Food Review June 2021

www.foodreview.co.za

June 2021 Vol. 49 • No. 6

SOUTH AFRICAN JOURNAL FOR FOOD AND BEVERAGE MANUFACTURERS

99

REDUCES BACTERIA BY:

It’s a new era for blending & mixing tech How to limit risk in SA’s food value chain

.99%

Use safe and efficient rPET for a sustainable future

The laminate is impregnated with the ANTI-MICROBIAL product thus it will not wear out or wash off and it will last for the product's lifetime.

Best taste since 1875

CURT GEORGI FLAVOURS – Quality made in Germany

Natural and nature-identical flavours for confectionery, bakery, dairy, co ee and tea.

Since 1875, Curt Georgi stands for remarkable natural and nature-identical flavours for confectionery, bakery and dairy industries – Quality made in Germany. The German flavour specialist is active in more than 50 countries worldwide and o ers tailor-made solutions to his customers.

Be it a low budget or a high end product, a halal, kosher or other certification, an intensive product development for and with the customer supported by experienced confectionery consultants: The Curt Georgi team loves the challenge and finding the best solution for the customer is always the center of interest.

Curt Georgi GmbH & Co. KG Otto-Lilienthal-Str. 35-37 71034 Boeblingen Tel +49 (0) 7031 640101 Fax +49 (0) 7031 640120 www.curtgeorgi.de curtgeorgi@curtgeorgi.de

www.brenntag.com/en-za CT: 021 020 1800 • Jhb: 010 020 9100 Email: InfoZA@brenntag.co.za

EDITOR’S COMMENT

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

Could COVID-19

Layout & Design: Naresh Budraj

be the ingredient of change we’ve been waiting for?

ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0) 83 260 6060 carla.melless@newmedia.co.za Sales Executive: Càndida Giambò-Kruger +27 (0) 71 438 1918 càndida.giambò-kruger@newmedia.co.za

Since the start of the pandemic, food manufacturers have been concentrating on reducing their risk. With the third wave currently underway, stakeholders are placing increasing importance on how companies in the sector approach worker safety.

I

n this edition of Food Review, we unpack

With the new ERP regulations which

the questions of risk management in all its

came into effect in May this year, all

guises. The feature kicks off on page 18

packaging streams in South Africa now

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

with the new launch of AssureCloud, which

have six months to comply to regulations.

CIRCULATION

looks at all aspects of hygiene and safety

By November is will be compulsory for all

throughout South Africa’s value chain. New

converters, manufacturers, importers,

Circulation Manager: Felicity Garbers felicity.garbers@newmedia.co.za

vision analysis technology can improve

brand owners and retailers to either belong

PUBLISHING TEAM

product quality, boost yield and increase

to a PRO or to have formed their own

General Manager: Dev Naidoo

line productivity. Find out how Sightline’s

independent EPR scheme. Turn to page 38

Production Controller: Mandy Ackerman

customisable systems can benefit your

for the full story.

Art Director: David Kyslinger

On a more personal note, I would like to

processes on page 20.

While the pandemic has forced people

introduce you to Tennille Aron who will be

to adapt to new way of working and living,

taking over as editor on Food Review from

it has also highlighted the importance

1 July. Tennille has a strong background

of sustainable food systems. Rentokil’s

in B2B magazines and I am sure that she

informative article (page 22) looks at how

will be an amazing addition to the team!

pest control contributes to customers’

My family and I are taking the plunge and

sustainable agendas. Don’t miss it!

relocating to the UK at the end of the year.

Butter and other fats are important

I want to thank you all for your

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components of bakery and confectionery

wonderful support during my

MANAGING DIRECTOR: Aileen Lamb

products. They provide softness, texture,

7 years as editor. I am going

COMMERCIAL DIRECTOR: Maria Tiganis

lubrication, and a sense of indulgence.

to miss you all.

BRAND STRATEGY DIRECTOR: Andrew Nunneley

Carabuta NH is an innovative ingredient that can be used on its own or in conjunction

CHIEF FINANCIAL OFFICER: Venette Malone

Happy reading,

CEO: MEDIA24: Ishmet Davidson

with butter to achieve a cost-effective

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solution – more on page 33.

We end this edition with a comprehensive article on the PVC market in South Africa.

@foodreview13

@SA_FoodReview

SA_FoodReview

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

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 Aubrey Parsons

Dr Heidi Grimmer

Managing director of Symrise South Africa; chairman of SAAFFI.

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

Rudy McLean

Gail Angela Macleod

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

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

Food Review is printed and bound by CTP Printers.

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3

June 2021 | FOOD RE VIEW

CONTENTS JUNE 2021 Vol. 49 • No. 6

11

“The F&B industry constantly faces the challenge to keep a balance between consistent high product quality, consumer safety and efficient production”

7

WHAT’S NEW

Pushing the boundaries of new product development

8

NEWS

Palsgaard’s next level PGPR The all-round goodness of Vitamin D

Meet Gericke’s new family of mixing solutions

Get creative with these oil blends

The perfect solution for beverage powders

29

18

RISK MANAGEMENT

Safety assured with AssureCloud

New range of filament pirani gauges launched

A new standard in quality control

BLENDING & MIXING TECHNOLOGY

How bottom-mounted magnetic technology can work for you

www.foodreview.co.za

FATS & OILS

How to select the right blender for powder mixing plants

Elke Crouch appointed SU research chair

12

28

Limit pests for increased food sustainability Flexible warehousing solutions that keep your staff safe How to be a food safety warrior

CONVENIENCE FOOD PROCESSING

Integrated solutions for speed and efficiency

36

BEVERAGE PROCESSING TECHNOLOGY

rPET revolutionises the future of beverages

37

FLEXIBLE PACKAGING

Food pigments gives products added shelf shout

Wastewater treatment in plastics recycling

Label friendly plantbased alternatives

Vinyls PackagingPro launches

A butter substitute for better baking

Reduce repacking with these innovate solutions

GEA has the right slicing solution for you

How COVID-19 changed consumer packaging

FOOD RE VIEW | June 2021

5

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June 2021 | FOOD RE VIEW

15 – 30 ONLINE INTERNATIONAL FOOD EXPO Online www.intfoodexpo.com 23 – 25 AFRICA’S BIG 7 Johannesburg, South Africa www.africabig7.com

September 17 – 21 INTERNATIONAL BAKING INDUSTRY EXPOSITION Last Vegas, US https://www.bakingexpo.com 22 - 23 PACKAGING INNOVATIONS & LUXURY PACKAGING 2021 London, UK www.packaginglondon.com 27 – 29 PACK EXPO Las Vegas, US www.packexpolasvegas.com

WHAT'S NEW

New packaging is

rooted in goodness Rhodes Quality is owned by one of South Africa’s leading canned food companies, RFG which has been producing canned foods for over 125 years. RFG is internationally recognised for producing convenient meal solutions for customers throughout South Africa, sub-Saharan Africa and in major global markets. The Rhodes Quality ‘Rooted in Goodness’ repackaging will be seen on the shelf from May 2021, along with the winter campaign. Maria Soares, head of marketing at RFG explains, “The new packaging updates are aimed at

strengthening consumer sentiment towards the brand by addressing their needs for wholesome meal solutions while maintaining quality and convenience codes, which Rhodes Quality is known for and associated with.” Tamara Patel, brand manager for Rhodes Quality says that the wholesome products and connection to source means that the brand offers consumers the quality, convenience and care, packed into convenient and innovative packaging across a range of goods.

“The pack refresh consists of a shift in

logo colour towards a more natural and vibrant green, a modernised font and an evolution to a fresh, 3D logo. “The onpack photography highlights the quality ingredients we use in our products while driving the connection to source, and makes use of clever food styling which cues visuals of ‘freshly prepared’ food aimed at demonstrating the appetite appeal of our range.” •

Introducing a proudly South African,

zero sugar, low alcohol hard seltzer Freely’s new zero sugar, low alcohol hard

into the beer and cider market as a low carb

seltzer is the latest buzzword on the South

alternative. On the global front, the hard seltzer

African dinks scene. The beverage has been

market is expected to grow at a phenomenal

launched in step with the growing global trend

annual rate of 16.5% over the next six years.

towards alternative refreshment for a lighter, more balanced lifestyle.

What sets Freely apart from other hard seltzers, is its lower alcohol content (just 3%),

Crafted by Nature’s Own Beverages, a small,

lower calories (23 kilocalories per 100ml), zero

independent local producer, Freely is a proudly

sugar and, above all, premium taste. As a spirit

South African sparkling water with a splash of

based drink, Freely is also gluten free and vegan

premium distilled vodka and pure fruit taste.

friendly and available in three refreshing flavours

Hard seltzers are low calorie blends of

– zesty Lime, perky Peach and a burst of Wild

sparkling water, alcohol and natural fruit flavours.

Berry – in stylish glass bottles for the ultimate

In the US, hard seltzers are making inroads

pure taste experience. •

A hint of garlic to spice things up Nando’s has announced the launch of its new Garlic PERinaise – a welcome addition to its fan-favourite PERinaise range. Now available in selected supermarkets, PERinaise fans can dip, cover and smother their Nando’s deliveries, and home cooked meals in the flavour-filled sauce whilst at home, in lockdown and beyond. The condiment features the creaminess of a dressing mixed

with the spiciness of PERi-PERi coupled to a burst of garlicky goodness. This makes it the perfect accompaniment for chips and crisps, sandwiches and salads, and anything that deserves a little creamier pizzazz. Out of things to have it on? Just have it on a spoon. Garlic PERinaise joins Nando’s beloved PERinaise range along with Medium, Hot and Lite alternatives, also available to purchase.

FOOD RE VIEW | June 2021

7

NEWS

PALSGAARD LAUNCHES NEXT-LEVEL PGPR

FOR USE IN CHOCOLATE The company has launched a new PGPR product which offers chocolate manufacturers prominent levels of functionality and efficiency. PGPR (polyglycerol polyricinoleate) is used in chocolate production for mould optimisation, flow control and viscosity reduction. Palsgaard’s existing product, Palsgaard PGPR 4150, is a market leader, but the company’s latest offering takes PGPR performance to new levels.

Developed exclusively for chocolate, Palsgaard PGPR 4190 is 15% more

efficient at controlling viscosity than Palsgaard PGPR 4150 and can be used at a dose 30 to 40% lower than other PGPRs, making it highly costeffective. Other benefits include easier flow, better coating of inclusions, and taste- and odour-neutrality. Palsgaard PGPR 4190 will be subject to batch-tobatch checks guaranteeing uniform stability. Morten Hoffmann Kyed, director of product management explains, “We’ve led the market for many years, but this really is the next level for

STUDY EXPLORES HOW VITAMIN D can help reduce the risk of falling

PGPR. Palsgaard PGPR 4190 is the result of years of research and innovation, and it will offer chocolate manufacturers unique, best-in-class functionality. Furthermore, because a tiny drop delivers a huge effect, its benefits also include very high cost-in-use savings.” Although it works well with traditional chocolate emulsifier lecithin, it is an ideal partner for Palsgaard AMP 4455, an alternative to lecithin with better organoleptic properties. •

FRUIT INDUSTRY

strengthened by new SU Research Chair

The link between vitamin D and

“The message of our latest Mind

a reduction in the risk of older

the Gap resource is simple:

adults suffering from a fall is the

increasing vitamin D intake is

focus of IADSA’s latest ‘Mind the

a way to help older adults keep

Leaders in the South African

Gap’ resource. Falling is a risk

their bones strong and reduce

fruit industry believe that the

factor for bone fractures among

the risk of suffering a fall. With

creation of the new Post-Harvest

men and women aged 60 years

many people becoming less active

Physiology Research Chair in

and older. According to the World

because of lockdowns and self-

Deciduous Fruit at Stellenbosch

Health Organisation (WHO), there

isolation, the central message of

University will improve know how

are 37.3 million falls every year –

this new story is more important

about the handling of deciduous

more than 100 000 a day – that

now than ever.”

fruit and be to the benefit of

are serious enough to require attention.

