant in a changing climate.

Amid these considerations, one factor remains critical: Top sealing of trays plays a major role in preserving products and reducing food wastage. The development and introduction of any new pack format or material must never be to the detriment of shelf-life. •

future-proofing. This will enable them to be adapted to handle new formats as they are introduced, while formats that are no longer required can be removed.

Flexibility is one of the most important requirements of tray sealing machines for

packaging (MAP) meant gas flushing became

Trempak is the South African agent for Proseal tray sealers. The company brings 33 years of local industry knowledge, and expertise in both packaging machinery and flexible packaging materials to the relationship and offering. Trempak is perfectly poised to marry up customer requirements with the appropriate Proseal option and provide expert sales, service and spares back-up to the local market.

Trempak intimately understands MAP technology and has years of expertise in servicing customers in this market sector. They provide a one-stop solution for machinery, spares and servicing, as well as a multitude of complementary films and technical support for fit-for-purpose solutions to players in the meat and poultry, fresh produce, prepared and convenience food sectors.

important benefit of a tray sealer is its

different formats. This helps to ensure that

“…the anti-plastic backlash in the consumer media has led to many companies and retailers seeking alternative materials or lightweight existing trays”

FAST FACT:

ABOUT THE AUTHOR TONY BURGESS head of sales at Proseal in the UK.

meat poultry and fish. To meet the everevolving requirements for their packaging, the latest packs and technologies must offer the following:

Trempak – www.trempak.co.za

extended the shelf-life of protein produce across the board. More recent developments (such as skin packaging) have further advanced the benefits of on-shelf presentation and product protection.

While this opened huge opportunities

Motion and intelligent buffering capabilities enable trays to continuously feed into a tray sealer

for meat and poultry processor, it also brought challenges to the table. The biggest is that processors must react quickly to changing market requirements and consumer

February 2020 | Food Review

37

M A P & VAC U U M PAC K AG I N G On-the-go consumers are looking or convenience

MAP fits the bill for modern consumers

The crux of successful food packaging is to protect, preserve and where possible extend the shelf life of products. If you add visual appeal and branding, environmental issues and production efficiencies, food packaging must deliver a great deal.

T

he benefits of extended shelf life by using MAP techniques cannot be overstated. By controlling

levels of carbon and oxygen and temperature, it’s possible to slow down product degradation to maintain

FAST FACT:

All the efforts to preserve, protect and extend shelf life, amount to nothing if the packing is unattractive and lacks visual appeal.

Trempak is a proudly South African

Tremfresh, the speciality division within Trempak focusses on all aspects

total solution flexible packaging

of shelf life extension, in active and

company, providing diverse and

passive applications.

high-quality packaging materials, packaging formats and machinery

Active MAP is generally used in the meat and poultry industry, which

options. The company offers food-tech

introduces gas into the package via gas-

services to develop optimal packaging

flushing and also uses vacuum packing.

specifications for end products on

The passive approach is to micro-

behalf of customers.

perforate the film to create the correct

Using laser technology, the film is

balance between O2 and CO2, whether

perforated to exacting specifications for

tray sealing, shrink-wrapping, form-fill-

every food application – not a one size

seal or hand-filling bags.

fits all approach. This technology can be applied to tray lidding, film for form-

With the correct packaging applications, carefully specified

fill-seal applications, bags

materials and perforating

and pouches.

name of the game.

The number one benefit of shelf-life extension is to reduce food waste. In a country, indeed a world, where

DID YOU KNOW?

Trempak has been the sole representative in

Trempak is the South African agent for Proseal tray-sealing equipment; Smipack shrinkwrapping machinery and Audion sealing and vacuum packing machinery.

and consumers.

Extended shelf life results in fewer deliveries to stores, meaning lower

shrink film for over 18 years. Whether you are looking for barrier properties for MAP, antifog or perforated film

range has an applicable film.

target should be paramount for producers, retailers

South Africa for Bolloré

for breathability, the Bolfresh

millions are starving, this

Bolloré films are also an environmentally friendly alternative to PVC shrink.

The range delivers on quality optics,

carbon emission from transportation.

liquid leakage protection preventing

If fewer products are thrown away

contamination, high puncture resistance,

due to spoilage, less packaging ends

high-speed production and extended

up in a landfill. This could, in turn,

shelf life.

contribute to lower overall costs in the

In conjunction with Italian shrink-

supply chain, resulting in consumer

wrapping machinery, Smipack (also in

savings and reduced environmental

the Trempak stable) a complete shrink-

impact.

wrapping solution is covered.

38

Food Review | February 2020

combination of machinery and materials is the goal for all producers. Increasing automation and packing speed not only but may also contribute to improved

nutritional value.

optimising shelf life is the

to packaging. Having the perfect

contributes to production efficiencies

visual appeal, aroma, flavour and

patterns, extending and

Production efficiencies are an important factor when it comes

shelf life due to faster packing and rapid storage at the correct temperature.

On pack printing vs. labelling is more convenient from a production standpoint. It’s usually kinder to the environment as it’s easier to recycle without the label. There’s no danger of the label being incorrectly applied to cover the perforations, rendering them compromised or ineffective and shortening shelf life.

Trempak offers digital printing expertise through its sister company, Didget, with inhouse design support. The benefits of digital printing with zero origination costs, outstanding print quality and small MOQs mean the potential and possibilities are available to large and small producers alike. Seasonal and promotional packs are seamlessly integrated with the others, with no production-line tweaks necessary.

‘We supply, commission and service all machinery, keeping spare-parts and service items on hand.

We stock a full range of flexible packaging, including speciality laminates, polyolefin shrink film, anti-mist lidding, film, bags, printed and unprinted options and food tech support, Trempak is uniquely geared to offer customers comprehensive, professional and relevant packaging solutions, backed by over 30 years expertise and service to the industry,’ Brenda Harris of Trempak concludes. •

Trempak – www.trempak.co.za

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

Modified packs for the freshest product In the food sector fresh, perfectly hygienically and safely packaged goods are vitally important. The range of food products requiring packaging is extremely diverse and extends from fresh fruit and vegetables to meat, cheese, ready meals and convenience food. packaging system that can be adapted to

meet the barrier property requirements of a

meet these objectives.

respective product.

SKIN PACKAGING

respective parts by the end-user, and either the

Multivac being one of the pioneers, has

paper carrier material or the complete paper

many years of experience in vacuum skin

composite can be put into the recycling loop.

All materials can be separated into their

1

1 & 2: Multivac has extensive experience in skin packaging

technology. MultiFresh packaging machines

packaging materials is that paper fibres can

of pack size, output and level of automation.

be reliably regained from recycling streams of

They are designed for packing a wide range

other packaging materials.

product protrusion heights.

The special MultiFresh films combine

ecure packaging lines must deliver products of consistent high quality that fulfil several functions, although

one takes priority. Packaging solutions must ensure that after long transport distances and storage periods, goods retain their freshness and reach the supermarket with the original packaging intact.

MODIFIED ATMOSPHERE PACKAGING (MAP) One way to improve presentation is through modified atmosphere packaging (MAP). The technology modifies gas atmosphere in a pack so that its composition differs from that of regular air atmosphere. In comparison with chemical or thermal processes, packaging with protective gas is a gentle process. Other methods for extending shelf life can be used in combination. Using MAP only delays the deterioration and spoilage of food. Flawlessly hygienic processing and high-quality raw materials must be guaranteed.

A wide range of automated packaging systems that enable producers and processors to implement MAP technology is available.

All Multivac's roll stock thermoform systems, automatic and semi-automatic tray sealers and vacuum chamber systems have MAP capabilities. Processors can even thermoform

An additional advantage of paper-based

meet all the market requirements in terms

of meat and sausage products with different

S

2

Another benefit of Multivac PaperBoard material is the wide range of designs that can be printed. This contributes significantly to

functional benefits with outstanding visual

differentiation at the point of sale. Product data

properties. Films protect the product

can be displayed on the paper carrier material.

reliably without deforming it and feature

This eliminates the need for large labels.

a high level of transparency and brilliant gloss. Thanks to the unique interaction of machine and packaging material, vacuum skin packs of ground-breaking quality and perfection are produced.

ALTERNATIVE PACKAGING CONCEPTS With Multivac PaperBoard, Multivac supports

“All Multivac's roll stock thermoform systems, automatic and semiautomatic tray sealers and vacuum chamber systems have MAP capabilities”

customers to increase the recyclability of packaging concepts and to reduce the

Multivac works with manufacturers on the

consumption of plastic film. Multivac’s

development of suitable materials, which

PaperBoard material can be run on

can be run on standard packaging machines.

packaging systems in rolls, pre-cuts or trays.

Thermoforming packaging machines and

Paper fibre and cardboard composites with

tray sealers can be individually customised

different grammages and functional layers

to the particular output requirements of

are available.

customers. MAP and skin packs made from

The use of functional layers makes it possible to produce paper-based packs that

paper fibre-based materials can be run on Multivac systems.

Skin packs based on flat cardboard carrier

MAP packaging can improve the appearance of a product

material can be produced on Multivac thermoforming packaging machines and tray sealers.

In contrast to tray sealers, where cardboard pre-cuts are run, thermoforming packaging machines can use material from a roll. This makes the technology far more flexible with regards to the shape and design of the pack. Running the material from a roll is also significantly more efficient. •

a custom-shape re-sealable box in line with a modified atmosphere. No matter what the processor's needs and goals are, there is a

40

Food Review | February 2020

Multivac – www.multivac.com

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

Successful shelf life extension Extending a product’s shelf-life should offer benefits that will justify the capital investment required. The move from cheap packaging, wrapped in cling film to more appealing trays and lidding film can assure that the shelf-life is extended by between 10 to 15 days from packing.

A

to match another shaped container

motz Gola, of A.G.Q.P.E.,

should you wish.’

spoke to Food Review about the packaging

out that the containers and

The FP 400 is the smallest machine currently available, which can seal food in a vacuum, map or skin.

the correct containers

benefits of doing this instore, with minimum capital investment.

The company offers a range of machines constructed by Italian

Golan is quick to point

DID YOU KNOW?

and film on offer and

Group, Ilpra. ‘The smallest machine we offer is the FP Basic Progas. The tabletop units, FoodPack Basic and Energy offer you the

lidding film must be chosen by the customer. 'We must guide you to use and to ensure that the packaging material is correct.’ The same applies to lidding film. The film’s properties must match the properties of the

tray. ‘Together, this will form a box

option of MAP applications and allows the

extending the shelf life of food. The film

user to vacuum, seal or just seal food in

will have the required barrier; it will be

trays,’ he points out.

clear and will have anti-fog properties.' •

Ilpra manufactures a full range of machines up to fully commercial sealers. ‘It is possible to order a second sealing head

A.G.Q.P.E. - www.foopackagingsystems.com

The Ilpra tray sealer

February 2020 | Food Review

41

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Sales executive +27 (0)82 976 6541

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Sales executive +27 (0)83 260 6060

Càndida GiambÒ-Kruger Sales executive +27 (0)71 438 1918

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