Mind the Gap is an information

producers and consumers. The

resource created by IADSA –

activities of the Chair are being

the International Alliance of

led by Dr Elke Crouch, a senior

Institute on Ageing both suggest

Dietary/Food Supplement

lecturer in the Department of

that a lack of vitamin D could

Associations. It facilitates the

Horticultural Science at Stellenbosch University (SU).

increase the risk of suffering

sharing of positive stories about

a fracture because of a fall.

the benefits that nutrition offers

physiological disorders which occur when apples and pears

The European Commission,

to consumers all over the world

are stored or ripened after picking. This includes internal

meanwhile, has approved a health

and society at large. It also

discolouration and blemishes on the peel of the fruit. She

claim for vitamin D and a reduced

seeks to fill gaps in our scientific

is searching for ways to retain the quality of fruit post-

risk of falling.

knowledge, while promoting

harvest until they are ready for consumers to enjoy. Her

real-life examples of successful

work is also increasingly focused on understanding how

national nutrition programmes. •

conditions being experienced while fruit are still on the

WHO and the US National

Simon Pettman, executive director of IADSA, comments,

Elke Crouch

Dr Crouch focuses on ways to eliminate various

tree affect their quality. “I enjoy finding out why something goes wrong, and to find solutions to ensure that it does not happen again,” Dr Crouch explains the driving force behind her research.

Since 2002 Dr Crouch has been appointed in a research position in the Department of Horticultural Science focusing on postharvest matters. The post has been funded by the fruit industry since the 1980s, through the Molteno and Lombardi Trusts. Thanks to further financial support from Hortgro, the industry body for deciduous fruit in South Africa, the research chair could be established this year.

8

June 2021 | FOOD RE VIEW

NEWS

Compressed air without compromise

with CompAir’s latest L-series range CompAir has announced its latest oillubricated compressors as part of its renowned L-Series range, delivering reliable and efficient compressed air without compromise.

The latest range covers air-cooled models from 55 to 75 kW and is available in both fixed and regulated speeds.

When compared with previous models, the new compressors offer up to 8% efficiency improvements, as well as up to 5% higher flow rate.

The range incorporates many of the market-leading features that the previous models offered – such as an automatic motor lubrication system as standard to help reduce downtime and increase the lifespan of motor bearings, as well as a semi-integrated airend and Victaulic fittings for easy maintenance and reduced leakage risks – but encompasses a range of key new

benefits, too.

One of these is the newly designed, semi-integrated airend. Featuring a new rotor profile that delivers outstanding performance while reducing noise and vibration levels, the airend is manufactured in-house, at the company’s Centre of Excellence in Simmern, Germany. It has also been designed with a larger-sized inlet and outlet. This helps to increase air flow and limit pressure drop, thereby providing owners and operators with best-in-class compressed air performance for this range.

For variable speed models, the new airend comes with an automatic oil regulation valve, which controls the oil’s discharge temperature according to environmental conditions. Not only does this remove the risk of condensate and – as a result – corrosion, but it also

ensures the oil in the system remains at suitably high standard at all times and can improve efficiency levels by up to five per cent.

This has been cleverly integrated, along with the oil filter, into the airend’s housing, helping to eliminate the risk of oil leaks while simplifying maintenance too.

In addition, the new airend is supported by CompAir’s Assure warranty, which covers the airend for up to ten years or for 44 000 hours.

Service and maintenance are a hassle-free undertaking with the latest L-Series compressors from CompAir. All doors on the unit are hinged and can be easily removed, improving accessibility for users while also assisting with space requirements. •

LEYBOLD RELEASES A SERIES OF ROBUST

and compact filament pirani gauges With compact Increased process efficiency and reliability

high end electronics and interfaces,

and rugged

including a bright light ring which

filaments, this

immediately indicates the pressure

latest innovation

range locally.

from the vacuum

the vacuum level in a given vacuum process is key in creating the highest efficiencies.

This is why Leybold has developed the THERMOVAC TTR-RN series, a new compact filament Pirani gauge for all vacuum applications requiring a measurement range from atmosphere to 1e-4 mbar (7.5e-5torr).

A perfect solution for analytical applications and any robust industrial process.

10

June 2021 | FOOD RE VIEW

With reliable and reproducible

specialist is

measurement results, even the roughest

equally well

vacuum processes can be optimised easily

suited for

and quickly. As a result, dead process time is

analytical

reduced and the throughputs in the vacuum

applications and

processes are increased.

robust industrial

The ability to reliably measure and control

measurements. This has been coupled to

dimensions

For standard processes the Thermovac

processes. All in

TTR-RN series has a tungsten filament,

all, the use of the

while for harsher process applications

Thermovac TTR-

a corrosion resistant platinum variant is

RN series from

available. To further increase the reliability

Leybold will support users to more easily

of the gauge a filter is integrated into

monitor small and large vacuum systems

the flange, blocking particles that would

and thus be able to control and scale them

otherwise damage the filament.

in a more targeted manner. The Thermovac

The Thermovac TTR-RN Pirani gauges

TTR-RN series is globally available from

series is available with many flexible options

today onwards.

to suit your need – starting with standard or

The core element of the measuring device

corrosion-resistant measuring cells which

is its new filament technology. By advancing

can be combined with an array of flange

filament technology Leybold increases

types, communication protocols (0-10v,

the sensitivity and thus the accuracy of

RS232, RS485) and output scaling options. •

INDUSTRY TALK

What is behind rising inflation figures?

Food inflation was the primary driver of higher inflation figures recorded for April and Statistics South Africa announced that inflation was 4.4% for April, a 1.2% increase from March, writes Ian van Niekerk, MD of Oakland Group.

I

nflation on food and non-alcoholic beverages came in at 5.2% according to Statistics South Africa’s Consumer Price Index in February 2021 while the National Agricultural Marketing Council’s Food Price Monitor reveals that inflation on their basic urban food basket is 9.8%.

Poorer households appear to be hardest hit by the rising cost of food.

The Pietermaritzburg Household Affordability Index, annualised for March 2021, reveals that inflation on their household food basket is an alarming 12.6%. The Pietermaritzburg Economic Justice & Dignity Group, which compiles the index, expects food prices to rise even higher this year as a result of fuel and electricity price hikes.

“Agricultural economist Wandile Sihlobo says he does not expect food price inflation to exceed an average 5% year-onyear this year based on the fact that many parts of the country had respectable rains, favourable weather conditions and are expecting good harvests” What exactly is driving food inflation?

In 2019/2020 South Africa recorded the second-largest grain harvest on record and impressive output was reported for most major crops and fruit. Despite this, food inflation figures have been steadily increasing since the last quarter of 2020.

While higher international maize prices, a delayed maize planting season, increased demand for maize from neighbouring Zimbabwe and further afield from China, and a weaker Rand have all been suggested as some of the reasons for driving food inflation, the rising cost of agricultural inputs is also driving food inflation higher. In fact, agricultural producer price inflation was already on the rise last year, increasing 12.3% between November 2019 and November 2020.

Manufactured producer food price inflation has also risen from around 4% last year to 8.1% in March this year.

According to Statistics South Africa annual producer price inflation for final manufacturing was 6.7% in April 2021, up from 5.2% in March 2021. The Producer Price Index (PPI) – which measures the changes in the prices of locally produced commodities - increased by 0.7% month-on-month for April 2021.

Food products, says Statistics South Africa, is one of the main contributors to the headline PPI annual inflation rate.

Agricultural economist Wandile Sihlobo says he does not expect food price inflation to exceed an average 5% year-on-year this year based on the fact that many parts of the country had respectable rains, favourable weather conditions and are expecting good harvests. He is optimistic that neighbouring countries will have similarly good harvests which means that there will be less regional demand.

Last year higher regional demand for maize, in particular, put upward pressure on local maize prices. A potentially lower maize price this year will be positive for food price inflation.

However, there is no escaping the risk that higher fuel prices and an increased electricity tariff provide. In the dairy industry these are unavoidable costs. Rising feed prices, including the cost of maize, has a direct correlation

Ian van Niekerk

with the cost of milk production. While most commercial dairy farmers are implementing efficiencies wherever possible, these input costs remain fixed.

The South African Reserve Bank shares concerns around the country’s inflation outlook. The Monetary Policy Committee (MPC) statement pointed to higher oil prices and price pressures from raw materials and intermediate inputs to food.

In the commercial dairy industry producers are typically forced to absorb higher input costs rather than allowing these to be passed on to retailers and consumers, a situation which will ultimately not be sustainable for most commercial milk producers. This, coupled with growing competition from dairy products imported from countries with high dairy farming subsidies, is threatening the existence of smaller milk producers.

It is important for farmers to become part of the distribution chain and for milk organisations that represent farmers to communicate with supermarkets on production price and the need to support local. •

FOOD RE VIEW | June 2021

11

BLENDING & MIXING TECHNOLOGY

The benefits of bottom-mounted

magnetic mixing technology The F&B industry constantly faces the challenge to keep a balance between consistent high product quality, consumer safety and efficient production.

T

o meet these challenges in homogenisation, emulsification and suspension processes, Van der Molen SA as part of NEUMO Ehrenberg Group, provides AWH VPureMix magnetic mixing technology. This can be used in all the above processes with liquid volumes from 3L to 30 000L and a maximum viscosity of 800cP. F&B customers probably tend to think of magnetic coupled mixers as high-priced agitators, which are mainly utilised in pharmaceutical industries, not in their own.

However, product purity and safety, as well as associated consumer safety, are a big concern in both industries.

As a result, the boundaries between the F&B and pharmaceutical industries are becoming blurred.

Hygienic standards in the F&B industry have increased over the past few years, and are increasingly influenced by the pharmaceutical industry.

Strict quality and safety standards are intended to ensure this. But they also make high demands on the entire production plant, where mixing processes are often the ‘Achilles’ heel’ for potential contaminations.

This happens especially when they are equipped with agitators with rotating shafts and

12

June 2021 | FOOD RE VIEW

mechanical seals. In addition to high maintenance requirements and associated costs of mechanical seals, it is often the sealing material itself that increases the risk of contamination due to inadequate chemical, temperature and pH resistance combined with overuse in production, as well as cleaning and sterilisation processes (CIP, SIP).

“The specially designed product-wetted low-shear impeller with magnetic outer rotor and ceramic bearing is hermetically separated from the drive unit with a magnetic inner rotor outside the tank with the help of a weld-in tank plate in the vessel bottom” In addition, shaft penetration contributes to vibrations with an impact on seals, product residues even after cleaning, and additional installation and deinstallation space requirements.

Magnetic mixers provide a remedy by using a permanent magnet coupling instead of shaft

Bottom-mounted magnetic mixing technology enhances safety, sterility and efficiency in F&B production plants

and seals. The specially designed product-wetted low-shear impeller with a magnetic outer rotor and ceramic bearing is hermetically separated from the drive unit with a magnetic inner rotor outside the tank with the help of a weld-in tank plate in the vessel bottom. Thus, the vessel integrity remains preserved and ensures a sterile process. Bottom-mounted impellers in tanks also provide an efficient but gentle mixing result in processes, e.g., liquid/liquid blending, solid dissolution and suspension or heat transfer. This is made possible due to the induction of a radial flow pattern toward the vessel wall and an axial pump flow.

Additionally, low-level mixing can result in a better yield and less residue, because the product is mixed until the very last drop.

This allows subsequent cleaning and sterilisation in-place without needing to remove the bearings and impellers.

In conclusion, magnetic mixers can make a huge contribution towards ideal mixing results, cleanability, sterilisation, and ultimately reduced costs. • About the author: Anja Hauffe is product manager mixing technology for Armaturenwerk Hötensleben GmbH, Germany.

AWH – www.awh.eu

MIXING & BLENDING TECHNOLOGY

This compact mixer is one step ahead

Gericke’s comprehensive experience in continuous mixing and feeding resulted in a new family of mixing solutions, perfectly suited for many food and pet food applications.

T

2

he TCM Turbo Compact Mixer makes it possible to continuously, and fully automatically, feed and mix

up to four streams with minimum space requirements and high accuracy.

In many applications, the demand for flexibility in production is increasing, but without compromising on hygiene and

1 1, 2: Gericke’s TCM Turbo Compact Mixer

cleanability. This often leads to complex The mixing process is both fast and

systems that require time-consuming and

The complete disassembly allows easy

costly dismantling and cleaning. The new

and quick cleaning and even the mixing

gentle, and prevents demixing when used

TCM compact mixer is aimed precisely at

chamber is removable. Downtime due to

directly before filling or extrusion lines.

such processes where demanding additives

cleaning can be reduced by up to 90%.

such as colours or flavours are added. Due

In South Africa, Gericke is represented

by Capack, which is based in Johannesburg.

With small volumes, recipe accuracy is

to the end-of-line addition strategy, only a

guaranteed even with frequent start-stop

The company specialises in powder

few equipment parts need to be cleaned.

operation, which has been confirmed in

handling and packaging solutions. •

This makes the TCM ideally suited for

an extensive series of tests. Despite the

products that must guarantee zero cross-

compact size, capacities of up to 20 000l/h

contamination handling of allergens.

can be realised.

Capack – www.capack.co.za PMD Packaging Systemswww.pmdpackaging.co.za

Leading Edge Powder Processing Technology since 1894

MAXIMISE VALUE  MINIMISE WORRIES Your trusted partner for conveying, feeding, mixing, engineering, automation and service.

Your local contact:

Capack (Pty) Ltd T +27 11 795 1994 info@capack.co.za

gerickegroup.com

FOOD RE VIEW | June 2021

13

BLENDING & MIXING TECHNOLOGY

Selecting the right blender for

powder mixing plants One of the most significant functions and consequently one of the most important aspects in a powder processing system is blending. In this article we look at how to increase value of products in food applications - whether manufacturing sports nutrition products or bakery or anything in between.

A

growing challenge in the powder handling industry is how to accommodate a wide portfolio

well here, such as tumble-blending or ribbon blending.

• On the other hand, for cohesive, sticky

of recipes and vast array of different

powders to mix homogeneously, work

ingredients, several of which pose an

needs to be applied to the material,

allergen risk. Some companies have been

forcing the particles to fold and join. In

willing to spend significant amounts of

this case, blenders offering high shear

capital installing highest speed mixers

in the form of knives or intensifiers are

and packing lines in order to achieve

required. Applying the right amount of

high efficiency and throughput. But just

shear is vital to intermesh and blend

because a mixer is high speed, does it

the particles, however, if mismanaged,

necessarily mean that it provides the best

particle degradation and heat build-up

process solution?

may occur.

Whether you are just getting started, or are a seasoned professional, the choice

BATCH SIZE

of mixers is so vast that the process can

• B ig isn’t necessarily beautiful for

become very confusing. This article poses

blenders. It might be large enough to

some questions to be considered when

match the order amount and batch size

making that all important selection.

but watch out for loading times. Take

Before we get started, the most

into account how long it will take to fill

The Matcon IBC Blender module enables the mixing of any recipe, at any time

important decision is whether to batch or

by ripping and tipping 25kg sacks of

continuously manufacture. Do you need

ingredients. Then think about how long it

operation. It might well only take four

to swap recipes on a regular basis or are

will take to empty the product to packing.

minutes to blend, but it could take two

you producing the same product day in

During this time the mixer will stand idle

hours to load and three hours for packing

day out? If there are no changes to be

and be unproductive which is not Lean.

to call off. Giving a total blending time of

made, then it makes sense to consider

Companies often do not realise the cost

continuous processing with large fixed

of this lost time in filling and emptying the

mixers which are coupled to the upstream

mixer. But it should be challenged for the

longer for the blend cycle (often 10 to

and downstream processes.

waste that it clearly represents.

15 minutes), but in the long run you save

As a lot of manufacturers are finding

• A lso consider whether you will have

five hours and four minutes.

• In-bin/IBC Blending might take a little

time as formulation of the recipe is done

however, consumer desire for more variety

different batch size demands. Do your

off-line and the container is removed

means more and more recipes being added

customers always want the same size

immediately from the blender and

to the ever expanding product portfolio.

orders? Do you have to make small sized

taken off to packing. The filling, mixing

The consequence of which is more recipe

batches of half or a quarter of the large

and packing process steps take place

changes than ever before and means you

batches? If you have wide variability

simultaneously. The blender itself doesn’t

need to take a close look at how you plan

consider using IBCs (Intermediate

need cleaning so it is free to go back into

to conduct mixing. Here batch processing

Bulk Container) Systems for blending,

service immediately. The only limiting

is the only way. The points raised in this

whereby different sized containers can be

factor is how quickly your operators

article refer mainly to the case for batch

accommodated on the one blender.

can install and remove the bins from

processing as it is assumed this is an expanding area of consideration.

the blender.

MIXING TIME • Don’t be fooled by claims of only a four

CHANGEOVER TIME

POWDER CHARACTERISTICS

minute blend time. It’s important to

• If you are making several recipe changes

• A free-flowing powder with similar

weigh up the full end to end process

throughout the day, using a fixed mixer

ingredient particle sizes will mix easily.

stage of blending, from filling the mixer to

can be inflexible. You will need to

A gentler blending approach will work

it being emptied and ready to go back into

conduct a clean-down each time, thereby

14

June 2021 | FOOD RE VIEW

MIXING & BLENDING TECHNOLOGY

increasing the full end to end blending time even further.

• W ith in-bin blending, only the container is cleaned, which is conducted off-

• In bin blending on the other hand offers

line. Even if the IBC has a complicated

immediate change-over as there is no

split butterfly valve which needs to

cleaning of the blender, enabling up to

be removed for cleaning, this won’t

four batches per hour to be completed.

affect the OEE (Overall Equipment Effectiveness) rate of the blender as

EASE OF CLEANING

other previously cleaned IBCs will be

• It is important to ensure that the

returned to the manufacturing process to

expensive, value-adding ingredients

maintain the optimum flow.

aren’t ‘lost’ during the mixing process.

Have you ever considered what you might

RISK OF CROSS-CONTAMINATION

be leaving behind in the blender? All

• W ith an increasing number of products

Rapid batch changeovers and reduced cleaning downtime as the ingredients are fully contained within the IBC

fixed mixers will have some residue left

containing allergens, it can be

behind at the base of the mixer bowl or

challenging to manage changeovers

clinging to the sidewalls, shaft, paddles

and clean-downs. Particularly tricky are

and bearings; this product is then washed

the fixed mixers and in-line conveying

size of the discharge point, as some

away during cleaning. This is valuable

systems because the system is coupled,

powders might be sticky and will have

product that costs money and shouldn’t

so it can take a long time to clean down

poor flow properties so are likely to

be flushed down the drain.

between recipes and to validate that it

become stuck. Then again, the free-

really is clean.

flowing products could suffer from a

• B ear in mind what ‘hold up’ areas there might be in the mixer you are choosing.

• If different recipes are to be mixed on the

core flow through these discharge points which will cause segregation.

Can operators safely and easily access all

same mixer then you need to consider the

the corners and joints? Are the paddles/

risk of cross-contamination if cleaning

shafts removable? Are there easy access

is not done properly. To mitigate the risk,

segregation. Not only is the product

doors? What safety locking systems are

some companies dedicate a blender to

mixed within the container, but it is then

incorporated?

any allergen recipes. This is acceptable if

transported to feed to packing where it

only one additional fixed mixer is needed,

is coupled to the infeed hopper reducing

between recipes can vary from as little

but is it really practical to consider half

the drop height.

as half an hour for a dry clean between

a dozen?

• On a fixed mixer, clean-down time

non-allergen recipes, up to taking a full

• For allergen handling, in-bin blending

• IBCs help to reduce the issue of

A note of caution, not all IBCs are equal.

eight-hour shift for a full wet clean and

offers a simple, safe solution. Containers

Those with butterfly valves can still get

dry. This represents a significant amount

can be used one time for allergens then

product segregation issues due to core

of not only waste, but manpower costs as

cleaned and used next time for a non-

flow and rolling of particles.

this is usually a labour intensive activity.

allergen product. A common blender can

Where this is a high risk, it is worth

be used as there are no product contact

using cone valve IBCs which offer the best

points on the blender.

protection against segregation due to product flowing under mass-flow discharge

AFTER MIXING SEGREGATION RISK

with all particles moving down through the bin in unison.

• Even though the fixed mixer may be

The Matcon IBC Blender module enables the mixing of any recipe, at any time

providing well blended material, this does

FACTORY SPACE

not guarantee production of a quality

• Don’t just consider the size of the mixer

product as it needs to be transferred out

itself - take into account what space you

of the mixer. This is when segregation

need around the mixer for loading and

of the mix might occur as air displaced

unloading product and cleaning. Also

by powder leaving the mixer carries the

check on what ceiling height is necessary

‘fines’ back up through the powder. This is further exacerbated if large product

for access above and below.

• IBC blenders tend to have a small

transfer heights are involved. Here the

footprint and head height, so if space is

particles have more chance to move apart

an issue, then it is worth exploring these

and de-mix the blend as some will move

further. The IBC Blenders can be located

faster than others depending on their

in open areas with low hygiene control as

particle density and characteristics.

they provide a closed process.

• You also need to consider the ease of discharge from the fixed mixer. Ensure

When selecting a mixer, it pays to do

the mixer empties fully with no residual

some research and we hope that this

product held up. Consider the opening

article has given you something to think

FOOD RE VIEW | June 2021

15

BLENDING & MIXING TECHNOLOGY

about. If you choose the right one you also have the added benefits of: • Increased capacity -B y reducing the down time of the mixer for non-value add functions greater efficiency can be obtained and

Matcon Blender can accommodate a range of IBC sizes

production capacity increased.

-Q uick product changeovers due to no cleaning of the IBC Blender provides increased production capacity.

-M ultiple batch sizes can be mixed in one IBC Blender therefore eliminating the need for multiple mixers.

• Cost savings • Improved Product Quality -T hrough reducing the amount of idle time wastage.

- I ncorporating more efficiency in the Blending process can reduce the number of shifts required.

- Lower manpower costs for cleaning.

- Prevent segregation for a better

- Eliminating Inventory or WIP.

have done as good research as you have).

final product that is of high quality

Think differently and see where it may

every time.

take you. •

- Removal of the risk of cross-contamination.

- Closed hygienic system.

-M inimised lost product via residue or scrap due to it becoming de-mixed.

‘what everyone else has got’ (they may not

Don’t just be swayed by choosing the cheapest option just to get started or using

Matcon - www.matconibc.com PMD Packaging Systems www.pmdpackaging.co.za

Dumping from safety cages eliminated with

SMK Nutra Makers improves production of a protein shake sports drink by switching from the manual dumping of powdered ingredients from an elevated safety cage, to emptying handheld sacks at floor level into mobile flexible screw conveyors

flexible screw conveyors SMK Nutra Makers, a formulator and contract manufacturer of dietary supplements and nutritional products, improved production of a protein shake sports drink by switching from manual dumping of a powdered chocolate mix from an elevated safety cage, to dumping of the mix at floor level into mobile flexible screw conveyors.

P

reviously, operators in a safety cage were raised by a forklift to dump 25kg bags of the shake powder

into either of two screeners positioned

feeds a screener and, in turn, a blender.

positioned beyond the discharge point,

above blenders.

SMK owner Avni Patel says, “Manual

precluding material contact with bearings

handling at floor level has increased

or seals.

To improve the laborious, dusty procedure, the company purchased two

productivity, eliminated dust, and improved

mobile, high-capacity flexible screw

worker safety.”

conveyors, each dedicated to a separate

Supplied by Flexicon, each of the Bev-

The conveyor’s charging adapter consists of a trough at the outlet of a pyramidal hopper that exposes the intake

blender. The powder is now dumped at floor

Con model conveyors includes a 7.5m long

end of the spiral to the powdered mix. A

level into the hopper of a conveyor, which

beveled-edge spiral driven by a motor

pneumatically-actuated vibrator fitted

16

June 2021 | FOOD RE VIEW

MIXING & BLENDING TECHNOLOGY

Castor-mounted frame with support boom allows rolling of the unit into position with discharge above the screener, and thereafter to a cleaning area

SMK Nutra Makers formulate and manufacture dietary supplements and nutritional products in powder and capsule forms

to the hopper wall promotes the flow of

Patel says, "We also considered a solid

powder into the trough as the rotating

shaft auger conveyor among other options,

conveyors, bulk bag unloaders, bulk bag

spiral moves it at a 45° incline through

ultimately deciding on the Flexicon

conditioners, bag dump stations, drum/

the enclosed tube, discharging it into

conveyors. The conveyors are precisely

box/container tippers, weigh batching

the screener.

what we needed,” she points out. “We

and blending systems, and engineered

no longer have issues of dust, safety

plant-wide bulk handling systems with

support boom enables operators to roll

and fatigue when moving the chocolate

automated controls.

the unit into position with the conveyor

powder. We’re in the process of expanding

discharge directly above the screener,

and will be ordering additional units.”

A 3.6m high castor-mounted frame with

and thereafter to a cleaning area. Mobility

conveying systems, tubular cable

The company also manufacture other

of the units also provides SMK with the

configurations of flexible screw conveyors,

flexibility to satisfy new processes.

as well as bulk bag fillers, pneumatic

Flexicon - www.flexicon.co.za

GRAMEC MIXER

The features of the Gramec Twin Shaft Paddle Mixer are as follows: MIXED IN 60 SECONDS In many cases, mixing times are as low as 10 seconds, with an average mixing time of less than one minute!

SMALL OR LARGE BATCHES Our mixers are manufactured in 12 sizes from 28 to 5000 litre batch capacity.

Batch levels range from 30% to 100% of nominal.

GENTLE PRODUCT HANDLING Gramec mixers provide such gentle product handling that they can even mix breakfast cereals without breakage.

COMPLETE HOMOGENEITY Gramec mixers offer high-precision blending with a coefficient of variation regularly below 5%.

G0028 Batches from 6kg to 22kg

ELECTRICITY SAVINGS Because of low power input and extremely short mixing times, Gramec mixers save up to 60% of your electricity costs.

VERSATILE FOR LIQUID ADDITION Liquids of varying viscosities can be added to powders, granules or pellets.

G2100 Batches from 500kg to 1400kg

Other products that we manufacture include industrial dryers, vacuum coaters and grinding/pin mills

ONLY MIX WITH THE BEST

GRAMEC (PTY) LTD Contact: Niels Ellefsen Tel (011) 882 1914 • Fax 086 615 1547 • Cell 082 653 6069 niels@gramec.com • www.gramec.com

Gramec half page.indd 1

2021/06/07 12:47

FOOD RE VIEW | June 2021

17

RISK MANAGEMENT

Solutions for working in a focused food safety environment

AssureCloud launches to assure hygiene and

safety throughout SA’s food value chain South Africa’s fast-growing safety and testing powerhouse Safety SA has relaunched its Food and Occupational Health and Safety divisions to position the business for growth in an increasingly safety focused market.

T

he division, under the banner of

choice across the southern African food

testing division a strong identity as it grows

AssureCloud, is the largest group

value chain.

into the future. AssureCloud fields South

of sector-focused laboratories in

Africa’s largest and most comprehensive

The testing division, previously named

southern Africa. Assuring safety from

NOSA Testing and Aspirata, is headed

group of food safety and veterinary

“farm to fork”, it caters for the entire value

by MD Venisha Bachulal, who has

laboratories, with custom-built, state-

chain across audit, inspection, testing,

spearheaded the business’s growth and

of-the-art chemical and microbiological

certification and training.

two acquisitions since 2017, to make it the

laboratories across South Africa and into

largest environmental health practitioners

Zambia, as well as highly qualified food

Pieter Erasmus says AssureCloud has

in the private sector in the country, turning

safety auditors.

grown through acquisitions and strategic

over more than R250 million last year.

Safety SA group chief executive officer,

development in recent years, to position

AssureCloud is an accredited Inspection Body and acts as a Department of Labour

Erasmus says the new branding

it as the food safety assurance partner of

consolidates the acquisitions and gives the

Approved Inspection Authority (AIA), with

MLS National Laboratory Services and Supplies MIDRAND SANAS ACCREDITED

Services we offer:

Microbiological Chemical Organoleptic Nutritional Aflatoxins Allergens Independent Sampling Trend Analysis

CAPE TOWN A2LA ACCREDITED

Effluent Water Pesticides DNA Residues Shelf-Life info@mlslabs.co.za Swabs/Food Analysis Assist with sampling plan development Pathogen Reduction Programs

mlslabs

18

June 2021 | FOOD RE VIEW

082 853 2247

mls_labs_

ltlgroup

RISK MANAGEMENT

a presence in South Africa and across

“We make sure that if people consume it;

health and safety products and services

Africa. The company has capabilities

it’s safe. We test food safety and the quality

encompass occupational health and safety

to carry out surface and environmental

of products at origin, throughout the value

audits, OHS training and certification,

sampling for the detection of Coronavirus

chain as well as in the environment where

environmental, food testing, quality

S gene specific to COVID-19, in accordance

food is consumed – such as in quick service

assurance and digital solutions.

with the World Health Organization (WHO)

restaurants,” Erasmus says. He says the

“Due to the COVID-19 pandemic and

protocols for health care and public

focus on environmental and food safety

increased awareness of hygiene, health

health. AssureCloud also includes South

has increased considerably in recent years,

and safety, the Safety SA group has seen

Africa’s only CO2 accredited Laboratory,

due to the Listeriosis outbreak of 2017-18,

a surge in demand for our laboratory

the country’s first Asbestos Accredited

and a heightened awareness around food

testing and digital services, and as

Laboratory, and Biotoxin Laboratory, and

safety globally by consumers. In addition,

restrictions on movement eased, we are

has capabilities to carry out specialised

a drive to boost South African poultry

also seeing exponential growth in demand

salmonella serotype testing, quality testing

production has increased demand for

for workplace safety services, testing,

for the fishing export sector, quality testing

rigorous testing throughout the poultry

technology and consulting,” says Erasmus.•

focused on the dairy sector, specialised

value chain.

support for the poultry sector, and

AssureCloud falls under the Safety

nutritional labelling support. AssureCloud

SA group alongside SafetyCloud and

also has an occupational hygiene

MetrixCloud. With the motto ‘life is

testing laboratory.

precious’, Safety SA’s risk management,

Aspirata – www.aspirata.co.za

Farm to fork food safety assurance.

The new home of Aspirata, Deltamune laboratories, and SAI Global Africa Assurance (QPRO and SAIGAS).

www.assurecloud.co.za

FOOD RE VIEW | June 2021

19

FUNCTIONAL RISK MANAGEMENT INGREDIENTS

Visualise a new standard for quality control

Estimated at up to $10tr per year, the global food market is a major part of the world economy and represents a significant part of personal expenses.

I

n the baking and snack food industry,

parameters such as length and

consumers have a greater variety of

width, area, shape, colour, volume

products to choose from, and a key

and slopes, thickness, inclusions,

challenge for producers is achieving and

and foreign objects. Measurements

maintaining exceptional product quality

can be combined to provide a

that will drive new sales and generate

comprehensive quality control

loyal customers.

test for each product with pre-

“Improve product quality, boost yield, increase inline productivity and lower production costs with automated vision inspection technology” For baked goods, product appearance is critical to consumer acceptance. Size, shape, colour, and texture are just some of

determined limits for pass/fail.

Sightline Vision Inspection Systems are available in bench top models for at-line or lab analysis, automate these measurements, providing

as well as over-line and in-line

objective reliable results in real time for

models for 100% inspection (and rejection)

100% inspection. Since 2009, Sightline

of products up to 100 objects per second.

Process Control, a KPM Analytics brand,

Sightline’s proprietary measura software

has been providing some of the world’s

suite supports each system and provides

largest food manufacturers with 3D/ colour

complete configuration, inspection,

vision inspection and automation solutions

monitoring and reporting capabilities within

that improve product quality, boost yield,

every production facility.

increase line productivity, and reduce operating costs.

“Analytical Solutions are the authorised distributers of the KPM Sightline Visual

Sightline’s customisable systems

Inspection System and we also offer a wide

properties that make baked goods appealing

can extract virtually any size, shape or

range of products specifically for the Food,

and secure market share. Traditional

colour attribute from product images

Feed, and Beverage industries, from raw

methods for quality control include manual

captured at full line speed—converting

products monitoring to final packaging

inspection, physical measurements, colour

them into standard units for analysis

inspection,” concludes sales manager

meters and comparison to reference charts.

against compliance specifications and

Marius Janse van Rensburg. •

These manual methods are slow, labour

automatically rejecting non-

intensive, and often yield subjective results.

conforming products.

AUTOMATED QUALITY CONTROL

measurement library including over 100

New vision analysis technology can

basic and advanced algorithms to measure

20

June 2021 | FOOD RE VIEW

All Sightline systems come with a

Analytcal Solutions www.analy ticalsolutions.co.za

RISK MANAGEMENT

How pest control can contribute to

sustainability in the food sector After more than a year of economic and social upheaval caused by the Coronavirus pandemic, the world is at a crossroads.

A

ddressing the One Planet summit in Paris in January 2021, UN Secretary-General António

Guterres said, “In the year 2021, we must reconcile humanity with nature. Until now we have been destroying our planet. … We have been poisoning air, land and water and filling oceans with plastics. Now nature is fighting back.”

This focus is seen as a chance to put new energy into the UN’s 2030 Agenda for Sustainable Development, which was

reaches the consumer (food loss) – valued

food businesses can contribute to

adopted by all member states in 2015

at around $400 billion per year. On top

sustainability, including reducing food

and is centred on the 17 Sustainable

of that staggering amount is food waste,

loss and waste, lessening their impact

Development Goals (SDGs). There are

caused by the inefficient handling and

on the environment and lowering carbon

now just ten years left to achieve

use of food. Together, food loss and food

emissions in all areas of their operations.

these goals and the UN has called for

waste generate 8% of global greenhouse

a decade of action, including a drive

gas emissions, which amounts to 1.5

and-trusted technique to help prevent

for sustainable innovation, financial

gigatonnes of CO2 equivalent every year.

food losses caused by pests at all stages

investments and technology.

The pandemic has forced people to

And that was in a “normal” year.

Integrated pest management is a tried-

of the supply chain - in an environmentally

Food supply chains have been disrupted

sustainable way. When combined with

adapt to new ways of working and living,

by restriction of movement and

environmental policies that extend to all

and it has made more people realise that

Coronavirus quarantine measures,

products used, operations and services,

we cannot go on treating the planet the

causing increased losses, especially of

pest control can contribute to every food

same way. The UN Secretary-General

perishable food products.

business’s sustainability commitments.

added, “As we rebuild, we cannot revert

Buying habits have also changed by

to the old normal. Pandemic recovery is

both consumers and countries, so as to

our chance to change course. … Every

build stockpiles of non-perishable food,

country, city and business must adopt an

which causes more waste of other food.

HOW PEST CONTROL CONTRIBUTES TO CUSTOMERS’ SUSTAINABILITY

ambitious roadmap to achieve net zero

Measures that many countries have been

Pest control is one of the key factors

emissions by 2050.”

taking to reduce food loss and waste have

in preventing food losses throughout

been put at risk.

the food supply chain. As mentioned

FOOD SYSTEMS: AN ESSENTIAL PART OF SUSTAINABILITY

the first International Day of Awareness

contribution to CO2 emissions and are

Sustainable food systems are an essential

of Food Loss and Food Waste, organised

a major target in the UN’s sustainable

part of many of the SDGs because they

by the Food and Agriculture Organization

development goals.

impact numerous areas, including

(FAO) and the UN Environment

nutrition and health, poverty reduction,

Programme (UNEP). The aim is to urge

that can contribute to sustainability, both

water security, sustainable energy, CO2

everyone to do more to reduce food loss

in the focus across the whole business –

emissions and climate change.

and waste to protect food security and

such as reducing energy use in buildings

the environment.

and transport, minimising waste,

Every year, about 14% of the world’s food is lost to pests and spoilage before it

22

June 2021 | FOOD RE VIEW

In September 2020 the UN launched

There are multiple ways that

previously, food losses are a significant

There are multiple areas in pest control

using sustainable products – and in the

RISK MANAGEMENT

specific pest control solutions available to customers.

Integrated pest management (IPM)

food environments 4. Fluorescent tracking gel to effectively identify where rodents are present,

is the foundation of sustainable pest

and then apply more targeted

control, focusing on prevention and smart

control measures

for carbon emissions. Net zero refers to achieving an overall balance of CO2 emissions into and out of the atmosphere.

Under the legally binding Paris Agreement, 196 countries and territories

solutions to deter infestations occurring

5. Proofing technology to prevent rodents

and avoiding the use of toxic chemicals.

gaining access to buildings, including

below 2°C and, ideally, 1.5°C by 2050

IPM saves costs, uses fewer resources –

products to fill gaps (e.g: around dock

to reduce the devastating effects on

including energy and plastic – and is safer

levellers and expansion joints)

the environment as much as possible.

for the environment.

7 SUSTAINABLE SOLUTIONS TO IMPROVE FOOD SAFETY A wide range of non-toxic pest control

6. B iopesticides such as a fungus to

agreed to limit global warming to

Rentokil Initial has committed to reduce

control cockroaches, and bacteria

total carbon emissions to net zero by the

and sterile insect release to

end of 2040 – ten years ahead of the

control mosquitoes

Paris Agreement targets.

7. Digital technology which provide

Governments, the public, analysts

solutions are available so that companies

remote monitoring, rapid alerts of pest

and investors are increasingly expecting

can make environmentally friendly pest

presence, capture of vast amounts

businesses to show they are taking

control a part of their sustainability

of data on pest behaviour to provide

sustainability seriously. By partnering

policies. These products and solutions

new insights, and identification of

with a pest control company with a

include the following:

pest hotspots to enable more targeted

comprehensive sustainability plan, food

1. Heat treatments to eliminate pests

and effective pest control, which is

businesses can be assured that their

in whole rooms down to individual

especially important for food pests such

pest control operations contribute to the

small items

as stored product insects (SPI).

sustainable development goals both by

2. L ED insect light traps that safely

reducing food losses and protecting

capture insects in critical areas more

WHAT IS NET ZERO?

efficiently and use less energy

The UN Secretary General has called

3. Intelligent traps that capture and dispatch mice humanely and safely in

the environment. •

for businesses to adopt a sustainability agenda, including the net zero target

Rentokil – www.rentokil.co.za Two Biometric Signature Identification (BSI+) scanners on the Tomra C5

Reduce food losses and protect the environment By partnering with a pest control company like Rentokil that has its own comprehensive sustainability plan, you can be assured that pest control operations in your business contribute to sustainability by reducing food losses and protecting the environment.

Contact the Experts in Pest Control, today.

Part of

t: 0800 77 77 88 w: www.rentokil.co.za

FOOD RE VIEW | June 2021

23

RISK MANAGEMENT

No compromises:

ERD 220i redefines triad of compactness, safety and ergonomics The ERD 220i is designed for flexible use in the handling warehouse and to load and unload trucks has an L2 dimension of just 1 065mm and is therefore the most compact truck in its class.

C

ompared to its predecessor, the ERD

also makes it possible to offer the truck in

220i is more than 300mm shorter

two spacious platform versions without

thanks to its new lithium-ion battery

having to make any relevant sacrifices in

concept, which results in a space reduction

compactness and agility.

of approximately 25%. The compact particularly versatile and agile to drive. Its

SAFE AND SIMPLE USE ON THE RAMP

turning radius has been reduced to just

Jungheinrich developed various features

1 985mm. This creates new free space in

for the ERD 220i to offer increased

existing warehouses and enables precise

safety, comfort and ergonomics which

manoeuvring even in confined spaces.

also enable greater productivity. The

dimensions make the electric pallet truck

pallet truck recognises as soon as it is

can also be used for stacking. A new triple

COMPACT THANKS TO THE NEW LITHIUM-ION BATTERY CONCEPT

in a truck through an ultrasound sensor.

Instead of installing a large battery

lights, illuminates the truck and ensures

between the platform and forks,

pallets are lifted quickly and safely – this is

Jungheinrich has used two battery

particularly beneficial in the early morning

modules of 130 Ah in the ERD 220i that are

hours. The truck also reduces the speed

accommodated within the truck chassis.

to a tempo set by the customer so that

The removal of the heavy battery tray

the driver is able to get over the threshold

offers significant benefits in the truck

between the truck and warehouse without

performance. By doing this, Jungheinrich

putting unnecessary strain on their back.

has enhanced the weight distribution

The LED light “Floor Spot” was protected

of the ERD 220i in favour of the driving

and integrated into the side wall as a safety

parameters, which is evident in the

feature that can be ordered ex works and

powerful acceleration and enables driving

increases the visibility of the truck on its

speeds of up to 14km/h. The space saved

transport journeys in the warehouse.

Jungheinrich is also launching a new

USER-FRIENDLY STEERING AND LOADING

based on the truck platform of the ERD

Jungheinrich developed various features for the ERD 220i to offer increased safety, comfort and ergonomics which also enable greater productivity

This automatically activates the working

The smartPILOT allows the intuitive control of all truck functions with just one hand, comes with the option of an automatic centring of the steering wheel and is now adjustable in height as standard. The new charger interface ensures the direct connection of the truck to external quick chargers with the optional built-in charger that enables charging at any socket offers

lift mast offers by far the highest platform height of a truck in this segment at 3 760mm. The height of the lift mast is made so compact that the truck can be used problem-free in the truck trailer. The ERD 220i can also be used as a doubledecker by raising the support arm lift and can transport two pallets on top of each other, which offers significant efficiency gains, especially when loading and unloading trucks.

NEW ERE 225I battery-powered pallet truck on the market 220i. The ERE 225i is even more compact than the ERD 220i and ideal for operations without stacking tasks. The compact version of the truck has an L2 dimension of just 898 mm, which results in a reduction of 270 mm compared to its predecessor.

By eliminating the lift mast and removing the previous battery tray, the driver of the ERE 225i is much closer to the forks, which improves the view of the goods and

particular flexibility.

the forks. This significantly improves the

NEW TRIPLE LIFT MAST

makes driving more intuitive. •

overall view during the work process, which

Its new lift mast version allows the ERD 220i to be used even more broadly in future and, in addition to loading and unloading, it

24

June 2021 | FOOD RE VIEW

Jungheinrich – www.jungheinrich.co.za

The specialist for double-deck applications For the efficient transport of cargo over longer distances The versatile and powerful electric ERD stackers count among the most customisable stackers in the Jungheinrich portfolio.

Depending on the application scenario, platform, motor, battery compartment and mast frame can be tailored to meet your individual requirements.

0800 984001

www.jungheinrich.co.za

RISK MANAGEMENT

How to be a

food safety warrior of note!

Food handling organisations should be aware that the food products handled or produced can affect consumer safety.

F

ood is deemed unsafe when it was

as a preventive tool to systematically

behaviours and attitudes at all levels. These

unintentionally or intentionally

identify and assess food safety

behaviours or attitudes must support the

contaminated with foreign bodies,

hazards accidentally introduced and

organisation’s food safety performance

pathogenic micro-organisms, harmful

to enable identification of significant

(and not jeopardise it).

chemicals (which includes radiological

food safety hazards that need specific

substances) or allergens. An effective food

control measures.

safety management system is a preventive

• A n intelligence driven approach

A robust food safety culture must be driven by top management and engage all those who directly or indirectly affect

tool that enhances a food handling

to mitigate the risk of intentional

food safety. It is essential that food

organization’s ability to produce safe

contamination as a result of food fraud or

handlers understand their major role in

end products and gives the assurance that

malicious contamination due to ill-intent.

this regard and to align their behaviours

the FHO has systems in place to manage food safety.

• A management system that provides

and attitudes so that food safety

for systematic planning to address

policies can be implemented, and food

organisational risks and opportunities

safety objectives are consistently met.

processes have to be systematically

related to safe end products through

Leadership should lead by example and

managed. Food safety standards have been

considering the context of the

should never allow commercial interest

published and they dictate the “rules” for

organisation, implementation of

to jeopardize the safety of food products

ensuring safe end products.

operational and organisational control,

handled or produced. In this way, a sense

evaluation of the performance of the

of unwavering integrity is communicated

Broadly, safe end products are the result

food safety management system (FSMS)

from their level and over time this “right

of the following:

and finally taking action to improve

way of doing things” becomes engraved in

• A solid foundation of PRPs (prerequisite

the system.

the organization’s DNA, which becomes

Food manufacturing and handling

programmes). These are applied across the food chain and is aimed at creating

the environment in which food handlers’ Implementation of the above will only be

conditions suitable for safe food

effective if the “right” culture exists within

production. Good examples of PRPs include

the organisation. This is often referred

cleaning and sanitation, personal hygiene

to as a “food safety culture”. Food safety

and pest control, to name a few.

culture relates to the beliefs or values of

• A science-based HACCP system that serves

26

June 2021 | FOOD RE VIEW

the organization that directly affects the

behaviour speaks of integrity and commitment to safe end product. •

Annelie Coetzee Consulting – www.anneliecoetzee.com

Complete Prepared Food Solutions designed for your business •

Preparation & Processing

•

Frying & Oil Management

•

Batter & Breading

•

Branding & Searing

•

Cooking, Roasting & Drying

•

Coating & Seasoning

•

Product Handling

Across industries and applications, we design specialised solutions.

Bringing together leading brands in processing and packaging equipment for the Value-added industry. Our fryers, ovens, branders, searers and breading/batter applications can prepare and cook the highest quality meat, poultry and seafood products. Whatever your product needs, we can meet it with precision and passion.

info@heatandcontrol.com

|

heatandcontrol.com

FATS & OILS

The incredible diversity of

oil blends Rapid Oil Analysis with FT-NIR Spectroscopy FT-NIR is a powerful and effective technology for control of raw materials, intermediates and finished products. In contrast to most wet-chemical and other reference methods, FT-NIR technology is quick, cost-effective, non-destructive and safe, since it does not use chemicals, solvents or gases.

Kerfoot Group, a prominent supplier of natural and organic plant-based oils for the food industry, has commented on the rising creativity with oil blends seen in today’s new food product development processes.

T

he business, which supplies brands large and small with authentic plant-based oils, has seen a significant increase in demand for oil blends that use ingredient

innovation to meet intensifying consumer demand for new twists on everyday food purchases.

Joanne Deighton, commercial manager commented, "There’s a real wave of innovation happening across the food

Edible Oil Analysis:

manufacturing sector, from bakery and snacks through to

Measure important quality parameters like fatty acid profile, FFA, TFA, IV and various other parameters in seconds.

normality returns for the consumer, an experience is more

Quality Control of Olive Oil: Assess the fatty acid and TAG profile as well as acidity, oxidation parameters and indicators for fraud by thermal treatment or foreign oils simultaneously.

Degradation Testing of Frying Fats: Check for polar compounds, polymerized triacylglycerols, acid value and anisidine value to optimize the frying process for optimum taste.

Analysis of Omega-3 Oils: Determine EPA, DHA, DPA, SDA, total omega-3 and oxidation status in marine oils to ensure highest quality and brand reputation.

Bruker Optics has the industry‘s most comprehensive FT-NIR product line; from the very intuitive TANGO analyzer to the versatile Multi Purpose Analyzer MPA II and award-winning MATRIX-F system for real-time process measurements.

Ready-to-use calibrations are available for a quick and efficient start.

soups, sauces and even desserts. It’s clear that as a sense of important than ever. This means that product developers are pushing the envelope in flavours and scents engaging consumers on a whole new level.

“One of the most prominent ways we see this in real-time is through our oil blending services and the combinations that brands are now exploring in NPD. Blends combine multiple natural ingredients into one stock keeping unit supplied by Kerfoot, cutting down on the time and resources required in handling, storage and auditing for manufacturers. For food product developers and technologists, it’s also a fresh opportunity to get creative. Consumers are opening up to global flavours and a break from the norm, and as a result, we’re seeing brands get more exploratory with ingredient choice.”

While established blends such as garlic in sunflower oil or basil in extra virgin olive oil are still proving a great valueadding choice, there is notable interest in some of the more ‘niche’ food oils on the market.

Deighton continued, “Brands are seeing that consumers are seeking new culinary experiences and are becoming more adventurous with product selection. To engage this audience, some of the less commonly used oils and ingredients are taking the spotlight in blends and providing real commercial value for manufacturers. Great oil blend examples we have seen include truffle in grapeseed oil, providing effortless sophistication to recipes. This is proving to be a particularly strong choice as the market moves back towards premium and luxury products.

“We are also seeing more widespread use of citrus tones

Contact us for more details:

in formulations. Consumers are responding well to more

info.za@bruker.com www.food-analysis-nir.com

exploratory sensations in food products, and we are seeing this reflected in rapidly growing interest in orange or lemoninfused sunflower oil, particularly in baked goods and snacks that require a little extra zest to stand out on competitive store

Innovation with Integrity

F T- NIR

shelves,” she concludes. •

Kerfoot - www.kerfootgroup.co.uk.

28

June 2021 | FOOD RE VIEW

CONVENIENCE FOOD PROCESSING

Integrated solutions

bring speed, efficiency and quality benefits The installation of three high-performance Ishida integrated Total Packaging Systems (iTPS) at a German snack manufacturer improved weighing speeds by around 75% and almost eliminated product giveaway. The system also delivers higher quality snacks bags with fewer rejects and less product and film waste. This has led to a fast payback on investment.

T

he Ishida iTPS’s are part of three new packing lines for a range of

1

extruded corn snacks, including

the company’s top-selling onion rings and cheese puffs. It is a fully integrated snack food packing system, which combines a multihead weigher from the highperformance CCW-RV series with the Ishida

2

Inspira bagmaker specifically developed for snack foods. Both machines are seamlessly integrated and operated via a single

At the snack producer they produce pillow

control panel.

bags between 75g and 450g. Exceptional

Upgrading production capacity was

seal quality and seal integrity are essential,

the logical next step, especially replacing

because the bags do not contain inert

the company’s packing technology, which

gas. This means that only their tight

dated back to the 1990s and was no longer

seals prevent the snacks from oxidising.

capable of meeting demand. The situation

Automatic film centring and clamping

was all the more pressing because there were only two packing lines available for three production lines.

Each individual snack weighs just 1g, which can present a challenge for an

1, 2: Funnels guide the snacks to the gantrymounted Ishida CCW-RV multihead weigher and loadcells underneath the multihead’s dispersion tables allow for a consistent product flow to the radial feeder troughs

automated weighing system. It is also

Sealing takes place at high pressure, with product or flavouring being prevented from entering the sealing area thanks to a stripping mechanism and product-in-seal detection on the sealing jaws.

essential to minimise any build-up of

them again and select the combination

seasoning during the flavouring process,

that come closest to the required

as this can reduce speed and require more

target weight.

frequent cleaning.

functions ensure a consistent film delivery.

The Ishida multihead weighers can

SIMPLIFIED OPERATIONS AND INCREASED PRODUCTIVITY The bagmakers are also fitted with

complete many more weighing cycles than

controlled deflator plates to ensure

FILL RATE ALMOST DOUBLED

the snack producer’s previous volumetric

consistent bag air-fill and pack thickness.

Funnels guide the snacks to the gantry-

system. For a standard 150g bag, weighing

There are 500 pre-sets to simplify product

mounted Ishida CCW-RV multihead

speed has been increased from 60 to more

changes, while features such as easy

weigher. Loadcells underneath the

than 100 weighments per minute. The

forming tube loading and unloading, film

multihead’s dispersion tables allow for a

significant improvement in accuracy is also

spindle, tension rollers and a splice table

consistent product flow to the radial feeder

important with overfilling dramatically cut

light-bar enable fast product and film

troughs. The vibrating troughs transfer the

from 7.5% to almost zero.

changeovers and increased productivity.

product to a set of 14 pool hoppers, which

The weighed snacks are transferred to

In addition, the open frame structure of

hold them for a short time before supplying

the bagmaker via a high-speed parabolic

the bagmakers provides easy access for

them to another row of 14 weigh hoppers.

chute with integrated throat metal

these adjustments to take place as well

As soon as a weigh hopper becomes empty

detector - another benefit of the new

as enabling efficient cleaning

and is available for its next filling process, a

packing system.

and maintenance. •

signal is sent to the corresponding pool hopper.

The system's software then takes a

PERFECT SEALS, FREE OF PRODUCT PARTICLES

fraction of a second to calculate the three

The Ishida Inspira bagmakers are suitable

best weigh hopper combinations, check

for a wide range of film materials and sizes.

Ishida - www.ishidaeurope.com

FOOD RE VIEW | June 2021

29

CONVIENENCE FOOD PROCESSING

Don’t compromise on

food quality when using food pigments It is a well-known fact that the colour of a food or beverage product can impact how a consumer engages with it: we eat with our eyes first. Impactful colour plays a vital role during purchasing decisions by enhancing the sensory appeal and overall consumption experience.

T

raditionally organic lake pigments

• Batch to batch shade variation

of the colour particle and the dispersion

or FD&C lake pigments, iron oxides,

Major food pigment suppliers are

in the medium vitally affects the final

titanium dioxide, carbon black and

countered with issues of batch-to-batch

colour properties.

metallic pigments are used in various

shade variation which can be due to non-

capacities to achieve a vast range of

maintenance of batch records. Ideally

• Delayed Lead times

colour intensity.

a manufacturer should maintain the

The issue of delayed lead times is

retain sample library of each sample and

addressed by Koel’s production team

EVERY FOOD COLOUR HAS A PURPOSE

each commercial batch they ship to the

by manufacturing and sourcing 95% of

customers. Should they require any future

the raw materials locally. The reverse

The use of mineral (inorganic) pigments,

commercial orders or repeat orders, they

integrated manufacturing process enables

organic (lake) pigments and synthetic dyes

can refer to the sample retain library

Koel Colours to not be dependent on any

in food often varies as per the function of

and do the exact shade match as per

supplier. Since Koel Colours is the proven

the colours. Adding natural and synthetic

the parameters and send the matched

manufacturer, they have the ability to

colours in non-alcoholic beverages such

commercial batch accordingly.

control the production process and provide

as soft drinks and fruit-based drinks makes the drink look appealing. Here, the colour can attract the consumer to buy and try a product. For wine production, colours such as Allura Red are used. Lake pigments are added in some foods such as candies to give the consumer an experience where the colour can be left on the tongue.

A manufacturer looking to source an ideal colourant looks for quality and stability with a vibrant top colour, but there are certain challenges and new trends which focus on key selection criteria for product manufacturers.

• Sustainability & clean label requirements

“Major food pigment suppliers are countered with issues of batch-tobatch shade variation which can be due to non-maintenance of batch records. Ideally a manufacturer should maintain the retain sample library of each sample and commercial batch they ship to the customers”

short lead times.

• Retain shade during supplier transition A manufacturer looking to change the colour supplier, needs to ensure that the shade variation from the new supplier compared to the established standard shade should not happen. That is why the pigment manufacturer needs to have a specialised team who can custom develop the shades of the pigments as per the customers standards. This team should be able to match the exact shade to the customer’s standard and reduces the headache of the customer completely and customise the percentage of the dye content as per requirement.

This trend is headlining and fast turning

Koel’s proprietary manufacturing

into the new manufacturing normal. Clean

technology ensures bold and vibrant

colour labelling satisfies consumers' desire for healthy food that is naturally prepared.

• Pigment quality issues

shades for diverse applications of

It is a sustainable counter-trend to the

The tinctorial value of the FD&C lakes is

colouring food and beverages. •

almost limitless supply of industrially

dependent on physical properties and

manufactured food. Globally, food and

pure dye content. In all applications, lakes

manufacturers face key challenges such

must be thoroughly mixed into the medium

as batch-to-batch shade variations, supply

that is to be coloured. If not, then it leads

issues and delayed production lead times

to bleeding. This may involve grinding or

which could impact the final product.

mixing on special roll mills. The wetting out

30

June 2021 | FOOD RE VIEW

Koel Colours – www.koelcolours.com

CONVENIENCE FOOD PROCESSING

Keep plant-based

meat alternatives fresh with innovative products Global ingredient manufacturer provides label-friendly solutions to support growing consumer demand for this market segment in the EMEA region Continued on page 32

K

emin Industries, a global ingredient

products in favour of refrigerated ones.

manufacturer that strives to sustainably transform the quality

Euromonitor’s meat alternative

‘better-for-you’ products to promote health and wellbeing, they are also mindful of

market data illustrates this rapid growth,

choosing products that are convenient and

of life every day for 80% of the world

indicating the retail value of plant-based

easy to prepare. As manufacturers move

with its products and services, is helping

meat will grow 42% in Europe in the next

from frozen plant-based meat alternatives

food producers respond to consumer

three years, reaching a value of €2.3 billion.

to refrigerated options, protecting product

demand for ready-to-eat plant-based

“Many consumers want to reduce their

integrity is critical to ensuring taste and

meat alternatives that can be refrigerated

meat intake while maintaining protein

for longer. Kemin Food Technologies

consumption, so they are substituting with

provides label-friendly solutions that

plant-based meat alternatives that offer

solutions to help brands control oxidation

maintain taste and texture.

taste and texture similar to meat, but with

and microbial spoilage, maintaining the

nutritional benefits from plants.

freshness, quality and safety of plant-based

Consumers and retailers are looking for natural solutions that offer clear and

“As a result, flexitarianism – a diet that is

meat-like texture.”

Kemin offers a portfolio of label-friendly

meat alternative products.

transparent labelling with recognisable

centred on plant foods with the occasional

ingredients they can trust. Retail sales

inclusion of meat – is booming,” said Kelly

and green tea extracts, offers label-

of plant-based meat alternatives reflect

De Vadder, marketing director, Kemin Food

friendly oxidation control, delaying flavour

this shift in a dynamic category, as

Technologies, EMEA.

degradation to maintain texture, optimise

consumers are bypassing frozen

“While shoppers are looking for these

NaturFort, a blend of natural rosemary

the taste profile, retain colour for visual >>

Plant-based foods are saving the world, now it’s their turn to be saved.

Label friendly

Need Perfect Protection for your Plant-based Products? No veggie left behind with Kemin shelf life and food safety solutions. Keep your products safer, fresher, for longer with Kemin.

Discover all our solutions at

WWW.KEMIN.COM

©

Kemin Industries, Inc. and its group of companies 2021.

All rights reserved. ™ Trademarks of Kemin Industries, Inc., U.S.A

0521KEM278_AD_FoodManufacturing-V7.indd 1

4/06/2021 09:43

FOOD RE VIEW | June 2021

31

CONVENIENCE FOOD PROCESSING

Create rich, buttery aroma bakery products with Carabuta NH

Butter cookies, buttery caramel, bread and butter pudding and butter toffees, there are few things in life that tastes as good as butter. In a world where flavour is a big deciding factor for customers, using butter has become the gold standard in the baking and confectionary industry.

butter with high quality margarines. As Fats play a very important role during baking

the fat interact with other ingredients in the recipe to influence the texture and overall mouthfeel of a product, so choosing the right butter fat substitute is essential to bakery and confectionary products’ success in the market.

F

ats are an important component of

leavening agent giving volume increase,

bakery and confectionary products.

which is essential for soft and desirable

In bakery and confectionary,

baked goods.

caramels and toffies, fats provide

However, the challenge to reduce

“Imagine a butter fat substitute that will make your bakery or confectionary product taste like the original butter version with no artificial butter flavour taste” Imagine a butter fat substitute that will

tenderness, texture, lubrication and

cost, source quality butter and consumer

make your bakery or confectionary product

most importantly, the indulgent flavour,

trends for lower saturated and cholesterol

taste like the original butter version with

mouthfeel and richness that consumers

products and an increased vegan

no artificial butter flavour taste. Bunge

crave. In bakery the presence of water in

market, presents the opportunity for

Loders Croklaan has recently introduced

butter also acts as a vaporous

manufacturers to partly or fully substitute

Carabuta NH, a palm-based fat that has

and oil components in these products is a

ingredients on the stability of the final

common challenge for brands. Delivering

product,” said Anja Verbiest, CLS and

that offers clear and transparent labelling,

the texture and flavour consumers desire

quality assurance manager, Kemin Food

protects meat alternatives from microbial

can be very difficult if a product is not

Technologies– EMEA. “Whether formulating

spoilage while offering a balanced flavour

properly protected from oxidation,” De

a new product or reformulating an existing

profile. A buffered vinegar solution made

Vadder explained. “Microbial spoilage can

one, our CLS team can reduce testing time

with natural ingredients, BactoCease

also be an issue, so preventing it, as well, is

and meet go-to-market goals.”

NV is manufactured with naturally

essential for delivering a safe product to

sourced ingredients and contains 100%

the market.”

Continued from page 31

<< appeal and extend shelf life.

BactoCease NV, a trusted ingredient

bio-based carbon.

“Refrigerated products that are exposed to light oxidation decrease in shelf life and quality much quicker. Fat systems are a key

Kemin also offers in-house customer laboratory services (CLS) to help customer-

visit their website. •

“The CLS team provides dedicated support throughout all phases of testing

meat alternatives, yet the oxidation of fat

to understand the influences of all food

June 2021 | FOOD RE VIEW

solutions for plant-based meat alternatives

partners get to market faster.

component of great-tasting plant-based

32

To find out more about the Kemin portfolio of shelf-life and food safety

Kemin – www.kemin.com

CONVENIENCE FOOD PROCESSING

MILK FAT REPLACER FOR BAKED GOODS • Fat category – Flavoured fat • Product description – Nonhygrogenated, non-lauric texturised fat with flavour precursors that develops authentic flavour similar to natural milk fat • Value proposition – Cost-saving solution for baked good, milk fat replacer

Fats play a very important role

•C ustomer application – Cookies, biscuits, bread and toffee

during baking

• Packaging – Standard 25kg carton and customisation available upon request.

The milk fat flavour precursors, creating

for long shelf-life products. Carabuta NH

creamy notes of butter during baking.

can be used on its own or in conjunction

The flavour compound is stable in the fat

with butter to achieve a cost-effective

system and will only be released once the

solution. Carabuta NH is suitable for large

butter flavour precursors added that are

heat is induced, making it desirable in a

scale bakery and confectionary product

activated on heating. Carabuta NH acts as

bakery and confectionary manufacturing

manufacturers to small scale bakery and

a milk fat replacer in various bakery goods

environment. Carabuta NH contributes a

confectionary shops. •

such as bread, cookies, biscuit and crackers

natural buttery aroma and strong flavour

and in confectionary products like toffees

impact to the bakery and confectionary

and caramels.

goods. It also lengthens flavour retention

Savannah Fine Chemicals – www.savannah.co.za

INGREDIENT INNOVATION THAT’S VALUE DRIVEN

BASIC FOOD INGREDIENTS FOR EVERYDAY SOLUTIONS

We supply food manufacturers with quality ingredients and a wide range of additives to help create the taste, texture, performance and appearance you need for your food nutritional products. We represent leading global manufacturers & our specialists can provide you with unrivalled sales support bringing the highest quality products to market: Bakery ingredients: flavour, texture and fortification - Beverage ingredients for innovation - Confectionary: healthier & tastier alternatives to enhance your brand - Culinary solutions for sauces, dressings and prepared meals that will innovate - Dairy & Desserts: texture & functionality - Flavour & fragrance creation - Health & Sports nutrition.

Johannesburg: +27 11 856 4500 Cape Town: +27 21 551 5353

Durban: +27 31 202 0794 Email: info@savannah.co.za

www.savannah.co.za

FOOD RE VIEW | June 2021

33

CONVENIENCE FOOD PROCESSING

The ultimate in precise BREWERIES GO DIGITAL

slicing

GEA has launched the new GEA OptiSlicer 6000.

The technology includes a range of technological advancements to slice meat and cheese products more efficiently resulting in higher productivity, less downtime, easier maintenance, precision and total cost of operation.

OptiSlicer 6000

T

he OptiSlicer 6000 has a higher

without the need for crust freezing. The

be manually trimmed, simplifying machine

capacity, better blade design for a

OptiSlicer 6 000 can also be mirrored in

operation, saving time and potentially

smoother cutting action, eye-level

left and right-hand versions to minimise

reducing product losses.

Buyer’sguide

electronics and a new clear-view operator

footprint and enhance productivity.

BETTER BLADE DESIGN

THE

panel. The machine is easy to maintain,

HIGHER SPEED AND CAPACITY

The blade on the OptiSlicer 6000 avoids

The OptiSlicer 6000 operates at up to 1

balancing weights to improve hygiene

500rpm where the application requires.

and minimise noise. The wide inner hole

The wide cross section, up to 500mm width

allows to integrate the counterweight into

products, such as

x 200mm height is capable of handling

the rotor. The fixation screws close to the

calibrated sausage,

multiple product logs, of up to 1 850mm

blade edge enable to make it slimmer, more

salami, cooked ham

length simultaneously, giving the highest

stable, with a smoother cutting action.

and cheese can

capacity in the sector. The new FlexGripper

It’s also easier to maintain and exchange.

from GEA avoids the need for the logs to

The blades themselves have optimised

reliable and benefits from

GEA’s leading remote

maintenance service.

Regularly shaped

be handled easily

2017/2018

THE

Buyer’sguide

2020/2021

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

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

34

June 2021 | FOOD RE VIEW

2018/05/07 3:09 PM

CONVENIENCE FOOD PROCESSING geometry and a new coating, GEA Resyst, for a smooth, more accurate cut and better portion control and features GEA’s pioneering idle-cut rotor that moves the blade, not the product, during idle cuts to improve productivity and minimise product losses.

AN END TO CRUST FREEZING The combination of advanced blade and machine design have enabled even critical products to be sliced on the GEA OptiSlicer 6000, without the need for crust freezing. This eliminates the need for a freezing unit and the associated CO2 or N2 consumption.

ABSOLUTE CONTROL GEA’s SmartControl gives a clear view of the machine status and operation. It offers multi functions with optimal recipe management and access to all relevant documents including user manual. Operating rights can be allocated to each individual operator as desired and will be protected with personal RFID logins. The system also now offers optional Line Control that

CLEAR VISION TO MAXIMISE YIELD

allows an authorised person to control the whole line from any individual control panel, e.g. recipe change at one panel for the complete line.

EXTERNAL ELECTRICS The control and electrical systems on the OptiSlicer 6000 comply with all relevant European and US regulations, even UL (Underwriters Laboratories)-labelled execution is available. All

Want to raise productivity to reduce waste?

cabinets (pneumatic and electric) have been placed at eye level

Key Technology’s cutting-edge optical sorting

for convenient maintenance. Where required, the electrical

and conveying solutions set the standard for

control cabinet can be located externally.

maximising yield, efficiency and profitability.

STANDARD AND MIRRORED VERSION

At the same time, they deliver data-driven

The OptiSlicer 6000 is available as a standard version (operated

intelligence to continually optimise and

from left side) and a mirrored version (operated from right side).

improve your operations. Start your progress

This allows the machine to be adapted to production restrictions

with Heat and Control and Key Technology.

due to floor space or logistic needs.

SIMPLE MAINTENANCE The design uses common components

SORTING | CONVEYING | INTEGRATED SOLUTIONS

where possible. The same grippers are used on the OptiSlicer 6000 as on the MegaSlicer XXL and DualSlicer II 1200 and the blades are identical to the DualSlicer II 1200. Servo-controllers and other electronic and control parts are common to other GEA systems to simplify maintenance. GEA offers comprehensive maintenance contracts to keep all its equipment safe and reliable throughout its working life.

HIGH UPTIME WITH REMOTE SUPPORT GEA PerformancePlus gives online remote access to GEA service engineers whenever they are needed. By providing real-time advice and intervention, GEA can verify parameters and error messages to rectify faults, or optimise machine parameter

heatandcontrol.com

|

info@heatandcontrol.com

settings, reducing downtime and maximising productivity.

The OptiSlicer 6000 is available as 1 200mm and 1 850mm versions. The 1 200mm version can be upgraded to the 1 850mm version later, if required.•

GEA – www.gea.com HP_V_Key_2021_SAFoodReview_88.5w x 262h.indd 1

31/03/2021 1:14:11 PM

FOOD RE VIEW | June 2021

35

BEVERAGE PROCESSING TECHNOLOGY

Sustainable partnership

launches 100% rPET bottles les Since the middle of May this year Germany-based Eckes-Granini’s oneliter hohes C juice bottle has consisted entirely of recycled plastic (rPET) in conjunction with KHS’ Bottles & Shapes experts in Germany.

T

he company decided that with

bottler will cut its carbon emissions by

the EU’s plastic strategy and the

about 8 000 tonnes a year.

increase in recyclate quotas it

circular economy and set a good example

EFFICIENT AND SUSTAINABLE: THE INNOPET FRESHSAFE BLOCK

for the beverage industry,” explains

Finding ways of saving on resources

Hermann Naumann, plant manager

was not the only focus of the ambitious

for Eckes-Granini. “We aim to continue

project. The ability to do so on the KHS

steadily reducing our carbon footprint

InnoPET FreshSafe block in operation at

in production and in our packaging. This

Eckes-Granini since 2017 also had to be

means not only cutting down on the

investigated. “One of the concerns was

amount of material used but also closing

whether either the preforms or machine

the recycling loop.”

needed adapting,” explains Dr. Matthias

would now switch to using recycled PET only. “We want to be a pioneer in the

Kruse, head of PET Technology at KHS.

One-liter hohes C juice bottle has consisted entirely of recycled plastic (rPET)

“We thus assessed the quality of the recycled PET material. This is crucial, for large variances in colour, molecular

for example. No major changes to the

length and inhomogeneity quickly reduce

machinery or geometrical properties of

the efficiency of production.”

the preforms were required. “This enabled

The fact that Eckes-Granini procures

us to achieve a very high level of process efficiency while retaining the container

An InnoPET FreshSafe block from KHS has been in operation at Eckes-Granini since 2017

4 000 TONS OF NEW PLASTIC AND 8 000 TONS OF CO2 SAVED These are the exact issues KHS addressed first when implementing the current

“The geometry of the preform is essential for efficient processing, especially when a high percentage of rPET is used”

quality, thus fully meeting our customer’s requirements,” Kruse notes.

rPET HAS BARRIER PROPERTIES Eckes-Granini will continue to benefit from FreshSafe PET barrier protection also after converting to 100% rPET. The company has relied on the environmentally-friendly system from

project. With its holistic Bottles & Shapes

KHS since 2006. The oxygen barrier

consultancy programme, customers benefit from over 40 years of expertise

its preforms from two different suppliers

of chemically pure glass, a wafer-thin

in container design and production.

presented an added challenge. The

coating on the inside of the PET bottle,

Beverage producers state their

geometry of the preform is essential for

not only effectively protects the juice

preferences regarding the weight, shape

efficient processing, especially when a

from oxygen pickup but is also fully

or stability of the container. The systems

high percentage of rPET is used.

recyclable. The coating can be easily

supplier then assesses the feasibility of

Through extensive testing it was

washed off Eckes-Granini bottles during

the design with the help of laboratory

established that both makes of preform

the recycling process. The sustainable

tests and simulation.

function soundly on the block system.

packaging alternative therefore permits

All that was needed for optimum bottle

pure-grade bottle-to-bottle recycling. “By

specifications were clear: switch to 100%

production were minor adjustments to

combining rPET and future-proof product

rPET while maintaining the homogeneous

the heater on the stretch blow molder.

protection Eckes-Granini and KHS are

quality of the container. According to

KHS’ NIR or near infrared technology

again demonstrating their pioneering role

Eckes-Granini, the changeover of the

especially provides a wide processing

for the circular economy,” •

one-liter hohes C bottle to rPET will save

window for rPET, allowing preforms

over 4 000 metric tonnes of new PET

to be heated prior to the stretch blow

per annum. This in turn means that the

molding process with pinpoint accuracy,

In the case of Eckes-Granini, the

36

June 2021 | FOOD RE VIEW

KHS – www.khs.com

WATER PROCESSSING TECHNOLOGY

Wastewater treatment in plastics recycling Recycling lines for plastics are the circular economy’s lynchpins, and as such, make a vital contribution towards protecting our natural environment and putting an economic spin on valuable resources. They also consume resources - chief among them water.

A

recycling technology’s

is kept at a consistently high level of quality,”

sustainability must

she points out. “Last but not least, such

not be assessed by

treatment makes sure that the wastewater

the quality of its end-product

discharged into the municipal system

complies with the relevant specifications.”

Krones – www.krones.com

alone. The processes used to make this product play an equally important role. As a manufacturer of recycling lines, Krones sees itself as bearing a particular responsibility for meeting both these sustainability criteria.

The group’s MetaPure technology recovers materials like PET bottles and polyolefin packages – in a quality enabling the recyclate obtained to be used in equivalent applications.

In their work aimed at continuous system optimisation, the development people at Krones have now also been proactively examining the washing module’s water consumption.

Product manager Astrid Kadlubski explains, “In the recycling process, plastics are ground into flakes in wet mills and then washed. This produces wastewater containing various dissolved substances, depending on the input material concerned.”

“In many recycling lines, the water is recirculated and treated in a bypass,” Kadlubski explains. “With the result that the process water’s dirt load keeps on rising and ultimately impairs the end-product’s quality.” To counter this, Krones has, in conjunction with a prestigious associate, developed an intelligent solution for complete treatment of washing and mill water. That entails several advantages for recycling-line operation.

“Firstly, this reduces both fresh water consumption and wastewater incidence.

Secondly, the recycling process

FOOD RE VIEW | June 2021

37

FLEXIBLE PACKAGING

Vinylloop gets the go-ahead as new Vinyls Packaging Pro

Members of the Southern African Vinyls Association (SAVA) voted unanimously in favour of forming a separate producer recovery organisation (PRO) within the association, whose specific focus will be to manage the collection and recycling of post-consumer and post-industrial vinyl packaging waste.

E

xplaining the

fact that the volumes in this market was

set by government for the collection and

rationale for

considered to be too small to justify the

recycling of all PVC (vinyl) packaging that is

forming a new

costs of collection and transport. As part

used in the market over the next 5 years.

PRO for the vinyls

of our strategy for dealing with packaging

packaging industry,

waste submitted to Government’s Section

packaging industry, it will be VinylLoop’s

Monique Holtzhausen,

18 Industry Waste Management Plan,

duty to:

CEO of SAVA, explains

SAVA is currently developing a unique

• ensure the EPR scheme is audited

Monique Holtzhausen, that CEO of SAVA

70% of the local

PVC market goes into

collection model for household packaging waste that bear the Number 3 polymer

As the PRO representing the vinyl

by government, • c ollect and submit data to the SA Waste

non-packaging products that are used

identification code. This plan includes

Information system (including how much

in long-term applications such as pipes,

working closely with municipalities and the

PVC vinyl packaging is collected and how

window frames and doors, flooring, cables,

entire value chain.

much is successfully recycled), • put buyers and sellers of vinyl packaging

ceilings or in the healthcare industry.

"Some of these products last in excess of 150 years. It is therefore not the

VINYLLOOP OPERATIONS AND RESPONSIBILITIES EXPLAINED

waste in touch with each other, • keep records of identified products; • work with municipalities to develop

responsibility of these SAVA members to

VinylLoop operates

fund the collection and recycling activities

under the SAVA banner,

for vinyl packaging that occupies less than

but will be registered as

2% of the overall market. The decision

a separate non-profit

• integrate informal waste collection;

was therefore taken to form VinylLoop

company (NPC), with

• e stablish secondary markets for recycled

for packaging members, funded by

its own board, bank

packaging members and headed up by

account, membership

Adri Spangenberg.”

Adri Spangenberg

forms and invoicing

the necessary collection and recycling infrastructure

vinyl packaging waste.

The new EPR regulations came into

system in order to facilitate the bi-

effect on the 5th of May 2021 and all the

PVC (VINYL) AS PACKAGING MATERIAL

annual audits by government and avoid

packaging streams in South Africa now

administrative confusion.

have 6 months to comply. By 5 November

For more than half a century PVC (or

“Companies who sign up to become

vinyl) has been used on a global basis

members of VinylLoop will automatically

manufacturers, importers, brand owners

to meet specific functional food and

also become members of SAVA and will

and retailers to either belong to a PRO or to

beverage packaging needs. It suits many

therefore reap the benefits of belonging to

have formed their own independent

different food types, offering good clarity

both associations, e.g. the SAVA Product

EPR scheme.

and physical properties, including heat

Stewardship Commitment, LCA studies,

“The vinyls industry has been given the

tolerance, controllable gas and moisture

being awarded the Vinyl Product Label,

target of a 6% recycling rate to be achieved

vapour transmission capabilities and

having access to the latest international

between 5 November 2021 – 5 November

excellent sealing performance.

studies and scientific information,

2022. It is therefore crucial to get as many

networking with fellow industry members

role-players as possible involved in these

SIZE OF THE PVC PACKAGING MARKET IN SOUTH AFRICA

etc,” Spangenberg explains.

early stages, as we are now in the process

South Africa manufactures roughly about

pay an annual membership fee, VinylLoop

ultimately not only serve the interests of

12 000 tonnes of vinyl packaging per month

members will be required to pay a monthly

the individual members and our industry,

that goes into bottles, thermoformed

levy based on the declared amount of vinyl

but also those of our country and the

punnets, pharmaceutical blister packs,

packaging (in tonnages) they produce over

environment for generations to come,”

cling film etc. This represents less than 2%

the next six months. Initially this amount

Spangenberg concludes. •

of the total PVC market in the country.

will be R100 per tonne until 5 November

“Although vinyl products are readily

However, where normal SAVA members

of an adjusted membership levy. These

been a formal collection and recycling

funds will be used to set up the necessary

programme for post-consumer and post-

infrastructure to ensure VinylLoop

industrial vinyl packaging waste due to the

members reach the targets that have been

June 2021 | FOOD RE VIEW

of developing an industry-led plan that will

2021, after which members will be informed

recycled in South Africa, there has never

38

2021 it will be compulsory for all converter,

SAVA’s VinylLoop www.savinyls.co.za/vinylloop

FLEXIBLE PACKAGING

Reduce repacking activities and anticipate customised

retailing needs during production time

Changing consumer preferences, sustainability requirements as well as the growing need for customisation of added-value packs and new selling or shipping units are forcing manufacturers to adapt their production models and supply chains.

F

ood, home and personal Care (FHPC)

1

producers want to move towards a leaner and eco-friendlier secondary

packaging philosophy by re-evaluating their current use of repacking solutions, which generate significant cost, quality and sustainability side effects.

Smaller and larger case counts can minimise these effects by managing, storing and shipping products in suitable quantities with much more ease and flexibility for future customised retailing needs. To meet the need for extreme case counts while still dealing with the standard high-production formats, Sidel is launching Cermex EvoPack, a highly flexible Industry 4.0 case-packing platform for shaped containers in wrap-around blanks, trays & shelf ready packaging (SRP).

1, 2, 3: Sidel’s Cermex EvoPack is a highly flexible Industry 4.0 case-packing platform for shaped containers in wrap-around blanks, trays and shelf ready packaging

Consumers are becoming more demanding in their individual shopping

continuing e-commerce boom reflect this,

returning to the city centres to grant easy

needs, wanting to shop conveniently, at

but it can also be seen in the renaissance

access to everyday necessities.

any time or anywhere. Not only does the

of smaller urban stores, with major retailers

“Certain FHPC sub-categories or players

FOOD RE VIEW | June 2021

39

FLEXIBLE PACKAGING

2

three or four products, as well as very large transit cases with 24+ containers intended to go into repacking, while at the same time also being able to handle standard high-volume case formats. “With its flexible and extreme case count capabilities, the platform can help producers restore industrial margin thanks to significant cost savings as regards the use of material, equipment and energy. Additionally, it will certainly greatly contribute to meeting their carbon footprint reduction and sustainability goals,” Saussereau adds.

Delivering a remarkable ratio of up to

sometimes have customisation needs for

four products. These offer the opportunity

60 cases per minute in a compact footprint

up to 40% of their production volumes.

to manage, store and ship products more

of less than 30m2 , Cermex EvoPack offers

Until now, the most common way for

easily and flexibly for downstream tasks at

fast and repeatable format changeovers

producers to approach these requests

distribution centres or within e-commerce

ranging from just five minutes for a case

was to use manual repacking services,”

order preparations,” comments Saussereau.

format change up to 15 minutes when

says Didier Saussereau, packing product

In parallel, demand for complex product

changing both bottle and case formats.

manager at Sidel.

set-ups will remain and will still require

“Our goal was also to make the

manual repacking manipulations. So, with

equipment easy to operate and maintain,

LIMITING REPACKING ACTIVITIES AND ANTICIPATING FUTURE CUSTOMISED RETAILING NEEDS

upstream technical capabilities to supply

so we designed Cermex EvoPack by

larger case counts, producers could ship

embedding the latest Industry 4.0

the same number of products with less

technologies, to guide operators and

These repacking activities generate

secondary packaging used and wasted.

maintenance teams in their daily

costs not only via the extra packaging

“Now being able to produce both small

material used, but also by the additional

and large case counts will help them

manual labour tasks, which now exceed

better anticipate trends and accommodate

the acceptable limits as regards

new channels, as long as the traditional

manufacturers’ competitiveness and

high production volumes of the standard

margins. The associated environmental

formats are still handled on the same

waste is making repacking even less

production line and packing solution,”

sustainable. Finally, the additional handling

Saussereau adds.

operations,” Saussereau concludes.

3

during repacking may potentially generate

are seeing an increasing need for small

UNPRECEDENTED SECONDARY PACKAGING SIZE RANGE AND HIGH SPEED

case counts to help producers reduce the

Cermex EvoPack offers an unprecedented

number of products per shipping unit down

secondary packaging size range to manage

to the in-demand batches of two, three, or

reduced case counts, containing only two,

scratches or scuffing on the products.

“To reduce and simplify repacking, we

40

June 2021 | FOOD RE VIEW

Sidel – www.sidel.com

FLEXIBLE PACKAGING

Creating connections with consumers While COVID-19 has changed consumers’ buying habits, brand owners continue to shift their understanding of how to create meaningful experiences for consumers using their products’ packaging.

U

nderstanding emerging consumers

• Informed

– the speakers of the digital

Today’s consumers know more about

language of computers, videos,

what they’re buying because of the

video games and social media – is about

research they do. They have different

more than just the four traditional Ps

expectations of privacy, they expect

of marketing (product, price, place and

brands to demonstrate social responsibility,

promotion). We now need to also consider

they’re willing to pay for exclusive

the five Is (instrumental, interconnected,

experiences, they want to be entertained,

informed, in place and immediate):

and they want to collaborate and be recognised.

• Instrumental Smartphones are instrumental in the

• Interconnected

experiential and something they can share

way consumers now shop because it’s

We walk around with smartphones in

with their online tribes.

the smartphone that triggers a physical

our bags or pockets, enabling us to be

interaction with the digital world. To do

interconnected – a community. Today’s

• In place

this brand owners use QR codes printed

emerging consumers want to be part of a

Shoppers are looking for contextual

on the packaging, built-in near-field

community and connect with others who

information. They are shopping in-store

communication (NFC), and highly visual

share the same values as they do.

with their phones in their hands. They want

augmented reality (AR) systems.

They also want their packaging to be more

offers made specifically for them in the

FOOD RE VIEW | June 2021

41

FLEXIBLE PACKAGING place where they are, and in

• Create a connection

context with their buying behaviours

Pyrotec PackMedia is an innovative,

and values.

forward-thinking brand that

Connected consumers are not

understands the need for its

only informed but they’re also

customers to connect more

looking for solutions-based or

effectively with consumers. To help

functional, hard-working packaging

products make a statement at point

that wows at point of sale. In other

of sale, Pyrotec PackMedia offers

words, packaging that makes a

an array of solutions – including

statement – whether emotional,

QR codes, AR systems and NFC

practical, rational or irrational – and

tags – that demonstrate social

fills a need in consumers’ lives.

responsibility, offer exclusive

Maybe Wordsearch is better-see below

experiences through customisation • Immediate

and targeted communication, and

Everything is immediate and

entertain consumers while providing

product offers should be too. Instant

an opportunity for collaboration. •

gratification is a big driving force behind the way people do things today – ‘I want to buy it now’ or ‘I want that offer now’.

Pyrotec - www.pyrotec.co.za

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FOOD RE VIEW | June 2021

43